Lincoln Electric PRO 100 manual GUN Installation, GAS Connection Optional, Work Cable Installation

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A-4

INSTALLATION

A-4

 

 

 

Work Cable Installation

Refer to Figure A.2.

1.Open the wire feed section door on the right side of the PRO 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.

3.Route the cable under and around the back of the Wire Feed Gearbox (6).

4.For Innershield Only: Refer to Figure A.2. As delivered, the PRO 100 is connected for negative electrode polarity. This is the appropriate configu- ration for the Innershield process. To complete installation, use the provided wing nut to connect the work cable’s terminal lug to the positive (+) out- put terminal (5) located above the Wire Feed Gear- box (6). Make sure that both wing nuts are tight.

5.For GMAW Only: Refer to Figure A.4. To wire for positive polarity (required for the MIG process), connect the short cable attached to the connector block (1) to the positive (+) output terminal (4) and the work cable (3) to the negative (–) terminal (2).

FIGURE A.4

and installation details.

Connecting Gun Cable to the PRO 100

1.Refer to Figure A.2. Unplug the machine or turn power switch to the OFF “O” position.

2.Pass the insulated terminals of the gun trigger con- trol leads, one at a time, through the Gun Cable and Control Lead Access Slot (2) in the case front. The leads are to be routed under the Wire Feed Gearbox (6) and through the Cable Hanger (7) on the inner panel.

3.Insert the connector on the gun conductor cable through the Gun Cable Access Hole (2) in the PRO 100 case front. Make sure the connector is all the way in the brass connector block. Unscrew thumbscrew on the connector block a few turns if gun connector will not insert fully. Rotate the con- nector so control leads are on the underside and tighten the Thumbscrew (8) in the connector block.

4.Connect the gun trigger control lead terminals to the two insulated 1/4" (6,4 mm) tab terminal con- nector bushings located above the “Gun Trigger Connection” decal in the wire feed section (4). Either lead can go to either connector. Form the leads so that they are as close as possible to the inside panel.

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3

2

1

GUN INSTALLATION

As shipped from the factory, the PRO 100 gun is ready to feed 0.035” (0,9 mm) wire. If .023" – .025" (0,6 mm) or .030" (0.8 mm) wire is to be used for the GMAW (MIG) process, see the MAINTENANCE sec- tion for proper configuration of feeding components

CAUTION

If the gun trigger switch being used is other than that supplied with the PRO 100, the switch must be a normally open, momentary switch. The termi- nals of the switch must be insulated from the welding circuit. Malfunction of the PRO 100 may result if this switch shorts to the PRO 100 welding output circuit or is common to any electrical cir- cuit other than the PRO 100 trigger circuit.

GAS CONNECTION (OPTIONAL)

When using the GMAW process, a K610-1 MIG con- version kit and a cylinder of carbon dioxide (CO2) or argon-carbon dioxide mixed shielding gas must be obtained. For more information about the K610-1 MIG Conversion Kit for use with the PRO 100, refer to the ACCESSORIES section.

