Professional Documents
Culture Documents
OPERATOR’S MANUAL
Read and understand the following safety highlights. For additional safety information, it is strongly recommended that you
purchase a copy of “Safety in Welding & 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.
ELECTRIC AND
MAGNETIC FIELDS
____________________________________________________
1.c. Do not add the fuel near an open flame may be dangerous
welding arc or when the engine is running.
Stop the engine and allow it to cool before 2.a. Electric current flowing through any conductor causes
refueling to prevent spilled fuel from vaporiz- localized Electric and Magnetic Fields (EMF). Welding
ing on contact with hot engine parts and current creates EMF fields around welding cables and
igniting. Do not spill fuel when filling tank. If welding machines
fuel is spilled, wipe it up and do not start
engine until fumes have been eliminated. 2.b. EMF fields may interfere with some pacemakers, and
____________________________________________________ welders having a pacemaker should consult their physician
1.d. Keep all equipment safety guards, covers and devices in before welding.
position and in good repair.Keep hands, hair, clothing and
tools away from V-belts, gears, fans and all other moving 2.c. Exposure to EMF fields in welding may have other health
parts when starting, operating or repairing equipment. effects which are now not known.
____________________________________________________
1.e. In some cases it may be necessary to remove safety 2.d. All welders should use the following procedures in order to
guards to perform required maintenance. Remove minimize exposure to EMF fields from the welding circuit:
guards only when necessary and replace them when the
maintenance requiring their removal is complete. 2.d.1. Route the electrode and work cables together - Secure
Always use the greatest care when working near moving them with tape when possible.
parts.
___________________________________________________ 2.d.2. Never coil the electrode lead around your body.
1.f. Do not put your hands near the engine fan.
Do not attempt to override the governor or 2.d.3. Do not place your body between the electrode and
idler by pushing on the throttle control rods work cables. If the electrode cable is on your right
while the engine is running. side, the work cable should also be on your right side.
3.f. Maintain the electrode holder, work clamp, welding cable and 5.b. Do not weld in locations near chlorinated hydrocarbon vapors
welding machine in good, safe operating condition. Replace coming from degreasing, cleaning or spraying operations.
damaged insulation. The heat and rays of the arc can react with solvent vapors to
form phosgene, a highly toxic gas, and other irritating
3.g. Never dip the electrode in water for cooling. products.
3.h. Never simultaneously touch electrically “hot” parts of 5.c. Shielding gases used for arc welding can displace air and
electrode holders connected to two welders because voltage cause injury or death. Always use enough ventilation,
between the two can be the total of the open circuit voltage especially in confined areas, to insure breathing air is safe.
of both welders.
5.d. Read and understand the manufacturer’s instructions for this
3.i. When working above floor level, use a safety belt to protect equipment and the consumables to be used, including the
yourself from a fall should you get a shock. material safety data sheet (MSDS) and follow your
employer’s safety practices. MSDS forms are available from
3.j. Also see Items 6.c. and 8. your welding distributor or from the manufacturer.
6.b. Where compressed gases are to be used at the job site, 7.b. Always keep cylinders in an upright position securely
special precautions should be used to prevent hazardous chained to an undercarriage or fixed support.
situations. Refer to “Safety in Welding and Cutting” (ANSI
Standard Z49.1) and the operating information for the 7.c. Cylinders should be located:
equipment being used. • Away from areas where they may be struck or subjected to
physical damage.
6.c. When not welding, make certain no part of the electrode
circuit is touching the work or ground. Accidental contact • A safe distance from arc welding or cutting operations and
can cause overheating and create a fire hazard. any other source of heat, sparks, or flame.
6.d. Do not heat, cut or weld tanks, drums or containers until the 7.d. Never allow the electrode, electrode holder or any other
proper steps have been taken to insure that such procedures electrically “hot” parts to touch a cylinder.
will not cause flammable or toxic vapors from substances
inside. They can cause an explosion even though they have 7.e. Keep your head and face away from the cylinder valve outlet
been “cleaned”. For information, purchase “Recommended when opening the cylinder valve.
Safe Practices for the Preparation for Welding and Cutting of
Containers and Piping That Have Held Hazardous 7.f. Valve protection caps should always be in place and hand
Substances”, AWS F4.1 from the American Welding Society tight except when the cylinder is in use or connected for
use.
(see address above).
7.g. Read and follow the instructions on compressed gas
6.e. Vent hollow castings or containers before heating, cutting or
cylinders, associated equipment, and CGA publication P-l,
welding. They may explode.
“Precautions for Safe Handling of Compressed Gases in
Cylinders,” available from the Compressed Gas Association
6.f. Sparks and spatter are thrown from the welding arc. Wear oil
1235 Jefferson Davis Highway, Arlington, VA 22202.
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 FOR ELECTRICALLY
welding area. powered equipment.
6.g. Connect the work cable to the work as close to the welding
8.a. Turn off input power using the disconnect
area as practical. Work cables connected to the building
switch at the fuse box before working on
framework or other locations away from the welding area
the equipment.
increase the possibility of the welding current passing
through lifting chains, crane cables or other alternate cir-
8.b. Install equipment in accordance with the U.S. National
cuits. This can create fire hazards or overheat lifting chains
Electrical Code, all local codes and the manufacturer’s
or cables until they fail.
recommendations.
6.h. Also see item 1.c.
8.c. Ground the equipment in accordance with the U.S. National
Electrical Code and the manufacturer’s recommendations.
Mar ‘95
iv iv
SAFETY
zones où l’on pique le laitier.
PRÉCAUTIONS DE SÛRETÉ
Pour votre propre protection lire et observer toutes les instructions 6. Eloigner les matériaux inflammables ou les recouvrir afin de
et les précautions de sûreté specifiques qui parraissent dans ce prévenir tout risque d’incendie dû aux étincelles.
manuel aussi bien que les précautions de sûreté générales suiv-
antes: 7. Quand on ne soude pas, poser la pince à une endroit isolé de
la masse. Un court-circuit accidental peut provoquer un
Sûreté Pour Soudage A L’Arc échauffement et un risque d’incendie.
1. Protegez-vous contre la secousse électrique:
8. S’assurer que la masse est connectée le plus prés possible
a. Les circuits à l’électrode et à la piéce sont sous tension de la zone de travail qu’il est pratique de le faire. Si on place
quand la machine à souder est en marche. Eviter toujours la masse sur la charpente de la construction ou d’autres
tout contact entre les parties sous tension et la peau nue endroits éloignés de la zone de travail, on augmente le risque
ou les vétements mouillés. Porter des gants secs et sans de voir passer le courant de soudage par les chaines de lev-
trous pour isoler les mains. age, câbles de grue, ou autres circuits. Cela peut provoquer
b. Faire trés attention de bien s’isoler de la masse quand on des risques d’incendie ou d’echauffement des chaines et des
soude dans des endroits humides, ou sur un plancher câbles jusqu’à ce qu’ils se rompent.
metallique ou des grilles metalliques, principalement dans
les positions assis ou couché pour lesquelles une grande 9. Assurer une ventilation suffisante dans la zone de soudage.
partie du corps peut être en contact avec la masse. Ceci est particuliérement important pour le soudage de tôles
c. Maintenir le porte-électrode, la pince de masse, le câble galvanisées plombées, ou cadmiées ou tout autre métal qui
de soudage et la machine à souder en bon et sûr état produit des fumeés toxiques.
defonctionnement.
d.Ne jamais plonger le porte-électrode dans l’eau pour le 10. Ne pas souder en présence de vapeurs de chlore provenant
refroidir. d’opérations de dégraissage, nettoyage ou pistolage. La
e. Ne jamais toucher simultanément les parties sous tension chaleur ou les rayons de l’arc peuvent réagir avec les vapeurs
des porte-électrodes connectés à deux machines à souder du solvant pour produire du phosgéne (gas fortement toxique)
parce que la tension entre les deux pinces peut être le ou autres produits irritants.
total de la tension à vide des deux machines.
f. Si on utilise la machine à souder comme une source de 11. Pour obtenir de plus amples renseignements sur la sûreté,
courant pour soudage semi-automatique, ces precautions voir le code “Code for safety in welding and cutting” CSA
pour le porte-électrode s’applicuent aussi au pistolet de Standard W 117.2-1974.
soudage.
