Lincoln Weldpak 3200 HD

WELD-PAK 3200HD

OPERATORS MANUAL

IM759May, 2002

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:10932

• 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 •

Date of Purchase:Serial Number:Code Number:Model:Where Purchased:

ISO 9001

CERTIFICATE NUMBER: 30273

Designed and Manufactured Under aQuality Program Certified byABS Quality Evaluations, Inc.to ISO 9001 Requirements.

QMS

ANSI RAB

Copyright © 2002 Lincoln Global Inc.

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.

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.

CALIFORNIA PROPOSITION 65 WARNINGS

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 instruc-tions et les précautions de sûreté specifiques qui parraissentdans ce manuel aussi bien que les précautions de sûretégénérales suivantes:

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 unegrande partie du corps peut être en contact avec lamasse.

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 soud-er parce 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 pro-téger contre les chutes dans le cas ou on recoit un choc. Nejamais enrouler le câble-électrode autour de n’importe quellepartie du 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 durayonnement de l’arc et des projections quand on soudeou quand 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-inflamma-bles.

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

5. Toujours porter des lunettes de sécurité dans la zone desoudage. Utiliser des lunettes avec écrans lateraux dans leszones 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 lesvapeurs du solvant pour produire du phosgéne (gas forte-ment 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 codede l’électricité et aux recommendations du fabricant. Le dis-positif de montage ou la piece à souder doit être branché àune bonne mise à la terre.

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

3. Avant de faires des travaux à l’ interieur de poste, ladebrancher 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.

Model Name & Number _____________________________________

Code & Serial Number _____________________________________

Date of Purchase _____________________________________

Whenever you request replacement parts for or information on this equipment always supply the informationyou have recorded above.

vv

vi

MASTER TABLE OF CONTENTS FOR ALL SECTIONS

Page

Installation .......................................................................................................Section ATechnical Specifications ........................................................................................A-1Identify and Locate Components ...........................................................................A-2Select Suitable Location ........................................................................................A-3Output Connections...............................................................................................A-3Input Connections..................................................................................................A-6Code Requirements ..............................................................................................A-6Undercarriage Assembly .......................................................................................A-7

________________________________________________________________________Operation .........................................................................................................Section B

Safety Precautions ................................................................................................B-1General Description ...............................................................................................B-1Design Features..............................................................................................B-1,B-2Welding Capability .................................................................................................B-2Limitations..............................................................................................................B-2Controls and Settings ............................................................................................B-2Welding Operations ...............................................................................................B-3Overload Protection...............................................................................................B-6Learning to Weld....................................................................................................B-7Application Chart .................................................................................................B-18

________________________________________________________________________Accessories .....................................................................................................Section C

Optional Accessories.............................................................................................C-1Replacement Parts ................................................................................................C-2

________________________________________________________________________Maintenance ....................................................................................................Section D

Safety Precautions ................................................................................................D-1Items Requiring No Maintenance ..........................................................................D-1Routine Maintenance.............................................................................................D-1Gun and Cable Maintenance.................................................................................D-2Component Replacement Procedures ..................................................................D-3Changing Liner ......................................................................................................D-4Gun Handle Parts ..................................................................................................D-4

________________________________________________________________________Troubleshooting ..............................................................................................Section E

Safety Precautions.................................................................................................E-1How to Use Troubleshooting Guide.......................................................................E-1Troubleshooting Guide.........................................................................E-2 THRU E-4

________________________________________________________________________Wiring Diagrams ..............................................................................................Section F

SP-135T Wiring Diagram.......................................................................................F-1________________________________________________________________________

Parts Lists .....................................................................................P442 Series, P202-E________________________________________________________________________

A-1

WELD PAK 3200HD

A-1

Fuse orOutput Mode Input Voltage Breaker Size1 Input Amps Power Cord Extension Cord

Three Conductor#14 AWG

(2.1 mm2) or Larger

RATED 120V/60Hz 20 Amp 20 15 Amp, 125V, Up to 25 Ft. (7.6 mm)

Three Prong Plug Three Conductor(NEMA Type 5-15P) #12 AWG

(3.3 mm2) or LargerUp to 50 Ft. (15.2 mm)

INSTALLATION

TECHNICAL SPECIFICATIONS – WELD-PAK 3200HDINPUT – SINGLE PHASE ONLY

RATED OUTPUT

OUTPUT

RECOMMENDED INPUT CABLE AND FUSE SIZES

Height Width Depth Weight12.0 in 9.75 in 16.5 in 48 Ibs305 mm 248 mm 419 mm 21.8 kg

PHYSICAL DIMENSIONS

Standard Voltage/Frequency Input Current120V/60Hz 20 Amps - Rated Output

Duty Cycle Amps Volts at Rated Amperes20% Duty Cycle 90 19

Welding Current Range Maximum-Open Circuit Voltage 50 - 300 in/min25-135 Amps 29V (1.3 - 7.6 m/min)

1If connected to a circuit protected by fuses use Time Delay Fuse marked “D”.

A-2INSTALLATION

WELD-PAK 3200HD

A-2

Read entire installation section before startinginstallation.

