Lincoln Electric PRO100 IM784 User's Manual
Contents
1. Operates on 115 volt input Cold electrode until gun trigger is pressed for an added measure of safety Overload protection incorporates both a thermo stat and a circuit breaker Quality wire drive with electronic overload protec tion Quick Release idle roll pressure arm is easily adjusted Reversible dual groove drive roll Drive roll will feed 023 025 0 6 mm and 030 and 035 0 8 mm and 0 9 mm diameter wire No external shielding gas is required when used with Lincoln Innershield 035 0 9 mm 211 MP electrode Accommodates 4 100 mm diameter spool of wire Will accommodate 8 200 mm diameter with optional spindle WELDING CAPABILITY The PRO 100 is rated at 88 amps 18 volts at 20 duty cycle on a ten minute basis CSA rated output at 62 amps at 20 volts at 20 duty cycle It is capable of higher output currents at lower duty cycles LIMITATIONS Arc Gouging cannot be performed with the PRO 100 The PRO 100 is not recommended for pipe thawing or TIG welding CONTROLS AND SETTINGS Refer to Figure B 1a be exhausted out the louvers in the front of the machine OFF The welding output and wire feeder remain off until the gun trigger is pressed 1 Power ON OFF Switch When the power is on the fan motor will run and air will ON 2 Wire Speed Control Con trols the wire feed speed from 50 300 in min 1 3 7 6 m min The2. Set Screw Brass Cable Connector 3 Remove the gas diffuser from the gun tube by unscrewing counter clockwise 4 Lay the gun and cable out straight on a flat surface Loosen the set screw locat Liner Assembly ed in the brass connector at the wire ee 2 tight feeder end of the cable Pull the liner out of the cable 5 Insert a new untrimmed liner into the connector end of the cable Be sure the liner bushing is stenciled appropriately for the wire size being used 6 Fully seat the liner bushing into the con nector Tighten the set screw on the brass cable connector At this time the gas diffuser should not be installed onto the end of the gun tube 7 With the gas nozzle and diffuser removed from the gun tube be sure the cable is straight and then trim the liner to the length shown in the Figure D 2 Remove any burrs from the end of the liner 8 Screw the gas diffuser onto the end of the gun tube and securely tighten 9 Replace the contact tip and nozzle PRO 100 LINCOLN 8 D 5 MAINTENANCE D 5 GUN HANDLE PARTS The gun handle consists of two halves that are held together with a collar on each end To open up the handle turn the collars approximately 60 degrees counter clockwise until the collar reaches a stop Then pull the collar off the gun handle If the collars are diffi cult to turn position the gun handle against a corner place a screwdriver against the tab on the collar and give the screwdriver
3. WARNING CYLINDER may explode if dam aged Keep cylinder upright and chained to support Keep cylinder away from areas where it may be damaged Never lift welder with cylinder attached e Never allow welding electrode to touch cylinder Keep cylinder away from welding or other live electrical circuits WARNING BUILDUP OF SHIELDING GAS may 2 harm health or kill Shut off shielding gas supply when not in use SEE AMERICAN NATIONAL STANDARD Z 49 1 SAFETY IN WELDING AND CUTTING PUB LISHED BY THE AMERICAN WELDING SOCIETY 1 Chain the cylinder to a wall or other stationary sup port to prevent the cylinder from falling over Insu late the cylinder from the work circuit and earth ground Refer to Figure A 5 FIGURE A 5 Flow Regulator Cylinder Valve Gas Hose x INSTALLATION 2 With the cylinder securely installed remove the cylinder cap Stand to one side away from the out let and open the cylinder valve very slightly for an instant This blows away any dust or dirt which may have accumulated in the valve outlet WARNING BE SURE TO KEEP YOUR FACE AWAY FROM THE VALVE OUTLET WHEN CRACKING THE VALVE Never stand directly in front of or behind the flow regulator when opening the cylinder valve Always stand to one side 3 Attach the flow regulator to the cylinder valve and tighten the union nut securely with a wrench NOTE If connecting to 100 CO cylinder ins
4. cutting or welding They may explode Sparks and spatter are thrown from the welding arc Wear oil free protective garments such as leather gloves heavy shirt cuffless trousers high shoes and a cap over your hair Wear ear plugs when welding out of position or in confined places Always wear safety glasses with side shields when in a welding area Connect the work cable to the work as close to the welding area as practical Work cables connected to the building framework or other locations away from the welding area increase the possibility of the welding current passing through lifting chains crane cables or other alternate cir cuits This can create fire hazards or overheat lifting chains or cables until they fail 6 h Also see item 1 c LINCOLN 8 CYLINDER may explode if damaged 7 a Use only compressed gas cylinders containing the correct shielding gas for the process used and properly operating regulators designed for the gas and pressure used All hoses fittings etc should be suitable for the application and maintained in good condition Always keep cylinders in an upright position securely chained to an undercarriage or fixed support Cylinders should be located Away from areas where they may be struck or subjected to physical damage safe distance from arc welding or cutting operations and any other source of heat sparks or flame Never allow the electrode
5. electrode holder or any other electrically hot parts to touch a cylinder Keep your head and face away from the cylinder valve outlet when opening the cylinder valve Valve protection caps should always be in place and hand tight except when the cylinder is in use or connected for use Read and follow the instructions on compressed gas cylinders associated equipment and CGA publication Precautions for Safe Handling of Compressed Gases in Cylinders available from the Compressed Gas Association 1235 Jefferson Davis Highway Arlington VA 22202 FOR ELECTRICALLY powered equipment 8 a Turn off input power using the disconnect switch at the fuse box before working on the equipment Install equipment in accordance with the U S National Electrical Code all local codes and the manufacturer s recommendations Ground the equipment in accordance with the U S National Electrical Code and the manufacturer s recommendations Mar 95 SAFETY iv PR CAUTIONS DE S RET Pour votre propre protection lire et observer toutes les instructions et les pr cautions de s ret specifiques qui parraissent dans ce manuel aussi bien que les pr cautions de s ret g n rales suiv antes S ret Pour Soudage A L Arc 1 Protegez vous contre la secousse lectrique a Les circuits l lectrode et la pi ce sont sous tension quand la machine souder est en marche Eviter toujours
6. nozzle or semiautomatic welding gun are also electrically hot Always be sure the work cable makes a good electrical connection with the metal being welded The connection should be as close as possible to the area being welded Ground the work or metal to be welded to a good electrical earth ground Maintain the electrode holder work clamp welding cable and welding machine in good safe operating condition Replace damaged insulation Never dip the electrode in water for cooling Never simultaneously touch electrically hot parts of electrode holders connected to two welders because voltage between the two can be the total of the open circuit voltage of both welders When working above floor level use a safety belt to protect yourself from a fall should you get a shock Also see Items 6 c and 8 L ARC RAYS can burn 4 a Use a shield with the proper filter and cover plates to protect your eyes from sparks and the rays of the arc when welding or observing open arc welding Headshield and filter lens should conform to ANSI Z87 standards 4 b Use suitable clothing made from durable flame resistant 5 b material to protect your skin and that of your helpers from the arc rays Protect other nearby personnel with suitable non flammable screening and or warn them not to watch the arc nor expose themselves to the arc rays or to hot spatter or metal 9 FUMES AND GASES can be