Thank You to take pride in operating this Lincoln Electric Company product
••• as much pride as we have in bringing this product to you!
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.
- 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.
• 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 the safety instructions we have provided for your protection.
The level of seriousness to be applied to each is explained below:
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 or damage to
this equipment.
vi vi
TABLE OF CONTENTS
Page
Installation .......................................................................................................Section A
Technical Specifications ........................................................................................A-1
Identify and Locate Components ...........................................................................A-2
Select Suitable Location ........................................................................................A-3
Output Connections ...............................................................................................A-3
Input Connections..................................................................................................A-6
Code Requirements ..............................................................................................A-6
Operation .........................................................................................................Section B
Safety Precautions ................................................................................................B-1
General Description ...............................................................................................B-2
Design Features and Advantages...................................................................B-2
Welding Capability ..........................................................................................B-2
Limitations .......................................................................................................B-2
Controls and Settings......................................................................................B-2
Welding Operations ...............................................................................................B-3
Overload Protection ...............................................................................................B-6
Application Chart ...................................................................................................B-7
Accessories .....................................................................................................Section C
Accessories ...........................................................................................................C-1
Replacement Parts ................................................................................................C-1
Maintenance ....................................................................................................Section D
Safety Precautions ................................................................................................D-1
Items Requiring No Maintenance ..........................................................................D-1
Routine Maintenance.............................................................................................D-1
Gun and Cable Maintenance.................................................................................D-2
Configuration of Components in Wire Feeding System.........................................D-2
Component Replacement Procedures ..................................................................D-3
Troubleshooting ..............................................................................................Section E
Safety Precautions.................................................................................................E-1
How to Use Troubleshooting Guide.......................................................................E-1
Troubleshooting Guide.............................................................................E-2 thru E-4
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)
PHYSICAL DIMENSIONS
Height Width Depth Weight
12.0 in 9.75 in 16.5 in 47 Ibs
305 mm 248 mm 419 mm 21.4 kg
PRO 100
A-2 INSTALLATION A-2
Read entire installation section before starting FIGURE A.1
installation.
SAFETY PRECAUTIONS
1 2
WARNING
ELECTRIC SHOCK can kill.
PRO
100
• 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 (“O”) position when installing work 4
cable and gun and when connecting power
cord to input power.
3
1. PRO 100
5. Work clamp.
8. Instructional video.
(1)
The gun is ready to feed 0.035" (0,9 mm) Inner-
shield wire.
PRO 100
A-3 INSTALLATION A-3
SELECT SUITABLE LOCATION 6. Wire Feed Gearbox.
Locate the welder in a dry location where there is free 7. Cable Hanger.
circulation of clean air into the louvers in the back and
out the front of the unit. A location that minimizes the 8. Thumbscrew.
amount of smoke and dirt drawn into the rear louvers
reduces the chance of dirt accumulation that can block Work Clamp Installation
air passages and cause overheating.
Attach the work clamp per the following:
Each machine must be placed on a secure, level sur- 3. Fasten securely with the bolt and nut provided.
face, either directly or on a recommended undercar-
riage. The machine may topple over if this procedure
is not followed. FIGURE A.3
Work Cable
Refer to Figure A.2. Nut & Bolt
FIGURE A.2
4
5
DO NOT SWITCH
WHEN WELDING
+
PRO 100 8
-
3 6 7
1 2
PRO 100
A-4 INSTALLATION A-4
Work Cable Installation
Connecting Gun Cable to the PRO 100
Refer to Figure A.2.
1. Refer to Figure A.2. Unplug the machine or turn
1. Open the wire feed section door on the right side of power switch to the OFF “O” position.
the PRO 100.
