Table of Contents
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Date of Purchase:
Serial Number:
Code Number:
Model:
Where Purchased:
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 thoughtful operation
on your part. DO NOT INSTALL, OPERATE OR REPAIR
THIS EQUIPMENT WITHOUT READING THIS MANUAL
AND
THE
SAFETY
PRECAUTIONS
THROUGHOUT. And, most importantly, think before you act
and be careful.
TABLE OF CONTENTS
Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8
Technical Specification . . . . . . . . . . . . . . . . . . . . . .9
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15
Learn to Weld . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22
Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .39
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .41
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . .45
Wiring Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . .47
Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .48
W E E L L D D - - P P A A K K 1 1 0 0 0 0
W
La Seguridad Depende de Usted
Los equipos de corte y soldadura al arco Lincoln han sido
diseñados y construidos teniendo en cuenta su seguridad.
No obstante, ésta se verá incrementada si la instalación se
realiza correctamente, y si pone atención en el manejo de
los mismos.
NO INSTALE, UTILICE O REPARE ESTE
CONTAINED
EQUIPO SIN ANTES HABER LEIDO ESTE MANUAL Y LAS
MEDIDAS DE SEGURIDAD QUE CONTIENE. Y, lo más
importante, piense antes de actuar, y tenga mucho cuidado.
TABLA DE CONTENIDO
Seguridad . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2
Introducción . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8
Especificaciones Técnicas . . . . . . . . . . . . . . . . . . . . .9
Instalación . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10
Operación . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15
Aprendiendo a Soldar . . . . . . . . . . . . . . . . . . . . . . . . .22
Accesorios . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .39
Mantenimiento . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .41
Localización de averías . . . . . . . . . . . . . . . . . . . . . . .45
Diagramas de cableado . . . . . . . . . . . . . . . . . . . . . . .47
Partes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .48
22801 St. Clair Ave. Cleveland, Ohio 44117-1199 U.S.A.
WEB SITE: www.lincolnelectric.com
Tel. (216) 481-8100
RETURN TO MAIN MENU
OPERATOR'S MANUAL
MANUAL DE OPERACIÓN
MANUEL DE L'OPÉRATEUR
La sécurité dépend de vous
Le matériel de soudage et de coupage à l'arc Lincoln est
conçu et construit en tenant compte de la sécurité. Toutefois,
la sécurité en général peut être accrue grâce à une bonne
installation... et à la plus grande prudence de votre part. NE
PAS INSTALLER, UTILISER OU RÉPARER CE MATÉRIEL
SANS AVOIR LU CE MANUEL ET LES MESURES DE
SÉCURITÉ QU'IL CONTIENT.
réfléchissez avant d'agir et exercez la plus grande prudence.
TABLE DES MATIÈRES
Sécurité....................................................................2
Introduction ..............................................................8
Fiche technique .......................................................9
Installation ...............................................................10
Fonctionnement .......................................................15
Apprentissage du soudage ......................................22
Accessoires..............................................................39
Entretien...................................................................41
Dépannage ..............................................................45
Schéma de câblage .................................................47
Pièces ......................................................................48
Copyright © Lincoln Global Inc.
IMT460-D
January, 2010
Et, par dessus tout,
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Table of Contents
Troubleshooting
Related Manuals for Lincoln Electric WELD-PAK 100 IMT460-D
Summary of Contents for Lincoln Electric WELD-PAK 100 IMT460-D
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Page 1: Table Of Contents
Date of Purchase: Serial Number: Code Number: Model: Where Purchased: 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 thoughtful operation on your part. -
Page 2: Safety
ANSI Standard Z49.1” from the American Welding Society, P.O. Box 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, OPERA-... - Page 3 SAFETY ELECTRIC AND MAGNETIC FIELDS may be dangerous 3.a. Electric current flowing through any conductor causes localized Electric and Magnetic Fields (EMF). Welding current creates EMF fields around welding cables and weldingmachines 3.b. EMF fields may interfere with some pacemakers, and welders having a pacemaker should consult their physician before welding.
- Page 4 SAFETY WELDING SPARKS can cause fire or explosion. 4.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.
