Sign in today to find solutions:

Forgot your password?

Don't have an account? Sign up

 
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
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:
ISO 9001
ANSI RAB
QMS
Designed and Manufactured Under a
Quality Program Certified by
ABS Quality Evaluations, Inc.
to ISO 9001 Requirements.
CERTIFICATE NUMBER: 30273
• 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
WELD-PAK 3200HD
For use with machine Code Number:10932
THIS
OPERATORS MANUAL
• World's Leader in Welding and Cutting Products •
Copyright © 2002 Lincoln Global Inc.
IM759
May, 2002

Summary of Contents

  • Page 1

    WELD-PAK 3200HD 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...

  • Page 2

    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. 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. 3.b.

  • 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 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 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

    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 Undercarriage Assembly ...A-7 ________________________________________________________________________ Operation ...Section B Safety Precautions ...B-1 General Description ...B-1 Design Features...B-1,B-2 Welding Capability ...B-2...

  • Page 8: Technical Specifications

    TECHNICAL SPECIFICATIONS – WELD-PAK 3200HD Standard Voltage/Frequency 120V/60Hz Duty Cycle 20% Duty Cycle Welding Current Range 25-135 Amps RECOMMENDED INPUT CABLE AND FUSE SIZES Output Mode Input Voltage RATED 120V/60Hz Height 12.0 in 305 mm If connected to a circuit protected by fuses use Time Delay Fuse marked “D”.

  • Page 9: Identify And Locate Components

    COMPONENTS If you have not already done so, unpack the WELD- PAK 3200HD from its carton and remove all packing material around the WELD-PAK 3200HD. Remove the following loose items from the carton (see Figure A.1): 1. WELD-PAK 3200HD 2. Gun and cable assembly 3.

  • Page 10: Select Suitable Location, Output Connections

    STACKING WELD-PAK 3200HD cannot be stacked. TILTING Each machine must be placed on a secure, level sur- face, either directly or on either recommended cart.

  • Page 11

    FIGURE A.4 GUN INSTALLATION As shipped from the factory, the WELD-PAK 3200HD is ready to feed .023”-.025" (0.6 mm) solid wire. If .030 (0.8mm) solid wire. If .030" (0.8 mm) solid wire is to be used, change the contact tip to the appropriate size.

  • Page 12

    Connect the other end to the WELD-PAK 3200HD 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, Code Requirements

    The rated output with this installation is 90 amps,19 Volts, 20% duty cycle (2 minutes of every 10 minutes used for welding). POWER INPUT Do not connect the WELD-PAK 3200HD to an input CABLE power supply with a rated voltage that is greater than 125 volts.

  • Page 14: Undercarriage Assembly

    Weld-Pak 3200HD. • If the Weld-Pak 3200HD is going to be transport- ed, remove the under-carriage. • Do not lift the Weld-Pak 3200HD when a gas bot- tle is connected. • If the Weld-Pak 3200HD is going to be moved or lifted, remove the gas bottle.

  • Page 15

    .030” (0.8 mm) solid steel electrode and .035” (0.9 mm) Innershield ® NR-211-MP flux-cored wire. The WELD-PAK 3200HD is ideally suited for individu- als having access to 120 volt AC input power, and wanting the ease of use, quality and dependability of...

  • Page 16

    Accommodates both 4” (100 mm) diameter and 8” (200 mm) diameter spools of wire. WELDING CAPABILITY The WELD-PAK 3200HD is rated at 90 amps, 19 volts, at 20% duty cycle on a ten minute basis. It is capable of higher output currents at lower duty cycles.

  • Page 17

    Wire Spindle Shaft WELD-PAK 3200HD FIGURE B.2 8” Wire Spool To Wire Drive FIGURE B.3 4"...

  • Page 18

    FIGURE B.4 7. Refer to Figure B.5. Remove gas nozzle and con- tact tip from end of gun. 8. Turn the WELD-PAK 3200HD ON (“I”). 9. Straighten the gun cable assembly. 10. Depress the gun trigger switch and feed welding wire through the gun and cable.

  • Page 19: Safety Precautions

    PROCESS GUIDELINES The WELD-PAK 3200HD can be used for welding mild steel using the GMAW, single pass, process which requires a supply of shielding gas or it can be used for the self-shielded, Innershield ®...

  • Page 20

    The WELD-PAK 3200HD is suitable for .035" alu- minum wire and .030" stainless wire. Refer to Table B.1 for recommended procedure settings (requires K499 Argon Regulator Kit). TABLE B.1 Shielding Process Welding Wire 16 ga 14 ga 12 ga 10 ga MIG DC+ .035 Dia...

  • Page 21

    Electronic Components Cored Wire Protective Slag Weld Metal Bearings WELD-PAK 3200HD 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 22

    By gaining knowledge of the differences between the two processes, you will be able to select the best process for the job you have at hand. In selecting a process, you should consider: WELD-PAK 3200HD Gas nozzle Shielding gas Weld metal...

