featur - Lincoln Electric€¦ · 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

PRO 100

OPERATOR’S MANUAL

IM784April, 2004

Safety Depends on YouLincoln arc welding and cuttingequipment is designed and builtwith safety in mind. However, youroverall safety can be increased byproper installation ... and thought-ful operation on your part. DONOT INSTALL, OPERATE ORREPAIR THIS EQUIPMENTWITHOUT READING THISMANUAL AND THE SAFETYPRECAUTIONS CONTAINEDTHROUGHOUT. And, mostimportantly, think before you actand be careful.

For use with machine Code Number 10970

PRO 100

• Sales and Service through Subsidiaries and Distributors Worldwide •

Cleveland, Ohio 44117-1199 U.S.A. TEL: 216.481.8100 FAX: 216.486.1751 WEB SITE: www.lincolnelectric.com

• World's Leader in Welding and Cutting Products •

Copyright © 2004 Lincoln Global Inc.

This manual covers equipment which is no longer in production by The Lincoln Electric Co. Speci�cations and availability of optional features may have changed.

FOR ENGINEpowered equipment.

1.a. Turn the engine off before troubleshooting and maintenancework 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.

____________________________________________________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 beforerefueling to prevent spilled fuel from vaporiz-ing on contact with hot engine parts andigniting. Do not spill fuel when filling tank. Iffuel is spilled, wipe it up and do not startengine until fumes have been eliminated.

____________________________________________________1.d. Keep all equipment safety guards, covers and devices in

position and in good repair.Keep hands, hair, clothing andtools away from V-belts, gears, fans and all other movingparts when starting, operating or repairing equipment.

____________________________________________________

1.e. In some cases it may be necessary to remove safetyguards to perform required maintenance. Removeguards only when necessary and replace them when themaintenance requiring their removal is complete.Always use the greatest care when working near movingparts.

___________________________________________________1.f. Do not put your hands near the engine fan.

Do not attempt to override the governor oridler by pushing on the throttle control rodswhile the engine is running.

___________________________________________________1.g. To prevent accidentally starting gasoline engines while

turning the engine or welding generator during maintenancework, disconnect the spark plug wires, distributor cap ormagneto wire as appropriate.

iSAFETYi

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 understand the following safety highlights. For additional safety information, it is strongly recommended that youpurchase a copy of “Safety in Welding & Cutting - ANSI Standard Z49.1” from the American Welding Society, P.O. Box351040, Miami, Florida 33135 or CSA Standard W117.2-1974. A Free copy of “Arc Welding Safety” booklet E205 is availablefrom the Lincoln Electric Company, 22801 St. Clair Avenue, Cleveland, Ohio 44117-1199.

BE SURE THAT ALL INSTALLATION, OPERATION, MAINTENANCE AND REPAIR PROCEDURES AREPERFORMED ONLY BY QUALIFIED INDIVIDUALS.

WARNING

Mar ‘95

ELECTRIC AND MAGNETIC FIELDSmay be dangerous

2.a. Electric current flowing through any conductor causes localized Electric and Magnetic Fields (EMF). Welding current creates EMF fields around welding cables and welding machines

2.b. EMF fields may interfere with some pacemakers, andwelders having a pacemaker should consult their physicianbefore welding.

2.c. Exposure to EMF fields in welding may have other healtheffects which are now not known.

2.d. All welders should use the following procedures in order tominimize exposure to EMF fields from the welding circuit:

2.d.1. Route the electrode and work cables together - Securethem with tape when possible.

2.d.2. Never coil the electrode lead around your body.

2.d.3. Do not place your body between the electrode andwork cables. If the electrode cable is on your right side, the work cable should also be on your right side.

2.d.4. Connect the work cable to the workpiece as close aspossible to the area being welded.

2.d.5. Do not work next to welding power source.

1.h. To avoid scalding, do not remove theradiator pressure cap when the engine ishot.

CALIFORNIA PROPOSITION 65 WARNINGS

Diesel engine exhaust and some of its constituentsare known to the State of California to cause can-cer, birth defects, and other reproductive harm.

The engine exhaust from this product containschemicals known to the State of California to causecancer, birth defects, or other reproductive harm.

The Above For Diesel Engines The Above For Gasoline Engines

iiSAFETYii

ARC RAYS can burn.4.a. Use a shield with the proper filter and cover

plates to protect your eyes from sparks andthe rays of the arc when welding or observingopen arc welding. Headshield and filter lensshould conform to ANSI Z87. I standards.

4.b. Use suitable clothing made from durable flame-resistantmaterial to protect your skin and that of your helpers fromthe arc rays.

4.c. Protect other nearby personnel with suitable, non-flammablescreening and/or warn them not to watch the arc nor exposethemselves to the arc rays or to hot spatter or metal.

ELECTRIC SHOCK cankill.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 bareskin 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 fullarea of physical contact with work and ground.

In addition to the normal safety precautions, if weldingmust be performed under electrically hazardousconditions (in damp locations or while wearing wetclothing; on metal structures such as floors, gratings orscaffolds; when in cramped positions such as sitting,kneeling or lying, if there is a high risk of unavoidable oraccidental contact with the workpiece or ground) usethe following equipment:

• Semiautomatic DC Constant Voltage (Wire) Welder.• DC Manual (Stick) Welder.• AC Welder with Reduced Voltage Control.

3.c. In semiautomatic or automatic wire welding, the electrode,electrode reel, welding head, nozzle or semiautomaticwelding gun are also electrically “hot”.

3.d. Always be sure the work cable makes a good electricalconnection with the metal being welded. The connectionshould be as close as possible to the area being welded.

3.e. Ground the work or metal to be welded to a good electrical(earth) ground.

3.f. Maintain the electrode holder, work clamp, welding cable andwelding machine in good, safe operating condition. Replacedamaged insulation.

3.g. Never dip the electrode in water for cooling.

3.h. Never simultaneously touch electrically “hot” parts ofelectrode holders connected to two welders because voltagebetween the two can be the total of the open circuit voltageof both welders.

3.i. When working above floor level, use a safety belt to protectyourself from a fall should you get a shock.

3.j. Also see Items 6.c. and 8.

FUMES AND GASEScan be dangerous.5.a. Welding may produce fumes and gases

hazardous to health. Avoid breathing thesefumes and gases.When welding, keepyour head out of the fume. Use enoughventilation and/or exhaust at the arc to keep

fumes and gases away from the breathing zone. Whenwelding with electrodes which require specialventilation such as stainless or hard facing (seeinstructions on container or MSDS) or on lead orcadmium plated steel and other metals or coatingswhich produce highly toxic fumes, keep exposure aslow as possible and below Threshold Limit Values (TLV)using local exhaust or mechanical ventilation. Inconfined spaces or in some circumstances, outdoors, arespirator may be required. Additional precautions arealso required when welding on galvanized steel.

5.b. Do not weld in locations near chlorinated hydrocarbon vaporscoming from degreasing, cleaning or spraying operations.

The heat and rays of the arc can react with solvent vapors toform phosgene, a highly toxic gas, and other irritating products.

5.c. Shielding gases used for arc welding can displace air andcause injury or death. Always use enough ventilation,especially in confined areas, to insure breathing air is safe.

5.d. Read and understand the manufacturer’s instructions for thisequipment and the consumables to be used, including thematerial safety data sheet (MSDS) and follow youremployer’s safety practices. MSDS forms are available fromyour welding distributor or from the manufacturer.

5.e. Also see item 1.b. Mar ‘95

FOR ELECTRICALLYpowered equipment.

8.a. Turn off input power using the disconnectswitch at the fuse box before working onthe equipment.

8.b. Install equipment in accordance with the U.S. NationalElectrical Code, all local codes and the manufacturer’srecommendations.

8.c. Ground the equipment in accordance with the U.S. NationalElectrical Code and the manufacturer’s recommendations.