7. USO SIGA AS PRATICAS DE SEGURAN A DO EMPREGADOR 1 PRMOX A NHRBEE lt RA ETHBRLTF SU HAA RUE GUERRA RRR ERR 0 FAIS Sei 44g FFM BHC tULTHHORAMEI ETF SU 3p A7 ED ECKE Aal veel d illai Qui AAL oig Gail guet Ca L LINCOLN 8 e World s Leader in Welding and Cutting Products e e Sales and Service through Subsidiaries and Distributors Worldwide e Cleveland Ohio 44117 1199 U S A TEL 216 481 8100 FAX 216 486 1751 WEB SITE www lincolnelectric com
8. a sharp blow to turn the collar past an internal locking rib See Figure D 3 FIGURE D 3 hedoiak 100 LINCOLN TROUBLESHOOTING 1 HOW USE TROUBLESHOOTING GUIDE WARNING Service and Repair should only be performed by Lincoln Electric Factory Trained Personnel Unauthorized repairs performed on this equipment may result in danger to the technician and machine operator and will invalidate your factory warranty For your safety and to avoid Elec trical Shock please observe all safety notes and precautions detailed throughout this manual This Troubleshooting Guide is provided to help you locate and remedy possible prob lems with machine setup or operation Sim ply follow the three step procedure listed below Step 1 LOCATE PROBLEM SYMPTOM Look under the column labeled PROBLEM SYMPTOMS This column describes pos sible symptoms that the machine may exhibit Find the listing that best describes the symptom thatthe machine is exhibiting Symptoms are grouped into three main cat egories output problems function prob lems welding problems Step 2 PERFORM EXTERNAL TESTS The second column labeled POSSIBLE AREAS OF MISADJ USTMENT S lists the obvious external possibilities that may con tribute to the machine symptom Perform these tests checks in the order listed In general these tests can be conducted with out removing the case wrap around cover Step 3 PERFORM COM
9. ouvido e corpo A HAUSHERMRELTTF HRSESOREME ez 119 HSE de lag al gl eg Al aun y READ AND UNDERSTAND THE MANUFACTURER S INSTRUCTION FOR THIS EQUIPMENT AND THE CONSUMABLES TO BE USED AND FOLLOW YOUR EMPLOYER S SAFETY PRACTICES SE RECOMIENDA LEER Y ENTENDER LAS INSTRUCCIONES DEL FABRICANTE PARA EL USO DE ESTE EQUIPO Y LOS CONSUMIBLES QUE VA A UTILIZAR SIGA LAS MEDIDAS DE SEGURIDAD DE SU SUPERVISOR LISEZ ET COMPRENEZ LES INSTRUCTIONS DU FABRICANT EN CE QUI REGARDE CET EQUIPMENT ET LES PRODUITS A ETRE EMPLOYES ET SUIVEZ LES PROCEDURES DE SECURITE DE VOTRE EMPLOYEUR LESEN SIE UND BEFOLGEN SIE DIE BETRIEBSANLEITUNG DER ANLAGE UND DEN ELEKTRODENEINSATZ DES HER STELLERS DIE UNFALLVERHUTUNGSVORSCHRIFTEN DES ARBEITGEBERS SIND EBENFALLS ZU BEACHTEN Keep your head out of fumes Use ventilation or exhaust to remove fumes from breathing zone Los humos fuera de la zona de res piraci n Mantenga la cabeza fuera de los humos Utilice ventilaci n aspiraci n para gases Gardez la t te a l cart des fum es Utilisez un ventilateur ou un aspira teur pour ter les fum es des zones de travail Vermeiden Sie das Einatmen von Schweibrauch Sorgen Sie fiir gute Be und Entliif tung des Arbeitsplatzes e Mantenha seu rosto da fumaca Use ventila o e exhaust o para remover fumo da zona respirat ria 9
10. panel 3 Insert the connector on the gun conductor cable through the Gun Cable Access Hole 2 in the PRO 100 case front Make sure the connector 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 con nector so control leads are on the underside and tighten the Thumbscrew 8 in the connector 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 PRO 100 the switch must be a normally open momentary switch The termi nals of the switch must be insulated from the welding circuit Malfunction of the PRO 100 may result if this switch shorts to the PRO 100 welding output circuit or is common to any electrical cir cuit other than the PRO 100 trigger circuit GAS CONNECTION OPTIONAL When using the GMAW process a K610 1 MIG con version kit and a cylinder of carbon dioxide CO or argon carbon dioxide mixed shielding gas must be obtained For more information about the K610 1 MIG Conversion Kit for use with the PRO 100 refer to the ACCESSORIES section PRO 100 LINCOLN 8 A 5
11. the amount of smoke and dirt drawn into the rear louvers reduces the chance of dirt accumulation that can block air passages and cause overheating STACKING PRO 100 s cannot be stacked TILTING Each machine must be placed on a secure level sur face either directly or on a recommended undercar riage The machine may topple over if this procedure is not followed OUTPUT CONNECTIONS Refer to Figure A 2 1 Work Cable Access Hole 2 Gun Cable and Control Lead Access Hole 3 Connector Block 4 Gun Trigger Lead Connectors 5 Positive and negative output terminals INSTALLATION 6 Wire Feed Gearbox 7 Cable Hanger 8 Thumbscrew Work Clamp Installation Attach the work clamp per the following 1 Unplug the machine or turn the power switch to the OFF position 2 Insert the work cable terminal lug with the larger hole through the strain relief hole in the work clamp as shown in Figure A 3 3 Fasten securely with the bolt and nut provided FIGURE A 3 Strain Relief Hole Work Cable Work Clamp FIGURE A 2 DO NOT SWITCH WHEN WELDING PRO 100 LINCOLN PRO 100 LINCOLN 8 4 INSTALLATION 4 Work Cable Installation Refer to Figure A 2 1 Open the wire feed section door on the right side of the PRO 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 fron
12. tout contact entre les parties sous tension et la peau nue ou les v tements mouill s Porter des gants secs et sans trous pour isoler les mains Faire tr s attention de bien s isoler de la masse quand on soude dans des endroits humides ou sur un plancher metallique ou des grilles metalliques principalement dans les positions assis ou couch pour lesquelles une grande partie du corps peut tre en contact avec la masse Maintenir le porte lectrode la pince de masse le c ble de soudage et la machine souder en bon et s r tat defonctionnement d Ne jamais plonger le porte lectrode dans l eau pour le refroidir Ne jamais toucher simultan ment les parties sous tension des porte lectrodes connect s deux machines souder parce que la tension entre les deux pinces peut tre le total de la tension vide des deux machines Si on utilise la machine souder comme une source de courant pour soudage semi automatique ces precautions pour le porte lectrode s applicuent aussi au pistolet de soudage 2 Dans le cas de travail au dessus du niveau du sol se prot ger zones o l on pique le laitier 6 Eloigner les mat riaux inflammables ou les recouvrir afin de pr venir tout risque d incendie d aux tincelles Quand on ne soude pas poser la pince une endroit isol de la masse Un court circuit accidental peut provoquer un chauffement et un risque d incendie S assurer que la masse est con
13. ui ozzers 3281002 EE dit H V6Z9lW ON Hed seo ORTUS PN Hed ajqeo pue unb 241M DIW 91ZZON pej05 xni4 104 204 D TOOL LOH AT1V21812313 34904193713 STIOH 0334 04554 5399141 ONY NO SI 394105 HAMOd ONIQT3M NIHM ONINHVM NOISNAL SNOS SIN LNOS 3004193733 HIOQIA3O0 31 LN3WNIVHAIN3 G 1 S31 339NO4N3 1S3 13101SIld 31N3130 v1 13 3HONVUS 153 31504 31 300SHO1 LN3W3SSILH3AV ayy 0 Ayyiqisuodsas ayy 1 quiesse 10 e jo 5 aui uoneuuojui jo ed siu aye sejqeuea pue Aquasse enuey ut SNOLLOVO3Hd AL34VS SNIQT3M uonoes ay pue 14 uo ay puejsiapun pue peal ans ag SU0 S19AU09 ON postnbas sayo 20 aas GatS 73438 3A00H5 3AOOU9 3A00u5 dW LLZ HN Q T13IHSH3NNI vid 6 0 seo 3HIA 1931 01105 via 90 620 13315 01105 via ww 870 060 qauooxnia3 SS31SV9 1 14 NO Q3H31N32 M3HOS 13S 1104 3AIHQ 3HN93S 53971 30109 40 H31N32 02 02 52 uobiy 409 54 G amp 9 10 029 9871 ef DM N109NI
14. 1 713315 1105 via 0 o 0 02 02 Sz 08 6 Sc Svo SNIGTSIHS SSANMHOIHL 13315 91819273 33S SONLLL3S ANY 14316 SS3TNIVIS Ux SNIQT3M SONILL3S 031539905 H 957 NIOONIT 13315 1105 90 620 diW LLZ HN Joa 11 5 a3H09 XM14 via 60 ur Geo 55315 9 9NIQTJA SS390Hd 791910313 PRO 100 LINCOLN E C 1 OPTIONAL ACCESSORIES 1 K520 Utility Cart Designed to transport the Lin family of small welders Has provisions for mounting a single gas cylinder Has front casters and large rear wheels Handle height is easily adjustable Bottom tray provided for tools and accessories Easy assembly required takes less than 15 minutes M15445 Spindle Mounts onto standard spool shaft for 4 100 mm spools to provide for mount ing 8 200 mm diameter spools with 2 51 mm 1 0 and up to 2 2 56 mm wide K664 2 Aluminum Feeding Kit This kit recom mended for welding with 035 Aluminum wire This kit may also be used for feeding 030 stainless wire Included with this kit are a drive roll gun liner and contact tip It is important when changing between welding with steel wire and aluminum to exchange these components due to the lubricant applied to steel wire Failure to do so may result in contam
15. ECTRIC SHOCK can kill Only qualified personnel should perform this installation Only personnel that have read and under stood the PRO 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 PRO 100 power switch is to be in the OFF position when installing work cable and gun and when connecting power cord to input power IDENTIFY AND LOCATE COMPONENTS If you have not already done so unpack the PRO 100 from its carton and remove all packing material around the PRO 100 Remove the following loose items from the carton see Figure A 1 1 PRO 100 2 Gun and cable assembly 3 Literature and miscellaneous including a This operating manual b Extra 035 contact tip c Hex key wrench for removal of drive roll 4 10 ft 3 0 m work cable 5 Work clamp 6 Sample spool of Innershield 035 0 9 mm NR 211 MP electrode 7 Handshield with filter plate and lens 8 Instructional video For available options and accessories refer to the Accessories Section of this manual The gun is ready to feed 0 035 0 9 mm Inner shield wire PRO 100 LINCOLN 8 A 3 SELECT SUITABLE LOCATION Locate the welder in a dry location where there is free circulation of clean air into the louvers in the back and out the front of the unit A location that minimizes
16. Insert spindle as shown in figure B 3 Reattach spacer and wing nut Note When loading and removing the 8 Spools make sure that the wing nut inside the wire spool spindle hub is turned 90 from the wire spool spindle locking tab If the wing nut is positioned in line with the locking tab the tab cannot be depressed to load or unload the wire spool Make certain the start end of the wire which may pro trude through the side of the spool does not contact any metallic case parts FIGURE B 3 Optional Wire Spool Spindle Locking Tab 8 Wire Spool Be sure that this stud engages the hole in the wire spool To Wire Drive Wire Spool must be pushed all the way on the spindle so that the spindle s tab will hold it in place The Wire Spool will rotate clock wise when wire is dereeled PRO 100 LINCOLN B 4 Note The brake should be adjusted with a spool of wire installed When properly adjusted it should move freely but not coast Friction Brake Adjustments 1 With wire spool installed check free movement and coast of the spool 2 To tighten the brake turn the wing nut clockwise in 1 4 turn increments until coasting stops 3 To loosen the brake turn the wing nut counter clockwise in 1 4 turn increments until the wire spool moves freely without coasting Wire Threading Refer to Figure B 4 1 Release the Spring Loaded Pressure Arm 1 rotate the Idle Roll Arm 2 away from the Wire Feed Dri
17. PONENT TESTS If you have exhausted all of the recom mended tests in Step 2 Consult your Local Authorized Field Service Facility CAUTION If for any reason you do not understand the test procedures or are unable to perform the tests repairs safely contact your LOCAL AUTHORIZED LINCOLN ELECTRIC FIELD SERVICE FACILITY for assistance before you proceed PRO 100 LINCOLN 8 E2 TROUBLESHOOTING TROUBLESHOOTING GUIDE Observe Safety Guidelines detailed in the beginning of this manual PROBLEMS POSSIBLE AREAS OF RECOMMENDED SYMPTOMS MISADJUSTMENT S COURSE OF ACTION OUTPUT PROBLEMS Major physical or electrical damage None is evident Contact your local Authorized Field Service Facility No wire feed weld output or gas 1 Make sure correct voltage is flow when gun trigger is pulled Fan applied to the machine 115vac does NOT operate Make certain that power switch is in the ON position Make sure circuit breaker is reset Contact your local Lincoln Authorized Field Service Facility No wire feed weld output or gas The thermostat may be tripped flow when gun trigger is pulled Fan due to overheating Let machine operates normally cool Weld at lower duty cycle Check for obstructions in air flow Check Gun Trigger connec tions See Installation section Gun trigger may be faulty A CAUTION If for any reason you do not understand the test procedures or are unable to perform the tests repa
18. RC RAYS burn eyes Observe all safety information throughout this manual PRO 100 LINCOLN B 2 OPERATION B 2 GENERAL DESCRIPTION The PRO 100 is a compact lightweight DC wire feed er power source It has been designed for workshop hobby and light maintenance It is capable of general purpose welding with self shielded flux cored Inner shield wire When combined with the optional 610 1 MIG Conversion Kit the PRO 100 is suitable for GMAW MIG welding applications The PRO 100 is ideally suited for individuals having access to 115 volt AC input power and wanting the ease of use quality and dependability of both the Innershield electrode process self shielded flux cored or FCAW and gas metal arc welding or GMAW also known as MIG welding The PRO 100 is a rugged and reliable machine that has been designed for dependable service and long life RECOMMENDED PROCESSES The PRO 100 can be used for welding mild steel using the self shielded Innershield electrode process FCAW or it can be used for the GMAW single pass process which requires a supply of shielding gas and the K610 1 MIG Conversion Kit The PRO 100 is con figured for use with the FCAW process as delivered from the factory OPERATIONAL FEATURES AND CONTROLS The PRO 100 has the following controls as standard Power ON OFF Switch Voltage Control Wire Speed Control Trigger Switch and a Circuit Breaker DESIGN FEATURES AND ADVANTAGES
19. RETURN TO MAIN MENU BE IM784 PRO 100 For use with machine Code Number 10970 Safety Depends on You Lincoln arc welding and cutting equipment is designed and built with safety in mind However your overall safety can be increased by proper installation and thought ful operation on your part DO NOT INSTALL OPERATE OR REPAIR THIS EQUIPMENT WITHOUT READING THIS MANUAL AND THE SAFETY PRECAUTIONS CONTAINED THROUGHOUT And most importantly think before you act and be careful OPERATOR S MANUAL 7 2004 Lincoln Global nc World s Leader in Welding and Cutting Products e Sales and Service through Subsidiaries and Distributors Worldwide e Cleveland Ohio 44117 1199 U S A TEL 216 481 8100 FAX 216 486 1751 WEB SITE www lincolnelectric com SAFETY WARNING A CALIFORNIA PROPOSITION 65 WARNINGS A Diesel engine exhaust and some of its constituents The engine exhaust from this product contains are known to the State of California to cause can chemicals known to the State of California to cause cer birth defects and other reproductive harm cancer birth defects or other reproductive harm The Above For Diesel Engines The Above For Gasoline Engines ARC WELDING CAN BE HAZARDOUS PROTECT YOURSELF AND OTHERS FROM POSSIBLE SERIOUS INJURY OR DEATH KEEP CHILDREN AWAY PACEMAKER WEARERS SHOULD CONSULT WITH THEIR DOCTOR BEFORE OPERATING Read and understan