SAFETY PRECAUTIONS

IDENTIFY AND LOCATE COMPONENTSIf you have not already done so, unpack the WELD-PAK 3200HD from its carton and remove all packingmaterial around the WELD-PAK 3200HD. Remove thefollowing loose items from the carton (see Figure A.1):

1. WELD-PAK 3200HD

2. Gun and cable assembly(1)

3. Literature and miscellaneous including:

a) This operating manual

b) 3 extra .023"-.025” (0.6 mm) contact tips

c) 3 extra .035” (.09mm)contact tips

d) Hex key wrench for removal of drive roll.

4. 10 ft (3.0 m) work cable.

5. Work clamp.

6. Sample spool of .025” (0.6 mm) L-56 MIG wire.

7. Sample spool of.035” (.09mm) NR-211 MPInnershield Flux Cored Wire

8. Handshield with filter plate and lens.

9. Adjustable mixed-Gas Regulator & Hose.

10. Mig Nozzle Assembly

ELECTRIC SHOCK can kill.

• Only qualified personnel should performthis installation.

• Only personnel that have read and under-stood the WELD-PAK 3200 HD OperatingManual should install and operate thisequipment.

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

• The WELD-PAK 3200 HD power switch isto be in the OFF (“O”) position wheninstalling work cable and gun and whenconnecting power cord to input power.

WARNING

FIGURE A.1

12

3

4

7

8

9

6

5

11. Undercarriage: a) Baseb) Gas bottle support basec) (2) Gas bottle support brackets

For available options and accessories refer to theAccessories Section of this manual.

1) As shipped from the factory, the WELD-PAK3200HD gun liner is ready to feed .023” (0.6 mm) -.035 (0.9 mm) wire. The contact tip is sized for .023”-.025” (0.6 mm) wire feeding.

A-3INSTALLATION

WELD-PAK 3200HD

A-3

45

8

3 6 71 2

+

-

FIGURE A.2

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

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

WELD-PAK 3200HD cannot be stacked.

TILTING

Each machine must be placed on a secure, level sur-face, either directly or on either recommended cart.The machine may topple over if this procedure is notfollowed.

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.6. Wire Feed Gearbox.7. Cable Hanger.8. Thumbscrew.

Strain Relief Hole

Nut & Bolt

Work Clamp

Work Cable

Work Cable InstallationRefer to Figure A.2.1. Open the wire feed section door on the right side of

the WELD-PAK 3200HD.

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.4. Asdelivered, The machine is connected for negativepolarity (required for the Innershield process), con-nect the short cable attached to the connectorblock (1) to the negative (–) output terminal (2) andthe work cable (3) to the positive (+) terminal (4).

5. For GMAW Only: Refer to Figure A..2. To wire forpositive electrode polarity. the appropriate configu-ration for the GMAW (MIG) process use the provid-ed wing nut to connect the work cable’s terminallug to the negative (–) output terminal (5) locatedabove the Wire Feed Gearbox (6). Make sure thatboth wing nuts are tight.

A-4INSTALLATION

WELD-PAK 3200HD

A-4

Connecting Gun Cable to the WELD-PAK3200HD.1. Refer to Figure A.2. Unplug the machine or turn

power switch to the OFF “O” position.

2. Pass the insulated terminals of the gun trigger con-trol leads, one at a time, through the Gun 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 theWELD-PAK 3200H case front. Make sure the con-nector is all the way in the brass connector block.Unscrew thumbscrew on the connector block a fewturns if gun connector will not insert fully. Rotatethe connector so control leads are on the under-side and tighten the Thumbscrew (8) in the con-nector block.

4. Connect the gun trigger control lead terminals tothe two insulated 1/4" (6.4 mm) tab terminal con-nector bushings located below 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 WELD-PAK 3200HD, theswitch must be a normally open, momentaryswitch. The terminals of the switch must be insu-lated from the welding circuit. Malfunction of theWELD-PAK 3200HD may result if this switchshorts to the WELD-PAK 3200HD welding outputcircuit or is common to any electrical circuit otherthan the WELD-PAK 3200HD trigger circuit.

GAS CONNECTION

When using the GMAW process, a cylinder of shield-ing gas, must be obtained. For more information aboutselecting gas cylinders for use with the WELD-PAK3200HD refer to the ACCESSORIES section.

2

43

1

FIGURE A.4

GUN INSTALLATION

As shipped from the factory, the WELD-PAK 3200HDis ready to feed .023”-.025" (0.6 mm) solid wire. If.030 (0.8mm) solid wire. If .030" (0.8 mm) solid wire isto be used, change the contact tip to the appropriatesize.

NOTE: If .035" (0.9 mm) Innershield flux-cored wire isto be used, assemble the mig nozzle and .035” tip onto gun and reverse drive roll.

CAUTION

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, if notusing undercarriage. Insulate the cylinder from thework circuit and earth ground. Refer to Figure A.5.

FIGURE A.5

A-5INSTALLATION

WELD-PAK 3200HD

A-5

WARNING

Cylinder Valve

Gas Hose

Flow Regulator

WARNING

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 FROMTHE VALVE OUTLET WHEN “CRACKING” THEVALVE. Never stand directly in front of or behindthe flow regulator when opening the cylindervalve. Always stand 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, makecertain the plastic washer is seated in the fittingthat attaches to the CO2 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.Connect the other end to the WELD-PAK 3200HDGas Solenoid Inlet Fitting (5/8-18 female threads— for CGA —.032 fitting). Make certain the gashose is not kinked or twisted.