CYLINDER may explodeif damaged.7.a. Use only compressed gas cylinders

containing the correct shielding gas for theprocess used and properly operatingregulators designed for the gas and

pressure used. All hoses, fittings, etc. should be suitable forthe application and maintained in good condition.

7.b. Always keep cylinders in an upright position securelychained to an undercarriage or fixed support.

7.c. Cylinders should be located:• Away from areas where they may be struck or subjected tophysical damage.

• A safe distance from arc welding or cutting operations andany other source of heat, sparks, or flame.

7.d. Never allow the electrode, electrode holder or any otherelectrically “hot” parts to touch a cylinder.

7.e. Keep your head and face away from the cylinder valve outletwhen opening the cylinder valve.

7.f. Valve protection caps should always be in place and handtight except when the cylinder is in use or connected foruse.

7.g. Read and follow the instructions on compressed gascylinders, associated equipment, and CGA publication P-l,“Precautions for Safe Handling of Compressed Gases inCylinders,” available from the Compressed Gas Association1235 Jefferson Davis Highway, Arlington, VA 22202.

iiiSAFETYiii

Mar ‘95

WELDING SPARKS cancause fire or explosion.6.a. Remove fire hazards from the welding area.

If this is not possible, cover them to preventthe welding sparks from starting a fire.Remember that welding sparks and hot

materials from welding can easily go through small cracksand openings to adjacent areas. Avoid welding nearhydraulic lines. Have a fire extinguisher readily available.

6.b. Where compressed gases are to be used at the job site,special precautions should be used to prevent hazardoussituations. Refer to “Safety in Welding and Cutting” (ANSIStandard Z49.1) and the operating information for theequipment being used.

6.c. When not welding, make certain no part of the electrodecircuit is touching the work or ground. Accidental contactcan cause overheating and create a fire hazard.

6.d. Do not heat, cut or weld tanks, drums or containers until theproper steps have been taken to insure that such procedureswill not cause flammable or toxic vapors from substancesinside. They can cause an explosion even though they havebeen “cleaned”. For information, purchase “RecommendedSafe Practices for the Preparation for Welding and Cutting ofContainers and Piping That Have Held HazardousSubstances”, AWS F4.1 from the American Welding Society(see address above).

6.e. Vent hollow castings or containers before heating, cutting orwelding. They may explode.

6.f. Sparks and spatter are thrown from the welding arc. Wear oilfree protective garments such as leather gloves, heavy shirt,cuffless trousers, high shoes and a cap over your hair. Wearear plugs when welding out of position or in confined places.Always wear safety glasses with side shields when in awelding area.

6.g. Connect the work cable to the work as close to the weldingarea as practical. Work cables connected to the buildingframework or other locations away from the welding areaincrease the possibility of the welding current passingthrough lifting chains, crane cables or other alternate cir-cuits. This can create fire hazards or overheat lifting chainsor cables until they fail.

6.h. Also see item 1.c.

ivSAFETYiv

PRÉCAUTIONS DE SÛRETÉPour votre propre protection lire et observer toutes les instructionset les précautions de sûreté specifiques qui parraissent dans cemanuel aussi bien que les précautions de sûreté générales suiv-antes:

Sûreté Pour Soudage A L’Arc1. Protegez-vous contre la secousse électrique:

a. Les circuits à l’électrode et à la piéce sont sous tensionquand la machine à souder est en marche. Eviter toujourstout contact entre les parties sous tension et la peau nueou les vétements mouillés. Porter des gants secs et sanstrous pour isoler les mains.

b. Faire trés attention de bien s’isoler de la masse quand onsoude dans des endroits humides, ou sur un planchermetallique ou des grilles metalliques, principalement dans les positions assis ou couché pour lesquelles une grandepartie du corps peut être en contact avec la masse.

c. Maintenir le porte-électrode, la pince de masse, le câblede soudage et la machine à souder en bon et sûr étatdefonctionnement.

d.Ne jamais plonger le porte-électrode dans l’eau pour lerefroidir.

e. Ne jamais toucher simultanément les parties sous tensiondes porte-électrodes connectés à deux machines à souderparce que la tension entre les deux pinces peut être letotal de la tension à vide des deux machines.

f. Si on utilise la machine à souder comme une source decourant pour soudage semi-automatique, ces precautionspour le porte-électrode s’applicuent aussi au pistolet desoudage.

2. Dans le cas de travail au dessus du niveau du sol, se protégercontre les chutes dans le cas ou on recoit un choc. Ne jamaisenrouler le câble-électrode autour de n’importe quelle partiedu corps.

3. Un coup d’arc peut être plus sévère qu’un coup de soliel,donc:

a. Utiliser un bon masque avec un verre filtrant appropriéainsi qu’un verre blanc afin de se protéger les yeux du ray-onnement de l’arc et des projections quand on soude ouquand on regarde l’arc.

b. Porter des vêtements convenables afin de protéger lapeau de soudeur et des aides contre le rayonnement del‘arc.

c. Protéger l’autre personnel travaillant à proximité ausoudage à l’aide d’écrans appropriés et non-inflammables.

4. Des gouttes de laitier en fusion sont émises de l’arc desoudage. Se protéger avec des vêtements de protection libresde l’huile, tels que les gants en cuir, chemise épaisse, pan-talons sans revers, et chaussures montantes.

5. Toujours porter des lunettes de sécurité dans la zone desoudage. Utiliser des lunettes avec écrans lateraux dans les

zones où l’on pique le laitier.

6. Eloigner les matériaux inflammables ou les recouvrir afin deprévenir tout risque d’incendie dû aux étincelles.

7. Quand on ne soude pas, poser la pince à une endroit isolé dela masse. Un court-circuit accidental peut provoquer unéchauffement et un risque d’incendie.

8. S’assurer que la masse est connectée le plus prés possiblede la zone de travail qu’il est pratique de le faire. Si on placela masse sur la charpente de la construction ou d’autresendroits éloignés de la zone de travail, on augmente le risquede voir passer le courant de soudage par les chaines de lev-age, câbles de grue, ou autres circuits. Cela peut provoquerdes risques d’incendie ou d’echauffement des chaines et descâbles jusqu’à ce qu’ils se rompent.

9. Assurer une ventilation suffisante dans la zone de soudage.Ceci est particuliérement important pour le soudage de tôlesgalvanisées plombées, ou cadmiées ou tout autre métal quiproduit des fumeés toxiques.

10. Ne pas souder en présence de vapeurs de chlore provenantd’opérations de dégraissage, nettoyage ou pistolage. Lachaleur ou les rayons de l’arc peuvent réagir avec les vapeursdu solvant pour produire du phosgéne (gas fortement toxique)ou autres produits irritants.

11. Pour obtenir de plus amples renseignements sur la sûreté,voir le code “Code for safety in welding and cutting” CSAStandard W 117.2-1974.

PRÉCAUTIONS DE SÛRETÉ POURLES MACHINES À SOUDER ÀTRANSFORMATEUR ET ÀREDRESSEUR

1. Relier à la terre le chassis du poste conformement au code del’électricité et aux recommendations du fabricant. Le dispositifde montage ou la piece à souder doit être branché à unebonne mise à la terre.

2. Autant que possible, I’installation et l’entretien du poste seronteffectués par un électricien qualifié.

3. Avant de faires des travaux à l’interieur de poste, la debranch-er à l’interrupteur à la boite de fusibles.

4. Garder tous les couvercles et dispositifs de sûreté à leurplace.

Mar. ‘93

Thank You for selecting a QUALITY product by Lincoln Electric. We want youto 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. Save this manual and keep ithandy 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:

WARNINGThis statement appears where the information must be followed exactly to avoid serious personal injury orloss of life.

This statement appears where the information must be followed to avoid minor personal injury or damage tothis equipment.

CAUTION

Please Examine Carton and Equipment For Damage ImmediatelyWhen this equipment is shipped, title passes to the purchaser upon receipt by the carrier. Consequently, Claimsfor material damaged in shipment must be made by the purchaser against the transportation company at thetime the shipment is received.

