Page 2 - SAFETY; WARNING; ARC WELDING can be hazardous.
i SAFETY WELD-PAK 100 PROTECT YOURSELF AND OTHERS FROM POSSIBLE SERIOUS INJURY OR DEATH. KEEP CHILDRENAWAY. PACEMAKER WEARERS SHOULD CONSULT WITH THEIR DOCTOR BEFORE OPERATING. Read and understand the following safety highlights. For additional safety information, it is strongly recommended that you...
Page 3 - ii
ii WELD-PAK 100 SAFETY FOR ELECTRICALLYpowered equipment. 6.a. Turn off input power using the disconnect switch at the fuse box before working onthe equipment. 6.b. Install equipment in accordance with the U.S. National Electrical Code, all local codes and the manufacturerʼsrecommendations. 6.c. Gro...
Page 4 - iii
iii SAFETY WELD-PAK 100 Mar. ʻ93 ELECTRIC AND MAGNETICFIELDSmay be dangerous 8 . a . E l e c t r i c c u r r e n t f l o w i n g t h r o u g h a n y c o n d u c t o r c a u s e s l o c a l i z e d E l e c t r i c a n d M a g n e t i c F i e l d s ( E M F ) . W e l d i n gc u r r e n t c r e a t e s ...
Page 5 - iv; PRÉCAUTIONS DE SÛRETÉ
iv SAFETY WELD-PAK 100 PRÉCAUTIONS DE SÛRETÉ Pour votre propre protection lire et observer toutes les instruc- tions et les précautions de sûreté specifiques qui parraissent d a n s c e m a n u e l a u s s i b i e n q u e l e s p r é c a u t i o n s d e s û r e t é générales suivantes: Sûreté Pour S...
Page 6 - Thank You; for selecting a; QUALITY; product by Lincoln Electric.; Please Examine Carton and Equipment For Damage Immediately
v WELD-PAK 100 Thank You for selecting a QUALITY product by Lincoln Electric. We want you to take pride in operating this LincolnElectric Company product ••• as much pride as wehave in bringing this product to you! Read this Operatorʼs Manual completely before attempting to use this equipment. Save ...
Page 7 - MASTER TABLE OF CONTENTS FOR ALL SECTIONS
vi FEB 95 WELD-PAK 100 MASTER TABLE OF CONTENTS FOR ALL SECTIONS Page Installation .......................................................................................................Section A Technical Specifications ..................................................................................
Page 8 - vii
Page 9 - INSTALLATION; TECHNICAL SPECIFICATIONS – WELD-PAK 100; INPUT – SINGLE PHASE ONLY
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. (7.6 mm) CSA 115V/60Hz 15 Amp 12 15 Amp, 125V, Three Conductor Three Prong Plug #1...
Page 10 - SAFETY PRECAUTIONS; ELECTRIC SHOCK can kill.
A-2 INSTALLATION WELD-PAK 100 JAN96 Read entire installation section before startinginstallation. SAFETY PRECAUTIONS IDENTIFY AND LOCATECOMPONENTS If you have not already done so, unpack the Weld-Pak100 from its carton and remove all packing materialaround the WELD-PAK 100. Remove the followingloose...
Page 11 - SELECT SUITABLE LOCATION; STACKING; OUTPUT CONNECTIONS; Work Clamp Installation
A-3 INSTALLATION WELD-PAK 100 SELECT SUITABLE LOCATION Locate the welder in a dry location where there is freecirculation of clean air into the louvers in the back andout the front of the unit. A location that minimizes theamount of smoke and dirt drawn into the rear louversreduces the chance of dir...
Page 12 - Work Cable Installation; For Innershield Only:; CAUTION
1 2 4 3 A-4 INSTALLATION WELD-PAK 100 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 WorkCable Access Hole (1) in the case front. 3....
Page 14 - INPUT CONNECTIONS; Requirements For Rated Output; Do not remove the power cord ground prong.; Requirements For CSA Rated Output
A-6 INSTALLATION WELD-PAK 100 INPUT CONNECTIONS FIGURE A.6 Refer to Figure A.6. The WELD-PAK 100 has a power input cable locatedon the rear of the machine. CODE REQUIREMENTS FOR INPUTCONNECTIONS This welding machine must be connected topower source in accordance with applicable elec-trical codes. Th...
