Work Cable Installation

Refer to Figure A.2.
1. Open the wire feed section door on the right side of
the WELD-PAK 3200HD.
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.4. As
delivered, The machine is connected for negative
polarity (required for the Innershield process), con-
nect the short cable attached to the connector
block (1) to the negative (–) output terminal (2) and
the work cable (3) to the positive (+) terminal (4).
5. For GMAW Only: Refer to Figure A..2. To wire for
positive electrode polarity. the appropriate configu-
ration for the GMAW (MIG) process use the provid-
ed wing nut to connect the work cable’s terminal
lug to the negative (–) output terminal (5) located
above the Wire Feed Gearbox (6). Make sure that
both wing nuts are tight.

A-4

INSTALLATION
WELD-PAK 3200HD

A-4

Connecting Gun Cable to the WELD-PAK
3200HD.
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 3200H case front. Make sure the con-
nector 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 below 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.
If the gun trigger switch being used is other than
that supplied with the WELD-PAK 3200HD, the
switch must be a normally open, momentary
switch. The terminals of the switch must be insu-
lated from the welding circuit. Malfunction of the
WELD-PAK 3200HD may result if this switch
shorts to the WELD-PAK 3200HD welding output
circuit or is common to any electrical circuit other
than the WELD-PAK 3200HD trigger circuit.
GAS CONNECTION
When using the GMAW process, a cylinder of shield-
ing gas, must be obtained. For more information about
selecting gas cylinders for use with the WELD-PAK
3200HD refer to the ACCESSORIES section.
2
43
1
FIGURE A.4
GUN INSTALLATION
As shipped from the factory, the WELD-PAK 3200HD
is ready to feed .023”-.025" (0.6 mm) solid wire. If
.030 (0.8mm) solid wire. If .030" (0.8 mm) solid wire is
to be used, change the contact tip to the appropriate
size.
NOTE: If .035" (0.9 mm) Innershield flux-cored wire is
to be used, assemble the mig nozzle and .035” tip on
to gun and reverse drive roll.
CAUTION