Please record your equipment identification information below for future reference. This information can befound 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 youhave recorded above. The code number is especially important when identifying the correct replacement parts.

vv

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 packetaccompanying 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.

vivi

TABLE OF CONTENTS

Page

Installation .......................................................................................................Section ATechnical Specifications ........................................................................................A-1Identify and Locate Components ...........................................................................A-2Select Suitable Location ........................................................................................A-3Output Connections...............................................................................................A-3Input Connections..................................................................................................A-6Code Requirements ..............................................................................................A-6

Operation .........................................................................................................Section BSafety Precautions ................................................................................................B-1General Description ...............................................................................................B-2

Design Features and Advantages...................................................................B-2Welding Capability ..........................................................................................B-2Limitations .......................................................................................................B-2Controls and Settings......................................................................................B-2

Welding Operations ...............................................................................................B-3Overload Protection...............................................................................................B-6Application Chart ...................................................................................................B-7

Accessories .....................................................................................................Section CAccessories ...........................................................................................................C-1Replacement Parts ................................................................................................C-1

Maintenance ....................................................................................................Section DSafety Precautions ................................................................................................D-1Items Requiring No Maintenance ..........................................................................D-1Routine Maintenance.............................................................................................D-1Gun and Cable Maintenance.................................................................................D-2Configuration of Components in Wire Feeding System.........................................D-2Component Replacement Procedures ..................................................................D-3

Troubleshooting ..............................................................................................Section ESafety Precautions.................................................................................................E-1How to Use Troubleshooting Guide.......................................................................E-1Troubleshooting Guide.............................................................................E-2 thru E-4

Wiring Diagrams ..............................................................................................Section FPRO 100 Wiring Diagram ......................................................................................F-1

PRO 100 Parts Manual................................................................P464 Series & P202-E

A-1

PRO 100

A-1 INSTALLATION

Fuse orOutput 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 mm2) or LargerUp to 25 Ft. (7.6 mm)

CSA 115V/60Hz 15 Amp 12 15 Amp, 125V, Three ConductorThree Prong Plug #12 AWG

(NEMA Type 5-15P) (3.3 mm2) or LargerUp to 50 Ft. (15.2 mm)

TECHNICAL SPECIFICATIONS – PRO 100INPUT – SINGLE PHASE ONLY

RATED OUTPUT

OUTPUT

RECOMMENDED INPUT CABLE AND FUSE SIZES

Height Width Depth Weight12.0 in 9.75 in 16.5 in 47 Ibs305 mm 248 mm 419 mm 21.4 kg

PHYSICAL DIMENSIONS

Standard Voltage/Frequency Input Current115V/60Hz 20 Amps - Rated Output115V/60Hz 15 Amps - CSA Rated output

Duty Cycle Current Voltage20% Duty Cycle 88Amps 18V

20% Duty Cycle – CSA Rated Output 62Amps 20V

Welding Current Range Maximum Open Circuit Voltage Wire Speed RangeRated DC Output: 30 - 100 amps 32V 50 - 300 IPM

(1.3 - 7.6 m/min)

A-2INSTALLATION

PRO 100

A-2

Read entire installation section before startinginstallation.

SAFETY PRECAUTIONS

IDENTIFY AND LOCATE COMPONENTS

If you have not already done so, unpack the PRO 100from its carton and remove all packing materialaround the PRO 100. Remove the following looseitems from the carton (see Figure A.1):

1. PRO 100

2. Gun and cable assembly(1)

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 theAccessories Section of this manual.

(1) The gun is ready to feed 0.035" (0,9 mm) Inner-shield wire.

ELECTRIC SHOCK can kill.

• Only qualified personnel should performthis installation.

• Only personnel that have read and under-stood the PRO 100 Operating Manualshould install and operate this equipment.

• Machine must be plugged into a receptaclewhich is grounded per any national, localor other applicable electrical codes.

• The PRO 100 power switch is to be in theOFF (“O”) position when installing workcable and gun and when connecting powercord to input power.

WARNING

FIGURE A.1

PRO 100

1 2

3

4

6

7 8

5

A-3INSTALLATION

PRO 100

A-3

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 dirt accumulation that can blockair 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 procedureis 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.

PRO 100

1 2

DO NOT SWITCHWHEN WELDING

45

8

3 6 7

+

-

FIGURE A.2

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 largerhole through the strain relief hole in the work clampas shown in Figure A-3.

3. Fasten securely with the bolt and nut provided.

FIGURE A.3

Strain Relief Hole

Nut & Bolt

Work Clamp

Work Cable

A-4INSTALLATION

PRO 100

A-4

Connecting Gun Cable to the PRO 100

1. Refer to Figure A.2. Unplug the machine or turnpower 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 Cableand Control Lead Access Slot (2) in the case front.The leads are to be routed under the Wire FeedGearbox (6) and through the Cable Hanger (7) onthe inner panel.

3. Insert the connector on the gun conductor cablethrough the Gun Cable Access Hole (2) in thePRO 100 case front. Make sure the connector is allthe way in the brass connector block. Unscrewthumbscrew on the connector block a few turns ifgun connector will not insert fully. Rotate the con-nector so control leads are on the underside andtighten the Thumbscrew (8) in the connector block.

4. Connect the gun trigger control lead terminals tothe two insulated 1/4" (6,4 mm) tab terminal con-nector bushings located above the “Gun TriggerConnection” decal in the wire feed section (4).Either lead can go to either connector. Form theleads so that they are as close as possible to theinside panel.

If the gun trigger switch being used is other thanthat supplied with the PRO 100, the switch mustbe a normally open, momentary switch. The termi-nals of the switch must be insulated from thewelding circuit. Malfunction of the PRO 100 mayresult if this switch shorts to the PRO 100 weldingoutput 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 (CO2) orargon-carbon dioxide mixed shielding gas must beobtained. For more information about the K610-1 MIGConversion Kit for use with the PRO 100, refer to theACCESSORIES section.

Work Cable Installation


1. Open the wire feed section door on the right side ofthe PRO 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. Route the cable under and around the back of theWire Feed Gearbox (6).

4. For Innershield Only: Refer to Figure A.2. Asdelivered, the PRO 100 is connected for negativeelectrode polarity. This is the appropriate configu-ration for the Innershield process. To completeinstallation, use the provided wing nut to connectthe 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. For GMAW Only: Refer to Figure A.4. To wire forpositive polarity (required for the MIG process),connect the short cable attached to the connectorblock (1) to the positive (+) output terminal (4) andthe work cable (3) to the negative (–) terminal (2).

FIGURE A.4

GUN INSTALLATION

As shipped from the factory, the PRO 100 gun isready 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 theGMAW (MIG) process, see the MAINTENANCE sec-tion for proper configuration of feeding componentsand installation details.

1

2

4

3

CAUTION

2. With the cylinder securely installed, remove thecylinder cap. Stand to one side away from the out-let and open the cylinder valve very slightly for aninstant. This blows away any dust or dirt which mayhave accumulated in the valve outlet.

BE SURE TO KEEP YOUR FACE AWAY FROM THEVALVE OUTLET WHEN “CRACKING” THE VALVE.Never stand directly in front of or behind the flowregulator when opening the cylinder valve. Alwaysstand to one side.

3. Attach the flow regulator to the cylinder valve andtighten the union nut securely with a wrench..

NOTE: If connecting to 100% CO2 cylinder, insertregulator adapter (provided with MIG ConversionKit for the PRO 100) between regulator and cylin-der valve. If adapter is equipped with a plasticwasher, be sure it is seated for connection to theCO2 cylinder.

4. Refer to Figure A.6. Attach one end of inlet gashose to the outlet fitting of the flow regulator andtighten the union nut securely with a wrench. Con-nect the other end to the PRO 100 Gas SolenoidInlet Fitting (5/8-18 female threads — for CGA —032 fitting). Make certain the gas hose is notkinked or twisted.

WARNING

A-5INSTALLATION

PRO 100

A-5

WARNING

CYLINDER may explode if dam-aged. Keep cylinder upright andchained to support

• Keep cylinder away from areaswhere it may be damaged.

• Never lift welder with cylinderattached.

• Never allow welding electrode totouch cylinder.

• Keep cylinder away from weldingor other live electrical circuits.

BUILDUP OF SHIELDING GAS mayharm health or kill.

• Shut off shielding gas supplywhen not in use.

• SEE AMERICAN NATIONALSTANDARD Z-49.1, “SAFETY INWELDING AND CUTTING” PUB-LISHED BY THE AMERICANWELDING 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 earthground. Refer to Figure A.5.

FIGURE A.5

WARNING

Cylinder Valve

Gas Hose

Flow Regulator

A-6INSTALLATION

PRO 100

A-6

INPUT CONNECTIONS

FIGURE A.6


The PRO 100 has a power input cable located on therear of the machine.

CODE REQUIREMENTS FOR INPUT CONNECTIONS

This welding machine must be connected topower source in accordance with applicable elec-trical codes.

The National Electrical Code provides standardsfor amperage handling capability of supply con-ductors based on duty cycle of the weldingsource.

If there is any question about the installationmeeting applicable electrical code requirements,consult a qualified electrician.

Requirements For Rated Output

A power cord with a 15 amp, 125 volt, three prongplug (NEMA Type 5-15P) is factory installed on thePRO 100. Connect this plug to a mating groundedreceptacle which is 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, 18Volts, 20% duty cycle (2 minutes of every 10 minutesused for welding).

Do not connect the PRO 100 to an input powersupply with a rated voltage that is greater than 125volts.

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 thisplug 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 anoutput of 62 amps, 20 volts, 20% duty cycle.

WARNING

CAUTION

POWER INPUTCABLE

OPTIONAL GASSOLENOID INLET FITTING

B-1OPERATIONB-1

PRO 100

Read entire operation section beforeoperating the PRO 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 insulatinggloves.

FUMES AND GASES can bedangerous.• Keep your head out of fumes.

• Use ventilation or exhaust toremove fumes from breathingzone.

WELDING SPARKS cancause fire or explosion.• Keep flammable material away.

• Do not weld on closed contain-ers.

ARC RAYS can burn eyesand skin.• Wear eye, ear and body protec-

tion.

Observe all safety information throughoutthis manual.

WARNING

B-2OPERATIONB-2

● No external shielding gas is required when usedwith Lincoln Innershield .035” (0,9 mm) NR®-211-MP electrode.

● Accommodates 4” (100 mm) diameter spool ofwire. Will accommodate 8” (200 mm) diameter withoptional spindle.

WELDING CAPABILITYThe PRO 100 is rated at 88 amps, 18 volts, at 20%duty cycle on a ten minute basis. CSA rated output at62 amps at 20 volts at 20% duty cycle. It is capable ofhigher output currents at lower duty cycles.

LIMITATIONSArc Gouging cannot be performed with the PRO 100.The PRO 100 is not recommended for pipe thawing orTIG welding.

CONTROLS AND SETTINGSRefer to Figure B.1a.

1. Power ON/OFF Switch —When the power is on thefan motor will run and air willbe exhausted out the louversin the front of the machine.The welding output and wirefeeder remain off until thegun trigger is pressed.

2. Wire Speed Control — Con-trols the wire feed speedfrom 50 – 300 in /min (1.3 –7.6 m/min). The control canbe preset on the dial to thesetting specified on the PRO100 Application Chart locat-ed on the inside of the wirefeed section door.

3. Voltage Control — A 4-posi-tion tap selector switch givesfull range adjustment ofpower source output voltage.Do not switch while welding.

Refer to Figure B.1b.

4. Circuit Breaker – Protects machine from damage ifmaximum output is exceeded. Button will extend out when tripped (Manual reset).

PRO 100

GENERAL DESCRIPTIONThe 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 generalpurpose welding with self-shielded flux-cored (Inner-shield®) wire. When combined with the optional K610-1 MIG Conversion Kit, the PRO 100 is suitable forGMAW (MIG) welding applications.

The PRO 100 is ideally suited for individuals havingaccess to 115 volt AC input power, and wanting theease of use, quality and dependability of both theInnershield electrode process (self-shielded flux-coredor FCAW) and gas metal arc welding or GMAW (alsoknown as MIG welding). The PRO 100 is a ruggedand reliable machine that has been designed fordependable service and long life.

RECOMMENDED PROCESSES

The PRO 100 can be used for welding mild steel usingthe self shielded, Innershield electrode process(FCAW) or it can be used for the GMAW, single pass,process which requires a supply of shielding gas andthe K610-1 MIG Conversion Kit. The PRO 100 is con-figured for use with the FCAW process as deliveredfrom the factory.

OPERATIONAL FEATURES AND CONTROLS

The PRO 100 has the following controls as standard:Power ON/OFF Switch, Voltage Control, Wire SpeedControl, Trigger Switch, and a Circuit Breaker.

DESIGN FEATURES AND ADVANTAGES● Operates on 115 volt input .

● “Cold electrode” until gun trigger is pressed for anadded 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 easilyadjusted.

● Reversible, dual groove drive roll. Drive roll willfeed .023 – .025” (0.6 mm) and .030" and .035"(0.8 mm and 0.9 mm) diameter wire.

OFF

ON

ARC VOLTS

WIRE SPEED

B-3OPERATIONB-3

FIGURE B.1a

FIGURE B.1b

WELDING OPERATIONS

SEQUENCE OF OPERATION

Wire LoadingRefer 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 shipped from the factory ready to feed4” (100 mm) diameter spools. A 4" (100 mm) diameterspool is mounted directly on the 5/8" (16 mm) diame-ter spindle that has a built-in adjustable friction braketo prevent overrun of the spool and excess slack inthe wire. The wing nut at the end of the shaft is usedto adjust the tension on the wire spool.

FIGURE B.2

To use 8" (200 mm) diameter spools, the 2" (51 mm)diameter M15445 spindle must be used. Remove thespacer and wing nut at the end of the shaft. Insertspindle as shown in figure B.3. Reattach spacer andwing nut.

Note: When loading and removing the 8” Spoolsmake sure that the wing nut (inside the wire spoolspindle hub) is turned 90° from the wire spool spindlelocking tab. If the wing nut is positioned in line with thelocking tab, the tab cannot be depressed to load orunload the wire spool.

Make certain the start end of the wire, which may pro-trude through the side of the spool, does not contactany metallic case parts.

FIGURE B.3

PRO 100

PRO 100

DO NOT SWITCHWHEN WELDING

3

21

Wire Spindle Shaft 4" Wire Spool

Wing Nutand Spacer

Wire Spool must be pushed all the way on the spindle so that thespindle’s tab will hold it in place. The Wire Spool will rotate clock-wise when wire is dereeled.

8” Wire Spool

Optional

Wire Spool Spindle

Be sure that this stud engagesthe hole in the wire spool.

To Wire Drive

Locking Tab

To wire drive

4

Gun Handle

Gas Diffuser/Contact Tip

Gas Nozzle

FIGURE B.5

B-4OPERATIONB-4

Note: The brake should be adjusted with a spool ofwire installed. When properly adjusted it shouldmove freely but not coast.

Friction Brake Adjustments

1. With wire spool installed, check free movementand coast of the spool.

2. To tighten the brake turn the wing nut clockwise in1/4 turn increments until coasting stops.

3. To loosen the brake turn the wing nut counter-clockwise in 1/4 turn increments until the wirespool moves freely without coasting.

Wire Threading Refer to Figure B-41. Release the Spring Loaded Pressure Arm (1)

rotate the Idle Roll Arm (2) away from. the WireFeed Drive Roll (3). Ensure that the groove size inthe feeding position on the drive roll matches thewire size being used.