Page 15 - OPERATION
WELD-PAK 100 B-1 OPERATION R e a d e n t i r e o p e r a t i o n s e c t i o n b e f o r eoperating the WELD-PAK 100. ELECTRIC SHOCK can kill. • Do not touch electrically live parts or electrode with skin orwet clothing. Insulate yourselffrom work and ground. • Always wear dry insulating gloves. FUM...
Page 16 - GENERAL DESCRIPTION; RECOMMENDED PROCESSES; WELDING CAPABILITY; OFF
WELD-PAK 100 JAN96 B-2 OPERATION GENERAL DESCRIPTION The WELD-PAK 100 is a compact lightweight DC wirefeeder/power source. It has been designed for work-shop, hobby, and light maintenance. It is capable ofgeneral purpose welding with self-shielded flux-cored(Innershield ® ) wire. When combined with ...
Page 17 - WELDING OPERATIONS; SEQUENCE OF OPERATION; Wire Loading
WELD-PAK 100 B-3 OPERATION out when tripped (Manual reset). FIGURE B.1a 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 theOFF (“O”) position before working inside the wire feedenclosure. The machine is shippe...
Page 18 - Friction Brake Adjustment
WELD-PAK 100 B-4 OPERATION Friction Brake Adjustment 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 incr...
Page 19 - Making A Weld; PROCESS GUIDELINES
WELD-PAK 100 B-5 OPERATION 100 is now ready to weld. Making A Weld 1. See “Process Guidelines” in this section for selec- tion of welding wire and shielding gas and forrange of metal thicknesses that can be welded. 2. See the Application chart on the inside of the wire feed compartment door for info...
Page 20 - Shielding Gas; OVERLOAD PROTECTION; Output Overload
WELD-PAK 100 B-6 OPERATION thinner, CO 2 gas is recommended because it gives equal or better performance than a blended gas at alower cost. A mixed gas consisting of 75 to 80% Argonand 20 to 25% CO 2 is recommended for welding on heavier gauge [12 gauge (2,5 mm) for example] steel. The WELD-PAK 100 ...
Page 21 - LEARNING TO WELD; THE ARC-WELDING CIRCUIT; • Avoid contact with eyes and skin.
WELD-PAK 100 B-7 LEARNING TO WELD LEARNING TO WELD No one can learn to weld simply by reading about it.Skill comes only with practice. The following pages willhelp the inexperienced operator to understand weld-ing and develop this skill. For more detailed informa-tion, order a copy of “New Lessons i...
Page 22 - PROCESS SELECTION
WELD-PAK 100 B-8 LEARNING TO WELD The “arc stream” is seen in the middle of the picture.This is the electric arc created by the electric currentflowing through the space between the end of the wireelectrode and the base metal. The temperature of thisarc is about 6000°F, which is more than enough tom...
Page 23 - COMMON METALS; The Correct Welding Position
WELD-PAK 100 B-9 LEARNING TO WELD 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 questionsG M A W m a y b e t h e p r o c e s s f o r y o u . I f y ...
Page 24 - ARC RAYS can burn eyes and skin.
WELD-PAK 100 B-10 LEARNING TO WELD ARC RAYS can burn eyes and skin. When using an open arc process, itIs necessary to use correct eye,head and body protection. Protect yourself and others, read“ARC RAYS can burn” at the frontof this manual. 2. The Correct Way To Strike An Arc 1. Be sure the work cla...
Page 25 - Helpful Hints; Mild Steel
WELD-PAK 100 B-11 LEARNING TO WELD Helpful Hints 1. For general welding, it is not necessary to weave the arc, neither forward or backward nor sideways.Weld along at a steady pace. You will find it easier. 2. When welding on thin plate, you will find that you will have to increase the welding speed,...
Page 27 - The Correct Welding Speed
WELD-PAK 100 B-13 LEARNING TO WELD FIGURE B.17 3. The Correct Electrical Stickout (ESO) The electrical stickout (ESO) is the distance fromthe end of the contact tip to the end of the wire.See Figure B.17. Once the arc has been established, maintainingthe correct ESO becomes extremely important.The E...
Page 28 - JOINT TYPES AND POSITIONS; Butt Welds
WELD-PAK 100 B-14 LEARNING TO WELD 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, ...
Page 29 - Vertical-down Welding; Welding In The Vertical Position; Vertical-up And Overhead Welding
FIGURE B.24 Vertical-down Welding Refer to Figure B.25 Vertical-down welds are appliedat a fast pace. These welds are therefore shallow andnarrow and, as such, are excellent for sheet metal.Vertical-down welds may be applied to 5/32” (3.9 mm)and lighter material. Use stringer beads and tip the gun i...