2. Pass the insulated terminals of the gun trigger con-
2. Pass the end of the work cable that has the termi- trol leads, one at a time, through the Gun Cable
nal lug with the smaller hole through the Work and Control Lead Access Slot (2) in the case front.
Cable Access Hole (1) in the case front. The leads are to be routed under the Wire Feed
Gearbox (6) and through the Cable Hanger (7) on
3. Route the cable under and around the back of the the inner panel.
Wire Feed Gearbox (6).
3. Insert the connector on the gun conductor cable
4. For Innershield Only: Refer to Figure A.2. As through the Gun Cable Access Hole (2) in the
delivered, the PRO 100 is connected for negative PRO 100 case front. Make sure the connector is all
electrode polarity. This is the appropriate configu- the way in the brass connector block. Unscrew
ration for the Innershield process. To complete thumbscrew on the connector block a few turns if
installation, use the provided wing nut to connect gun connector will not insert fully. Rotate the con-
the work cable’s terminal lug to the positive (+) out- nector so control leads are on the underside and
put terminal (5) located above the Wire Feed Gear- tighten the Thumbscrew (8) in the connector block.
box (6). Make sure that both wing nuts are tight.
4. Connect the gun trigger control lead terminals to
5. For GMAW Only: Refer to Figure A.4. To wire for the two insulated 1/4" (6,4 mm) tab terminal con-
positive polarity (required for the MIG process), nector bushings located above the “Gun Trigger
connect the short cable attached to the connector Connection” decal in the wire feed section (4).
block (1) to the positive (+) output terminal (4) and Either lead can go to either connector. Form the
the work cable (3) to the negative (–) terminal (2). leads so that they are as close as possible to the
inside panel.
FIGURE A.4
4 CAUTION
If the gun trigger switch being used is other than
3 that supplied with the PRO 100, the switch must
2 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
1 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.
PRO 100
A-5 INSTALLATION A-5
WARNING
CYLINDER may explode if dam- 2. With the cylinder securely installed, remove the
aged. Keep cylinder upright and cylinder cap. Stand to one side away from the out-
chained to support let and open the cylinder valve very slightly for an
instant. This blows away any dust or dirt which may
• Keep cylinder away from areas
have accumulated in the valve outlet.
where it may be damaged.
• Never lift welder with cylinder
attached. WARNING
• Never allow welding electrode to
touch cylinder. BE SURE TO KEEP YOUR FACE AWAY FROM THE
VALVE OUTLET WHEN “CRACKING” THE VALVE.
• Keep cylinder away from welding Never stand directly in front of or behind the flow
or other live electrical circuits. regulator when opening the cylinder valve. Always
stand to one side.
WARNING
3. Attach the flow regulator to the cylinder valve and
BUILDUP OF SHIELDING GAS may tighten the union nut securely with a wrench..
harm health or kill.
NOTE: If connecting to 100% CO2 cylinder, insert
• Shut off shielding gas supply regulator adapter (provided with MIG Conversion
when not in use. Kit for the PRO 100) between regulator and cylin-
• SEE AMERICAN NATIONAL der valve. If adapter is equipped with a plastic
STANDARD Z-49.1, “SAFETY IN washer, be sure it is seated for connection to the
WELDING AND CUTTING” PUB- CO2 cylinder.
LISHED BY THE AMERICAN
WELDING SOCIETY. 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-
1. Chain the cylinder to a wall or other stationary sup- nect the other end to the PRO 100 Gas Solenoid
port to prevent the cylinder from falling over. Insu- Inlet Fitting (5/8-18 female threads — for CGA —
late the cylinder from the work circuit and earth 032 fitting). Make certain the gas hose is not
ground. Refer to Figure A.5. kinked or twisted.
FIGURE A.5
Gas Hose
PRO 100
A-6 INSTALLATION A-6
INPUT CONNECTIONS Requirements For Rated Output
FIGURE A.6 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 is connected to a 20 amp branch cir-
cuit with a nominal voltage rating of 115 to 125 volts,
60 Hertz, AC only.
WARNING
This welding machine must be connected to
power source in accordance with applicable elec-
trical codes.
