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Lincoln Electric MIG PAK HD IM822 Operator's Manual

Lincoln electric welding system user manual
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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:
• 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
MIG PAK HD
For use with machine Code Number:11062
THIS
OPERATOR'S MANUAL
• World's Leader in Welding and Cutting Products •
Copyright © 2003 Lincoln Global Inc.
IM822
February, 2003

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Summary of Contents for Lincoln Electric MIG PAK HD IM822

  • Page 1 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...

  • Page 2: California Proposition 65 Warnings

    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

    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 Stacking ...A-3 Changing Polarity ...A-3 Gun Installation...A-3 Input Connections...A-3 Gas Connections ...A-3 Shielding Gas Connections ...A-4 Code Requirements ...A-4 ________________________________________________________________________ Operation ...Section B Safety Precautions ...B-1...

  • Page 8: Installation

    TECHNICAL SPECIFICATIONS – MIG PAK HD Standard Voltage/Frequency 120V/60Hz Duty Cycle 20% Duty Cycle Welding Current Range DC OUTPUT: 35-88 Amps RECOMMENDED INPUT CABLE AND FUSE SIZES Output Mode Input Voltage RATED 120V/60Hz OUTPUT Height 12.8 in 325 mm If connected to a circuit protected by fuses use Time Delay Fuse marked “D”. INSTALLATION INPUT –...

  • Page 9: 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 Machine Operating Manual should install and operate this equipment. •...

  • Page 10: Select Suitable Location

    SELECT SUITABLE LOCATION Place the machine on a secure, level surface or rec- ommended undercarriage. The machine may topple over if this procedure is not followed. To minimize over heating, locate the welder in a dry location where there is free circulation of clean air. Do not place on com- bustible surfaces.

  • Page 11: Shielding Gas Connections

    SHIELDING GAS CONNECTION (FIGURE A.5) REGULATOR CYLINDER VALVE HOSE GAS CYLINDER Refer to Figure A.5. 1. Chain the cylinder to a wall or other stationary sup- port to prevent the cylinder from falling over. Insulate the cylinder from the work circuit work ground.

  • Page 12: Operation

    Read entire operation section before operating the machine. 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. FUMES AND GASES can be dangerous.

  • Page 13: Welding Capability

    WELDING CAPABILITY The machine is rated at 70 amps, 17 volts, at 20% duty cycle on a ten minute basis. It is capable of high- er output currents at lower duty cycles. LIMITATIONS The machine is recommended for welding on mild steel up to 1/8”...

  • Page 14: Shielding Gas

    FIGURE B.3 – WIRE THREADING DETAILS SPRING LOADED THUMSCREW IDLER ROLL ARM WIRE FEED LOWER DRIVE ROLL Refer to Figure B.3. 4. Release the spring loaded thumbscrew and rotate the idle roll arm away from the wire feed drive roll. Ensure that the visible, stenciled size on the drive roll side facing you matches the wire size being used.
  • Page 15 2. Select and install the welding wire to match the process. Use Genuine Lincoln Electric Brand wire. Wire quality is essential for successful welding. 3. Install the drive roll, contact tip, and nozzle appro- priate for the weld process.

  • Page 16: Cleaning Tip And Gas Nozzle

    OPERATION CLEANING TIP AND GAS NOZZLE Keep the contact tip and nozzle clean to avoid arc bridging between them. Bridging can result in a short- ed nozzle, poor welds and an overheated gun. Hint: Anti-stick spray or gel, available from a welding suppli- er, may reduce buildup and aid in spatter removal.