PRO 100

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Contents PRO California Proposition 65 Warnings SafetyElectric Shock can kill Iii Welding Sparks can cause fire or explosionSûreté Pour Soudage a L’Arc Précautions DE SûretéPlease Examine Carton and Equipment For Damage Immediately Thank YouTable of Contents Technical Specifications PRO InstallationIdentify and Locate Components Safety PrecautionsRead entire installation section before starting InstallationStacking Work Clamp InstallationSelect Suitable Location Output ConnectionsGAS Connection Optional GUN InstallationWork Cable Installation Connecting Gun Cable to the PROFigure A.5 Requirements For CSA Rated Output Input ConnectionsRequirements For Rated Output Code Requirements for Input ConnectionsWelding Sparks can cause fire or explosion Observe all safety information throughout this manual1OPERATIONB-1 Fumes and Gases can be dangerousOperation Sequence of Operation Wire LoadingWelding Operations Wire Threading Friction Brake AdjustmentsMaking a Weld Cleaning Tip And NozzleProcess Guidelines Overload Protection Changing Machine Over to Feed Other Wire SizesWelding with Gmaw MIG SELF-SHIELDED Fcaw Welding ARC Learning to WeldLearning to Weld ARC-WELDING CircuitFor Gmaw MIG Process Gmaw MIG Welding ARCProcess Selection Butt Welds Common MetalsJoint Types and Positions For Fcaw Innershield ProcessFillet Welds Welding In The Vertical PositionPenetration Correct Welding Position Machine SET UP for the SELF-SHIELDED Fcaw ProcessWelding Techniques for the SELF- Shielded Fcaw Process Vertical-down WeldingCorrect Welding Speed Correct Electrical Stickout ESOPractice Helpful HintsWelding Techniques for the Gmaw MIG Process Machine SET UP for the Gmaw MIG ProcessFor the PRO 100, use the following To Eliminate Stubbing* in order of importance Troubleshooting WeldsTo Eliminate a Ropy Convex Bead in order of importance To Correct Poor Penetration in order of impor- tanceProper Gun Handling Application Chart K610-1 MIG Conversion Kit for the PRO AccessoriesOptional Accessories MIG ConversionRoutine Maintenance MaintenanceMaintenance Safety Precautions Contact Tip Cable Liner Drive Roll GUN and Cable MaintenanceConfiguration of Components in Wire Feeding System For Magnum 100L GUNChanging Drive Roll Component Replacement ProceduresChanging the Contact TIP Liner trim length Changing LinerFigure D.3 GUN Handle PartsHOW to USE Troubleshooting Guide 1TROUBLESHOOTINGE-1Recommended Course of Action TroubleshootingTroubleshooting Guide Problems Possible Areas Symptoms MisadjustmentsFeeding Problems Welding Problems PRO100 Wiring Diagram DiagramsPRO $700.00 How To Read Shop DrawingsNew Lessons in Arc Welding Need Welding Training?Precaucion Warnung

PRO 100 specifications

The Lincoln Electric PRO 100 is a compact and versatile multi-process welder designed to meet the needs of both novice and experienced welders. Known for its robust build quality and advanced features, the PRO 100 is engineered for tasks ranging from light fabrication to heavy-duty welding projects.

One of the standout features of the PRO 100 is its multi-process capability. It can seamlessly switch between MIG, Stick, and TIG welding, allowing users to tackle various materials including aluminum, stainless steel, and mild steel with ease. This versatility makes it an essential tool for welding professionals and hobbyists alike, enhancing productivity and efficiency on the job.

The machine is equipped with Lincoln Electric's unique Auto-Set technology, which simplifies the setup process for users. By automatically adjusting the voltage and wire feed speed based on the selected material and thickness, it enables welders to achieve optimal results without extensive experience or technical knowledge. This feature not only saves time but also reduces the likelihood of mistakes, making it ideal for beginners.

Powering the PRO 100 is a reliable inverter-based technology that ensures smooth and consistent arcs. This technology not only enhances performance but also improves energy efficiency, making the machine more cost-effective in the long run. The compact design allows for portability, making it convenient for job sites where space may be limited.

The PRO 100 also boasts several safety features that protect both the user and the machine. It includes an overload protection system that prevents overheating, ensuring the longevity of the welder. Additionally, the welder features a rugged construction that can withstand demanding work environments, further enhancing its durability.

Furthermore, the PRO 100 is designed for user comfort and control. The intuitive interface and large color display provide clear readability of settings and parameters, allowing for quick adjustments. The adjustable wire feed speed and voltage settings give welders the flexibility to customize their welding experience.

In summary, the Lincoln Electric PRO 100 stands out in the crowd of welding machines for its multi-process capabilities, Auto-Set technology, and inverter-based power system. Its combination of portability, durability, and user-friendly features makes it an excellent choice for a wide range of welding applications, whether at home, in the workshop, or on the field. This well-rounded welder can help elevate the quality of the work for both the novice and the seasoned professional.
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