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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-PACK 100 PLUS IM546
Summary of Contents for Lincoln Electric WELD-PACK 100 PLUS IM546
- Page 1 WELD-PAK 100 PLUS For use with machine Code Numbers 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.
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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 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.
- Page 4 FOR ENGINE powered equipment. 7.a. Turn the engine off before troubleshooting and maintenance work unless the maintenance work requires it to be running. ____________________________________________________ 7.b. Operate engines in open, well-ventilated areas or vent the engine exhaust fumes outdoors. ____________________________________________________ 7.c. Do not add the fuel near an open flame welding arc or when the engine is running.
- Page 5 PRÉCAUTIONS DE SÛRETÉ Pour votre propre protection lire et observer toutes les instruc- tions et les précautions de sûreté specifiques qui parraissent dans ce manuel aussi bien que les précautions de sûreté générales suivantes: Sûreté Pour Soudage A LʼArc 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. WELD-PAK 100 for selecting a QUALITY product by Lincoln Electric. We want you to take pride in operating this Lincoln Electric Company product ••• as much pride as we...
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Page 7: Table Of Contents
MASTER TABLE OF CONTENTS FOR ALL SECTIONS 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... - Page 8 WELD-PAK 100...
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Page 9: Installation
TECHNICAL SPECIFICATIONS – WELD-PAK 100 Standard Voltage/Frequency 115V/60Hz 115V/60Hz Duty Cycle 20% Duty Cycle 20% Duty Cycle – CSA Rated Output Welding Current Range (Continuous) Maximum Open Circuit Voltage Rated DC Output: 0 - 88 amps CSA Rated DC Output: 0 - 62 amps RECOMMENDED INPUT CABLE AND FUSE SIZES Output Mode Input Voltage... -
Page 10: 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 WELD-PAK 100 Operating Manual should install and operate this equipment. -
Page 11: 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 12: Work Cable Installation
Work Cable Installation Refer to Figure A.2. 1. Open the wire feed section door on the right side of the WELD-PAK 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 13 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 14: Input Connections
INPUT CONNECTIONS FIGURE A.6 OPTIONAL GAS SOLENOID INLET FITTING Refer to Figure A.6. The WELD-PAK 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 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
GENERAL DESCRIPTION The WELD-PAK 100 is a compact lightweight DC wire feeder/power source. It has been designed for work- shop, hobby, and light maintenance. It is capable of general purpose welding with self-shielded flux-cored ® (Innershield ) wire. When combined with the optional K610-1 MIG Conversion Kit, the WELD-PAK 100 is suitable for GMAW (MIG) welding applications. -
Page 17: Welding Operations
out when tripped (Manual reset). WELD-PAK 100 WELD-PAK 100 FIGURE B.1a 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 18 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
FIGURE B.6 Contact Tip Wire Electrode 3/8" – 1/2" Electrical Stickout 100 is now ready to weld. 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. -
Page 20: Overload Protection
thinner, CO gas is recommended because it gives equal or better performance than a blended gas at a lower cost. A mixed gas consisting of 75 to 80% Argon and 20 to 25% CO is recommended for welding on heavier gauge [12 gauge (2,5 mm) for example] steel. The WELD-PAK 100 is suitable for .035"... -
Page 21: Learning To Weld
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 weld- ing and develop this skill. For more detailed informa- tion, order a copy of “New Lessons in Arc Welding” listed at the end of this manual. -
Page 22: Process Selection
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. -
Page 23: Common Metals
2. Can I afford the extra expense, space, and lack of portability required for gas cylinders and gas sup- ply? 3. Do I require clean, finished-looking welds? If you have answered yes to all the above questions GMAW may be the process for you. If you have answered no to any of the above questions, then you should consider using the FCAW process. - Page 24 B-10 FIGURE B.11 WARNING ARC RAYS can burn eyes and skin. When using an open arc process, it Is necessary to use correct eye, head and body protection. Protect yourself and others, read “ARC RAYS can burn” at the front of this manual.
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Page 25: Helpful Hints
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. 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 more slowly in order to get good penetration. - Page 26 B-12 MACHINE SET UP FOR THE GMAW (MIG) 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. See the Application Guide on the inside of wire feed section door for information on setting the controls.
- Page 27 FIGURE B.17 Contact Tip Wire Electrode 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.17. Once the arc has been established, maintaining the correct ESO becomes extremely important.