  • Page 23: Welding Capability, Learning To Weld

    This is referred to as the “pull technique”. On thin gauge sheet metal, use the “push technique”. See “Welding Techniques for GMAW (MIG) Process”. WELD-PAK 3200HD Lap weld Fillet weld Corner weld FIGURE B.11...

  • Page 24

    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. WELD-PAK 3200HD B-10 45° FIGURE B.15 WARNING...

  • Page 25

    (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. WELD-PAK 3200HD B-11...

  • Page 26

    (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 WELD-PAK 3200HD B-12 3/8 – 1/2” (10 – 12 mm) Electrical Stickout (ESO) FIGURE B.19 Molten puddle FIGURE B.20...

  • Page 27

    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 WELD-PAK 3200HD, use the following: Mild Steel Electrode Voltage Setting “V” Wire Feed Speed “o|o” Refer to Figure B.22.

  • Page 28

    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. WELD-PAK 3200HD B-14 FIGURE B.23 WARNING ARC RAYS can burn eyes and skin.

  • Page 29

    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 WELD-PAK 3200HD, use the following: Mild Steel Electrode Voltage Setting “V” Wire Feed Speed “o|o”...

  • Page 30

    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. WELD-PAK 3200HD B-16...

  • Page 31

    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 WELD-PAK 3200HD B-17...

  • Page 32: Application Chart

    B-18 B-18 APPLICATION CHART WELD-PAK 3200HD...

  • Page 33: Optional Accessories

    Handle height is easily adjustable. Bottom tray provided for tools and accessories. Easy assembly required; takes less than 15 minutes. 4. K586-1 Deluxe Adjustable Gas Regulator & Hose Kit Accommodates CO 2 or mixed Gas Cylinders. WELD-PAK 3200HD...

  • Page 34: Replacement Parts

    Gas Nozzle M16294 Gas Nozzle-Tip Recessed 3/8” (9.5 mm) Opening I.D. M16684 Gas Nozzle-Tip Recessed 1/2” (12.7 mm) Opening I.D. M16684-1 Gas Nozzle-Tip Recessed 5/8” (15.9 mm) Opening I.D. M16684-2 Spot Welding Nozzle M17846 Gasless Nozzle (Innershield Only) M16418 WELD-PAK 3200HD...

  • Page 35: Routine Maintenance, Safety Precautions

    WARNING ELECTRIC SHOCK can kill. • Disconnect input power by removing plug from receptacle before working inside WELD-PAK 3200HD. Use only grounded receptacle. Do not touch elec- trically “hot” parts inside WELD-PAK 3200HD. • Have qualified personnel do the mainte- nance and trouble shooting work.

  • Page 36: Gun And Cable Maintenance

    CONFIGURATION OF COMPONENTS IN WIRE FEEDING SYSTEM Components shipped with WELD-PAK 3200HD• K664-2 .035 (0.9mm) Aluminum or Stainless Kit* • F0r 0.025 wire feeding use the included S19726-1 contact tip.

  • Page 37: Component Replacement Procedures

    Make certain the set screw is located on the flat portion of the shaft and tighten. WELD-PAK 3200HD FIGURE D.1...

  • Page 38: Changing Liner, Gun Handle Parts

    See Figure D-3. WELD-PAK 3200HD Counter-clockwise FIGURE D.3...

  • Page 39: How To Use Troubleshooting Guide

    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 40

    2. Check for obstructions in air flow. Check Gun Trigger connec- tions. See Installation section. 3. Gun trigger may be faulty. CAUTION WELD-PAK 3200HD RECOMMENDED COURSE OF ACTION If all recommended possible areas of misadjustment have been checked and the problem persists,...

  • Page 41

    1. Check gas supply, flow regulator and gas hoses. 2. Check gun connection to machine for obstruction or leaky seals. CAUTION WELD-PAK 3200HD RECOMMENDED COURSE OF ACTION If all recommended possible areas of misadjustment have been checked and the problem persists,...

  • Page 42

    6. Check gun for damage or breaks. 7. Check for proper drive roll orien- tation and alignment. 8. Check liner for proper size. CAUTION WELD-PAK 3200HD RECOMMENDED COURSE OF ACTION If all recommended possible areas of misadjustment have been checked and the problem persists,...

  • Page 43

    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. WELD-PAK 3200HD...

  • Page 44

    NOTES WELD-PAK 3200HD...

  • Page 45

    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 46

    ● WARNING ● Spanish ● AVISO DE PRECAUCION ● French ● ATTENTION ● ● German WARNUNG ● Portuguese ● ATENÇÃO ● Japanese Chinese Korean Arabic ● ● ● ● ● ● ● ● ● ●...

  • Page 47

    ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● Spanish ● PRECAUCION French ● ATTENTION ● German WARNUNG Portuguese ● ● Japanese Chinese Korean Arabic WARNING AVISO DE ATENÇÃO...

  • Page 48

    • 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...

Comments to this Manuals

Symbols: 0

Latest comments:

×

Select the desired size and copy embed code

Copy your embed code and put on your site: