Instruction/ maintenance manual of the product PRO 100 Lincoln Electric
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PRO 100 OPERA TOR’S MANUAL IM562-B May, 2000 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.
FOR ENGINE powered equipment. 1.a. Turn the engine off before troubleshooting and maintenance work unless the maintenance work requires it to be running. ____________________________________________________ 1.b. Operate engines in open, well-ventilated areas or vent the engine exhaust fumes outdoors.
ii SAFETY ii ARC RA YS 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. I standards.
FOR ELECTRICALL Y powered equipment. 8.a. Turn off input power using the disconnect switch at the fuse box before working on the equipment. 8.b. Install equipment in accordance with the U.S. National Electrical Code, all local codes and the manufacturer ’ s recommendations.
iv SAFETY iv PR É CA UTIONS DE S Û RET É Pour votre propre protection lire et observer toutes les instructions et les pr é cautions de s û ret é specifiques qui parraissent dans ce manuel aussi bien que les pr é cautions de s û ret é g é n é rales suiv- antes: S û ret é Pour Soudage A L ’ Arc 1.
Thank You for selecting a QUALITY product by Lincoln Electric. We want you to take pride in operating this Lincoln Electric Company product ••• as much pride as we have in bringing this product to you! Read this Operators Manual completely before attempting to use this equipment.
vi T ABLE OF CONTENTS Page Installation .......................................................................................................Section A Technical Specifications .........................................................................
A-1 PRO 100 A-1 INST ALLA TION Fuse or Output Mode Input Voltage Breaker Size Input Amps Power Cord Extension Cord RATED 115V/60Hz 20 Amp 20 15 Amp, 125V, Three Conductor Three Prong Plug #14 AWG (NEMA Type 5-15P) (2.1 mm 2 ) or Larger Up to 25 Ft. (7.
A-2 INST ALLA TION PRO 100 A-2 Read entire installation section before starting installation. SAFETY PRECA UTIONS IDENTIFY AND LOCA TE COMPONENTS If you have not already done so, unpack the PRO 100 from its carton and remove all packing material around the PRO 100.
A-3 INST ALLA TION PRO 100 A-3 SELECT SUIT ABLE LOCA TION 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-4 INST ALLA TION PRO 100 A-4 and installation details. Connecting Gun Cable to the PR O 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.
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. BE SURE TO KEEP YOUR FACE AWAY FROM THE VALVE OUTLET WHEN “ CRACKING ” THE VALVE.
A-6 INST ALLA TION PRO 100 A-6 INPUT CONNECTIONS FIGURE A.6 Refer to Figure A.6. The PRO 100 has a power input cable located on the rear of the machine. CODE REQUIREMENTS FOR INPUT CONNECTIONS This welding machine must be connected to power source in accordance with applicable elec- trical codes.
B-1 OPERA TION B-1 PRO 100 Read entire operation section before operating the PRO 100. 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 dry insulating gloves.
B-2 OPERA TION B-2 ● No external shielding gas is required when used with Lincoln Innershield .035 ” (0,9 mm) NR ® -211- MP electrode. ● Accommodates 4 ” (100 mm) diameter spool of wire. Will accommodate 8 ” (200 mm) diameter with optional spindle.
B-3 OPERA TION B-3 FIGURE B.1a FIGURE B.1b WELDING OPERA TIONS SEQUENCE OF OPERA TION 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.
Gun Handle Gas Diffuser/ Contact Tip Gas Nozzle FIGURE B.5 B-4 OPERA TION 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.
B-5 OPERA TION B-5 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. 2. See the Application chart on the inside of the wire feed compartment door for information on setting the PRO 100 controls.
B-6 OPERA TION B-6 lower cost. A mixed gas consisting of 75 to 80% Argon and 20 to 25% CO 2 is recommended for weld- ing on heavier gauge [12 gauge (2,5 mm) for exam- ple] steel. The PRO 100 is suitable for .035" aluminum wire and .030" stainless wire.
B-7 LEARNING T O WELD B-7 PRO 100 LEARNING T O WELD No one can learn to weld simply by reading about it. Skill comes only with practice. The following pages will help the inexperienced operator to understand welding and develop this skill.
B-8 LEARNING T O WELD B-8 PRO 100 The “ arc stream ” is seen in the middle of the picture. This is the electric arc created by the electric current flowing through the space between the end of the wire electrode and the base metal. The temperature of this arc is about 6000 ° F, which is more than enough to melt metal.
B-9 LEARNING T O WELD B-9 PRO 100 2. Can I afford the extra expense, space, and lack of portability required for gas cylinders and gas sup- ply? 3. Do I require clean, finished-looking welds? If you have answered yes to all the above questions GMAW may be the process for you.
B-10 LEARNING T O WELD B-10 PRO 100 FIGURE B.12 Penetration Unless a weld penetrates close to 100% of the metal thickness, a butt weld will be weaker than the material welded together. In the example shown in Figure B.13, the total weld is only half the thickness of the material thus the weld is only approximately half as strong as the metal.
B-11 LEARNING T O WELD B-11 PRO 100 FIGURE B.16 Vertical-down Welding Refer to Figure B.17 Vertical-down welds are applied at a fast pace. These welds are therefore shallow and narrow and, as such, are excellent for sheet metal. Vertical-down welds may be applied to 5/32 ” (3.
B-12 LEARNING T O WELD B-12 PRO 100 ARC RAYS can burn eyes and skin. When using an open arc process, it Is necessary to use correct eye, head and body protection. Protect yourself and others, read “ ARC RAYS can burn ” at the front of this manual.
B-13 LEARNING T O WELD B-13 PRO 100 Helpful Hints 1. For general welding, it is not necessary to weave the arc, neither forward or backward nor sideways.
B-14 LEARNING T O WELD B-14 PRO 100 MA CHINE SET UP FOR THE GMA W (MIG) PROCESS 1. See PROCESS GUIDELINES in the OPERATION section for selection of welding wire and shielding gas, and for range of metal thicknesses that can be welded. 2. See the Application Guide on the inside of wire feed section door for information on setting the controls.
B-15 LEARNING T O WELD B-15 PRO 100 FIGURE B.24 3. The Correct Electrical Stickout (ESO) The electrical stickout (ESO) is the distance from the end of the contact tip to the end of the wire. See Figure B.24. Once the arc has been established, maintaining the correct ESO becomes extremely important.
4. After you strike the arc, practice the correct electri- cal stickout. Learn to distinguish it by its sound. 5. When you are sure that you can hold the correct electrical stickout, with a smooth “ crackling ” arc, start moving. Look at the molten puddle constantly, 6.
B-17 LEARNING T O WELD B-17 PRO 100 Proper Gun Handling Most feeding problems are caused by improper han- dling of the gun cable or electrodes. 1. Do not kink or pull the gun around sharp corners 2. Keep the gun cable as straight as practical when welding.
B-18 APPLICA TION CHART B-18 PRO 100.
C-1 A CCESSORIES C-1 OPTIONAL A CCESSORIES 1. K520 Utility Cart — Designed to transport the Lin- coln family of small welders. Has provisions for mounting a single gas cylinder. Has front casters and large rear wheels. Handle height is easily adjustable.
D-1 MAINTENANCE D-1 PRO 100 MAINTENANCE SAFETY PRECA UTIONS ELECTRIC SHOCK can kill. • Disconnect input power by removing plug from receptacle before working inside PRO 100. Use only grounded receptacle. Do not touch electrically “ hot ” parts inside PRO 100.
D-2 MAINTENANCE D-2 GUN AND CABLE MAINTENANCE FOR MA GNUM ™ 100L GUN Gun Cable Cleaning Clean cable liner after using approximately 300 lbs (136 kg) of solid wire or 50 lbs (23 kg) of flux-cored wire. Remove the cable from the wire feeder and lay it out straight on the floor.
D-3 MAINTENANCE D-3 COMPONENT REPLA CEMENT PR OCEDURES CHANGING THE CONT A CT 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.
D-4 MAINTENANCE D-4 PRO 100 CHANGING LINER NOTICE: The variation in cable lengths pre- vents the interchangeability of liners. Once a liner has been cut for a particular gun, it should not be installed in another gun unless it can meet the liner cutoff length requirement.
D-5 MAINTENANCE D-5 PRO 100 GUN HANDLE P ARTS 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.
E-1 TR OUBLESHOO TING E-1 PRO 100 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) ” .
E-2 TR OUBLESHOO TING E-2 PRO 100 Observe Safety Guidelines detailed in the beginning of this manual. TR OUBLESHOO TING GUIDE PROBLEMS (SYMPT OMS) Major physical or electrical damage is evident. No wire feed, weld output or gas flow when gun trigger is pulled.
E-3 TR OUBLESHOO TING E-3 PRO 100 TR OUBLESHOO TING GUIDE Observe Safety Guidelines detailed in the beginning of this manual. PROBLEMS (SYMPT OMS) No wire feed when gun trigger is pulled. Fan runs, gas flows and machine has correct open circuit voltage (32vcd maximum) – weld output.
E-4 TR OUBLESHOO TING E-4 PRO 100 Observe Safety Guidelines detailed in the beginning of this manual. TR OUBLESHOO TING GUIDE 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.
F-1 DIA GRAMS F-1 PRO 100 S1 SWITCH D1 D3 D2 D4 204 204 204 203 203 203 C1 59,000 mf 40V 203 204 - + GUN CABLE CONDUCTOR BLOCK TO WORK ELECTRICAL SYMBOLS PER E1537 CAVITY NUMBERING SEQUENCE ( COMPONENT SIDE OF BOARD ) 539 541 T1 213 GUN TRIGGER THERMOSTAT 208 5K WIRE SPEED R2 (W) (B) N.
NO TES PRO 100.
Now A vailable...12th Edition The Procedure Handbook of Ar c W elding With over 500,000 copies of previous editions published since 1933, the Procedure Handbook is considered by many to be the “ Bible ” of the arc welding industry. This printing will go fast so don ’ t delay.
W ARNING A VISO DE PRECA UCION A TTENTION W ARNUNG A TEN ÇÃ O Spanish French German Portuguese Japanese Chinese Korean Arabic READ AND UNDERST AND THE MANUF ACTURER’S INSTRUCTION FOR THIS EQUIPMENT AND THE CONSUMABLES TO BE USED AND FOLLOW YOUR EMPLOYER’S SAFETY PRACTICES.
W ARNING A VISO DE PRECA UCION A TTENTION W ARNUNG A TEN ÇÃ O Spanish French German Portuguese Japanese Chinese Korean Arabic LEIA E COMPREENDA AS INSTRUÇÕES DO F ABRICANTE P ARA ESTE EQUIP AMENTO E AS PAR TES DE USO, E SIGA AS PRÁTICAS DE SEGURANÇA DO EMPREGADOR.
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An important point after buying a device Lincoln Electric PRO 100 (or even before the purchase) is to read its user manual. We should do this for several simple reasons:
If you have not bought Lincoln Electric PRO 100 yet, this is a good time to familiarize yourself with the basic data on the product. First of all view first pages of the manual, you can find above. You should find there the most important technical data Lincoln Electric PRO 100 - thus you can check whether the hardware meets your expectations. When delving into next pages of the user manual, Lincoln Electric PRO 100 you will learn all the available features of the product, as well as information on its operation. The information that you get Lincoln Electric PRO 100 will certainly help you make a decision on the purchase.
If you already are a holder of Lincoln Electric PRO 100, but have not read the manual yet, you should do it for the reasons described above. You will learn then if you properly used the available features, and whether you have not made any mistakes, which can shorten the lifetime Lincoln Electric PRO 100.
However, one of the most important roles played by the user manual is to help in solving problems with Lincoln Electric PRO 100. Almost always you will find there Troubleshooting, which are the most frequently occurring failures and malfunctions of the device Lincoln Electric PRO 100 along with tips on how to solve them. Even if you fail to solve the problem, the manual will show you a further procedure – contact to the customer service center or the nearest service center