2. Carefully detach the end of the wire from thespool. 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 thefirst 4” (100 mm).

4. Thread the wire through the In-going guide tube(4), over the drive roll (3), and into the out-goingguide tube (5).

5. Close the idle roll arm and latch the spring loadedpressure arm (2) in place. Rotate the spool coun-terclockwise if required in order to take up extraslack in the wire.

When inching the welding wire, the drive rolls, thegun connector block and the gun contact tip areelectrically energized relative to work and groundand remain energized for several seconds afterthe gun trigger is released.

6. The idle roll pressure adjustment wing nut is nor-mally set for mid-position on the pressure armthreads. If feeding problems occur because thewire is flattened excessively, turn the pressureadjustment counter-clockwise to reduce distortionof the wire. Slightly less pressure may be requiredwhen using 0.023 – 0.025” (0,6 mm) wire. If thedrive roll slips while feeding wire, the pressureshould be increaseduntil the wire feeds properly.

7. Refer to Figure B.5. Remove gas nozzle and con-tact tip from end of gun.

8. Turn the PRO 100 ON (“I”).

9. Straighten the gun cable assembly.

10. Depress the gun trigger switch and feed weldingwire through the gun and cable. (Point gun awayfrom yourself and others while feeding wire.)Release gun trigger after wire appears at end ofgun.

11. Turn the PRO 100 OFF (“O”).

12. Replace contact tip and gas nozzle.

13. 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 isnow ready to weld.

PRO 100

WARNING

FIGURE B.4

The Wire Drive Feed Roll canaccommodate two wire sizes byflipping the wire drive feed rollover.

2

53

41

B-5OPERATIONB-5

Making A Weld1. 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 wirefeed compartment door for information on settingthe PRO 100 controls. Refer to Table B.1 for alu-minum and stainless wire.

3. Set the Voltage (“V”) and Wire Speed (“olo’”) con-trols to the settings suggested for the welding wireand base metal thickness being used, refer toApplications chart on the inside of the wire drivecompartment door.

4. Check that the polarity is correct for the weldingwire being used and that the gas supply, ifrequired, is turned on.

5. When using Innershield electrode, remove the gasnozzle and install the gasless nozzle. This willimprove visibility of the arc and protect the gas dif-fuser from weld spatter. Refer to the MAINTE-NANCE section for details on nozzle replacement.

6. Refer to Figure B.7. Connect work clamp to metalto be welded. Work clamp must make good elec-trical contact to the workpiece. The workpiecemust also be grounded as stated in “Arc WeldingSafety Precautions” in the beginning of this manu-al.

7. Position gun over joint. End of wire may be lightlytouching the work.

8. Lower welding helmet, close gun trigger, andbegin welding. Hold the gun so the contact tip towork distance is about 3/8 inch (10 mm).

9. To stop welding, release the gun trigger and thenpull the gun away from the work after the arc goesout.

10. When no more welding is to be done, close valveon gas cylinder (if used), momentarily operate guntrigger to release gas pressure, and turn off thePRO 100.

Cleaning Tip And NozzleClean the contact tip and nozzle to avoid arc bridgingbetween the nozzle and contact tip which can result ina shorted nozzle, poor welds and an overheated gun.Hint: Anti-stick spray or gel, available from a weldingsupply distributor, may reduce buildup and aid in spat-ter removal.

PROCESS GUIDELINESThe PRO 100 as shipped, can be used for weldingmild steel using the self shielded, Innershield elec-trode process or it can be used for the GMAW (MIG),single pass, process which requires a supply ofshielding gas and the K610-1 MIG Conversion Kit.

The recommended electrode for the self-shieldedprocess is 0.035” (0,9 mm) diameter Lincoln Inner-shield NR-211-MP. Requires optional spindle – referto Accessories section. This electrode can be used forall position welding of 20 gauge through 5/16” (1,0 –8,0 mm) thick steel [multiple passes are required for1/4” and 5/16” (6,0 and 8,0 mm)].

The recommended gas and electrode for GMAW iswelding grade CO2 gas and 0.025” (0 6 mm) diameterLincoln Super Arc L-56 mild-steel welding wire [sup-plied on 12-1/2 Ib (6 kg) spools]. For 14 gauge (2,0mm) and thinner, CO2 gas is recommended becauseit gives equal or better performance than a blendedgas at a lower cost. A mixed gas consisting of 75 to80% Argon and 20 to 25% CO2 is recommended forwelding on heavier gauge steel, 12 gauge (2,5 mm)for example.

PRO 100

FIGURE B.6

FIGURE B.7

PRO 100

WORKPIECE

GUN CABLE

ARC

WORK CLAMP

Contact Tip

Electrode

3/8”-1/2”(10-12mm)ContactTip to Work Distance(CTWD)

B-6OPERATIONB-6

The 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 MIGConversion Kit and K664-2 Aluminum - StainlessFeeding Kit.)

It is important when changing between weldingwith steel wire and aluminum to exchange feedingcomponents due to the lubricant applied to steelwire. Failure to do so may result in contaminatedwelds when welding aluminum.------------------------------------------------------------------------

TABLE B.1

Shielding Voltage/Wire Speed

Process Welding Wire Gas 22 ga 16 ga 12 ga 1/8” 3/16” 1/4”

.035 Dia(0.9mm 100% Argon A-4.5 C-8.5 D-10 NR* NR* NR*4043 AluminumWire

MIG DC+ 16 ga 14 ga 12 ga 10 ga

.030 Dia 98% Argon/ A-3 C-6 D-7.5 D-7.5308L Stainless 2% Oxygen

Steel Wire

*NR-Not Recommended

CHANGING MACHINE OVER TOFEED OTHER WIRE SIZES

The PRO 100 is shipped from the factory ready tofeed 0.035” (0,9 mm) diameter cored wire. To operatethe PRO 100 with other sizes and types of wire, itmaybe necessary to change the contact tip and driveroll orientation. Refer to the MAINTENANCE section,for component configuration and replacement proce-dures.

WELDING WITH GMAW (MIG)

Shielding GasWhen using the GMAW process, obtain and install theK610-1 MIG Conversion Kit and a cylinder of carbondioxide (CO2) or argon-carbon dioxide mixed shield-ing gas. Refer to the ACCESSORIES section for moreinformation about installing the K610-1 Kit for use withthe PRO 100. Also see the MAINTENANCE sectionfor proper contact tip, nozzle liner and drive roll config-uration.

1. For CO2, open the cylinder very slowly. For argon-mixed gas, open cylinder valve slowly a fraction ofa turn. When the cylinder pressure gauge pointerstops moving, open the valve fully.

2. If using a regulator with an adjustable flow meter,close the gun trigger and adjust the flow to give 15– 20 cubic ft per hour (CFH) (7 – 10 I/min) [use 20– 25 CFH (10 – 12 I/min) when welding out ofposition or in a drafty location for CO2]. For argonmixed gas, trigger to release gas pressure, andturn off the adjust the flow to give 25 – 30 CFH(12 – 14 I/min).

3. Keep the cylinder valve closed, except when usingthe PRO 100. When finished welding:

a) Close the cylinder valve to stop gas flow.

b) Depress the gun trigger briefly to release thepressure in the gas hose.

c) Turn off the PRO 100.

OVERLOAD PROTECTION

Output OverloadThe PRO 100 is equipped with a circuit breaker and athermostat which protects the machine from damage ifmaximum output is exceeded. The circuit breaker but-ton will extend out when tripped. The circuit breakermust be manually reset.

Thermal ProtectionThe PRO 100 has a rated output duty cycle of 20%. Ifthe duty cycle is exceeded, a thermal protector willshut 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 ProtectionThe PRO 100 has built-in protection for wire drivemotor overload.