WARNING

A-6INSTALLATION

WELD-PAK 3200HD

A-6

INPUT CONNECTIONS

Refer to Figure A.6.

The WELD-PAK 3200HD has a power input cablelocated on the rear of the machine.

FIGURE A.6

CODE REQUIREMENTS FOR INPUT CONNECTIONS

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

The United States National Electrical Code (Article630-B, 1990 Edition) provides standards foramperage handling capability of supply conduc-tors based on duty cycle of the welding source.

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 theWELD-PAK 3200HD. Connect this plug to a matinggrounded receptacle which is connected to a 20 ampbranch circuit with a nominal voltage rating of 115 to125 volts, 60 Hertz, AC only.

The rated output with this installation is 90 amps,19Volts, 20% duty cycle (2 minutes of every 10 minutesused for welding).

Do not connect the WELD-PAK 3200HD to an inputpower supply with a rated voltage that is greaterthan 125 volts.

Do not remove the power cord ground prong.

POWER INPUTCABLE

GAS SOLENOIDINLET FITTING

WARNING

CAUTION

A-7INSTALLATION

WELD-PAK 3200HD

A-7

UNDERCARRIAGE ASSEMBLY

CYLINDER may explodeif damaged.• Keep cylinder upright and securedto support.

• Keep cylinder away from areas where it may bedamaged.

• Never lift welder with cylinder attached.• Never allow welding electrode to touch cylinder.• Keep cylinder away from welding or other live

electrical circuits.• The undercarriage is not intended for transport-

ing the Weld-Pak 3200HD.• If the Weld-Pak 3200HD is going to be transport-

ed, remove the under-carriage.• Do not lift the Weld-Pak 3200HD when a gas bot-

tle is connected.• If the Weld-Pak 3200HD is going to be moved or

lifted, remove the gas bottle.------------------------------------------------------------------------(Refer to Figure A.7)

Note: The following instructions assume a gas bottleis going to be used. If a gas bottle is not going to beused, skip steps 5 and steps 7-10.

1. Remove both sheet metal screws (1) from case.

2. Align undercarriage base (2) with side mount screwholes as shown. Make sure the two caster mount-ing holes are located in front of the machine.

3. Replace sheet metal screws removed in step 1making sure to secure undercarriage to the Weld-Pak 3200HD (1).

4. Use both supplied black round head screws tosecure door side of the Weld-Pak 3200HD (3) toundercarriage.

5. Attach Gas Bottle Support Base to rear of undercar-riage using supplied 1/4"-20 fasteners (4).

6. Attach the supplied fixed casters to the rear of theundercarriage assembly (5).

7. Attach the supplied swivel caster to the front of theundercarriage with the supplied 5/16" acorn nuts.

8. Attach both Gas Bottle Support Brackets (6) asshown.

9. Insert gas bottle if available.

10. Tighten Gas Bottle Support Brackets with supplied1/4"-20 wing screws and wing nuts.

FIGURE A.7WARNING

1

2

3

45

67

B-1OPERATIONB-1

WELD-PAK 3200HD

Read entire operation section beforeoperating the WELD-PAK 3200HD.

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

GENERAL DESCRIPTIONThe WELD-PAK 3200HD is a complete semiautomaticconstant-voltage DC wire feeder / power source arcwelder. It has been designed for workshop, hobby,automotive and light maintenance. Included is a tap-switch controlled, single phase constant voltage trans-former / rectifier power source and a wire feeder weld-ing gun for feeding .023 - .025” (0.6 mm) through.030” (0.8 mm) solid steel electrode and .035” (0.9mm) Innershield® NR-211-MP flux-cored wire.

The WELD-PAK 3200HD is ideally suited for individu-als having access to 120 volt AC input power, andwanting the ease of use, quality and dependability ofboth gas metal arc welding or GMAW (also known asMIG welding) and the Innershield electrode process(self shielded flux cored or FCAW). The WELD-PAK3200HD is a rugged and reliable machine that hasbeen designed for dependable service and long life.

RECOMMENDED PROCESSES

The WELD-PAK 3200HD can be used for weldingmild steel using the Gas Metal Arc Welding (GMAW orMIG, Metal Inert Gas) single pass process, whichrequires a supply of shielding gas, or the flux-coredarc welding (FCAW) process using Innershield® elec-trode wire. The WELD-PAK 3200HD is configured foruse with the FCAW process as delivered from the fac-tory.

OPERATIONAL CONTROLS

The WELD-PAK 3200HD has the following controls asstandard: Control Power ON/OFF Switch, VoltageControl, Wire Speed Control, Trigger Switch, and aCircuit Breaker. With the optional Spot/Stitch Timer Kitinstalled, the following controls are also included:Mode switch and Time Control.

DESIGN FEATURES ● Operates on 120 volt input — no special wiring

required.

● “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" - .035" (0.8 -0.9 mm) diameter wire.

B-2OPERATIONB-2

Refer to Figure B.1b.4. Circuit Breaker – Protects machine from damage if

maximum output is exceeded. Button will extendout when tripped (Manual reset) Refer to Figure B.1b.