Page 30 - TROUBLESHOOTING WELDS; To Eliminate Porosity; To Eliminate a Ropy Convex Bead
WELD-PAK 100 B-16 LEARNING TO WELD TROUBLESHOOTING WELDS Good welds have excellent appearance. To Eliminate Porosity (in order of importance): 1. Turn on gas supply, if used 2. Decrease voltage. 3. Increase stickout. 4. Increase WFS (wire feed speed). 5. Decrease drag angle. 6. Decrease travel speed...
Page 31 - Proper Gun Handling
WELD-PAK 100 B-17 LEARNING TO WELD 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. 3. Do not allow dolly wheels or trucks to run...
Page 32 - APPLICATION CHART
Page 33 - ACCESSORIES; OPTIONAL ACCESSORIES; K664-1 Aluminum Feeding Kit; MIG CONVERSION
C-1 ACCESSORIES WELD-PAK 100 3. Change drive roll orientation (if required) for the wire size selected. See “ChangingDrive Roll” in Maintenance section fordetails. 4. Install the proper gun liner and tip for the w i r e s i z e s e l e c t e d . S e e “ C o m p o n e n tReplacement” in Maintenance s...
Page 34 - NOTES
Page 35 - MAINTENANCE; ROUTINE MAINTENANCE; POWER SOURCE COMPARTMENT; not
D-1 MAINTENANCE WELD-PAK 100 MAINTENANCE SAFETY PRECAUTIONS ELECTRIC SHOCK can kill. • Disconnect input power by removing plug from receptacle before workinginside WELD-PAK 100. Use only ground-ed receptacle. Do not touch electrically“hot” parts inside WELD-PAK 100. • Have qualified personnel do the...
Page 36 - CHANGING THE CONTACT TIP; Gun Cable Cleaning
D-2 MAINTENANCE WELD-PAK 100 5. To remove gun tube from gun, remove g a s n o z z l e o r g a s l e s s n o z z l e a n dremove diffuser from gun tube. Removeboth collars from each end of the gunhandle and separate the handle halves.Loosen the locking nut holding the guntube in place against the gun...
Page 37 - CHANGING DRIVE ROLL
D-3 MAINTENANCE WELD-PAK 100 CHANGING DRIVE ROLL The drive roll has two grooves; one for .023"– .025" (0.6 mm) solid steel electrode and alarger knurled groove for .030" (0.8 mm)solid and .035" (0.9 mm) flux-cored steele l e c t r o d e . A s s h i p p e d , t h e d r i v e r o l l i...
Page 38 - CHANGING LINER; Liner trim length
D-4 MAINTENANCE WELD-PAK 100 CHANGING LINER NOTICE: The variation in cable lengths pre-vents the interchangeability of liners. Oncea liner has been cut for a particular gun, its h o u l d n o t b e i n s t a l l e d i n a n o t h e r g u nunless it can meet the liner cutoff lengthrequirement. Refer ...
Page 39 - GUN HANDLE PARTS
D-5 MAINTENANCE WELD-PAK 100 GUN HANDLE PARTS The gun handle consists of two halves thatare held together with a collar on each end.T o o p e n u p t h e h a n d l e , t u r n t h e c o l l a r sapproximately 60 degrees counter-clock-wise until the collar reaches a stop. Thenpull the collar off the ...
Page 41 - TROUBLESHOOTING; HOW TO USE TROUBLESHOOTING GUIDE; LOCAL AUTHORIZED LINCOLN ELECTRIC
E-1 TROUBLESHOOTING WELD-PAK 100 This Troubleshooting Guide is provided tohelp you locate and remedy possible prob-l e m s w i t h m a c h i n e s e t u p o r o p e r a t i o n .S i m p l y f o l l o w t h e t h r e e - s t e p p r o c e d u r elisted below. Step 1. LOCATE PROBLEM (SYMPTOM). Look un...
Page 42 - TROUBLESHOOTING GUIDE; OUTPUT PROBLEMS
E-2 TROUBLESHOOTING WELD-PAK 100 Observe Safety Guidelines detailed in the beginning of this manual. TROUBLESHOOTING GUIDE PROBLEMS(SYMPTOMS) Major physical or electrical damageis evident. No wire feed, weld output or gasflow when gun trigger is pulled. Fandoes NOT operate. No wire feed, weld output...
