Lincoln Electric IM546 manual 2INSTALLATION, Safety Precautions, Identify and Locate Components

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A-2INSTALLATION

Read entire installation section before starting	FIGURE A.1
installation.

SAFETY PRECAUTIONS

WARNING

ELECTRIC SHOCK can kill.

1	2

• Only qualified personnel should perform this installation.

• Only personnel that have read and under- stood the WELD-PAK 100 Operating Manual should install and operate this equipment.

• Machine must be plugged into a receptacle which is grounded per any national, local or other applicable electrical codes.

• The WELD-PAK 100 power switch is to be
in the OFF (“O”) position when installing
work cable and gun and when connecting	4
power cord to input power.	4

3

IDENTIFY AND LOCATE

COMPONENTS

If you have not already done so, unpack the Weld-Pak 100 from its carton and remove all packing material around the WELD-PAK 100. Remove the following loose items from the carton (see Figure A.1):

1.WELD-PAK 100

2.Gun and cable assembly(1)

3.Literature and miscellaneous including:

a)This operating manual

b)10 extra .035" contact tips

c)Hex key wrench for removal of drive roll.

4.10 ft (3,0 m) work cable.

5.Work clamp.

6.Sample 10 lb. spool of Innershield .035" (0,9 mm) NR-211-MP electrode.

7.Handshield with filter plate and lens.

8.Instructional video.

9.8” Spool Adapter (2” Spindle) for mounting 10 lb. Spools

10.Chipping hammer/wire brush

For available options and accessories refer to the Accessories Section of this manual.

(1)The gun is ready to feed 0.035" (0,9 mm) Innershield wire.

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WELD-PAK 100 JAN96

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Contents Safety Depends on You WELD-PAK 100 PlusSafety ARC Welding can be hazardousCylinder may explode if damaged Electric and Magnetic Fields IiiPrécautions DE Sûreté Sûreté Pour Soudage a LʼArcPlease Examine Carton and Equipment For Damage Immediately Master Table of Contents for ALL Sections Vii INSTALLATIONA-1 Technical Specifications WELD-PAKSafety Precautions 2INSTALLATIONIdentify and Locate Components Output Connections INSTALLATIONA-3Select Suitable Location StackingWork Cable Installation 4INSTALLATIONGUN Installation Connecting Gun Cable to the WELD-PAKINSTALLATIONA-5 Figure A.5Requirements For Rated Output 6INSTALLATIONInput Connections Code Requirements for Input ConnectionsFumes and Gases can be dangerous Observe all safety information throughout this manualOPERATIONB-1 Welding Sparks can cause fire or explosion2OPERATION Welding Operations Wire LoadingOPERATIONB-3 Sequence of OperationWire Threading Friction Brake Adjustment4OPERATION Process Guidelines Cleaning Tip And NozzleOPERATIONB-5 Making a WeldWelding with Gmaw MIG Changing Machine Over to Feed Other Wire Sizes6OPERATION Overload ProtectionARC-WELDING Circuit Learning to WeldLearning to Weld SELF-SHIELDED Fcaw Welding ARCProcess Selection Gmaw MIG Welding ARCFor Gmaw MIG Process Welding Techniques for the SELF- Shielded Fcaw Process Machine SET UP for the SELF-SHIELDED Fcaw ProcessCommon Metals For Fcaw Innershield ProcessCorrect Electrical Stickout ESO Correct Welding SpeedPractice Electrode Voltage Setting Wire Feed Speed ooHelpful Hints Back-SteppingMachine SET UP for the Gmaw MIG Process Welding Techniques for the Gmaw MIG ProcessMild Steel Voltage Setting Wire Feed Speed ooElectrode Butt Welds Joint Types and PositionsPenetration Fillet WeldsWelding In The Vertical Position Vertical-down WeldingTo Correct Poor Penetration in order of impor- tance Troubleshooting WeldsTo Eliminate a Ropy Convex Bead in order of importance To Eliminate Stubbing* in order of importanceProper Gun Handling Application Chart Optional Accessories ACCESSORIESC-1MIG Conversion 2NOTES Maintenance Safety Precautions MAINTENANCED-1Routine Maintenance Component Replacement Procedures 2MAINTENANCEGUN and Cable Maintenance For Magnum 100L GUNMAINTENANCED-3 Changing Drive RollChanging Liner 4MAINTENANCELiner trim length MAINTENANCED-5 GUN Handle Parts6NOTES TROUBLESHOOTINGE-1 HOW to USE Troubleshooting GuideProblems Possible Areas Symptoms Misadjustments 2TROUBLESHOOTINGTroubleshooting Guide Recommended Course of ActionTROUBLESHOOTINGE-3 Feeding Problems4TROUBLESHOOTING Welding ProblemsWeldpak 100 Wiring Diagram Wiring Diagrams100 2NOTES WELD-PAK PartsMain Exploded Diagram 2PARTSDescription Reqʼd Complete Drive ASSEMBLY/MOTOR 4PARTSCase Front Assembly PARTS5RECTIFIER, FAN and Bracket Assembly 6PARTSCenter Panel Assembly PARTS7Magnum 100L Assembly 8PARTSSquare Wave TIG Square Wave TIG Need Welding Training? How To Read Shop DrawingsNew Lessons in Arc Welding $700.00Precaucion Guards off Superseded