20. ach 10 minutes of arc time or as required 4 Be sure the gas nozzle is fully screwed onto the diffuser for gas shielded processes For the Inner shield process the gasless nozzle should be screws onto the diffuser 5 To remove gun tube from gun remove gas nozzle or gasless nozzle and remove diffuser from gun tube Remove both collars from each end of the gun handle and separate the handle halves Loosen the locking nut holding the gun tube in place against the gun end cable connector Unscrew gun tube from cable connector To install gun tube screw the locking nut on the gun tube as far as possible Then screw the gun tube into the cable connector until it bottoms Then unscrew no more than one turn the gun tube until its axis is perpendicular to the flat sides of the cable connec tor and pointed in the direction of the trigger Tight en the locking nut so as to maintain the proper relationship between the gun tube and the cable connector Replace the gun handle trigger and dif fuser Replace the gas nozzle or gasless nozzle CONFIGURATION OF COMPONENTS IN WIRE FEEDING SYSTEM Po Contact Tip Cable Liner Drive Roll KP2039 3B1 035 0 9mm KP1937 3 025 035 0 6 0 9mm M16190 Large Knurled Small Smooth groove Small 023 025 0 6mm Large 030 035 0 8 0 9mm Components shipped with PRO 100 K610 1 023 025 0 6mm MIG Conversion Kite KP2039 1B1 025 0 6mm KP1937 2 030 0 8mm U
21. control can be preset on the dial to the setting specified on the PRO 100 Application Chart locat ed on the inside of the wire feed section door WIRE SPEED 3 Voltage Control A 4 posi tion tap selector switch gives full range adjustment of power source output voltage Do not switch while welding ARC VOLTS Refer to Figure B 1b 4 Circuit Breaker Protects machine from damage if maximum output is exceeded Button will extend out when tripped Manual reset PRO 100 LINCOLN 3 OPERATION B 3 FIGURE B 1a WIRE SPEED ARC VOLTS DO NOT SWITCH WHEN WELDING LINCOLN PRO 100 FIGURE B 1b WELDING OPERATIONS SEQUENCE OF OPERATION Wire Loading Refer to Figure B 2 AND B3 The machine power switch should be turned to the OFF O position before working inside the wire feed enclosure The machine is shipped from the factory ready to feed 4 100 mm diameter spools A 4 100 mm diameter spool is mounted directly on the 5 8 16 mm diame ter spindle that has a built in adjustable friction brake to prevent overrun of the spool and excess slack in the wire The wing nut at the end of the shaft is used to adjust the tension on the wire spool Wire Spindle Shaft 4 Wire Spool Wing Nut and Spacer To wire drive FIGURE B 2 To use 8 200 mm diameter spools the 2 51 mm diameter M15445 spindle must be used Remove the spacer and wing nut at the end of the shaft
22. ct to you Please Examine Carton and Equipment For Damage Immediately When this equipment is shipped title passes to the purchaser upon receipt by the carrier Consequently Claims for material damaged in shipment must be made by the purchaser against the transportation company at the time the shipment is received Please record your equipment identification information below for future reference This information can be found on your machine nameplate Product Model Number Code Number or Date Code Serial Number Date Purchased Where Purchased Whenever you request replacement parts or information on this equipment always supply the information you have recorded above The code number is especially important when identifying the correct replacement parts On Line Product Registration Register your machine with Lincoln Electric either via fax or over the Internet For faxing Complete the form on the back of the warranty statement included in the literature packet accompanying this machine and fax the form per the instructions printed on it e For On Line Registration Go to our WEB SITE at www lincolnelectric com Choose Quick Links and then Prod uct Registration Please complete the form and submit your registration Read this Operators Manual completely before attempting to use this equipment Save this manual and keep it handy for quick reference Pay particular attention to th
23. d the following safety highlights For additional safety information it is strongly recommended that you purchase a copy of Safety Welding amp Cutting ANSI Standard Z49 1 from the American Welding Society P O Box 351040 Miami Florida 33135 or CSA Standard W117 2 1974 A Free copy of Arc Welding Safety booklet E205 is available from the Lincoln Electric Company 22801 St Clair Avenue Cleveland Ohio 44117 1199 BE SURE THAT ALL INSTALLATION OPERATION MAINTENANCE AND REPAIR PROCEDURES ARE PERFORMED ONLY BY QUALIFIED INDIVIDUALS powered equipment 1 Turn the engine off before troubleshooting and maintenance work unless the maintenance work requires it to be running 3 SX 1 h To avoid scalding do not remove the radiator pressure cap when the engine is hot 1 b Operate engines in open well ventilated areas or vent the engine exhaust fumes outdoors ELECTRIC AND 3 mm MAGNETIC FIELDS may be dangerous 1 c Do not add the fuel near an open flame welding arc or when the engine is running Stop the engine and allow it to cool before refueling to prevent spilled fuel from vaporiz ing on contact with hot engine parts and igniting Do not spill fuel when filling tank If fuel is spilled wipe it up and do not start engine until fumes have been eliminated 2 a Electric current flowing through any conductor causes localized Electric and Mag
24. dangerous 5 a Welding may produce fumes and gases hazardous to health Avoid breathing these fumes and gases When welding keep your head out of the fume Use enough ventilation and or exhaust at the arc to keep fumes and gases away from the breathing zone When welding with electrodes which require special ventilation such as stainless or hard facing see instructions on container or MSDS or on lead or cadmium plated steel and other metals or coatings which produce highly toxic fumes keep exposure as low as possible and below Threshold Limit Values TLV using local exhaust or mechanical ventilation In confined spaces or in some circumstances outdoors a respirator may be required Additional precautions are also required when welding on galvanized steel Do not weld in locations near chlorinated hydrocarbon vapors coming from degreasing cleaning or spraying operations The heat and rays of the arc can react with solvent vapors to form phosgene a highly toxic gas and other irritating products 5 6 5 LINCOLN Shielding gases used for arc welding displace air cause injury or death Always use enough ventilation especially in confined areas to insure breathing air is safe Read and understand the manufacturer s instructions for this equipment and the consumables to be used including the material safety data sheet MSDS and follow your employer s safety practices MSDS forms are available fro
25. e safety instructions we have provided for your protection The level of seriousness to be applied to each is explained below A WARNING This statement appears where the information must be followed exactly to avoid serious personal injury or loss of life CAUTION This statement appears where the information must be followed to avoid minor personal injury damage to this equipment vi TABLE OF CONTENTS Page ct Section Technical 1 Identify and Locate Components A 2 Select Suitable Locetion sis A 3 le tele TEE A 3 Input ee TEE A 6 Ee HE A 6 nee este ae tee es duce nce nn ee Section B Safety eege deeg pete Rise ER repe 1 General Descripliono use ree era Dung B 2 Design Features and Advantages B 2 Welding te B 2 Bue EE B 2 Controls and Settin OS is B 2 Welding Operations reet recette xeu EA Rer B 3 Overload le DTN B 6 Application nd rs rade es red cerner B 7 ACCESSOT ES KS Section C ACCOSSOLIOS EE C 1 Replacement Parts tenait C 1 Maintenance Section D Safety ee EE D 1 Items Requiring No Maintenance D 1 ate laisse CEP D 1 Gun and Cable Maintenance D 2 Configuration of Comp
