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Lincoln Electric PRO 100 Operator's Manual

Lincoln electric welder user manual
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For use with machine Code Number
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.
Date of Purchase:
Serial Number:
Code Number:
Model:
Where Purchased:
• 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
PRO 100
OPERATOR'S MANUAL
• World's Leader in Welding and Cutting Products •
10270, 10479, 10683
IM562-B

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Summary of Contents for Lincoln Electric PRO 100

  • Page 1 • 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 RETURN TO MAIN MENU PRO 100 10270, 10479, 10683 IM562-B...

  • 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

    ELECTRIC SHOCK can kill. 3.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 clothing. Wear dry, hole-free gloves to insulate hands.
  • Page 4 WELDING SPARKS can cause fire or explosion. 6.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.
  • Page 5 PRÉCAUTIONS DE SÛRETÉ Pour votre propre protection lire et observer toutes les instructions et les précautions de sûreté specifiques qui parraissent dans ce manuel aussi bien que les précautions de sûreté générales suiv- antes: Sûreté Pour Soudage A L’Arc 1. Protegez-vous contre la secousse électrique: a.
  • Page 6 This statement appears where the information must be followed to avoid minor personal injury or damage to this equipment. for selecting a QUALITY product by Lincoln Electric. We want you to take pride in operating this Lincoln Electric Company product •••...

  • Page 7: Table Of Contents

    Configuration of Components in Wire Feeding System...D-2 Component Replacement Procedures ...D-3 Troubleshooting ...Section E Safety Precautions...E-1 How to Use Troubleshooting Guide...E-1 Troubleshooting Guide ...E-2 Wiring Diagrams ...Section F PRO 100 Wiring Diagram ...F-1 PRO 100 Parts Manual...P280 Series & P202-E Page...

  • Page 8: Installation

    TECHNICAL SPECIFICATIONS – PRO 100 Standard Voltage/Frequency 115V/60Hz 115V/60Hz Duty Cycle 20% Duty Cycle 20% Duty Cycle – CSA Rated Output Welding Current Range Rated DC Output: 30 - 88 amps CSA Rated DC Output: 30 - 62 amps RECOMMENDED INPUT CABLE AND FUSE SIZES...

  • Page 9: Identify And Locate Components

    • Machine must be plugged into a receptacle which is grounded per any national, local or other applicable electrical codes. • The PRO 100 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

    SELECT SUITABLE LOCATION 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 and cause overheating.

  • Page 11: Gun Installation

    (CO 2 ) or argon-carbon dioxide mixed shielding gas must be obtained. For more information about the K610-1 MIG Conversion Kit for use with the PRO 100, refer to the ACCESSORIES section. PRO 100...
  • Page 12 Con- nect the other end to the PRO 100 Gas Solenoid Inlet Fitting (5/8-18 female threads — for CGA — 032 fitting). Make certain the gas hose is not kinked or twisted.

  • Page 13: Input Connections

    INPUT CONNECTIONS FIGURE A.6 OPTIONAL GAS SOLENOID INLET FITTING Refer to Figure A.6. The PRO 100 has a power input cable located on the rear of the machine. CODE REQUIREMENTS FOR INPUT CONNECTIONS WARNING This welding machine must be connected to power source in accordance with applicable elec- trical codes.

  • Page 14: Operation

    Read entire operation section before operating the PRO 100. Observe all safety information throughout this manual. OPERATION WARNING ELECTRIC SHOCK can kill. • Do not touch electrically live parts or electrode with skin or wet clothing. Insulate yourself from work and ground.

  • Page 15: General Description

    WELDING CAPABILITY The PRO 100 is rated at 88 amps, 18 volts, at 20% duty cycle on a ten minute basis. CSA rated output at 62 amps at 20 volts at 20% duty cycle. It is capable of higher output currents at lower duty cycles.

  • Page 16: Welding Operations

    FIGURE B.1a DO NOT SWITCH WHEN WELDING PRO 100 FIGURE B.1b WELDING OPERATIONS SEQUENCE OF OPERATION 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.
  • Page 17 11. Turn the PRO 100 OFF (“O”). 12. Replace contact tip and gas nozzle. 13. Refer to Figure B-6. Cut the wire off 1/4” – 3/8” (6 – 10 mm) from the end of the tip. The PRO 100 is now ready to weld. FIGURE B.5...
  • Page 18 2. See the Application chart on the inside of the wire feed compartment door for information on setting the PRO 100 controls. Refer to Table B.1 for alu- minum and stainless wire. 3. Set the Voltage (“V”) and Wire Speed (“olo’”) con-...

  • Page 19: Overload Protection

    The PRO 100 is shipped from the factory ready to feed 0.035” (0,9 mm) diameter cored wire. To operate the PRO 100 with other sizes and types of wire, it is necessary to change the contact tip, drive roll and cable liner configuration.