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Page 28: Joint Types And Positions
B-14 4. After you strike the arc, practice the correct electri- cal stickout. Learn to distinguish it by its sound. 5. When you are sure that you can hold the correct electrical stickout, with a smooth “crackling” arc, start moving. Look at the molten puddle constantly, 6. -
Page 29: Welding In The Vertical Position
FIGURE B.23 45° Welding In The Vertical Position Welding in the vertical position can be done either ver- tical-up or vertical-down. Vertical-up is used whenev- era larger, stronger weld is desired. Vertical-down is used primarily on sheet metal 5/32” (3.9 mm) and under for fast, low penetrating welds. -
Page 30: Troubleshooting Welds
B-16 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 31 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. 3.
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Page 32: Application Chart
B-18 APPLICATION CHART WELD-PAK 100... -
Page 33: Accessories
ACCESSORIES OPTIONAL ACCESSORIES 1. K520 Utility Cart — Designed to trans- port 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. - 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
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 37 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"...
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Page 38: Changing Liner
FIGURE D.2 Liner trim length Set Screw Brass Cable Connector Liner Assembly (Liner bushing to be sealed tight against brass cable connector) WELD-PAK 100 MAINTENANCE CHANGING LINER 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... -
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 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
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. WELD-PAK 100 TROUBLESHOOTING... - Page 43 (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 44 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. 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 15a – 15c Case Door (Sheet Metal) See Center Decal, “Lincoln Logo”, Purchase Panel Assby decal package Item 19 S8025-70 Welder Application Chart, Purchase L8623-1 decal package Item 19 S8025-65 Door Hinge Power Plug Grommet See Drive Power Plug & Cord...
- Page 50 COMPLETE DRIVE ASSEMBLY/MOTOR Item Description Complete New Drive Assembly/ Motor, Includes All Items 1 – 10 below Gearbox Mounting Plate Guide Tube Retainer Round Head Screw, #8-32, 0.75" Long #8 Shakeproof Lockwasher #8 Flatwasher Motor & Gearbox Assembly, Includes 1 – 1d and 2a Motor Leads Idle Roll Arm Idle Roll Shaft...
- Page 51 Item Description Molded Case Front Nameplate Fastener Buttons On/Off Switch, Includes 4a Line Switch Mounting Bracket Wire Speed Potentiometer, 5k, 2w, Linear (Includes lock washer, hex nut) Wire Speed Potentiometer Knob Arc Volts Selector Switch Assembly, M15750 Includes 7a – 7e Rotor Spring Moving Contact...
- Page 52 RECTIFIER, FAN AND BRACKET ASSEMBLY Item Description 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 PARTS Part No. Complete Assembly, Includes L7680-2 Items 1 – 5 below Bracket for Fan &...
- Page 53 Item Description Center Panel (Sheet Metal), Includes 2a – 2i, and Items 4, 5, 6 Center Panel (Sheet Metal) Slotted Hex Head Screw, #10-3/8" long, blunt point Slotted Hex Head Screw, #10-1/2" P.C. Board Snap-In Support Cable Hanger Gun & Trigger Connection Receptacle Ground Screw, Pan Head Phillips, #10-24 Thread Forming Screw...
- Page 54 MAGNUM 100L ASSEMBLY ACCESSORIES AND EXPENDABLE REPLACEMENT PARTS FOR MAGNUM 100L DESCRIPTION COMPLETE GUN & CABLE ASSEMBLY 1. CABLE LINER For cables 15' (4.5 m) and less 2. CONTACT TIPS Standard Duty CONTACT TIPS Tapered 3. GAS DIFFUSER 4. GAS NOZZLE — Fixed GAS NOZZLE —...
- Page 55 NOTES SQUARE WAVE TIG 255...
- Page 56 NOTES SQUARE WAVE TIG 255...
- Page 57 _______________________________________________ _______________________________________________ Telephone: _______________________________________________ |_|_| |_|_| Exp Date Month Year 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, Price Code $5.00 $15.00 $4.50 $5.00...
- Page 58 ● WARNING ● Spanish ● AVISO DE PRECAUCION ● French ● ATTENTION ● ● German WARNUNG ● Portuguese ● ATENÇÃO ● Japanese Chinese Korean Arabic ● ● ● ● ● ● ● ● ● ●...
- Page 59 ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● Spanish ● PRECAUCION French ● ATTENTION ● German WARNUNG Portuguese ● ● Japanese Chinese Korean Arabic WARNING AVISO DE ATENÇÃO...
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Page 60: Limited Warranty
Equipment manufactured for the Lincoln Electric Company is subject to the warranty period of the original manufacturer. All engines and engine accessories are warranted by the engine or engine accessory manufacturer and are not covered by this warranty.