26. e size selected See Changing Drive Roll in Maintenance section for details 4 Install the proper gun liner Note 1 and tip for the wire size selected See Component Replacement in Maintenance section for details 5 Remove gasless nozzle if installed and install gas nozzle To remove simply unscrew 6 Load wire into machine and thread into gun and cable per Welding Wire Loading section Note 1 The factory installed gun liner will feed 025 035 0 6 0 9 mm wire PRO 100 LINCOLN 8 D 1 MAINTENANCE D 1 MAINTENANCE SAFETY PRECAUTIONS WARNING ELECTRIC SHOCK can kill Disconnect input power removing plug from receptacle before working inside PRO 100 Use only grounded receptacle Do not touch electrically hot parts inside PRO 100 Have qualified personnel do the mainte nance and trouble shooting work ROUTINE MAINTENANCE POWER SOURCE COMPARTMENT No user serviceable parts inside Do not attempt to perform service in the power source fixed side of the PRO 100 Take the unit to an authorized Lincoln Service Center if you experi ence problems NO maintenance is required WIRE FEED COMPARTMENT 1 When necessary vacuum accumulated dirt from gearbox and wire feed section 2 Occasionally inspect the incoming guide tube and clean inside diameter is necessary 3 Motor and gearbox have lifetime lubrication and require no maintenance FAN MOTOR Has l
27. e wire drive feed roll over Refer to Figure B 5 Remove gas nozzle and con tact tip from end of gun Turn the PRO 100 ON 1 Straighten the gun cable assembly Depress the gun trigger switch and feed welding wire through the gun and cable Point gun away from yourself and others while feeding wire Release gun trigger after wire appears at end of gun Turn the PRO 100 OFF O Replace contact tip and gas nozzle Refer to Figure B 6 Cut the wire off 3 8 1 2 10 13 mm from the end of the tip The PRO 100 is now ready to weld FIGURE B 5 Gun Handle Gas Diffuser Contact Tip Gas Nozzle FIGURE B 6 Contact Tip Electrode 3 8 1 2 10 12mm Contact Tip to Work Distance CTWD Making A Weld 1 See Process Guidelines in this section for selec tion of welding wire and shielding gas and for range of metal thicknesses that can be welded See the Application chart on the inside of the wire feed compartment door for information on setting the PRO 100 controls Refer to Table B 1 for alu minum and stainless wire Set the Voltage V and Wire Speed olo con trols to the settings suggested for the welding wire and base metal thickness being used refer to Applications chart on the inside of the wire drive compartment door Check that the polarity is correct for the welding wire being used and that the gas supply if required is turn
28. ed on When using Innershield electrode remove the gas nozzle and install the gasless nozzle This will improve visibility of the arc and protect the gas dif fuser from weld spatter Refer to the MAINTE NANCE section for details on nozzle replacement FIGURE B 7 GUN CABLE WORK CLAMP OPERATION B 5 6 Refer to Figure B 7 Connect work clamp to metal to be welded Work clamp must make good elec trical contact to the workpiece The workpiece must also be grounded as stated in Arc Welding Safety Precautions in the beginning of this manu al 7 Position gun over joint End of wire may be lightly touching the work 8 Lower welding helmet close gun trigger and begin welding Hold the gun so the contact tip to work distance is about 3 8 inch 10 mm 9 To stop welding release the gun trigger and then pull the gun away from the work after the arc goes out 10 When no more welding is to be done close valve on gas oylinder if used momentarily operate gun trigger to release gas pressure and turn off the PRO 100 Cleaning Tip And Nozzle Clean the contact tip and nozzle to avoid arc bridging between the nozzle and contact tip which can result in a shorted nozzle poor welds and an overheated gun Hint Anti stick spray or gel available from a welding supply distributor may reduce buildup and aid in spat ter removal PROCESS GUIDELINES The PRO 100 as shipped can be used for welding mild ste
29. eed to minimum and jog the drive unit with the trigger switch until the drive roll set screw is facing up CAUTION When inching the welding wire the drive rolls gun connector block and gun contact tip are energized relative to work and ground and remain energized for several seconds after the gun trig ger is released 5 Turn the power switch to OFF marked O 6 Loosen the drive roll set screw with the 5 64 2 0 mm hex wrench supplied 7 Remove the drive roll flip over and reinstall with the 023 025 0 6 mm groove the smaller groove closest to the gearbox 8 Push a length of straightened welding wire through the wire feeder guide tubes and adjust the position of the drive roll so that the groove is centered on the wire Make certain the set screw is located on the flat portion of the shaft and tighten FIGURE D 1 PRO 100 LINCOLN 8 D 4 MAINTENANCE D 4 FIGURE 0 2 CHANGING LINER Liner trim length NOTICE The variation in cable lengths pre vents the interchangeability of liners Once 1 1 4 81 8 mm a liner has been cut for a particular gun it Liner Length Should not be installed in another gun unless it can meet the liner cutoff length a requirement Refer to Figure 0 2 1 Remove the gas nozzle from the gun by Gas Diffuser LR unscrewing counter clockwise 2 Remove the existing contact tip from the Gas Nozzle or gun by unscrewing counter clockwise Gasless Nozzle
30. el using the self shielded Innershield elec trode process or it can be used for the GMAW MIG single pass process which requires a supply of shielding gas and the K610 1 MIG Conversion Kit The recommended electrode for the self shielded process is 0 035 0 9 mm diameter Lincoln Inner shield NR 211 MP Requires optional spindle refer to Accessories section This electrode can be used for all position welding of 20 gauge through 5 16 1 0 8 0 mm thick steel multiple passes are required for 1 4 and 5 16 6 0 and 8 0 mm The recommended gas and electrode for GMAW is welding grade CO gas and 0 025 0 6 mm diameter Lincoln Super Arc L 56 mild steel welding wire sup plied on 12 1 2 Ib 6 kg spools For 14 gauge 2 0 mm and thinner CO 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 CO is recommended for welding on heavier gauge steel 12 gauge 2 5 mm for example PRO 100 LINCOLN B 6 OPERATION B 6 PRO 100 is suitable for 035 aluminum wire and 030 stainless wire Refer to Table B 1 for recom mended procedure settings Requires K610 1 MIG Conversion Kit and K664 2 Aluminum Stainless Feeding Kit CAUTION It is important when changing between welding with steel wire and aluminum to exchange feeding components due to the lubricant applied to steel wire Failure to do so may re
31. er les yeux du ray 1 onnement de et des projections quand on soude ou quand on regarde b Porter des v tements convenables afin de prot ger la peau de soudeur et des aides contre le rayonnement de l arc c Prot ger l autre personnel travaillant proximit au soudage l aide d crans appropri s et non inflammables Des gouttes de laitier en fusion sont mises de l arc de soudage Se prot ger avec des v tements de protection libres de l huile tels que les gants en cuir chemise paisse pan talons sans revers et chaussures montantes Toujours porter des lunettes de s curit dans la zone de soudage Utiliser des lunettes avec crans lateraux dans les LINCOLN 8 TRANSFORMATEUR ET Relier la terre le chassis du poste conformement au code de l lectricit et aux recommendations du fabricant Le dispositif de montage ou la piece souder doit tre branch une bonne mise la terre Autant que possible l installation et l entretien du poste seront effectu s par un lectricien qualifi Avant de faires des travaux l interieur de poste la debranch er l interrupteur la boite de fusibles Garder tous les couvercles et dispositifs de s ret leur place V V for selecting a QUALITY product by Lincoln Electric We want you Thank You to take pride in operating this Lincoln Electric Company product eee as much pride as we have in bringing this produ