5. Gun Trigger - Activates welding output, wire feed,and gas solenoid operation. Releasing the triggerdeactivates welding and simultaneously activatesthe “burnback” function so that the welding wiredoes not stick in the weld puddle.

● No external shielding gas is required when usedwith Lincoln Innershield® .035” (0.9 mm) NR-211-MP electrode.

● Accommodates both 4” (100 mm) diameter and 8”(200 mm) diameter spools of wire.

WELDING CAPABILITYThe WELD-PAK 3200HD is rated at 90 amps, 19volts, at 20% duty cycle on a ten minute basis. It iscapable of higher output currents at lower duty cycles.

LIMITATIONSArc Gouging cannot be performed with the WELD-PAK 3200HD. The WELD-PAK 3200HD is not recom-mended for pipe thawing or TIG welding.

CONTROLS AND SETTINGSRefer to Figure B.1a.

1. Control Power ON/OFF Switch— When the power is on thefan motor will run and air will beexhausted out the louvers in thefront of the machine. The weld-ing output and wire feederremain off until the gun triggeris pressed.

2. Wire Speed Control —Controls the wire feed speedfrom 50 – 300 in /min (1.3 –7.6 m/min). The control canbe preset on the dial to thesetting specif ied on theW E L D P A K 3 2 0 0 H DApplication Chart located onthe inside of the wire feedsection door.

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

WELD-PAK 3200HD

OFF

ON

ARC VOLTS

WIRE SPEED

B-3OPERATIONB-3

FIGURE B.1a

FIGURE B.1b

WELDING OPERATIONS

SEQUENCE OF OPERATION

Wire LoadingRefer to Figures B.2 and B.3.

The machine power switch should be turned to theOFF (“O”) position before working inside the wire feedenclosure.

The welder is shipped from the factory ready to feed8" (200 mm) diameter spools with 2.2" (56 mm) maxi-mum width. These spools fit on a 2" (51 mm) diameterspindle that has a built in, adjustable friction brake toprevent overrun of the spool and excess slack in the wire.

Note:When loading and removing the 8” Spools makesure that the wing nut (inside the wire spool spindlehub) is turned 90° from the wire spool spindle lockingtab. If the wing nut is positioned in line with the lockingtab, the tab cannot be depressed to load or unload thewire spool.

FIGURE B.2

Load an 8” (200 mm) diameter spool on the wire spoolspindle shown in Figure B.2.

To use 4” (100 mm) diameter spools, the 2” (50 mm)diameter spindle must be removed (See Figure B.3).Remove the wing nut and spacer at the end of theshaft and remove the outside plastic wire spool spin-dle. The spindle can be stored in the wire feed com-partment. A 4” (100 mm) diameter spool is mounteddirectly on the 5/8” (16 mm) diameter shaft and held inplace with the previously removed hardware. Alsomake 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

WELD-PAK 3200HD

DO NOT SWITCHWHEN WELDING

3

21

Wire Spindle Shaft

To Wire Drive

4" Wire Spool

Wing Nut and 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.

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

To Wire Drive

Wire Spool Spindle

8” Wire Spool

B-4OPERATIONB-4

Friction Brake Adjustment

With wire spool installed on the spindle shaft and thewing nut loose, turn the spool by hand while slowlytightening the wing nut until a light drag is felt. Tightenthe wing nut an additional 1/4 turn.

Note: When properly adjusted, the brake should pro-vide only enough drag to prevent overrun of the spooland excess slack in the wire. Too much drag mayresult in wire feeding problems, and may cause pre-mature wear of wire drive system components.

Wire Threading Refer to Figure B.4

1. 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 (2) and latch the springloaded pressure arm (1) in place. Rotate the spoolcounterclockwise if required in order to take upextra slack in the wire.

6. The idle roll pressure adjustment wing nut is factoryset to approximately five full turns from where thewing nut first engages the threads of the pressurearm (1). If feeding problems occur because the wireis flattened excessively, turn the pressure adjust-ment counter-clockwise to reduce distortion of thewire. Slightly less pressure may be required whenusing 0.023 – 0.025" (0,6 mm) wire. If the drive rollslips while feeding wire, the pressure should beincreased until the wire feeds properly.

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.

FIGURE B.4

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

8. Turn the WELD-PAK 3200HD 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 WELD-PAK 3200HD OFF (“O”).

12. Replace contact tip and gas nozzle.

13. Refer to Figure B-6. Cut the wire off 1/4” – 3/8” (6– 10 mm) from the end of the tip. The WELD-PAK3200HD is now ready to weld.

FIGURE B.5

WELD-PAK 3200HD

WARNING

The Wire Drive Feed Roll canaccommodate two wire sizesby flipping the wire drive feedroll over.

1

2

345

Gun Handle

Gas Diffuser/Contact Tip

Gas Nozzle

B-5OPERATIONB-5

FIGURE B.6

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 WELD-PAK 3200HD controls. Refer to TableB.1 for aluminum 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.

FIGURE B.7

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 theWELD-PAK 3200HD.

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 GUIDELINES

The WELD-PAK 3200HD can be used for weldingmild steel using the GMAW, single pass, processwhich requires a supply of shielding gas or it can beused for the self-shielded, Innershield® process(FCAW).