PRO 100
B-1 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 dry insulating
gloves.
PRO 100
B-2 OPERATION B-2
GENERAL DESCRIPTION ● No external shielding gas is required when used
with Lincoln Innershield .035” (0,9 mm) NR®-211-
The PRO 100 is a compact lightweight DC wire feed- MP electrode.
er/power source. It has been designed for workshop,
● Accommodates 4” (100 mm) diameter spool of
hobby, and light maintenance. It is capable of general
wire. Will accommodate 8” (200 mm) diameter with
purpose welding with self-shielded flux-cored (Inner-
optional spindle.
shield®) wire. When combined with the optional K610-
1 MIG Conversion Kit, the PRO 100 is suitable for
GMAW (MIG) welding applications.
WELDING CAPABILITY
The PRO 100 is ideally suited for individuals having The PRO 100 is rated at 88 amps, 18 volts, at 20%
access to 115 volt AC input power, and wanting the duty cycle on a ten minute basis. CSA rated output at
ease of use, quality and dependability of both the 62 amps at 20 volts at 20% duty cycle. It is capable of
Innershield electrode process (self-shielded flux-cored higher output currents at lower duty cycles.
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 LIMITATIONS
dependable service and long life.
Arc Gouging cannot be performed with the PRO 100.
The PRO 100 is not recommended for pipe thawing or
RECOMMENDED PROCESSES TIG welding.
The PRO 100 can be used for welding mild steel using
the self shielded, Innershield electrode process CONTROLS AND SETTINGS
(FCAW) or it can be used for the GMAW, single pass,
process which requires a supply of shielding gas and Refer to Figure B.1a.
the K610-1 MIG Conversion Kit. The PRO 100 is con-
figured for use with the FCAW process as delivered 1. Power ON/OFF Switch —
from the factory. When the power is on the
fan motor will run and air will
be exhausted out the louvers
OPERATIONAL FEATURES AND in the front of the machine. OFF
CONTROLS The welding output and wire
feeder remain off until the
The PRO 100 has the following controls as standard: gun trigger is pressed.
Power ON/OFF Switch, Voltage Control, Wire Speed ON
Control, Trigger Switch, and a Circuit Breaker. 2. Wire Speed Control — Con-
trols the wire feed speed
from 50 – 300 in /min (1.3 –
DESIGN FEATURES AND 7.6 m/min). The control can
ADVANTAGES be preset on the dial to the
WIRE SPEED
setting specified on the PRO
● Operates on 115 volt input . 100 Application Chart locat-
● “Cold electrode” until gun trigger is pressed for an ed on the inside of the wire
added measure of safety. feed section door.
PRO 100
B-3 OPERATION B-3
FIGURE B.1a
3
DO NOT SWITCH
WHEN WELDING
Wing Nut
PRO 100 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
FIGURE B.1b spacer and wing nut at the end of the shaft. Insert
spindle as shown in figure B.3. Reattach spacer and
wing nut.
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
Wire Loading
Refer to Figure B.2 AND B3.
PRO 100
B-4 OPERATION B-4
FIGURE 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
2. Carefully detach the end of the wire from the 9. Straighten the gun cable assembly.
spool. To prevent the spool from unwinding,
maintain tension on the wire until after step 5. 10. Depress the gun trigger switch and feed welding
wire through the gun and cable. (Point gun away
3. Cut the bent portion of wire off and straighten the from yourself and others while feeding wire.)
first 4” (100 mm). Release gun trigger after wire appears at end of
gun.
4. Thread the wire through the In-going guide tube
(4), over the drive roll (3), and into the out-going 11. Turn the PRO 100 OFF (“O”).
guide tube (5).
12. Replace contact tip and gas nozzle.
5. Close the idle roll arm and latch the spring loaded
pressure arm (2) in place. Rotate the spool coun- 13. Refer to Figure B-6. Cut the wire off 3/8” – 1/2” (10
terclockwise if required in order to take up extra – 13 mm) from the end of the tip. The PRO 100 is
slack in the wire. now ready to weld.