PRO 100

CAUTION

B-7APPLICATION CHARTB-7

PRO 100

C-1ACCESSORIESC-1

OPTIONAL ACCESSORIES

1. K520 Utility Cart — Designed to transport the Lin-coln family of small welders. Has provisions formounting a single gas cylinder. Has front castersand large rear wheels. Handle height is easilyadjustable. Bottom tray provided for tools andaccessories. Easy assembly required; takes lessthan 15 minutes.

2. M15445 Spindle — Mounts onto standard spoolshaft for 4" (100 mm) spools to provide for mount-ing 8" (200 mm) diameter spools with 2" (51 mm)I.D. and up to 2.2" (56 mm) wide.

3. K664-2 Aluminum Feeding Kit — This kit recom-mended for welding with .035 Aluminum wire. Thiskit may also be used for feeding .030 stainlesswire. Included with this kit are a drive roll, gun linerand contact tip. It is important when changingbetween welding with steel wire and aluminumto exchange these components due to thelubricant applied to steel wire. Failure to do somay result in contaminated welds when weld-ing aluminum.

See Maintenance section for instructions oninstalling drive roll, cable liner, contact tip and theirproper configuration.

4. K610-1 MIG Conversion Kit for the PRO 100 —Complete kit for use with .025" (0.6 mm) electrodewire and either CO2 or Argon-mixed gas. Includes.025-.030" (0.6-0.8 mm) cable liner, two .025" (0.6mm) 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 andgas 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 electrodewire.

See Maintenance section for instructions on flip-ping over the drive roll, changing the cable linerand contact tip, and their proper configuration.

MIG CONVERSION

Several changes are needed to convert the unit foroperation with the MIG (GMAW) process. The K610-1MIG Conversion Kit for the PRO 100 includes all thenecessary accessories for this conversion and is pro-vided for this purpose. The following conversionsshould be made using the contents of this kit:

1. Install the gas solenoid. Complete instructions areincluded with the kit.

2. Change the output polarity to DC(+). See “WorkCable Installation” in Installation section for details.

3. Change drive roll orientation (if required) for thewire size selected. See “Changing Drive Roll” inMaintenance section for details.

4. Install the proper gun liner (Note 1) and tip for thewire size selected. See “Component Replacement”in Maintenance section for details.

5. Remove gasless nozzle (if installed) and install gasnozzle. To remove, simply unscrew.

6. Load wire into machine and thread into gun andcable per “Welding Wire Loading” section.

(Note 1) The factory installed gun liner will feed.025 - .035 (0.6 - 0.9 mm) wire.

PRO 100

D-1MAINTENANCED-1

PRO 100

MAINTENANCE

SAFETY PRECAUTIONS

ELECTRIC SHOCK can kill.

• Disconnect input power by removingplug from receptacle before workinginside PRO 100. Use only groundedreceptacle. Do not touch electrically“hot” parts inside PRO 100.

• Have qualified personnel do the mainte-nance and trouble shooting work.

ROUTINE MAINTENANCE

POWER SOURCE COMPARTMENTNo user serviceable parts inside! Do not attempt to performservice in the power source (fixed) side of the PRO 100. Takethe 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 gearboxand wire feed section.

2. Occasionally inspect the incoming guide tube and cleaninside diameter is necessary.

3. Motor and gearbox have lifetime lubrication and require nomaintenance.

FAN MOTOR

Has lifetime lubrication — requires no maintenance.

WIRE REEL SPINDLE

Requires no maintenance. Do not lubricate shaft.

WARNING

D-2MAINTENANCED-2

GUN AND CABLE MAINTENANCE

FOR MAGNUM™ 100L GUN

Gun Cable CleaningClean cable liner after using approximately 300 lbs(136 kg) of solid wire or 50 lbs (23 kg) of flux-coredwire. Remove the cable from the wire feeder and lay itout straight on the floor. Remove the contact tip fromthe gun. Using low pressure air, gently blow out thecable liner from the gas diffuser end.

Excessive pressure at the start may cause the dirtto form a plug.

Flex the cable over its entire length and again blowout the cable. Repeat this procedure until no furtherdirt comes out.

Contact Tips, Nozzles, and Gun Tubes1. Dirt can accumulate in the contact tip hole and

restrict wire feeding. After each spool of wire isused, 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 maybe adhering to the wall of the hole through the tip.

2. Replace worn contact tips as required. A variableor “hunting” arc is a typical symptom of a worn con-tact tip. To install a new tip, choose the correct sizecontact tip for the electrode being used (wire size isstenciled on the side of the contact tip) and screw itsnugly into the gas diffuser.

3. Remove spatter from inside of gas nozzle and fromtip after each 10 minutes of arc time or as required.

4. Be sure the gas nozzle is fully screwed onto thediffuser for gas shielded processes. For the Inner-shield® process, the gasless nozzle should bescrews onto the diffuser.

5. To remove gun tube from gun, remove gas nozzleor gasless nozzle and remove diffuser from guntube. Remove both collars from each end of thegun handle and separate the handle halves.Loosen the locking nut holding the gun tube inplace against the gun end cable connector.Unscrew gun tube from cable connector. To installgun tube, screw the locking nut on the gun tube asfar as possible. Then screw the gun tube into thecable connector until it bottoms. Then unscrew (nomore than one turn) the gun tube until its axis isperpendicular 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 properrelationship between the gun tube and the cableconnector. Replace the gun handle, trigger and dif-fuser. Replace the gas nozzle or gasless nozzle.

PRO 100

CONFIGURATION OF COMPONENTS IN WIRE FEEDING SYSTEMContact Tip Cable Liner Drive Roll

Components shipped with KP2039-3B1 KP1937-3 M16190PRO 100 .035” (0.9mm) .025 - .035 Large Knurled, Small Smooth groove

(0.6 - 0.9mm) Small .023-.025 (0.6mm)Large .030/.035” (0.8/0.9mm)

K610-1 .023/.025” (0.6mm) KP2039-1B1 KP1937-2 Use Standard Drive RollMIG Conversion Kit• .025” (0.6mm) .030 (0.8mm) Small Smooth Groove

K664-2 .035 (0.9mm) KP2078-1B1 M18971-1 M19631Aluminum or Stainless Kit* .035A (0.9mm) .035” (0.9mm)

• 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. Failureto do so may result in contaminated welds when welding aluminum.

D-3MAINTENANCED-3

COMPONENTREPLACEMENTPROCEDURES

CHANGING THE CONTACT TIP

1. Refer to Figure D.2. Remove the gas nozzle fromthe gun by unscrewing counter-clockwise.

2. Remove the existing contact tip from the gun byunscrewing 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 knurledgroove for .030" (0.8 mm) solid and .035" (0.9 mm)flux-cored steel electrode. As shipped, the drive roll isinstalled in the .030"/.035" (0.8/0.9 mm) position.

If .023" – .025" (0.6 mm) wire is to be used, the driveroll must be reversed as follows:

1. Connect the machine to its rated input power perinstructions in Installation section.

2. Release the spring-loaded pressure arm and lift theidle roll arm away from the drive roll.

3. Turn the power switch to ON (marked “I”).

4. Set the wire speed to minimum and jog the driveunit with the trigger switch until the drive roll setscrew is facing up.

When inching the welding wire, the drive rolls,gun connector block, and gun contact tip areenergized relative to work and ground and remainenergized 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" (2.0mm) 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 throughthe wire feeder guide tubes and adjust the positionof the drive roll so that the groove is centered onthe wire. Make certain the set screw is located onthe flat portion of the shaft and tighten.

PRO 100

3

2

1

FIGURE D.1

CAUTION

D-4MAINTENANCED-4

PRO 100

CHANGING LINER

NOTICE: The variation in cable lengths pre-vents the interchangeability of liners. Oncea liner has been cut for a particular gun, itshould not be installed in another gununless it can meet the liner cutoff lengthrequirement. Refer to Figure D.2.