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Page 5: Electric Shock Can Kill
ELECTRIC SHOCK can kill. 5.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 cloth- ing. Wear dry, hole-free gloves to insulate hands. - Page 6 SAFETY FUMES AND GASES can be dangerous. 6.a.Welding may produce fumes and gases hazardous to health. Avoid breathing these fumes and gases.When welding, keep your head out of the fume. Use enough ventila- tion and/or exhaust at the arc to keep fumes and gases away from the breathing zone.
- Page 7 SAFETY CYLINDER may explode if damaged. 7.a. Use only compressed gas cylinders containing the correct shielding gas for the process used and properly operat- ing regulators designed for the gas and pressure used. All hoses, fittings, etc. should be suitable for the application and maintained in good condition.
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Page 8: Introduction
INTRODUCTION Read the entire manual before installing and operating the WELD-PAK WARNING ELECTRIC SHOCK can kill. • Only qualified personnel should installation or operate this equipment. • Machine must be plugged into a receptacle which is grounded per any national, local or other applicable electrical codes. -
Page 9: Technical Specification
TECHNICAL SPECIFICATIONS INPUT – SINGLE PHASE ONLY Voltage/Frequency Input Current 115V/60Hz 20 Amps - Rated Output 115V/60Hz 15 Amps - CSA Rated output RATED OUTPUT Duty Cycle Amps Volts CSA RATED OUTPUT Duty Cycle Amps Volts OUTPUT RANGE Welding Current Range Rated DC Output: 30 - 100 amps Maximum Open Circuit Voltage... -
Page 10: Installation
INSTALLATION IDENTIFY AND LOCATE COMPONENTS If you have not already done so, unpack the Weld-Pak from its carton and remove all packing material around the WELD- PAK. Remove the following loose items from the carton): Ensamble de la antorcha y cable WELD-PAK 1 lb. - Page 11 INSTALLATION LOCATION Locate the welder on a secure level surface in a dry location. Locate where there is free circulation of clean air. Blocked air passages can cause overheating. WORK CLAMP INSTALLATION Attach the work clamp to the work cable by inserting the cable end with the larger terminal lug hole through the strain relief hole in the clamp.
- Page 12 INSTALLATION FIGURE 1 GUN INSTALLATION 1. Refer to Figure 1. Unplug the machine or turn power switch to the off “O” position. 2. Pass the insulated terminals of the gun trigger control leads, one at a time, through the Gun Cable and Control Lead Access Slot (2) in the case front.
- Page 13 INSTALLATION INPUT POWER CONNECTIONS FOR RATED OUTPUT WARNING • This welding machine must be connected to power source in accordance with applicable electrical codes. • If there is any question about the installation meeting applicable electrical code requirements, consult a qualified electrician.
- Page 14 • 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 electri- cal circuits.
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Page 15: Operation
OPERATION CONTROLS AND SETTINGS Refer to the case front t of the WELD-PAK. 1. Power ON/OFF Switch — When the power is on the fan motor will run and air will be exhausted out the louvers in the front of the machine. - Page 16 OPERATION WELDING SEQUENCE OF OPERATION WIRE LOADING The machine power switch should be turned to the OFF (“O”) position before working inside the wire feed enclosure. The machine is shipped from the factory ready to feed 4” (100 mm) diameter spools. A 4" (100 mm) diameter spool is mounted directly on the 5/8"...
- Page 17 OPERATION Optional Wire Spool Spindle 8” Wire Spool Be sure that this stud engages the hole in the wire spool. 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. The Wire Spool will rotate clockwise when wire is dereeled.
- Page 18 OPERATION The Wire Drive Feed Roll can accommodate two wire sizes by flipping the wire drive feed roll over. Figure 2 Close the idle roll arm and latch the spring loaded pres- sure arm (2) in place . Rotate the spool counterclock- wise if required in order to take up extra slack in the wire.
- Page 19 OPERATION 7. Remove gas nozzle and contact tip from end of gun. Gun Handle Gas Diffuser/ Contact Tip Gas Nozzle 8. Turn the WELD-PAK ON (“I”). 9. Straighten the gun cable assembly. 10. Depress the gun trigger switch and feed welding wire through the gun and cable.
- Page 20 OPERATION GUN CABLE WORKPIECE WORK CLAMP Figure 3 Connect work clamp to metal to be welded. Work clamp must make good electrical contact to the workpiece. The workpiece must also be grounded as stated in “Arc Welding Safety Precautions” in the beginning of this manual.