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. FIGURE B.5
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
Gun Handle
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 Gas Diffuser/
drive roll slips while feeding wire, the pressure Contact Tip
should be increaseduntil the wire feeds properly.
Gas Nozzle
PRO 100
B-5 OPERATION B-5
FIGURE B.6 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.
Contact Tip
4. Check that the polarity is correct for the welding PROCESS GUIDELINES
wire being used and that the gas supply, if
required, is turned on. The PRO 100 as shipped, can be used for welding
mild steel using the self shielded, Innershield elec-
5. When using Innershield electrode, remove the gas trode process or it can be used for the GMAW (MIG),
nozzle and install the gasless nozzle. This will single pass, process which requires a supply of
improve visibility of the arc and protect the gas dif- shielding gas and the K610-1 MIG Conversion Kit.
fuser from weld spatter. Refer to the MAINTE-
NANCE section for details on nozzle replacement. 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
FIGURE B.7 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)].
PRO 100
B-6 OPERATION B-6
The PRO 100 is suitable for .035" aluminum wire and 1. For CO2, open the cylinder very slowly. For argon-
.030" stainless wire. Refer to Table B.1 for recom- mixed gas, open cylinder valve slowly a fraction of
mended procedure settings. (Requires K610-1 MIG a turn. When the cylinder pressure gauge pointer
Conversion Kit and K664-2 Aluminum - Stainless stops moving, open the valve fully.
Feeding Kit.)
2. If using a regulator with an adjustable flow meter,
close the gun trigger and adjust the flow to give 15
CAUTION – 20 cubic ft per hour (CFH) (7 – 10 I/min) [use 20
– 25 CFH (10 – 12 I/min) when welding out of
It is important when changing between welding position or in a drafty location for CO2]. For argon
with steel wire and aluminum to exchange feeding mixed gas, trigger to release gas pressure, and
components due to the lubricant applied to steel turn off the adjust the flow to give 25 – 30 CFH
wire. Failure to do so may result in contaminated (12 – 14 I/min).
welds when welding aluminum.
------------------------------------------------------------------------ 3. Keep the cylinder valve closed, except when using
the PRO 100. When finished welding:
a) Close the cylinder valve to stop gas flow.
TABLE B.1
b) Depress the gun trigger briefly to release the
Shielding Voltage/Wire Speed
Process Welding Wire Gas 22 ga 16 ga 12 ga 1/8” 3/16” 1/4”
pressure in the gas hose.
.035 Dia(0.9mm 100% Argon A-4.5 C-8.5 D-10 NR* NR* NR* c) Turn off the PRO 100.
4043 Aluminum
Wire
16 ga 14 ga 12 ga 10 ga
MIG DC+
.030 Dia 98% Argon/ A-3 C-6 D-7.5 D-7.5
308L Stainless 2% Oxygen
Steel Wire
OVERLOAD PROTECTION
*NR-Not Recommended 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-
CHANGING MACHINE OVER TO ton will extend out when tripped. The circuit breaker
FEED OTHER WIRE SIZES must be manually reset.
PRO 100
B-7 APPLICATION CHART B-7
PRO 100
C-1 ACCESSORIES C-1
OPTIONAL ACCESSORIES
MIG CONVERSION
1. K520 Utility Cart — Designed to transport the Lin-
coln family of small welders. Has provisions for Several changes are needed to convert the unit for
mounting a single gas cylinder. Has front casters operation with the MIG (GMAW) process. The K610-1
and large rear wheels. Handle height is easily MIG Conversion Kit for the PRO 100 includes all the
adjustable. Bottom tray provided for tools and necessary accessories for this conversion and is pro-
accessories. Easy assembly required; takes less vided for this purpose. The following conversions
than 15 minutes. should be made using the contents of this kit:
2. M15445 Spindle — Mounts onto standard spool 1. Install the gas solenoid. Complete instructions are
shaft for 4" (100 mm) spools to provide for mount- included with the kit.
ing 8" (200 mm) diameter spools with 2" (51 mm)
I.D. and up to 2.2" (56 mm) wide. 2. Change the output polarity to DC(+). See “Work
Cable Installation” in Installation section for details.