1. Remove the gas nozzle from the gun byunscrewing counter-clockwise.

2. Remove the existing contact tip from thegun by unscrewing counter-clockwise.

3. Remove the gas diffuser from the guntube by unscrewing counter-clockwise.

4. Lay the gun and cable out straight on aflat surface. Loosen the set screw locat-ed in the brass connector at the wirefeeder end of the cable. Pull the liner outof the cable.

5. Insert a new untrimmed liner into theconnector end of the cable. Be sure theliner bushing is stenciled appropriatelyfor the wire size being used.

6. Fully seat the liner bushing into the con-nector. Tighten the set screw on thebrass cable connector. At this time, thegas diffuser should not be installed ontothe end of the gun tube.

7. With the gas nozzle and diffuserremoved from the gun tube, be sure thecable is straight, and then trim the linerto the length shown in the Figure D.2.Remove any burrs from the end of theliner.

8. Screw the gas diffuser onto the end ofthe gun tube and securely tighten.

9. Replace the contact tip and nozzle.

1-1/4 (31.8 mm)Liner Trim Length

Gas Diffuser

Gas Nozzle orGasless Nozzle

Set Screw Brass CableConnector

Liner Assembly (Liner bushing to be sealed tightagainst brass cable connector)

FIGURE D.2Liner trim length

D-5MAINTENANCED-5

PRO 100

GUN HANDLE PARTS

The gun handle consists of two halves that are heldtogether with a collar on each end. To open up thehandle, turn the collars approximately 60 degreescounter-clockwise until the collar reaches a stop. Thenpull 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 andgive the screwdriver a sharp blow to turn the collarpast an internal locking rib. See Figure D-3.

FIGURE D.3

➣

Counter-clockwise

E-1TROUBLESHOOTINGE-1

PRO 100

This Troubleshooting Guide is provided tohelp you locate and remedy possible prob-lems with machine setup or operation. Sim-ply fol low 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 mayexhibit. Find the listing that best describesthe symptom that the 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 “POSSIBLEAREAS OF MISADJUSTMENT(S)” lists theobvious external possibilities that may con-tribute to the machine symptom. Performthese tests/checks in the order listed. Ingeneral, these tests can be conducted with-out removing the case wrap-around cover.

Step 3. PERFORM COMPONENT TESTS.If you have exhausted all of the recom-mended tests in Step 2, Consult your LocalAuthorized Field Service Facility.

HOW TO USE TROUBLESHOOTING GUIDE

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 andmachine 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.__________________________________________________________________________

WARNING

If for any reason you do not understand the test procedures or are unable to performthe tests/repairs safely, contact your LOCAL AUTHORIZED LINCOLN ELECTRICFIELD SERVICE FACILITY for assistance before you proceed._____________________________________________________________________

CAUTION


PRO 100

Observe Safety Guidelinesdetailed 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 or gasflow when gun trigger is pulled. Fanoperates normally.

POSSIBLE AREAS OFMISADJUSTMENT(S)

NoneContact your local Authorized FieldService Facility.

1. Make sure correct voltage isapplied to the machine (115vac).

2. Make certain that power switchis in the ON position.

3. Make sure circuit breaker isreset.

1. The thermostat may be trippeddue to overheating. Let machinecool. Weld at lower duty cycle.

2. Check for obstructions in airflow. Check Gun Trigger connec-tions. See Installation section.

3. Gun trigger may be faulty.

RECOMMENDEDCOURSE OF ACTION

Contact your local LincolnAuthorized Field Service Facility.

OUTPUT PROBLEMS

If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact yourLOCAL AUTHORIZED LINCOLN ELECTRIC FIELD SERVICE FACILITY for assistance before you proceed.

CAUTION


PRO 100

TROUBLESHOOTING GUIDEObserve 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.


1. If the wire drive motor is runningmake sure that the correct driverolls are installed in the machine.

2. Check for clogged cable liner orcontact tip.

3. Check for proper size cable linerand contact tip.



FEEDING PROBLEMS

PROBLEMS(SYMPTOMS)

Low or no gas flow when guntrigger is pulled. Wire feed, weldoutput and fan operate normally.(Optional MIG Conversion Kit only.)


1. Verify that gas solenoid is prop-erly installed. Refer to instruc-tions included with K610-1 MIGconversion kit.

2. Check gas supply, flow regulatorand gas hoses.

3. Check gun connection tomachine for obstruction or leakyseals.



GAS FLOW PROBLEMS


CAUTION


PRO 100

Observe Safety Guidelinesdetailed in the beginning of this manual.

TROUBLESHOOTING GUIDE


CAUTION

PROBLEMS(SYMPTOMS)

Arc is unstable – Poor starting


1. Check for correct input voltageto machine – 115vac.

2. Check for proper electrodepolarity for process.

3. Check gun tip for wear or dam-age and proper size – Replace.

4. Check for proper gas and flowrate for process. (For MIG only.)

5. Check work cable for loose orfaulty connections.

6. Check gun for damage orbreaks.

7. Check for proper drive roll orien-tation and alignment.

8. Check liner for proper size.



WELDING PROBLEMS

F-1DIAGRAMSF-1

PRO 100

S1

SW

ITC

H

D1

D3

D2

D4

204

204

204

203

203

203

C1

59,0

00 m

f40

V

203

204

-

+

GU

N C

AB

LEC

ON

DU

CTO

RB

LOC

K

TO WO

RK

ELE

CTR

ICA

L S

YM

BO

LS P

ER

E15

37

CA

VIT

Y N

UM

BE

RIN

G S

EQ

UE

NC

E(

CO

MP

ON

EN

T S

IDE

OF

BO

AR

D )

539

541

T1

213

GU

N T

RIG

GE

RTH

ER

MO

STA

T

208

5KW

IRE

SP

EE

D

R2

(W)

(B)

N.C

.

N.C

. C

OM

PO

NE

NT

VIE

WE

D F

RO

M R

EA

R.

ON

-OFF N

.C.

209

WIN

DIN

G

24V

AU

XIL

IAR

Y

FAN

MO

TOR

X1

202

X2

S2

SE

LEC

TOR

SW

ITC

H

CIR

CU

ITB

RE

AK

ER

115V

/60H

Z11

5V/6

0HZ

OU

TPU

TC

HO

KE

X3

X4

X5

+

H1

H1

H2

F154

120

420

320

920

8 539

213

214

12

34

LATC

H

5

67

89

10

12

34

56

78

910

GA

SS

OLE

NO

ID

CO

NTR

OL

P.C

. B

OA

RD

J1

J1

CR

1

H1

H2

LS1

H2

H2

N.O

.

214

N.B

.N

.D.

N.A

.

N.D

.

HIG

H V

OLT

AG

Ecan

kill

Only

qua

lifie

d pe

rson

s sh

ould

inst

all,

use

orse

rvic

e th

is m

achi

ne.

Do n

ot o

pera

te w

ith c

over

s re

mov

ed.

Do n

ot to

uch

elec

trica

lly li

ve p

arts

Disc

onne

ct in

put p

ower

by

unpl

uggi

ngpo

wer c

ord

befo

re s

ervi

cing

TO E

AR

TH G

RO

UN

D P

ER

NA

TIO

NA

L, L

OC

AL

OR

OTH

ER

AP

PLI

CA

BLE

ELE

CTR

ICA

L C

OD

ES

.

WIR

ING

DIA

GR

AM

GA

S S

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NO

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S P

AR

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IG C

ON

VE

RS

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KIT

.

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GR

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ND

ING

STU

D

N.A

. D

IOD

ES

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& D

4 A

RE

MO

UN

TED

O

N T

HE

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TSID

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EA

TSIN

K.

N.B

. D

IOD

ES

D1

& D

3 A

RE

MO

UN

TED

O

N T

HE

IN

SID

E H

EA

TSIN

K,

WH

ICH

I

S C

LOS

ES

T TO

TH

E C

EN

TER

PA

NE

L.