32. ert regulator adapter provided with MIG Conversion Kit for the PRO 100 between regulator and cylin der valve If adapter is equipped with a plastic washer be sure it is seated for connection to the CO cylinder 4 Refer to Figure A 6 Attach one end of inlet gas hose to the outlet fitting of the flow regulator and tighten the union nut securely with a wrench Con nect the other end to the PRO 100 Gas Solenoid Inlet Fitting 5 8 18 female threads for CGA 032 fitting Make certain the gas hose is not kinked or twisted PRO 100 LINCOLN A 6 INPUT CONNECTIONS FIGURE A 6 OPTIONAL GAS SOLENOID INLET FITTING POWER INPUT CABLE ll Refer Figure A 6 The PRO 100 has a power input cable located on the rear of the machine CODE REQUIREMENTS FOR INPUT CONNECTIONS WARNING This welding machine must be connected to power source in accordance with applicable elec trical codes The National Electrical Code provides standards for amperage handling capability of supply ductors based on duty cycle of the welding source If there is any question about the installation meeting applicable electrical code requirements consult a qualified electrician INSTALLATION Requirements For Rated Output A power cord with a 15 amp 125 volt three prong plug NEMA Type 5 15P is factory installed on the PRO 100 Connect this plug to a mating grounded receptacle which i
33. fsUPBHEILTASESUCFEU CARE 24758 else SUAS MAS sis PARAH 7 Qai Jung dul jua A Sarin e os Qui BALL cal z ue Turn power off before servicing Desconectar el cable de ali mentaci n de poder de la maquina antes de iniciar cualquier servicio e D branchez le courant avant l entre tien Strom vor Wartungsarbeiten abschalten Netzstrom v llig ff nen Maschine anhalten N o opere com as tampas removidas Desligue a corrente antes de fazer servico e N o toque as partes el tricas nuas e FHIR ET BRAY FE e HMDS RK AGS XA Aie Ao pha NM dust ale Do not operate with panel open or guards off No operar con panel abierto o guardas quitadas N op rez pas avec les panneaux ouverts ou avec les dispositifs de protection enlev s e Anlage nie ohne Schutzgeh use oder Innenschutzverkleidung in Betrieb setzen e Mantenha se afastado das partes moventes N o opere com os paineis abertos ou guardas removidas OSILDI RALE ARRIAN RE SHR Ro 20 Sel AE Asal HAS Abiyi 13 lu nde Aale Viel Al all Aaaa AVISO DE PRECAUCION French ATTENTION German WARNUNG ATEN AO BR Chinese LEIA COMPREENDA AS INSTRUCOES DO FABRICANTE PARA ESTE EQUIPAMENTO AS PARTES DE
34. ifetime lubrication requires no maintenance WIRE REEL SPINDLE Requires no maintenance Do not lubricate shaft PRO 100 LINCOLN 8 D 2 MAINTENANCE D 2 GUN AND CABLE MAINTENANCE FOR MAGNUM 100L GUN Gun Cable Cleaning Clean cable liner after using approximately 300 lbs 136 kg of solid wire or 50 Ibs 23 kg of flux cored wire Remove the cable from the wire feeder and lay it out straight on the floor Remove the contact tip from the gun Using low pressure air gently blow out the cable liner from the gas diffuser end Excessive pressure at the start may cause the dirt to form a plug Flex the cable over its entire length and again blow out the cable Repeat this procedure until no further dirt comes out Contact Tips Nozzles and Gun Tubes 1 Dirt can accumulate in the contact tip hole and restrict wire feeding After each spool of wire is used remove the contact tip and clean it by push ing a short piece of wire through the tip repeatedly Use the wire as a reamer to remove dirt that may be adhering to the wall of the hole through the tip 2 Replace worn contact tips as required A variable or hunting arc is a typical symptom of a worn con tact tip To install a new tip choose the correct size contact tip for the electrode being used wire size is stenciled on the side of the contact tip and screw it snugly into the gas diffuser 3 Remove spatter from inside of gas nozzle and from tip after e
35. inated welds when weld ing aluminum See Maintenance section for instructions on installing drive roll cable liner contact tip and their proper configuration K610 1 MIG Conversion Kit for the PRO 100 Complete kit for use with 025 0 6 mm electrode wire and either CO or Argon mixed gas Includes 025 030 0 6 0 8 mm cable liner two 025 0 6 mm contact tips gas nozzle 2 lb spool of 025 0 6 mm Super Arc L 56 electrode gas regulator gas hose regulator adapter for CO cylinders and gas solenoid assembly with all necessary hard ware and easy instructions for installing gas sole noid Use with 030 0 8 mm wire requires addi tional 030 0 8 mm contact tip and electrode wire See Maintenance section for instructions on flip ping over the drive roll changing the cable liner and contact tip and their proper configuration ACCESSORIES C 1 MIG CONVERSION Several changes are needed to convert the unit for operation with the MIG GMAW process The K610 1 MIG Conversion Kit for the PRO 100 includes all the necessary accessories for this conversion and is pro vided for this purpose The following conversions should be made using the contents of this kit 1 Install the gas solenoid Complete instructions are included with the kit 2 Change the output polarity to DC See Work Cable Installation in Installation section for details 3 Change drive roll orientation if required for the wir
36. irs safely contact your LOCAL AUTHORIZED LINCOLN ELECTRIC FIELD SERVICE FACILITY for assistance before you proceed PRO 100 LINCOLN 8 E 3 Observe Safety Guidelines detailed in the beginning of this manual PROBLEMS SYMPTOMS No wire feed when gun trigger is pulled Fan runs gas flows and machine has correct open circuit voltage 32vcd maximum weld output PROBLEMS SYMPTOMS Low or no gas flow when gun trigger is pulled Wire feed weld output and fan operate normally Optional MIG Conversion Kit only TROUBLESHOOTING E 3 TROUBLESHOOTING GUIDE POSSIBLE AREAS OF MISADJUSTMENT S FEEDING PROBLEMS 1 If the wire drive motor is running make sure that the correct drive rolls are installed in the machine 2 Check for clogged cable liner or contact tip 3 Check for proper size cable liner and contact tip RECOMMENDED COURSE OF ACTION Contact your local Lincoln Authorized Field Service Facility POSSIBLE AREAS OF RECOMMENDED MISADJUSTMENT S COURSE OF ACTION GAS FLOW PROBLEMS Verify that gas solenoid is prop erly installed Refer to instruc tions included with K610 1 MIG conversion kit Check gas supply flow regulator and gas hoses Check gun connection to machine for obstruction or leaky seals Contact your local Lincoln Authorized Field Service Facility CAUTION If for any reason you do not understand the test procedures or are unable to perform the tes
37. jsui pjnous 5005190 paijijenb Aug e syed out jeoujoeje uono jou og e Hulo Asas 910190 p109 samod 9 1ndui j2euuoosi e ONINUV AW 1 519 02 9121900 jou og e 1 ONIHOVLLVAY N3HM 076 9NINHOO MOQ GNNOdWOO LNIOP 758211 AHINDAY SNOILO3NNOO WANINNTV 431104 ON HOH q3M3lA LNANOdWOD O N I3NVd H31N39 AHL OL 1535010 SI HOIHM 5INISLV3H 3GISNI SHL NO G3INNON ta 39014 ON INISLV3H 3015100 AHL NO GALNNOW 7d SAGOIC V N o GX 8 N n HOLIMS 830193135 s QuVO8 7274 IOHINOO quvog 40 301 LNINOdWOO 99 3003 ONIYAGWNN ALIAVO 542009 1v9Iu19113 119V9l1ddv YAHLO HO 1V901 IVNOLLVN ddd GNNOYD H14V3 OL anis ONIGNNOYS ASVO LIN9419 ONIGNIM Ave HOLON ZHO9 AS LL l GION31OS Svo 1 ZHOQ AS LL I LIA NOISH3ANOO SIW 40 1dVd SI 010 4105 SVD INVH9VIG NOTE This diagram is for reference only It may not be accurate for all machines covered by this manual The specific diagram for a particular code is pasted inside the machine on one of the enclosure panels PRO 100 LINCOLN E NOTES PRO 100 LINCOLN 8 Spanish AVISO DE PRECAUCION French ATTENTION German WARNUNG ATEN AO Japanese BIR Korean Do not touch electrically live parts electrode with skin or wet clothing Insulate