3. K664-2 Aluminum Feeding Kit — This kit recom-
mended for welding with .035 Aluminum wire. This 3. Change drive roll orientation (if required) for the
kit may also be used for feeding .030 stainless wire size selected. See “Changing Drive Roll” in
wire. Included with this kit are a drive roll, gun liner Maintenance section for details.
and contact tip. It is important when changing
between welding with steel wire and aluminum 4. Install the proper gun liner (Note 1) and tip for the
to exchange these components due to the wire size selected. See “Component Replacement”
lubricant applied to steel wire. Failure to do so in Maintenance section for details.
may result in contaminated welds when weld-
ing aluminum. 5. Remove gasless nozzle (if installed) and install gas
nozzle. To remove, simply unscrew.
See Maintenance section for instructions on
installing drive roll, cable liner, contact tip and their 6. Load wire into machine and thread into gun and
proper configuration. cable per “Welding Wire Loading” section.
4. K610-1 MIG Conversion Kit for the PRO 100 — (Note 1) The factory installed gun liner will feed
Complete kit for use with .025" (0.6 mm) electrode .025 - .035 (0.6 - 0.9 mm) wire.
wire and either CO2 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 CO2 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.
PRO 100
D-1 MAINTENANCE D-1
MAINTENANCE
SAFETY PRECAUTIONS
WARNING
ELECTRIC SHOCK can kill.
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.
FAN MOTOR
PRO 100
D-2 MAINTENANCE D-2
Excessive pressure at the start may cause the dirt 5. To remove gun tube from gun, remove gas nozzle
to form a plug. or gasless nozzle and remove diffuser from gun
tube. Remove both collars from each end of the
gun handle and separate the handle halves.
Flex the cable over its entire length and again blow Loosen the locking nut holding the gun tube in
out the cable. Repeat this procedure until no further place against the gun end cable connector.
dirt comes out. 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
Contact Tips, Nozzles, and Gun Tubes cable connector until it bottoms. Then unscrew (no
1. Dirt can accumulate in the contact tip hole and more than one turn) the gun tube until its axis is
restrict wire feeding. After each spool of wire is perpendicular to the flat sides of the cable connec-
used, remove the contact tip and clean it by push- tor and pointed in the direction of the trigger. Tight-
ing a short piece of wire through the tip repeatedly. en the locking nut so as to maintain the proper
Use the wire as a reamer to remove dirt that may relationship between the gun tube and the cable
be adhering to the wall of the hole through the tip. connector. Replace the gun handle, trigger and dif-
fuser. Replace the gas nozzle or gasless nozzle.
* 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
D-3 MAINTENANCE D-3
1. Refer to Figure D.2. Remove the gas nozzle from FIGURE D.1
the gun by unscrewing counter-clockwise.
The drive roll has two grooves; one for .023" – .025"
(0.6 mm) solid steel electrode and a larger knurled 2
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. 1
If .023" – .025" (0.6 mm) wire is to be used, the drive
roll must be reversed as follows:
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.
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.
PRO 100
D-4 MAINTENANCE D-4
PRO 100
D-5 MAINTENANCE D-5
FIGURE D.3
➣
Counter-clockwise
PRO 100
E-1 TROUBLESHOOTING E-1
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
E-2 TROUBLESHOOTING E-2
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
E-3 TROUBLESHOOTING E-3
Observe Safety Guidelines TROUBLESHOOTING GUIDE
detailed in the beginning of this manual.
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
E-4 TROUBLESHOOTING E-4
TROUBLESHOOTING GUIDE Observe Safety Guidelines
detailed in the beginning of this manual.
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
F-1
WIRING DIAGRAM
Do not operate with covers removed.
GAS SOLENOID IS PART OF MIG CONVERSION KIT.
Disconnect input power by unplugging
power cord before servicing
S1
ON-OFF H2 1 2 3 4 5 6 7 8 9 10
N.O.
