Lincoln Electric PRO 100 Operator's Manual
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Lincoln Electric PRO 100 Operator's Manual

Lincoln Electric PRO 100 Operator's Manual

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This manual covers equipment which is no
longer in production by The Lincoln Electric Co.
Speci cations and availability of optional
features may have changed.
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
PRO 100
For use with machine Code Number
OPERATOR'S MANUAL
• World's Leader in Welding and Cutting Products •
10970
Copyright © 2004 Lincoln Global Inc.
IM784
April, 2004

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  • Page 1 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...

  • Page 2: California Proposition 65 Warnings

    SAFETY WARNING CALIFORNIA PROPOSITION 65 WARNINGS Diesel engine exhaust and some of its constituents The engine exhaust from this product contains are known to the State of California to cause can- chemicals known to the State of California to cause cer, birth defects, and other reproductive harm.

  • Page 3: Electric Shock Can Kill

    SAFETY ARC RAYS can burn. ELECTRIC SHOCK can 4.a. Use a shield with the proper filter and cover kill. plates to protect your eyes from sparks and 3.a. The electrode and work (or ground) circuits the rays of the arc when welding or observing are electrically “hot”...
  • Page 4 SAFETY WELDING SPARKS can CYLINDER may explode cause fire or explosion. if damaged. 6.a. Remove fire hazards from the welding area. 7.a. Use only compressed gas cylinders If this is not possible, cover them to prevent containing the correct shielding gas for the the welding sparks from starting a fire.
  • Page 5 SAFETY zones où l’on pique le laitier. PRÉCAUTIONS DE SÛRETÉ 6. Eloigner les matériaux inflammables ou les recouvrir afin de Pour votre propre protection lire et observer toutes les instructions prévenir tout risque d’incendie dû aux étincelles. et les précautions de sûreté specifiques qui parraissent dans ce manuel aussi bien que les précautions de sûreté...
  • Page 6 for selecting a QUALITY product by Lincoln Electric. We want you Thank You to take pride in operating this Lincoln Electric Company product ••• as much pride as we have in bringing this product to you! Please Examine Carton and Equipment For Damage Immediately When this equipment is shipped, title passes to the purchaser upon receipt by the carrier.

  • Page 7: Table Of Contents

    Configuration of Components in Wire Feeding System.........D-2 Component Replacement Procedures ..............D-3 Troubleshooting ....................Section E Safety Precautions....................E-1 How to Use Troubleshooting Guide...............E-1 Troubleshooting Guide................E-2 thru E-4 Wiring Diagrams ....................Section F PRO 100 Wiring Diagram ..................F-1 PRO 100 Parts Manual..............P464 Series & P202-E...

  • Page 8: Installation

    INSTALLATION TECHNICAL SPECIFICATIONS – PRO 100 INPUT – SINGLE PHASE ONLY Standard Voltage/Frequency Input Current 115V/60Hz 20 Amps - Rated Output 115V/60Hz 15 Amps - CSA Rated output RATED OUTPUT Duty Cycle Current Voltage 20% Duty Cycle 88Amps 20% Duty Cycle – CSA Rated Output...

  • Page 9: Identify And Locate Components

    • Machine must be plugged into a receptacle which is grounded per any national, local or other applicable electrical codes. • The PRO 100 power switch is to be in the OFF (“O”) position when installing work cable and gun and when connecting power cord to input power.

  • Page 10: Select Suitable Location

    1. Unplug the machine or turn the power switch to the STACKING “OFF” position. PRO 100’s cannot be stacked. 2. Insert the work cable terminal lug with the larger hole through the strain relief hole in the work clamp as shown in Figure A-3.

  • Page 11: Gun Installation

    GUN INSTALLATION obtained. For more information about the K610-1 MIG Conversion Kit for use with the PRO 100, refer to the ACCESSORIES section. As shipped from the factory, the PRO 100 gun is ready to feed 0.035”...
  • Page 12 Con- nect the other end to the PRO 100 Gas Solenoid 1. Chain the cylinder to a wall or other stationary sup- Inlet Fitting (5/8-18 female threads —...