Page 43 - FEEDING PROBLEMS; GAS FLOW PROBLEMS
E-3 TROUBLESHOOTING WELD-PAK 100 TROUBLESHOOTING GUIDE Observe Safety Guidelinesdetailed in the beginning of this manual. PROBLEMS(SYMPTOMS) No wire feed when gun trigger ispulled. Fan runs, gas flows andmachine has correct open circuitvoltage (32vcd maximum) – weldoutput. POSSIBLE AREAS OFMISADJUST...
Page 44 - WELDING PROBLEMS
E-4 TROUBLESHOOTING WELD-PAK 100 Observe Safety Guidelines detailed in the beginning of this manual. TROUBLESHOOTING 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 FACIL...
Page 45 - WIRING DIAGRAMS; WELD-PAK 100 WIRING DIAGRAM
F-1 WIRING DIAGRAMS WELD-PAK 100 WELD-PAK 100 WIRING DIAGRAM 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 WI...
Page 47 - PARTS MANUAL; PARTS
NOTE: This Parts Manual is provided as an informative guide only, when ordering parts always refer to the LincolnElectric Parts List. WELD-PAK 100 WELD-PAK 100 PARTS MANUAL PARTS
Page 48 - MAIN EXPLODED DIAGRAM
WELD-PAK 100 NOTE: This Parts Manual is provided as an informative guide only, when ordering parts always refer to the LincolnElectric Parts List. 2 PARTS MAIN EXPLODED DIAGRAM
Page 50 - COMPLETE DRIVE ASSEMBLY/MOTOR
WELD-PAK 100 NOTE: This Parts Manual is provided as an informative guide only, when ordering parts always refer to the LincolnElectric Parts List. 4 PARTS COMPLETE DRIVE ASSEMBLY/MOTOR Complete New Drive Assembly/ M15759-3 1 Motor, Includes All Items 1 – 10 below 1 Gearbox Mounting Plate L7829 1 1a ...
Page 51 - CASE FRONT ASSEMBLY
WELD-PAK 100 NOTE: This Parts Manual is provided as an informative guide only, when ordering parts always refer to the LincolnElectric Parts List. 5 PARTS CASE FRONT ASSEMBLY 1 Molded Case Front A464 1 2 Nameplate M16930-1 1 3 Fastener Buttons T14659-1 4 4 On/Off Switch, Includes 4a T10800-32 1 4a L...
Page 52 - RECTIFIER, FAN AND BRACKET ASSEMBLY
WELD-PAK 100 NOTE: This Parts Manual is provided as an informative guide only, when ordering parts always refer to the LincolnElectric Parts List. 6 PARTS RECTIFIER, FAN AND BRACKET ASSEMBLY Complete Assembly, Includes L7680-2 1 Items 1 – 5 below 1 Bracket for Fan & Rectifier G1839 1 2 Rectifier...
Page 53 - CENTER PANEL ASSEMBLY
WELD-PAK 100 NOTE: This Parts Manual is provided as an informative guide only, when ordering parts always refer to the LincolnElectric Parts List. 7 PARTS CENTER PANEL ASSEMBLY 2 Center Panel (Sheet Metal), L7569-8 1 Includes 2a – 2i, and Items 4, 5, 6 2a Center Panel (Sheet Metal) NSS 1 2b Slotted ...
Page 54 - ACCESSORIES AND EXPENDABLE REPLACEMENT PARTS FOR MAGNUM 100L
WELD-PAK 100 NOTE: This Parts Manual is provided as an informative guide only, when ordering parts always refer to the LincolnElectric Parts List. 8 PARTS MAGNUM 100L ASSEMBLY ACCESSORIES AND EXPENDABLE REPLACEMENT PARTS FOR MAGNUM 100L DESCRIPTION PART NUMBER SIZE COMPLETE GUN & CABLE ASSEMBLY ...
Page 57 - Lincoln Welding School; BASIC COURSE
Now Available...12th EditionThe Procedure Handbook of Arc Welding With over 500,000 copies of previous editions published since 1933, the Procedure Handbook is considered by many tobe the “Bible” of the arc welding industry. T h i s p r i n t i n g w i l l g o f a s t s o d o n ʼ t d e l a y . P l a...
Page 60 - CONDITIONS OF WARRANTY; WARRANTY LIMITATIONS; LIMITED WARRANTY; warranty superseded
STATEMENT OF LIMITED WARRANTY The Lincoln Electric Company (Lincoln) warrants to theend user (purchaser) of all new welding and cutting equip-ment, electrode and flux (collectively called the “Goods”)that it will be free of defects in workmanship and material. This warranty is void if Lincoln or its...