SWITCH
(W)
539 - WIRE
FEED
541 + MOTOR
(B)
OUTPUT
PRO 100
CIRCUIT
204
203 CHOKE
BREAKER
204
+
DIAGRAMS
S2 TO
SELECTOR 204
H1 D1 WORK
SWITCH D2 204
X2 202
+ 59,000 mf
X3
X4 N.B. C1 N.D. 40V
X5
N.D.
203
H2 X1 GUN CABLE
T1 N.A.
D4 CONDUCTOR
CASE BLOCK
N.A. DIODES D2 & D4 ARE MOUNTED D3 203
GROUNDING
ON THE OUTSIDE HEATSINK.
STUD -
N.B. DIODES D1 & D3 ARE MOUNTED 203
specific diagram for a particular code is pasted inside the machine on one of the enclosure panels.
CAVITY NUMBERING SEQUENCE
( COMPONENT SIDE OF BOARD ) 8-01G
NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual. The
F-1
M15732
NOTES
PRO 100
● Do not touch electrically live parts or ● Keep flammable materials away. ● Wear eye, ear and body protection.
French ● Ne laissez ni la peau ni des vête- ● Gardez à l’écart de tout matériel ● Protégez vos yeux, vos oreilles et
ments mouillés entrer en contact inflammable. votre corps.
ATTENTION avec des pièces sous tension.
● Isolez-vous du travail et de la terre.
German ● Berühren Sie keine stromführenden ● Entfernen Sie brennbarres Material! ● Tragen Sie Augen-, Ohren- und Kör-
Teile oder Elektroden mit Ihrem perschutz!
WARNUNG Körper oder feuchter Kleidung!
● Isolieren Sie sich von den Elektro-
den und dem Erdboden!
Portuguese
● Não toque partes elétricas e elec- ● Mantenha inflamáveis bem guarda- ● Use proteção para a vista, ouvido e
trodos com a pele ou roupa molha- dos. corpo.
ATENÇÃO da.
● Isole-se da peça e terra.
Japanese
Chinese
Korean
Arabic
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 UNFALLVERHÜTUNGSVORSCHRIFTEN DES ARBEITGEBERS SIND EBENFALLS ZU BEACHTEN.
● Keep your head out of fumes. ● Turn power off before servicing. ● Do not operate with panel open or
● Use ventilation or exhaust to
remove fumes from breathing zone.
guards off.
WARNING
● Los humos fuera de la zona de res- Spanish
● Desconectar el cable de ali- ● No operar con panel abierto o
piración.
● Mantenga la cabeza fuera de los
mentación de poder de la máquina
antes de iniciar cualquier servicio.
guardas quitadas. AVISO DE
humos. Utilice ventilación o
aspiración para gases.
PRECAUCION
● Gardez la tête à l’écart des fumées. ● Débranchez le courant avant l’entre- ● N’opérez pas avec les panneaux French
● Utilisez un ventilateur ou un aspira- tien. ouverts ou avec les dispositifs de
teur pour ôter les fumées des zones
de travail.
protection enlevés. ATTENTION
● Vermeiden Sie das Einatmen von ● Strom vor Wartungsarbeiten ● Anlage nie ohne Schutzgehäuse German
Schweibrauch! abschalten! (Netzstrom völlig öff- oder Innenschutzverkleidung in
● Sorgen Sie für gute Be- und Entlüf-
tung des Arbeitsplatzes!
nen; Maschine anhalten!) Betrieb setzen! WARNUNG
Portuguese
● Mantenha seu rosto da fumaça. ● Não opere com as tampas removidas. ● Mantenha-se afastado das partes
● Use ventilação e exhaustão para ● Desligue a corrente antes de fazer moventes.
remover fumo da zona respiratória. serviço. ● Não opere com os paineis abertos ATENÇÃO
● Não toque as partes elétricas nuas. ou guardas removidas.
Japanese
Chinese
Korean
Arabic
LEIA E COMPREENDA AS INSTRUÇÕES DO FABRICANTE PARA ESTE EQUIPAMENTO E AS PARTES DE USO, E SIGA AS
PRÁTICAS DE SEGURANÇA DO EMPREGADOR.
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