Lincoln Electric IM546 manual 4INSTALLATION, GUN Installation, GAS Connection Optional

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A-4INSTALLATION

Work Cable Installation

Refer to Figure A.2.

1.Open the wire feed section door on the right side of the WELD-PAK 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 WELD-PAK 100 is connected for negative electrode polarity. This is the appropriate configuration for the Innershield process. To com- plete installation, use the provided wing nut to con- nect the work cableʼs terminal lug to the positive (+) output terminal (5) located above the Wire Feed Gearbox (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

4

3

2

1

appropriate size. Additionally, the .023 – .030" (0.6 –

0.8mm) gun liner included in the K610-1 MIG Conversion Kit must be installed. Refer to the MAIN- TENANCE section for contact tip installation details.

Connecting Gun Cable to the WELD-PAK 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 WELD-PAK 100 case front. Make sure the connec- tor 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 connector so control leads are on the under- side and tighten the Thumbscrew (8) in the con- nector 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.

CAUTION

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

GUN INSTALLATION

As shipped from the factory, the WELD-PAK 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, change the contact tip to the

WELD-PAK 100

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 WELD-PAK 100, refer to the ACCESSORIES section.

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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-PAK2INSTALLATION Safety PrecautionsIdentify and Locate Components INSTALLATIONA-3 Select Suitable LocationOutput Connections Stacking4INSTALLATION GUN InstallationWork Cable Installation Connecting Gun Cable to the WELD-PAKINSTALLATIONA-5 Figure A.56INSTALLATION Input ConnectionsRequirements For Rated Output Code Requirements for Input ConnectionsObserve all safety information throughout this manual OPERATIONB-1Fumes and Gases can be dangerous Welding Sparks can cause fire or explosion2OPERATION Wire Loading OPERATIONB-3Welding Operations Sequence of OperationFriction Brake Adjustment Wire Threading4OPERATION Cleaning Tip And Nozzle OPERATIONB-5Process Guidelines Making a WeldChanging Machine Over to Feed Other Wire Sizes 6OPERATIONWelding with Gmaw MIG Overload ProtectionLearning to Weld Learning to WeldARC-WELDING Circuit SELF-SHIELDED Fcaw Welding ARCGmaw MIG Welding ARC Process SelectionFor Gmaw MIG Process Machine SET UP for the SELF-SHIELDED Fcaw Process Common MetalsWelding Techniques for the SELF- Shielded Fcaw Process For Fcaw Innershield ProcessCorrect Electrical Stickout ESO Correct Welding SpeedElectrode Voltage Setting Wire Feed Speed oo Helpful HintsPractice Back-SteppingMachine SET UP for the Gmaw MIG Process Welding Techniques for the Gmaw MIG ProcessVoltage Setting Wire Feed Speed oo Mild SteelElectrode Joint Types and Positions PenetrationButt Welds Fillet WeldsWelding In The Vertical Position Vertical-down WeldingTroubleshooting Welds To Eliminate a Ropy Convex Bead in order of importanceTo Correct Poor Penetration in order of impor- tance To Eliminate Stubbing* in order of importanceProper Gun Handling Application Chart ACCESSORIESC-1 Optional AccessoriesMIG Conversion 2NOTES MAINTENANCED-1 Maintenance Safety PrecautionsRoutine Maintenance 2MAINTENANCE GUN and Cable MaintenanceComponent Replacement Procedures For Magnum 100L GUNMAINTENANCED-3 Changing Drive Roll4MAINTENANCE Changing LinerLiner trim length MAINTENANCED-5 GUN Handle Parts6NOTES TROUBLESHOOTINGE-1 HOW to USE Troubleshooting Guide2TROUBLESHOOTING Troubleshooting GuideProblems Possible Areas Symptoms Misadjustments Recommended Course of ActionTROUBLESHOOTINGE-3 Feeding Problems4TROUBLESHOOTING Welding ProblemsWiring Diagrams Weldpak 100 Wiring Diagram100 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 How To Read Shop Drawings New Lessons in Arc WeldingNeed Welding Training? $700.00Precaucion Guards off Superseded
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