  • Page 17: 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 operator to understand welding and develop this skill. THE ARC-WELDING CIRCUIT The operator’s knowledge of arc welding must go beyond the arc itself.
  • Page 18 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 19 For GMAW (MIG) Process 1. Is most of my welding performed on 16 gauge and lighter materials? 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.
  • Page 20 Penetration Unless a weld penetrates close to 100% of the metal thickness, a butt joint will be weaker than the material welded together. In the example shown in Figure B.11, the total weld is only half the thickness of the material thus the weld is only approximately half as strong as the metal.
  • Page 21 B-10 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 B.14 Vertical-down Welding Refer to Figure B.15 Vertical-down welds are applied at a fast pace. These welds are therefore shallow and narrow and, as such, are excellent for sheet metal.
  • Page 22 B-11 FIGURE B.16 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.
  • Page 23 B-12 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 24 B-13 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 25 B-14 Contact Tip Wire Electrode FIGURE B.22 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.22. Once the arc has been established, maintaining the correct ESO becomes extremely important.

  • Page 26: Troubleshooting Welds

    B-15 TROUBLESHOOTING WELDS Good welds have excellent appearance. To Eliminate Porosity (In order of priority): 1. Check or reset WFS & Volts on chart inside door. 2. Clean joints from moisture, paint, rust etc. 3. Increase stickout. 4. Decrease drag angle. 5.
  • Page 27 B-16 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.

  • Page 28: Accessories

    ACCESSORIES INNERSHIELD WELDING WIRE NR-211-MP Innershield welding wire - .035” (0.9 mm) diameter flux-cored electrode. MIG WELDING WIRE Lincoln L56- .025” (0.6mm) diameter solid steel elec- trode) CONSUMABLE PARTS The following items are commonly consumed over the life of the welder and may need to be ordered. See the complete parts list at the end of this manual for machine replacement parts.

  • Page 29: Maintenance

    MAINTENANCE SAFETY PRECAUTIONS ITEMS REQUIRING NO MAINTENANCE • Drive Motor and Gearbox – Lifetime lubrication • Wire Reel Spindle – Do NOT lubricate shaft ROUTINE AND PERIODIC MAINTENANCE BEFORE EACH USE • Check over machine and accessories for any obvious condi- tion that may prevent safe performance or operation.

  • Page 30: Cleaning The Gun Liner

    CLEANING THE GUN LINER • Unplug the machine or turn the power switch to the OFF - “0” position. • Remove the gas nozzle and contact tip from the gun. • Clean the inside diameter with a short piece of wire. •...

  • Page 31: Gun Assembly Removal

    3. Remove the Thumbscrew holding the drive roll. 4. Replace the drive roll so that the desired size, sten- ciled on the side of the drive roll, is toward the inside and visible. 5. Replace the Thumbscrew and tighten. GUN ASSEMBLY REMOVAL 1.

  • Page 32: 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 33 Observe all Safety Guidelines detailed throughout this manual PROBLEMS (SYMPTOMS) Major physical or electrical damage is evident. No wire feed, weld output or gas flow when gun trigger is pulled. No weld output when gun trigger is pulled. If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed.
  • Page 34 Observe all Safety Guidelines detailed throughout this manual PROBLEMS (SYMPTOMS) No wire feed when gun trigger is pulled. If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed. TROUBLESHOOTING POSSIBLE AREAS OF MISADJUSTMENT(S)
  • Page 35 Observe all Safety Guidelines detailed throughout this manual PROBLEMS (SYMPTOMS) Bead is too thin (intermittently). Bead is too thick (intermittently). Bead does not penetrate base metal. Wire sputters and sticks to work- piece. Edge of weld has ragged depres- sions. If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed.
  • Page 36 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. DIAGRAMS MIG PAK HD...
  • Page 37 ● WARNING ● Spanish ● AVISO DE PRECAUCION ● French ● ATTENTION ● ● German WARNUNG ● Portuguese ● ATENÇÃO ● Japanese Chinese Korean Arabic ● ● ● ● ● ● ● ● ● ●...
  • Page 38 ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● Spanish ● PRECAUCION French ● ATTENTION ● German WARNUNG Portuguese ● ● Japanese Chinese Korean Arabic WARNING AVISO DE ATENÇÃO...
  • Page 39 • 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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