The recommended gases and electrodes for GMAWare welding grade CO2 gas or an argon-CO2 blendedgas (75 to 80% argon and 25 to 20% CO2) and .025"(0.6 mm) diameter Lincoln L-56 mild-steel weldingwire, supplied on 12-1/2 lb (5.7 kg) spools. The blend-ed gas is recommended for welding on heavier steel,14 gauge (2.0 mm), for example.

The recommended electrode for the self-shieldedprocess is .035” (0.9 mm) diameter LincolnInnershield® NR-211-MP on 10 lb (4.5 kg) spools.This electrode can be used for all position welding of20 gauge (1.0 mm) through 5/16" (8 mm) steel.Thickness of 1/4" (6 mm) and 5/16" (8 mm) requiremultiple passes. This wire can also be used for thewelding of galvanized coated sheet metal.

WELD-PAK 3200HD

3/8" – 1/2" Electrical Stickout

Contact Tip

Wire Electrode

WORKPIECE

GUN CABLE

ARC

WORK CLAMP

B-6OPERATIONB-6

The WELD-PAK 3200HD is suitable for .035" alu-minum wire and .030" stainless wire. Refer to TableB.1 for recommended procedure settings (requiresK499 Argon Regulator Kit).

TABLE B.1

CHANGING MACHINE OVER TOFEED OTHER WIRE SIZES

The WELD-PAK 3200HD is shipped from the factoryready to feed 023”-.025” (0.6 mm) diameter wire. Tooperate the WELD-PAK 3200HD with other sizes ofwire, it is necessary to change the contact tip andchange the drive roll over to other sizes. Refer toChanging the Contact Tip and Changing the DriveRoll, in the MAINTENANCE section, for specific infor-mation on these procedures.

WELDING WITH GMAW (MIG)

Shielding Gas

When using the GMAW process, obtain and install agas regulator and hose kit; K463 (for CO2) or K499(Argon mixed) gas regulator and hose kit.

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, andadjust the flow to give 25 – 30 CFH (12 – 14I/min).

3. Keep the cylinder valve closed, except when usingthe WELD-PAK 3200HD. 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 WELD-PAK 3200HD.

WELDING WITH FCAW (Innershield)

When using the FCAW process, the correct drive rolland electrode polarity must be used. See Work CableInstallation in INSTALLATION section for changingthe polarity.

OVERLOAD PROTECTION

Output OverloadThe WELD-PAK 3200HD is equipped with a circuitbreaker and a thermostat which protects the machinefrom damage if maximum output is exceeded. The cir-cuit breaker button will extend out when tripped. Thecircuit breaker must be manually reset.

Thermal ProtectionThe WELD-PAK 3200HD has a rated output dutycycle of 20%. If the duty cycle is exceeded, a thermalprotector will shut off the output until the machinecools to a reasonable operating temperature. This isan automatic function of the WELD-PAK 3200HD anddoes not require user intervention. The fan continuesto run during cooling.

Electronic Wire Drive Motor ProtectionThe WELD-PAK 3200HD has built-in protection forwire drive motor overload.

WELD-PAK 3200HD

Shielding Voltage/Wire SpeedProcess Welding Wire Gas 16 ga 14 ga 12 ga 10 ga

MIG DC+ .035 Dia 100% Argon B-5 D-7 D-9 D-94043 AluminumWire

MIG DC+ .035 Dia 100% Argon B-5 C-7 D-9 D-105356 AluminumWire

MIG DC+ .030 Dia 98% Argon/ A-3 C-6 D-7.5 D-7.5308L Stainless 2% OxygenSteel Wire

B-7LEARNING TO WELDB-7

LEARNING TO WELD

No one can learn to weld simply by reading about it.Skill comes only with practice. The following pageswill help the inexperienced operator to understandwelding and develop this skill. For more detailed infor-mation, order a copy of “New Lessons in Arc Welding”listed at the end of this manual.

THE ARC-WELDING CIRCUIT

The OPERATORS knowledge of arc welding must gobeyond the arc itself. The operator must know how tocontrol the arc, and this requires a knowledge of thewelding circuit and the equipment that provides theelectric current used in the arc. Figure B.7 illustratesthe welding circuit for a typical welding machine. Thecircuit begins where the gun cable is attached to thewelding machine. Current flows through the guncable, gun, and contact tip, to the wire and across thearc. On the work side of the arc, current flows throughthe base metal to the work cable and back to thewelding machine. This circuit must be complete for thecurrent to flow.

This machine’s welding circuit has a voltage output of32 volts DC maximum. This voltage is quite low and isonly present when the gun triggers depressed.

To weld, the work clamp must be tightly connected toclean base metal. Remove paint, rust, dirt or oil asnecessary and connect the work clamp as close aspossible to the area you wish to weld. This helps pre-vent current from going through an unwanted path.Avoid allowing the welding circuit to pass throughhinges, bearings, electronic components, or similardevices that can be damaged. See Figure B.8. Alwaysdisconnect electrical devices before welding uponthem.

FIGURE B.8

Fumes and slag generated fromInnershield type electrodes recom-mended for use with this weldingmachine can be toxic.

• Avoid contact with eyes and skin.

• Do not take internally.

• Keep out of reach of children.

• Follow all safety precautionsfound in this operating manual.