38. m your welding distributor or from the manufacturer Also see item 1 b Mar 95 SAFETY 7 WELDING SPARKS lt gt cause fire or explosion 6 a Remove fire hazards from the welding area If this is not possible cover them to prevent the welding sparks from starting a fire Remember that welding sparks and hot materials from welding can easily go through small cracks and openings to adjacent areas Avoid welding near hydraulic lines Have a fire extinguisher readily available Where compressed gases are to be used at the job site special precautions should be used to prevent hazardous situations Refer to Safety in Welding and Cutting ANSI Standard Z49 1 and the operating information for the equipment being used When not welding make certain no part of the electrode circuit is touching the work or ground Accidental contact can cause overheating and create a fire hazard Do not heat cut or weld tanks drums or containers until the proper steps have been taken to insure that such procedures will not cause flammable or toxic vapors from substances inside They can cause an explosion even though they have been cleaned For information purchase Recommended Safe Practices for the Preparation for Welding and Cutting of Containers and Piping That Have Held Hazardous Substances AWS F4 1 from the American Welding Society see address above Vent hollow castings or containers before heating
39. nect e le plus pr s possible de la zone de travail qu il est pratique de le faire Si on place la masse sur la charpente de la construction ou d autres endroits loign s de la zone de travail on augmente le risque de voir passer le courant de soudage par les chaines de lev age c bles de grue ou autres circuits Cela peut provoquer des risques d incendie ou d echauffement des chaines et des c bles jusqu ce qu ils se rompent Assurer une ventilation suffisante dans la zone de soudage Ceci est particuli rement important pour le soudage de t les galvanis es plomb es ou cadmi es ou tout autre m tal qui produit des fume s toxiques Ne pas souder en pr sence de vapeurs de chlore provenant d op rations de d graissage nettoyage ou pistolage La chaleur ou les rayons de l arc peuvent r agir avec les vapeurs du solvant pour produire du phosg ne gas fortement toxique ou autres produits irritants Pour obtenir de plus amples renseignements sur la s ret voir le code Code for safety in welding and cutting CSA Standard W 117 2 1974 contre les chutes dans le cas ou on recoit un choc Ne jamais PR CAUTIONS DE S RET POUR enrouler le c ble lectrode autour de n importe quelle partie en LES MACHINES SOUDER Un coup d arc peut tre plus s v re qu un coup de soliel donc REDRESSEUR a Utiliser un bon masque avec un verre filtrant appropri ainsi qu un verre blanc afin de se prot g
40. netic Fields EMF Welding current creates EMF fields around welding cables and welding machines EMF fields may interfere with some pacemakers and welders having a pacemaker should consult their physician before welding 1 d Keep all equipment safety guards covers and devices in position and in good repair Keep hands hair clothing and tools away from V belts gears fans and all other moving parts when starting operating or repairing equipment Exposure to EMF fields in welding may have other health effects which are now not known All welders should use the following procedures in order to 1 In some cases it may be necessary to remove safety nes minimize exposure to EMF fields from the welding circuit guards to perform required maintenance Remove guards only when necessary and replace them when the maintenance requiring their removal is complete Always use the greatest care when working near moving parts 2 d 1 Route the electrode and work cables together Secure them with tape when possible 2 4 2 Never coil the electrode lead around your body 1 f Do not put your hands near the engine fan ww Do not attempt to override the governor or idler by pushing on the throttle control rods while the engine is running 2 4 3 Do not place your body between the electrode and work cables If the electrode cable is on your right side the work cable should also be on you
41. onents in Wire Feeding D 2 Component Replacement Procedures nens D 3 Troubleshooting ss eene ense nnne nnn nnn innen nane nnns Section E Safety e e EE E 1 How to Use Troubleshooting E 1 Troubleshooting Guide E 2 thru E 4 Wiring al Le Section F PRO 100 Wiring Diarah EE F 1 PRO 100 Parts 1 nnn 464 202 ix INSTALLATION m TECHNICAL SPECIFICATIONS PRO 100 INPUT SINGLE PHASE ONLY Standard Voltage Frequency Input Current 115V 60Hz 20 Amps Rated Output 115V 60Hz 15 Amps CSA Rated output RATED OUTPUT Duty Cycle Current 2096 Duty Cycle 88Amps 2096 Duty Cycle CSA Rated Output 62Amps OUTPUT Welding Current Range Maximum Open Circuit Voltage Wire Speed Range Rated DC Output 30 100 amps 32V 50 300 IPM 1 3 7 6 m min RECOMMENDED INPUT CABLE AND FUSE SIZES Fuse or RATED 115V 60Hz 20 Amp 15 Amp 125V Three Conductor Three Prong Plug PIRA NEMA Type 5 15P 2 1 mm or Larger Up to 25 Ft 7 6 mm 115V 60Hz 15 Amp 15 Amp 125V Three Conductor Three Prong Plug 12 AWG NEMA Type 5 15P 3 3 mm or Larger Up to 50 Ft 15 2 mm PHYSICAL DIMENSIONS PRO 100 LINCOLN 8 2 INSTALLATION 2 Read entire installation section before starting FIGURE A 1 installation SAFETY PRECAUTIONS WARNING EL
42. r right side X 8 Connect the work cable to the workpiece as close as possible to the area being welded 1 9 To prevent accidentally starting gasoline engines while turning the engine or welding generator during maintenance work disconnect the spark plug wires distributor cap or magneto wire as appropriate Do not work next to welding power source Mar 95 LINCOLN 8 SAFETY ELECTRIC SHOCK can kill 3 a The electrode and work or ground circuits are electrically hot when the welder is on Do not touch these hot parts with your bare skin or wet clothing Wear dry hole free gloves to insulate hands 3 b Insulate yourself from work and ground using dry insulation Make certain the insulation is large enough to cover your full area of physical contact with work and ground In addition to the normal safety precautions if welding must be performed under electrically hazardous conditions in damp locations or while wearing wet clothing on metal structures such as floors gratings or scaffolds when in cramped positions such as sitting kneeling or lying if there is a high risk of unavoidable or accidental contact with the workpiece or ground use the following equipment Semiautomatic DC Constant Voltage Wire Welder DC Manual Stick Welder AC Welder with Reduced Voltage Control In semiautomatic or automatic wire welding the electrode electrode reel welding head
43. s connected to a 20 amp branch cir cuit with a nominal voltage rating of 115 to 125 volts 60 Hertz AC only The rated output with this installation is 88 amps 18 Volts 20 duty cycle 2 minutes of every 10 minutes used for welding CAUTION Do not connect the PRO 100 to an input power supply with a rated voltage that is greater than 125 volts Do not remove the power cord ground prong Requirements For CSA Rated Output A line cord with a 15 amp 125 volt three prong plug NEMA Type 5 15P is factory installed Connect this plug to a mating grounded receptacle which is con nected to a 15 amp branch circuit with a nominal volt age rating of 115 volts to 125 volts 60 hertz AC only With this installation the PRO 100 can be used at an output of 62 amps 20 volts 20 duty cycle PRO 100 LINCOLN 8 OPERATION B 1 Read entire operation section before operating the PRO 100 WARNING ELECTRIC SHOCK can kill Do not touch electrically live parts or electrode with skin or wet clothing Insulate yourself from work and ground Always wear insulating gloves FUMES AND GASES can be dangerous Keep your head out of fumes e Use ventilation or exhaust to remove fumes from breathing zone WELDING SPARKS can TE cause fire or explosion Keep flammable material away Do not weld on closed contain ers and skin e Wear eye ear and body protec tion 4 A