  • Page 13: Input Connections

    Requirements For CSA Rated Output Refer to Figure A.6. A line cord with a 15 amp, 125 volt, three-prong plug The PRO 100 has a power input cable located on the (NEMA Type 5-15P) is factory installed. Connect this rear of the machine.

  • Page 14: Operation

    OPERATION Read entire operation section before operating the PRO 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.

  • Page 15: General Description

    WELDING CAPABILITY The PRO 100 is ideally suited for individuals having The PRO 100 is rated at 88 amps, 18 volts, at 20% access to 115 volt AC input power, and wanting the duty cycle on a ten minute basis. CSA rated output at ease of use, quality and dependability of both the 62 amps at 20 volts at 20% duty cycle.

  • Page 16: Welding Operations

    Wire Spindle Shaft 4" Wire Spool DO NOT SWITCH WHEN WELDING Wing Nut PRO 100 and Spacer To wire drive FIGURE B.2 To use 8" (200 mm) diameter spools, the 2" (51 mm) diameter M15445 spindle must be used. Remove the spacer and wing nut at the end of the shaft.
  • Page 17 13. Refer to Figure B-6. Cut the wire off 3/8” – 1/2” (10 pressure arm (2) in place. Rotate the spool coun- – 13 mm) from the end of the tip. The PRO 100 is terclockwise if required in order to take up extra now ready to weld.
  • Page 18 PRO 100. the PRO 100 controls. Refer to Table B.1 for alu- minum and stainless wire. Cleaning Tip And Nozzle Clean the contact tip and nozzle to avoid arc bridging 3.

  • Page 19: Overload Protection

    Thermal Protection the PRO 100 with other sizes and types of wire, it The PRO 100 has a rated output duty cycle of 20%. If maybe necessary to change the contact tip and drive the duty cycle is exceeded, a thermal protector will roll orientation.

  • Page 20: Application Chart

    APPLICATION CHART PRO 100...

  • Page 21: Accessories

    MIG (GMAW) process. The K610-1 mounting a single gas cylinder. Has front casters MIG Conversion Kit for the PRO 100 includes all the and large rear wheels. Handle height is easily necessary accessories for this conversion and is pro- adjustable.

  • Page 22: 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. NO maintenance is required.

  • Page 23: Gun And Cable Maintenance

    CONFIGURATION OF COMPONENTS IN WIRE FEEDING SYSTEM Contact Tip Cable Liner Drive Roll Components shipped with KP2039-3B1 KP1937-3 M16190 PRO 100 .035” (0.9mm) .025 - .035 Large Knurled, Small Smooth groove (0.6 - 0.9mm) Small .023-.025 (0.6mm) Large .030/.035” (0.8/0.9mm) K610-1 .023/.025” (0.6mm)

  • Page 24: Component Replacement Procedures

    6. Loosen the drive roll set screw with the 5/64" (2.0 mm) hex wrench supplied. 7. Remove the drive roll, flip over and reinstall with the .023 – .025" (0.6 mm) groove (the smaller groove) closest to the gearbox. PRO 100...
  • Page 25 Figure D.2. Remove any burrs from the end of the liner. 8. Screw the gas diffuser onto the end of the gun tube and securely tighten. 9. Replace the contact tip and nozzle. PRO 100...
  • Page 26 See Figure D-3. FIGURE D.3 Counter-clockwise PRO 100...

  • Page 27: Troubleshooting

    CAUTION 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. _____________________________________________________________________ PRO 100...

  • Page 28: Troubleshooting Guide

    3. Gun trigger may be faulty. CAUTION 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. PRO 100...
  • Page 29 CAUTION 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. PRO 100...
  • Page 30 8. Check liner for proper size. CAUTION 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. PRO 100...
  • 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 ● ● ● Do not touch electrically live parts or Keep flammable materials away. Wear eye, ear and body protection. WARNING electrode with skin or wet clothing. ● Insulate yourself from work and ground. Spanish ● ● ● No toque las partes o los electrodos Mantenga el material combustible Protéjase los ojos, los oídos y el AVISO DE...
  • Page 34 ● ● ● Keep your head out of fumes. Turn power off before servicing. Do not operate with panel open or ● Use ventilation or exhaust to guards off. WARNING remove fumes from breathing zone. ● Spanish Los humos fuera de la zona de res- ●...
  • 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...

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