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RETURN TO MAIN MENU
IM784
PRO 100
April, 2004
For use with machine Code Number
10970
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.
OPERATOR'S MANUAL
Copyright © 2004 Lincoln Global Inc.
• 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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Related Manuals for Lincoln Electric PRO100 IM784
Summary of Contents for Lincoln Electric PRO100 IM784
- Page 1 RETURN TO MAIN MENU IM784 PRO 100 April, 2004 For use with machine Code Number 10970 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 ...
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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 The code number is especially important when identifying the correct replacement parts. - Register your machine with Lincoln Electric either via fax or over the Internet. • For faxing: Complete the form on the back of the warranty statement included in the literature packet accompanying this machine and fax the form per the instructions printed on it.
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Page 7: Table Of Contents
TABLE OF CONTENTS 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 Controls and Settings...B-2 Welding Operations ...B-3... -
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 - 100 amps RECOMMENDED INPUT CABLE AND FUSE SIZES Output Mode Input Voltage RATED 115V/60Hz 115V/60Hz... -
Page 9: Identify And Locate Components
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 PRO 100 Operating Manual should install and operate this equipment. •... -
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
Work Cable Installation Refer to Figure A.2. 1. Open the wire feed section door on the right side of the PRO 100. 2. Pass the end of the work cable that has the termi- nal lug with the smaller hole through the Work Cable Access Hole (1) in the case front. - Page 12 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 electrical circuits.
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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
GENERAL DESCRIPTION The PRO 100 is a compact lightweight DC wire feed- er/power source. It has been designed for workshop, hobby, and light maintenance. It is capable of general purpose welding with self-shielded flux-cored (Inner- shield ® ) wire. When combined with the optional K610- 1 MIG Conversion Kit, the PRO 100 is suitable for GMAW (MIG) welding applications. -
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 Note: The brake should be adjusted with a spool of wire installed. When properly adjusted it should move freely but not coast. Friction Brake Adjustments 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.
- Page 18 FIGURE B.6 Contact Tip Electrode 3/8”-1/2”(10-12mm)Contact Tip to Work Distance(CTWD) Making A Weld 1. See “Process Guidelines” in this section for selec- tion of welding wire and shielding gas and for range of metal thicknesses that can be welded. 2. See the Application chart on the inside of the wire feed compartment door for information on setting the PRO 100 controls.
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Page 19: Overload Protection
The PRO 100 is suitable for .035" aluminum wire and .030" stainless wire. Refer to Table B.1 for recom- mended procedure settings. (Requires K610-1 MIG Conversion Kit and K664-2 Aluminum - Stainless Feeding Kit.) CAUTION It is important when changing between welding with steel wire and aluminum to exchange feeding components due to the lubricant applied to steel wire. -
Page 20: Application Chart
APPLICATION CHART PRO 100... -
Page 21: Accessories
OPTIONAL ACCESSORIES 1. K520 Utility Cart — Designed to transport the Lin- coln 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. -
Page 22: Maintenance
MAINTENANCE SAFETY PRECAUTIONS ROUTINE 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. -
Page 23: Gun And Cable Maintenance
GUN AND CABLE MAINTENANCE FOR MAGNUM™ 100L GUN 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. -
Page 24: Component Replacement Procedures
COMPONENT REPLACEMENT PROCEDURES CHANGING THE CONTACT TIP 1. Refer to Figure D.2. Remove the gas nozzle from the gun by unscrewing counter-clockwise. 2. Remove the existing contact tip from the gun by unscrewing counter-clockwise. 3. Insert and hand tighten desired contact tip. 4. - Page 25 FIGURE D.2 Liner trim length Set Screw Brass Cable Connector Liner Assembly (Liner bushing to be sealed tight against brass cable connector) MAINTENANCE 1-1/4 (31.8 mm) Liner Trim Length Gas Diffuser Gas Nozzle or Gasless Nozzle PRO 100 CHANGING LINER NOTICE: The variation in cable lengths pre- vents the interchangeability of liners.
- Page 26 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-clockwise until the collar reaches a stop. Then pull the collar off the gun handle.
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Page 27: 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 28: 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 29 (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 30 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 31 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 32 NOTES PRO 100...
- Page 33 ● WARNING ● Spanish ● AVISO DE PRECAUCION ● French ● ATTENTION ● ● German WARNUNG ● Portuguese ● ATENÇÃO ● Japanese Chinese Korean Arabic ● ● ● ● ● ● ● ● ● ●...
- Page 34 ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● Spanish ● PRECAUCION French ● ATTENTION ● German WARNUNG Portuguese ● ● Japanese Chinese Korean Arabic WARNING AVISO DE ATENÇÃO...
- Page 35 • 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...