44. se Standard Drive Roll Small Smooth Groove K664 2 035 0 9mm Aluminum or Stainless Kit KP2078 1B1 035A 0 9mm M18971 1 035 0 9mm M19631 If 030 Solid wire feeding is desired obtain an KP2039 2B1 Contact Tip It is important when changing between welding with steel wire and aluminum to exchange feeding components due to the lubricant applied to steel wire Failure to do so may result in contaminated welds when welding aluminum PRO 100 LINCOLN 8 D 3 MAINTENANCE D 3 COMPONENT REPLACEMENT PROCEDURES CHANGING THE CONTACT TIP 1 Refer to Figure D 2 Remove the gas nozzle from the gun by unscrewing counter clockwise 2 Remove the existing contact tip from the gun by unscrewing counter clockwise 3 Insert and hand tighten desired contact tip 4 Replace gas nozzle CHANGING DRIVE ROLL The drive roll has two grooves one for 023 025 0 6 mm solid steel electrode and a larger knurled groove for 030 0 8 mm solid and 035 0 9 mm flux cored steel electrode As shipped the drive roll is installed in the 030 035 0 8 0 9 mm position If 023 025 0 6 mm wire is to be used the drive roll must be reversed as follows 1 Connect the machine to its rated input power per instructions in Installation section 2 Release the spring loaded pressure arm and lift the idle roll arm away from the drive roll 3 Turn the power switch to ON marked 4 Set the wire sp
45. sult in contaminated welds when welding aluminum TABLE B 1 Shielding Voltage Wire Speed Welding Wire Gas 22 ga 16 12 1 8 035 Dia 0 9mm 100 Argon 4 5 8 5 D 10 4043 Aluminum Wire 16 ga 14 ga 12 ga 030 Dia 98 Argon C 6 D 7 5 D 7 308L Stainless 2 Oxygen Steel Wire NR Not Recommended CHANGING MACHINE OVER TO FEED OTHER WIRE SIZES The PRO 100 is shipped from the factory ready to feed 0 035 0 9 mm diameter cored wire To operate the PRO 100 with other sizes and types of wire it maybe necessary to change the contact tip and drive roll orientation Refer to the MAINTENANCE section for component configuration and replacement proce dures 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 or argon carbon dioxide mixed shield ing gas Refer to the ACCESSORIES section for more information about installing the K610 1 Kit for use with the PRO 100 Also see the MAINTENANCE section for proper contact tip nozzle liner and drive roll config uration 1 For CO open the cylinder very slowly For argon mixed gas open cylinder valve slowly a fraction of a turn When the cylinder pressure gauge pointer stops moving open the valve fully 2 If using a regulator with an adjustable flow meter close the gun trigger and adj
46. t 3 Route the cable under and around the back of the Wire Feed Gearbox 6 4 For Innershield Only Refer to Figure 2 As delivered the PRO 100 is connected for negative electrode polarity This is the appropriate configu ration for the Innershield process To complete installation use the provided wing nut to connect the work cable s terminal lug to the positive out put terminal 5 located above the Wire Feed Gear box 6 Make sure that both wing nuts are tight 5 GMAW Only Refer to Figure A A 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 GUN INSTALLATION As shipped from the factory the PRO 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 see the MAINTENANCE sec tion for proper configuration of feeding components and installation details Connecting Gun Cable to the PRO 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
47. ts repairs safely contact your LOCAL AUTHORIZED LINCOLN ELECTRIC FIELD SERVICE FACILITY for assistance before you proceed PRO 100 LINCOLN E4 TROUBLESHOOTING en TROUBLESHOOTING GUIDE Observe Safety Guidelines detailed in the beginning of this manual PROBLEMS POSSIBLE AREAS OF RECOMMENDED SYMPTOMS MISADJUSTMENT S COURSE OF ACTION WELDING PROBLEMS Arc is unstable Poor starting Check for correct input voltage to machine 115vac Check for proper electrode polarity for process Check gun tip for wear or dam age and proper size Replace Contact your local Lincoln Check for proper gas and flow Authorized Field Service Facility rate for process For MIG only Check work cable for loose or faulty connections Check gun for damage or breaks Check for proper drive roll orien tation and alignment Check liner for proper size CAUTION If for any reason you do not understand the test procedures or are unable to perform the tests repairs safely contact your LOCAL AUTHORIZED LINCOLN ELECTRIC FIELD SERVICE FACILITY for assistance before you proceed PRO 100 LINCOLN 8 261911 F 1 ALIHM M Mov1d d 1409 40109 QV31 26813 d3d S 108WAS 19918193713 39018 YOLONGNOOD 314v9 NNO 330H9 LAdLNO DIAGRAMS 800 ED MS 0334 34lM p 4399141 1109 7236 OLGAINNON 7 1VISOWH3HL m ueo SIY 921 195 HOIH 10 esn je
48. ust the flow to give 15 20 cubic ft per hour 7 10 l min use 20 25 CFH 10 12 l min when welding out of position or in a drafty location for CO9 For argon mixed gas trigger to release gas pressure and turn off the adjust the flow to give 25 30 CFH 12 14 l min 3 Keep the cylinder valve closed except when using the PRO 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 PRO 100 OVERLOAD PROTECTION Output Overload The PRO 100 is equipped with a circuit breaker and a thermostat which protects the machine from damage if maximum output is exceeded The circuit breaker but ton will extend out when tripped The circuit breaker must be manually reset Thermal Protection The PRO 100 has a rated output duty cycle of 2096 If the duty cycle is exceeded a thermal protector will shut off the output until the machine cools to a reason able operating temperature This is an automatic func tion of the PRO 100 and does not require user inter vention The fan continues to run during cooling Electronic Wire Drive Motor Protection The PRO 100 has built in protection for wire drive motor overload PRO 100 LINCOLN APPLICATION CHART B 7 7 L c981 81791 ON Wed Ul 92 616 911 Saal SIM P9409 XnI4 91ZZON p Reetz ON ued 92 615 v 620 620
49. ve Roll 3 Ensure that the groove size in the feeding position on the drive roll matches the wire size being used 2 Carefully detach the end of the wire from the spool To prevent the spool from unwinding maintain tension on the wire until after step 5 3 Cut the bent portion of wire off and straighten the first 4 100 mm 4 Thread the wire through the In going guide tube 4 over the drive roll 3 and into the out going guide tube 5 5 Close the idle roll arm and latch the spring loaded pressure arm 2 in place Rotate the spool coun terclockwise if required in order to take up extra slack in the wire WARNING When inching the welding wire the drive rolls the gun connector block and the gun contact tip are electrically energized relative to work and ground and remain energized for several seconds after the gun trigger is released 6 The idle roll pressure adjustment wing nut is nor mally set for mid position on the pressure arm threads If feeding problems occur because the wire is flattened excessively turn the pressure adjustment counter clockwise to reduce distortion of the wire Slightly less pressure may be required when using 0 023 0 025 0 6 mm wire If the drive roll slips while feeding wire the pressure should be increaseduntil the wire feeds properly PRO 100 LINCOLN OPERATION B 4 FIGURE B 4 The Wire Drive Feed Roll can accommodate two wire sizes by flipping th
50. yourself from work and ground No toque las partes los electrodos bajo carga con la piel o ropa moja a Aislese del trabajo y de la tierra Ne laissez ni la peau ni des v te ments mouill s entrer en contact avec des pi ces sous tension Isolez vous du travail et de la terre Ber hren Sie keine stromfiihrenden Teile oder Elektroden mit Ihrem K rper oder feuchter Kleidung Isolieren Sie sich von den Elektro den und dem Erdboden e N o toque partes el tricas e elec trodos com a pele ou roupa molha da Isole se da pega e terra o REPOR ELE LATE MLMPT APSSAPREBS NTUWSHILT FSU E GUB MU DERNIERE GH Oa CRM ER e Xe sd a Sal e sis HIE Weal AMI W o Qi el all oa Y O el ai 1 d o El lala AA ll JS dan ule Y Jio moe Keep flammable materials away Mantenga el material combustible fuera del rea de trabajo Gardez l cart de tout mat riel inflammable Entfernen Sie brennbarres Material Mantenha inflamaveis bem guarda dos ORAPTUSOOM COREE CIE REA 0 7 5 eis A d s Jo ALD al gll pis Ac AI Wear eye ear and body protection Prot jase los ojos los o dos y el cuerpo Prot gez vos yeux vos oreilles et votre corps Tragen Sie Augen Ohren und K r perschutz Use prote o para a vista
Download Pdf Manuals
Related Search