The gun and cable assembly is held by the operatorwho guides the automatically fed wire along the joint,maintaining a contact tip to work distance of about 3/8to 1/2 inch (10 – 12 mm) This is called electrical stick-out. This electrical stickout (ESO) must be properlymaintained by the operator. The electric arc is madein the gap between the work and the tip end of a smalldiameter wire. When the power source is properly set,the arc gap is maintained automatically.

Arc welding is a manual skill requiring a steady hand,good physical condition, and good eyesight. The oper-ator controls the welding arc, and, therefore, the quali-ty of the weld made.

THE SELF-SHIELDED FCAW WELDINGARC

Figure B.9 illustrates the action taking place in the selfshielded FCAW (Innershield) welding arc. It closelyresembles what is actually seen while welding.

FIGURE B.9

WELD-PAK 3200HD

Electronic Components

Hinges Bearings

WARNING

Burning of core materialsinside wire electroderesults in shield of gas.

Arc Stream

Cored Wire

Protective Slag

Weld Metal


The “arc stream” is seen in the middle of the picture.This is the electric arc created by the electric currentflowing through the space between the end of the wireelectrode and the base metal. The temperature of thisarc is about 6000°F, which is more than enough tomelt metal. The arc is very bright, as well as hot, andcannot be looked at with the naked eye without riskingpainful injury. The very dark lens, specif icallydesigned for arc welding must be used with the handor face shield whenever viewing the arc.

The arc melts the base metal and actually digs into itmuch as water through a nozzle on a garden hosedigs into the earth. The molten metal forms a moltenpool or crater and tends to flow away from the arc. Asit moves away from the arc, it cools and solidifies.

The function of the Innershield cored wire electrode ismuch more than simply to carry current to the arc. Thewire core is composed of fluxes and/or alloying ingre-dients around which a steel sheath has been formed.It is simply a stick electrode turned inside out in a con-tinuous wire form.

The cored wire melts in the arc and tiny droplets ofmolten metal shoot across the arc into the moltenpool. The wire sheath provides additional filler metalfor the joint to fill the groove or gap between the twopieces of base metal.

The core materials also melt or burn in the arc andperform several functions. They make the arc stead-ier, provide a shield of smoke-like gas around the arcto keep oxygen and nitrogen in the air away from themolten metal, and provide a flux for the molten pool.The flux picks up impurities and forms the protectiveslag on top of the weld during cooling.

After running a weld bead, the slag may be removedwith a chipping hammer and wire brush. Thisimproves appearance and allows for inspection of thefinished weld.

Since machine size and output characteristics limit thesize and type of wire electrode which can be used,Lincoln 0.035’ (0.9 mm) NR-211-MP Innershield elec-trode is recommended for Self-Shielded Flux CoredArc Welding.

THE GMAW (MIG) WELDING ARC

Figure B.10 illustrates the GMAW (MIG) welding arc.Solid wire does not contain fluxes or ingredients toform its own shielding and no slag forms to protect themolten weld metal. For this reason, a continuous evenflow of shielding gas is needed to protect the moltenweld metal from atmospheric contaminant's such asoxygen and nitrogen. Shielding gas is suppliedthrough the gun and cable assembly, through the gasnozzle and into the welding zone.

When comparing the GMAW and FCAW processes,you can see that the principal difference between thetwo lies in the type of shielding used. GMAW uses gasfor shielding, thus we have Gas Metal Arc Welding.FCAW uses the melting or burning of the core ingredi-ents for shielding, and is thus termed Self-ShieldedFlux Cored Arc Welding.

The recommended wire for Gas Metal Arc Welding(MIG) is Lincolnweld 0.025” (0.6 mm) L-56 electrode.Lincolnweld” L-56 is capable of welding a wide rangeof mild steels in all positions, however, more skill ISrequired for out-of-position welding with the GMAWprocess.

PROCESS SELECTION

By gaining knowledge of the differences between thetwo processes, you will be able to select the bestprocess for the job you have at hand. In selecting aprocess, you should consider:

WELD-PAK 3200HD

FIGURE B.10

Gas nozzle

Shielding gasSolid wireelectrode

Base metalWeld metal


WELD-PAK 3200HD

For GMAW (MIG) Process1. Is most of my welding performed on 16 gauge and

lighter materials?

2. Can I afford the extra expense, space, and lack ofportability required for gas cylinders and gas sup-ply?

3. Do I require clean, finished-looking welds?

If you have answered yes to all the above questionsGMAW may be the process for you. If you haveanswered no to any of the above questions, then youshould consider using the FCAW process.

For FCAW (Innershield) Process1. Do I want simplicity and portability?

2. Will welding be performed outdoors or under windyconditions?

3. Do I require good all position welding capability?

4. Will most welding be performed on 16 gauge andheavier, somewhat rusty or dirty materials?

5. Weld must be cleaned prior to painting.

COMMON METALS

Most metals found around the farm, small shop orhome are low carbon steel, sometimes referred to asmild steel. Typical items made with this type of steelinclude most sheet metal, plate, pipe and rolledshapes such as channels and angle irons. This type ofsteel can usually be easily welded without special pre-cautions. Some steels, however, contain higher car-bon levels or other alloys and are more difficult toweld. Basically, if a magnet sticks to the metal andyou can easily cut the metal with a file, chances aregood that the metal is mild steel and that you will beable to weld the material. In addition, aluminum andstainless steel can be welded using the K664-1Aluminum Welding Kit. For further information onidentifying various types of steels and other metals,and for proper procedures for welding them, we againsuggest you purchase a copy of “New Lessons in ArcWelding”.

