Lincoln Electric IM546 manual 6OPERATION, Changing Machine Over to Feed Other Wire Sizes

B-6OPERATION

thinner, CO2 gas is recommended because it gives equal or better performance than a blended gas at a lower cost. A mixed gas consisting of 75 to 80% Argon and 20 to 25% CO2 is recommended for welding on heavier gauge [12 gauge (2,5 mm) for example] steel.

The WELD-PAK 100 is suitable for .035" aluminum wire and .030" stainless wire. Refer to Table B.1 for recommended procedure settings.

		Shielding	Voltage/Wire Speed
Process	Welding Wire	Gas	16 ga	14 ga	12 ga	10 ga
MIG DC+	.035 Dia	100% Argon	B-5	D-7	D-9	D-9
	4043 Aluminum
	Wire
MIG DC+	.035 Dia	100% Argon	B-5	C-7	D-9	D-10
	5356 Aluminum
	Wire
MIG DC+	.030 Dia	98% Argon/	A-3	C-6	D-7.5	D-7.5
	308L Stainless	2% Oxygen
	Steel Wire

TABLE B.1

CHANGING MACHINE OVER TO FEED OTHER WIRE SIZES

The WELD-PAK 100 is shipped from the factory ready to feed 0.035” (0,9 mm) diameter wire. To operate the WELD-PAK 100 with other sizes of wire, it is neces- sary to change the contact tip and change the drive roll over to other sizes. Refer to Changing the Contact Tip and Changing the Drive Roll, in the MAINTE- NANCE section, for specific information on these pro- cedures.

WELDING WITH GMAW (MIG)

Shielding Gas

When using the GMAW process, obtain and install the K610-1 MIG Conversion Kit and a cylinder of carbon dioxide (CO2) or argon-carbon dioxide mixed shielding gas. Refer to the ACCESSORIES section for more information about installing the K610-1 Kit for use with the WELD-PAK 100.

1.For CO2, open the cylinder very slowly. For argon- mixed gas, open cylinder valve slowly a fraction of a turn. When the cylinder pressure gauge pointer

WELD-PAK 100

stops moving, open the valve fully.

2.If using a regulator with an adjustable flow meter, close the gun trigger and adjust the flow to give 15

–20 cubic ft per hour (CFH) (7 – 10 I/min) [use 20

–25 CFH (10 – 12 I/min) when welding out of

position or in a drafty location for CO2]. For argon mixed gas, trigger to release gas pressure, and turn off the adjust the flow to give 25 – 30 CFH (12 – 14 I/min).

3.Keep the cylinder valve closed, except when using the WELD-PAK 100. When finished welding:

a) Close the cylinder valve to stop gas flow.

b) Depress the gun trigger briefly to release the pressure in the gas hose.

c) Turn off the WELD-PAK 100.

OVERLOAD PROTECTION

Output Overload

The WELD-PAK 100 is equipped with a circuit breaker and a thermostat which protects the machine from damage if maximum output is exceeded. The circuit breaker button will extend out when tripped. The cir- cuit breaker must be manually reset.

Thermal Protection

The WELD-PAK 100 has a rated output duty cycle of 20%. If the duty cycle is exceeded, a thermal protector will shut off the output until the machine cools to a rea- sonable operating temperature. This is an automatic function of the WELD-PAK 100 and does not require user intervention. The fan continues to run during cooling.

Electronic Wire Drive Motor Protection

The WELD-PAK 100 has built-in protection for wire drive motor overload.