N.D

. B

OLT

ED

ALU

MIN

UM

CO

NN

EC

TIO

NS

LEA

D C

OLO

R C

OD

E:

B-B

LAC

KW

-WH

ITE

(DO

W C

OR

NIN

G 3

40)

WH

EN

RE

ATT

AC

HIN

G.

RE

QU

IRE

T12

837

JOIN

T C

OM

PO

UN

D

8-01

G

S1

SW

ITC

H

D1

D3

D2

D4

204

204

204

203

203

203

C1

59,0

00 m

f40

V

203

204

-

+

GU

N C

AB

LEC

ON

DU

CTO

RB

LOC

K

TO WO

RK

ELE

CTR

ICA

L S

YM

BO

LS P

ER

E15

37

CA

VIT

Y N

UM

BE

RIN

G S

EQ

UE

NC

E(

CO

MP

ON

EN

T S

IDE

OF

BO

AR

D )

539

541

T1

213

GU

N T

RIG

GE

RTH

ER

MO

STA

T

208

5KW

IRE

SP

EE

D

R2

(W)

(B)

N.C

.

N.C

. C

OM

PO

NE

NT

VIE

WE

D F

RO

M R

EA

R.

ON

-OFF N

.C.

209

WIN

DIN

G

24V

AU

XIL

IAR

Y

FAN

MO

TOR

X1

202

X2

S2

SE

LEC

TOR

SW

ITC

H

CIR

CU

ITB

RE

AK

ER

115V

/60H

Z11

5V/6

0HZ

OU

TPU

TC

HO

KE

X3

X4

X5

+

H1

H1

H2

F154

120

420

320

920

8 539

213

214

12

34

LATC

H

5

67

89

10

12

34

56

78

910

GA

SS

OLE

NO

ID

CO

NTR

OL

P.C

. B

OA

RD

J1

J1

CR

1

H1

H2

LS1

H2

H2

N.O

.

214

N.B

.N

.D.

N.A

.

N.D

.

HIG

H V

OLT

AG

Ecan

kill

Only

qua

lifie

d pe

rson

s sh

ould

inst

all,

use

orse

rvic

e th

is m

achi

ne.

Do n

ot o

pera

te w

ith c

over

s re

mov

ed.

Do n

ot to

uch

elec

trica

lly li

ve p

arts

Disc

onne

ct in

put p

ower

by

unpl

uggi

ngpo

wer c

ord

befo

re s

ervi

cing

TO E

AR

TH G

RO

UN

D P

ER

NA

TIO

NA

L, L

OC

AL

OR

OTH

ER

AP

PLI

CA

BLE

ELE

CTR

ICA

L C

OD

ES

.

M

1573

2

GA

S S

OLE

NO

ID I

S P

AR

T O

F M

IG C

ON

VE

RS

ION

KIT

.

- +

(MO

UN

TED

TO

SE

C.

CO

IL)

WIR

EFE

ED

MO

TOR

CA

SE

GR

OU

ND

ING

STU

D

N.A

. D

IOD

ES

D2

& D

4 A

RE

MO

UN

TED

O

N T

HE

OU

TSID

E H

EA

TSIN

K.

N.B

. D

IOD

ES

D1

& D

3 A

RE

MO

UN

TED

O

N T

HE

IN

SID

E H

EA

TSIN

K,

WH

ICH

I

S C

LOS

ES

T TO

TH

E C

EN

TER

PA

NE

L.

N.D

. B

OLT

ED

ALU

MIN

UM

CO

NN

EC

TIO

NS

LEA

D C

OLO

R C

OD

E:

B-B

LAC

KW

-WH

ITE

(DO

W C

OR

NIN

G 3

40)

WH

EN

RE

ATT

AC

HIN

G.

RE

QU

IRE

T12

837

JOIN

T C

OM

PO

UN

D

NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual. Thespecific diagram for a particular code is pasted inside the machine on one of the enclosure panels.

NOTES

PRO 100

WARNING

AVISO DEPRECAUCION

ATTENTION

WARNUNG

ATENÇÃO

Spanish

French

German

Portuguese

Japanese

Chinese

Korean

Arabic

READ AND UNDERSTAND THE MANUFACTURER’S INSTRUCTION FOR THIS EQUIPMENT AND THE CONSUMABLES TO BEUSED AND FOLLOW YOUR EMPLOYER’S SAFETY PRACTICES.

SE RECOMIENDA LEER Y ENTENDER LAS INSTRUCCIONES DEL FABRICANTE PARA EL USO DE ESTE EQUIPO Y LOSCONSUMIBLES 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 AETRE 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.

● Do not touch electrically live parts orelectrode with skin or wet clothing.

● Insulate yourself from work andground.

● No toque las partes o los electrodosbajo carga con la piel o ropa moja-da.

● Aislese del trabajo y de la tierra.

● Ne laissez ni la peau ni des vête-ments mouillés entrer en contactavec des pièces sous tension.

● Isolez-vous du travail et de la terre.

● Berühren Sie keine stromführendenTeile oder Elektroden mit IhremKörper oder feuchter Kleidung!

● Isolieren Sie sich von den Elektro-den und dem Erdboden!

● Não toque partes elétricas e elec-trodos com a pele ou roupa molha-da.

● Isole-se da peça e terra.

● Keep flammable materials away.

● Mantenga el material combustiblefuera del área de trabajo.

● Gardez à l’écart de tout matérielinflammable.

● Entfernen Sie brennbarres Material!

● Mantenha inflamáveis bem guarda-dos.

● Wear eye, ear and body protection.

● Protéjase los ojos, los oídos y elcuerpo.

● Protégez vos yeux, vos oreilles etvotre corps.

● Tragen Sie Augen-, Ohren- und Kör-perschutz!

● Use proteção para a vista, ouvido ecorpo.

WARNING

AVISO DEPRECAUCION

ATTENTION

WARNUNG

ATENÇÃO

Spanish

French

German

Portuguese

Japanese

Chinese

Korean

Arabic

LEIA E COMPREENDA AS INSTRUÇÕES DO FABRICANTE PARA ESTE EQUIPAMENTO E AS PARTES DE USO, E SIGA ASPRÁTICAS DE SEGURANÇA DO EMPREGADOR.

● Keep your head out of fumes.● Use ventilation or exhaust to

remove fumes from breathing zone.

● Los humos fuera de la zona de res-piración.

● Mantenga la cabeza fuera de loshumos. Utilice ventilación oaspiración para gases.

● Gardez la tête à l’écart des fumées.● Utilisez un ventilateur ou un aspira-

teur pour ôter les fumées des zonesde travail.

● Vermeiden Sie das Einatmen vonSchweibrauch!

● Sorgen Sie für gute Be- und Entlüf-tung des Arbeitsplatzes!

● Mantenha seu rosto da fumaça.● Use ventilação e exhaustão para

remover fumo da zona respiratória.

● Turn power off before servicing.

● Desconectar el cable de ali-mentación de poder de la máquinaantes de iniciar cualquier servicio.

● Débranchez le courant avant l’entre-tien.

● Strom vor Wartungsarbeitenabschalten! (Netzstrom völlig öff-nen; Maschine anhalten!)

● Não opere com as tampas removidas.● Desligue a corrente antes de fazer

serviço.● Não toque as partes elétricas nuas.

● Do not operate with panel open orguards off.

● No operar con panel abierto oguardas quitadas.

● N’opérez pas avec les panneauxouverts ou avec les dispositifs deprotection enlevés.

● Anlage nie ohne Schutzgehäuseoder Innenschutzverkleidung inBetrieb setzen!

● Mantenha-se afastado das partesmoventes.

● Não opere com os paineis abertosou guardas removidas.

• Sales and Service through Subsidiaries and Distributors Worldwide •Cleveland, Ohio 44117-1199 U.S.A. TEL: 216.481.8100 FAX: 216.486.1751 WEB SITE: www.lincolnelectric.com

• World's Leader in Welding and Cutting Products •

Documents

featur - Lincoln Electric€¦ · 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