Regardless of the type of metal being welded, in orderto get a quality weld, it is important that the metal isfree of oil, paint, rust or other contaminant's.

JOINT TYPES AND POSITIONS

Five types of welding joints are: Butt Welds, FilletWelds, Lap Welds, Edge Welds and Corner Welds.See Figure B.11.

Of these, the Butt Weld and Fillet Weld are the twomost common welds.

FIGURE B.11

Butt WeldsPlace two plates side by side, leaving a space approx-imately one half the thickness of the metal betweenthem in order to get deeper penetration.

Securely clamp or tack weld the plates at both ends,otherwise the heat will cause the plates to move apart.See Figure B.12.

Now weld the two plates together. Weld from left toright (if right handed). Point the wire electrode down inthe crack between the two plates, keeping the gunslightly tilted in the direction of travel. Watch themolten metal to be sure it distributes itself evenly onboth edges and in between the plates. This is referredto as the “pull technique”. On thin gauge sheet metal,use the “push technique”. See “Welding Techniquesfor GMAW (MIG) Process”.

Butt weld Lap weld

Edge weld Fillet weld Corner weld


WELD-PAK 3200HD

FIGURE B.12PenetrationUnless a weld penetrates close to 100% of the metalthickness, a butt weld will be weaker than the materialwelded together. In the example shown in FigureB.13, the total weld is only half the thickness of thematerial thus the weld is only approximately half asstrong as the metal.

FIGURE B.13

FIGURE B.14

In the example shown in Figure B.14, the joint hasbeen welded so that 100% penetration could beachieved. The weld, if properly made, is as strong asor stronger than the original metal.

Fillet WeldsWhen welding fillet welds, it is very important to holdthe wire electrode at a 45° angle between the twosides or the metal will not distribute itself evenly. Thegun nozzle is generally formed at an angle to facilitatethis. See Figure B.15.

FIGURE B.15

Welding In The Vertical Position

Welding in the vertical position can be done either ver-tical-up or vertical-down. Vertical-up is used whenevera larger, stronger weld is desired. Vertical-down isused primarily on sheet metal 5/32” (3.9 mm) andunder for fast, low penetrating welds.

Use of this unit on thicker materials than recom-mended may result in poor welds. The welds may“look” good, but may just be “sitting” on top, ofthe plate. This is called “Cold Casting” and willresult in weld failure.

Vertical-up And Overhead WeldingThe problem, when welding vertical-up, is to put themolten metal where it is wanted and make it staythere. If too much molten metal is deposited, gravitywill pull it downwards and make it “drip”. Therefore, acertain technique has to be followed.

When welding out-of-position, run stringer beads.Don’t whip, break the arc, move out of the puddle, ormove too fast in any direction. Use Wire Feed Speed(WFS) in the low portion of the range. The generaltechnique and proper gun angle is illustrated in FigureB.16.

Generally, keep the electrode nearly perpendicular tothe joint as illustrated. The maximum angle above per-pendicular may be required if porosity becomes aproblem.

45°

WARNING


WELD-PAK 3200HD

FIGURE B.16

Vertical-down WeldingRefer to Figure B.17 Vertical-down welds are appliedat a fast pace. These welds are therefore shallow andnarrow and, as such, are excellent for sheet metal.Vertical-down welds may be applied to 5/32” (3.9 mm)and lighter material.

Use stringer beads and tip the gun in the direction oftravel so the arc force helps hold the molten metal inthe joint. Move as fast as possible consistent withdesired bead shape.

The important thing is to continue lowering the entirearm as the weld is made so the angle of the gun doesnot change. Move the electrode wire fast enough thatthe slag does not catch up with the arc. Vertical-downwelding gives thin, shallow welds. It should not beused on heavy material where large welds arerequired.

FIGURE B.17

PROPER GUN ANGLEFOR GMAW PROCESSWELDING IN THE VERTICAL UP POSITION

PROPER GUN ANGLEFOR FCAW PROCESSWELDING IN THE VERTICAL UP POSITION

MACHINE SET UP FOR THE SELF-SHIELDED FCAW PROCESS

1. See PROCESS GUIDELINES in the OPERATIONsection for selection of welding wire and shieldinggas, and for range of metal thicknesses that can bewelded.

2. See the Application Guide on the inside of wirefeed section door for information on setting thecontrols.

3. Set the “Voltage” and “Wire Speed” controls to thesettings suggested on the Application Guide for thewelding wire and base metal thickness being used.The voltage control is marked “V” and the wire feedspeed is marked ‘’olo.’’

4. Check that the polarity is correct for the weldingwire being used. Set the polarity for DC(–) whenwelding with NR-211-MP Innershield electrode.See Work Cable Installation in the INSTALLATIONsection for instructions on changing polarity.

5. When using Innershield electrode, the gasless noz-zle may be used instead of a gas nozzle to improvevisibility of the arc.

6. Connect work clamp to metal to be welded. Workclamp must make good electrical contact to thework piece. The work piece must also be groundedas stated in the “Arc Welding Safety Precautions”at the beginning of this manual.