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Page 21: Process Guidelines
OPERATION PROCESS GUIDELINES Refer to the Application chart on the inside of the wire feed compartment door for information on setting the WELD-PAK for mild steel. The WELD-PAK is also suitable for .035" aluminum wire and .030" stainless wire. Refer the Table below for recommended procedure settings. -
Page 22: Learn To Weld
OPERATION LEARNING TO WELD No one can learn to weld simply by reading about it. Skill comes only with practice. The following pages will help the inexperienced operator to understand welding and develop this skill. For more detailed information, order a copy of “New Lessons in Arc Welding”... - Page 23 OPERATION 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. • Do not take internally. • Keep out of reach of children. •...
- Page 24 OPERATION The “arc stream” is seen in the middle of the picture. This is the electric arc created by the electric current flowing through the space between the end of the wire electrode and the base metal. The temperature of this arc is about 6000°F, which is more than enough to melt metal.
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Page 25: Process Selection
OPERATION When comparing the GMAW and FCAW processes, you can see that the principal difference between the two lies in the type of shielding used. GMAW uses gas for shielding, thus we have Gas Metal Arc Welding. FCAW uses the melting or burning of the core ingredients for shielding, and is thus termed Self-Shielded Flux Cored Arc Welding. -
Page 26: Common Metals
OPERATION For FCAW (Innershield) Process 1. Do I want simplicity and portability? 2. Will welding be performed outdoors or under windy con- ditions? 3. Do I require good all position welding capability? 4. Will most welding be performed on 16 gauge and heav- ier, somewhat rusty or dirty materials? 5. - Page 27 OPERATION Butt Welds Place two plates side by side, leaving a space approximate- ly one half the thickness of the metal between them in order to get deeper penetration. Securely clamp or tack weld the plates at both ends, other- wise the heat will cause the plates to move apart.
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Page 28: Welding In The Vertical Position
OPERATION Fillet Welds When welding fillet welds, it is very important to hold the wire electrode at a 45° angle between the two sides or the metal will not distribute itself evenly. The gun nozzle is generally formed at an angle to facilitate this. See Figure 11. 45°... - Page 29 OPERATION PROPER GUN ANGLE PROPER GUN ANGLE FOR GMAW PROCESS FOR FCAW PROCESS WELDING IN THE VERTICAL UP POSITION WELDING IN THE VERTICAL UP POSITION FIGURE 12 Vertical-down Welding Refer to Figure 13 Vertical-down welds are applied at a fast pace.
- Page 30 OPERATION WELDING TECHNIQUES FOR THE SELF-SHIELDED FCAW PROCESS Four simple manipulations are of prime importance when welding. With complete mastery of the four, welding will be easy. They are as follows: 1. The Correct Welding Position Figure 14 illustrates the correct welding position for right handed people.
- Page 31 OPERATION 3. The Correct Contact Tip to Work Distance(CTWD) The Contact Tip to Work (CTWD) is the distance from the end of the contact tip to the end of the wire. (See Figure 15.) Once the arc has been established, maintaining the cor- rect (CTWD) becomes extremely important.
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Page 32: Helpful Hints
OPERATION Helpful Hints 1. For general welding, it is not necessary to weave the arc. Weld along at a steady pace. You will find it easier. 2. When welding on thin plate, you will find that you will have to increase the welding speed, whereas when weld- ing on heavy plate, it is necessary to go more slowly in order to get good penetration. - Page 33 OPERATION Contact Tip Punta de contacto Tube contact 4. After you strike the arc, practice the correct contact tip to work distance. Learn to distinguish it by its sound. 5. When you are sure that you can hold the correct electri- cal stickout, with a smooth “crackling”...
- Page 34 OPERATION When using the GMAW process on light gauge material, weld from right to left (if you are right handed). This results in a colder weld and has less tendency for burn through. 2. The Correct Way To Strike An Arc Be sure the work clamp makes good electrical con- tact to the work.
- Page 35 OPERATION 4. The Correct Welding Speed The important thing to watch while welding is the puddle of molten metal right behind the arc. See Figure 21. Do not watch the arc itself. It is the appearance of the pud- dle and the ridge where the molten Puddle solidifies that indicates correct welding speed.