  • Page 20: Learning To Weld

    Electronic Components Cored Wire Protective Slag Weld Metal Bearings PRO 100 WARNING Fumes and slag generated from Innershield type electrodes recom- mended for use with this welding machine can be toxic. • Avoid contact with eyes and skin.
  • Page 21 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 100 Gas nozzle Shielding gas Weld metal FIGURE B.10...
  • Page 22 This is referred to as the “pull technique”. On thin gauge sheet metal, use the “push technique”. See “Welding Techniques for GMAW (MIG) Process”. PRO 100 Lap weld Fillet weld Corner weld FIGURE B.11...
  • Page 23 Figure B.16. 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 100 B-10 45° FIGURE B.15 WARNING...
  • Page 24 (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.18. PRO 100 B-11...
  • Page 25 (10 mm) behind the wire electrode. Most beginners tend to weld too fast, resulting in a thin uneven, “wormy” looking bead. They are not watching the molten metal. Solidifying ridge PRO 100 B-12 3/8 – 1/2” (10 – 12 mm) Electrical Stickout (ESO) FIGURE B.19 Molten puddle FIGURE B.20...
  • Page 26 2. Correct way to strike an arc 3. Correct electrical stickout 4. Correct welding speed is to perform the following exercise. Contact LEARNING TO WELD For the PRO 100, use the following: Mild Steel Electrode Voltage Setting “V” Wire Feed Speed “o|o” Refer to Figure B.22.
  • Page 27 6. When no more welding is to be done, close the valve on the gas cylinder, momentarily operate the gun trigger to release gas pressure, then turn off the machine. PRO 100 B-14 FIGURE B.23 WARNING ARC RAYS can burn eyes and skin.
  • Page 28 1. Correct welding position 2. Correct way to strike an arc 3. Correct electrical stickout 4. Correct welding speed is to perform the following exercise. For the PRO 100, use the following: Mild Steel Electrode Voltage Setting “V” Wire Feed Speed “o|o”...

  • Page 29: Troubleshooting Welds

    1. Increase voltage 2. Decrease WFS (wire feed speed) 3. Decrease stickout 4. Increase drag angle * Stubbing occurs when the electrode drives through the molten puddle and hits the bottom plate tending to push the gun up. PRO 100 B-16...
  • Page 30 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. LEARNING TO WELD PRO 100 B-17...

  • Page 31: Application Chart

    B-18 B-18 APPLICATION CHART PRO 100...

  • Page 32: Accessories

    See Maintenance section for instructions on installing drive roll, cable liner, contact tip and their proper configuration. 4. K610-1 MIG Conversion Kit for the PRO 100 — Complete kit for use with .025" (0.6 mm) electrode wire and either CO 2 or Argon-mixed gas. Includes .025-.030"...

  • 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 100. Take the unit to an authorized Lincoln Service Center if you experi- ence problems. NO maintenance is required.

  • Page 34: Gun And Cable Maintenance

    Use the wire as a reamer to remove dirt that may be adhering to the wall of the hole through the tip. CONFIGURATION OF COMPONENTS IN WIRE FEEDING SYSTEM Components shipped with PRO 100 K610-1 .023/.025” (0.6mm) MIG Conversion Kit• K664-2 .035 (0.9mm) Aluminum or Stainless Kit* •...

  • Page 35: Component Replacement Procedures

    Make certain the set screw is located on the flat portion of the shaft and tighten. PRO 100 FIGURE D.1...
  • Page 36 Figure D.2. Remove any burrs from the end of the liner. 8. Screw the gas diffuser onto the end of the gun tube and securely tighten. 9. Replace the contact tip and nozzle. PRO 100...
  • Page 37 See Figure D-3. FIGURE D.3 Counter-clockwise PRO 100...

  • Page 38: Troubleshooting

    HOW TO USE TROUBLESHOOTING GUIDE 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 Elec- trical Shock, please observe all safety notes and precautions detailed throughout this manual.

  • Page 39: Troubleshooting Guide

    Fan operates normally. 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. TROUBLESHOOTING POSSIBLE AREAS OF...
  • Page 40 (Optional MIG Conversion Kit only.) 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. TROUBLESHOOTING TROUBLESHOOTING GUIDE...
  • Page 41 Arc is unstable – Poor starting 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. TROUBLESHOOTING...
  • Page 42 DIAGRAMS 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. PRO 100...
  • Page 43 NOTES PRO 100...
  • Page 44 Address: Telephone: _______________________________________________ |_|_| |_|_| Exp Date Month 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 Telephone: 216-383-2211 or, Titles: Price New Lessons in Arc Welding $5.00...
  • Page 45 ● WARNING ● Spanish ● AVISO DE PRECAUCION ● French ● ATTENTION ● ● German WARNUNG ● Portuguese ● ATENÇÃO ● Japanese Chinese Korean Arabic ● ● ● ● ● ● ● ● ● ●...
  • Page 46 ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● Spanish ● PRECAUCION French ● ATTENTION German ● WARNUNG Portuguese ● ● Japanese Chinese Korean Arabic WARNING AVISO DE ATENÇÃO...
  • Page 47 • 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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