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B-6
thinner, CO
gas is recommended because it gives
2
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
2
heavier gauge [12 gauge (2,5 mm) for example] steel.
The WELD-PAK 100 is suitable for .035" aluminum
wire and .030" stainless wire. Refer to Table B.1 for
recommended procedure settings.
Shielding
Process
Welding Wire
Gas
MIG DC+ .035 Dia
100% Argon
4043 Aluminum
Wire
MIG DC+ .035 Dia
100% Argon
5356 Aluminum
Wire
MIG DC+ .030 Dia
98% Argon/
308L Stainless
2% Oxygen
Steel Wire
TABLE B.1
CHANGING MACHINE OVER TO
FEED OTHER WIRE SIZES
The WELD-PAK 100 is shipped from the factory ready
to feed 0.035" (0,9 mm) diameter wire. To operate the
WELD-PAK 100 with other sizes of wire, it is neces-
sary to change the contact tip and change the drive
roll over to other sizes. Refer to Changing the Contact
Tip and Changing the Drive Roll, in the MAINTE-
NANCE section, for specific information on these pro-
cedures.
WELDING WITH GMAW (MIG)
Shielding Gas
When using the GMAW process, obtain and install the
K610-1 MIG Conversion Kit and a cylinder of carbon
dioxide (CO
) or argon-carbon dioxide mixed shielding
2
gas. Refer to the ACCESSORIES section for more
information about installing the K610-1 Kit for use with
the WELD-PAK 100.
1. For CO
, open the cylinder very slowly. For argon-
2
mixed gas, open cylinder valve slowly a fraction of
a turn. When the cylinder pressure gauge pointer
WELD-PAK 100
OPERATION
Voltage/Wire Speed
16 ga 14 ga 12 ga 10 ga
B-5
D-7
D-9
D-9
B-5
C-7
D-9
D-10
A-3
C-6
D-7.5
D-7.5
stops moving, open the valve fully.
2. If using a regulator with an adjustable flow meter,
close the gun trigger and adjust the flow to give 15
– 20 cubic ft per hour (CFH) (7 – 10 I/min) [use 20
– 25 CFH (10 – 12 I/min) when welding out of
position or in a drafty location for CO
mixed gas, trigger to release gas pressure, and
turn off the adjust the flow to give 25 – 30 CFH
(12 – 14 I/min).
3. Keep the cylinder valve closed, except when using
the WELD-PAK 100. When finished welding:
a) Close the cylinder valve to stop gas flow.
b) Depress the gun trigger briefly to release the
pressure in the gas hose.
c) Turn off the WELD-PAK 100.
OVERLOAD PROTECTION
Output Overload
The WELD-PAK 100 is equipped with a circuit breaker
and a thermostat which protects the machine from
damage if maximum output is exceeded. The circuit
breaker button will extend out when tripped. The cir-
cuit breaker must be manually reset.
Thermal Protection
The WELD-PAK 100 has a rated output duty cycle of
20%. If the duty cycle is exceeded, a thermal protector
will shut off the output until the machine cools to a rea-
sonable operating temperature. This is an automatic
function of the WELD-PAK 100 and does not require
user intervention. The fan continues to run during
cooling.
Electronic Wire Drive Motor Protection
The WELD-PAK 100 has built-in protection for wire
drive motor overload.
]. For argon
2
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Troubleshooting