- Page 36 OPERATION Practice The best way of getting practice is to perform the following exercise. For the WELD-PAK, use the following: Mild Steel 16 gauge or 1/16 inch (1.6 mm) Electrode Lincolnweld 0.025 L-56 electrode CO 2 Voltage Setting “V” Wire Feed Speed “o|o” Refer to Figure 18.
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Page 37: Troubleshooting Welds
OPERATION TROUBLESHOOTING WELDS Good welds have excellent appearance. To Eliminate Porosity (in order of importance): 1. Turn on gas supply, if used 2. Decrease voltage. 3. Increase stickout. 4. Increase WFS (wire feed speed). 5. Decrease drag angle. 6. Decrease travel speed. NOTE: Always be sure the joint is free from moisture, oil, rust, paint or other contaminants. - Page 38 OPERATION To Reduce Spatter (in order of importance): 1. Increase voltage. 2. Increase drag angle. 3. Decrease stickout. 4. Increase WFS (wire feed speed). 5. Decrease travel speed. 6. Check for correct gas, if used. To Correct Poor Penetration (in order of importance): 1.
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Page 39: Accessories
ACCESSORIES OPTIONAL ACCESSORIES 1. K520 Utility Cart — Designed to transport the Lincoln 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. Easy assembly required;... - Page 40 ACCESSORIES 1. Install the gas solenoid. Complete instructions are includ- ed with the kit. 2. Change the output polarity to DC(+). See “Work Cable Installation” in Installation section for details. 3. Change drive roll orientation (if required) for the wire size selected.
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Page 41: Maintenance
MAINTENANCE SAFETY PRECAUTIONS WARNING ELECTRIC SHOCK can kill. • Disconnect input power by remov- ing plug from receptacle before working inside WELD-PAK. Use only grounded receptacle. Do not touch electrically “hot” parts inside WELD-PAK. • Have qualified personnel do the maintenance and trouble shooting work. -
Page 42: Gun And Cable Maintenance
MAINTENANCE GUN AND CABLE MAINTENANCE 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. Remove the contact tip from the gun. - Page 43 MAINTENANCE CHANGING DRIVE ROLL 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"...
- Page 44 MAINTENANCE CHANGING LINER NOTICE: The variation in cable lengths prevents the inter- changeability of liners. Once a liner has been cut for a par- ticular gun, it should not be installed in another gun unless it can meet the liner cutoff length requirement. Refer to Figure below.
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Page 45: Troubleshooting
TROUBLESHOOTING No wire feed, weld output or gas flow when gun trig- ger is pulled. Fan does NOT operate. Make sure correct voltage is applied to the machine. Make certain that power switch is in the ON position. Make sure circuit breaker inside wire drive com- partment is reset. - Page 46 TROUBLESHOOTING Low or no gas flow when gun trigger is pulled. Wire feed, weld output and fan operate normally. (Optional MIG Conversion Kit only.) Verify that gas solenoid is properly installed. Refer to instructions included with MIG conver- sion kit. Check gas supply, flow regulator and gas hoses.
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Page 47: 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. NOTA: Este diagrama es sólo para referencia. Es posible que no sea exacto para todas las máquinas que se mencionan en este manual. -
Page 48: Parts
PARTS Order parts from and authorized Lincoln Service Facility. The following replacement parts listing is for reference only. Refer to parts page listing P188 for latest list. Part Description Descripción de las partes Voltage Control Switch Assembly Ensamble del Interruptor de Control de Voltaje Knob (Voltage Switch) Perilla (Interruptor de Voltaje) Line Switch... - Page 49 NOTES-NOTAS...
- Page 50 Do not touch electrically live parts or electrode with skin or wet clothing. WARNING Insulate yourself from work and ground. Spanish No toque las partes o los electrodos AVISO DE bajo carga con la piel o ropa moja- PRECAUCION Aislese del trabajo y de la tierra. Ne laissez ni la peau ni des vête- French ments mouillés entrer en contact...
- Page 51 Turn power off before servicing. Do not operate with panel open or guards off. Desconectar el cable de ali- No operar con panel abierto o mentación de poder de la máquina guardas quitadas. antes de iniciar cualquier servicio. Débranchez le courant avant l’entre- N’opérez pas avec les panneaux tien.
- Page 52 World's Leader in Welding and Cutting Products...