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

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.