WELDING TECHNIQUES FOR THE SELF-SHIELDED FCAW PROCESS

Four simple manipulations are of prime importancewhen welding. With complete mastery of the four,welding will be easy. They are as follows:

1. The Correct Welding PositionFigure B.18 illustrates the correct welding positionfor right handed people. (For left handed people, itis the opposite.)

Hold the gun (of the gun and cable assembly) inyour right hand and hold the shield with your lefthand. (Left handers simply do the opposite.)

When using the FCAW Process, weld from left toright (if you are right handed). This enables you toclearly see what you are doing. (Left handers dothe opposite.) Tilt the gun toward the direction oftravel holding the electrode at an angle as shownin Figure B.18.


WELD-PAK 3200HD

ARC RAYS can burn eyes and skin.

When using an open arc process, itIs necessary to use correct eye,head and body protection.

Protect yourself and others, read“ARC RAYS can burn” at the frontof this manual.

2. The Correct Way To Strike An Arc1. Be sure the work clamp makes good electrical

contact to the work.

2. Position gun over joint. End of wire may belightly touching the work.

3. Position face shield to protect face and eyes,close gun trigger, and begin welding. Hold thegun so that the contact tip to work distance isabout 3/8 to 1/2 inch (10 – 12 mm).

4. To stop welding, release the gun trigger andthe pull the gun away from the work after thearc goes out.

5. A ball may form at the tip end of the wire afterwelding. For easier restrikes (with Innershieldwire) the ball may be removed by feeding out afew inches of wire and simply bending the wireback and forth until it breaks off.

6. When no more welding is to be done, turn offthe machine.

3. The Correct Electrical Stickout (ESO)The electrical stickout (ESO) is the distance fromthe end of the contact tip to the end of the wire.

See Figure B.19.

Once the arc has been established, maintainingthe correct ESO becomes extremely important.The ESO should be approximately 3/8 to 1/2 inch(10 to 12 mm) long.

The easiest way to tell whether the ESO is the cor-rect length is by listening to its sound. The correctESO has a distinctive “crackling” sound, very muchlike eggs frying in a pan. A long ESO has a hollow,blowing or hissing sound. If the ESO is too short,you may stick the contact tip or nozzle to the weldpuddle and/or fuse the wire to the contact tip.

4. The Correct Welding SpeedThe important thing to watch while welding is thepuddle of molten metal right behind the arc. SeeFigure B.20. Do not watch the arc itself. It is theappearance of the puddle and the ridge where themolten puddle solidifies that indicates correct weld-ing speed. The ridge should be approximately 3/8”(10 mm) behind the wire electrode.

Most beginners tend to weld too fast, resulting in athin uneven, “wormy” looking bead. They are notwatching the molten metal.

FIGURE B.20

FIGURE B.18

WARNINGFIGURE B.19

3/8 – 1/2” (10 – 12 mm)Electrical Stickout (ESO)

Contact Tip

Wire Electrode

Solidifying ridgeMolten puddle


WELD-PAK 3200HD

Helpful Hints

1. For general welding, it is not necessary to weavethe arc, neither forward or backward nor sideways.Weld along at a steady pace. You will find it easier.

2. When welding on thin plate, you will find that youwill have to increase the welding speed, whereaswhen welding on heavy plate, it is necessary to gomore slowly in order to get good penetration.

3. When welding sheet metal 16 gauge (1.5 mm) andlighter, heat buildup may cause part warpage andburn through. One way to eliminate these problemsis to use the back-stepping method illustrated inFigure B.21.

FIGURE B.21

Practice

The best way of getting practice in the four skills thatenable you to maintain:

1. Correct welding position

2. Correct way to strike an arc

3. Correct electrical stickout

4. Correct welding speed

is to perform the following exercise.

Refer to Figure B.22.

1. Learn to strike an arc by positioning the gun overthe joint and touching the wire to the work.

2. Position face shield to protect face and eyes.

3. Depress gun trigger, hold gun so contact tip towork distance is about 3/8 to 1/2 inch (10 to 12mm) and the gun is at proper angle.

4. After you strike the arc, practice the correct electri-cal stickout. Learn to distinguish it by its sound.

5. When you are sure that you can hold the correctelectrical stickout, with a smooth “crackling” arcstart moving. Look at the molten puddle constantly,and look at the “ridge” where the metal solidifies.

6. Run beads on a flat plate. Run them parallel to thetop edge (the edge farthest away from you). Thisgives you practice in running straight welds, andalso gives you an easy way to check yourprogress. The 10th weld will look considerably bet-ter than the first weld. By constantly checking onyour mistakes and your progress, welding will soonbe a matter of routine.

First weld from A to B; then from C to A; thenfrom D to C; then from E to D, and so on.

B A C D E

Back-Stepping

FIGURE B.22

ContactTip

Gun Angle

ESO

Mild Steel 12 gauge or 1/8 inch(3.0 mm)

Electrode 0.035" (0.9 mm)NR-211-MP

Innershield Wire

Voltage Setting “V” D

Wire Feed Speed “o|o” 3

For the WELD-PAK 3200HD, use the following:


WELD-PAK 3200HD

MACHINE SET UP FOR THE GMAW (MIG)PROCESS

1. See PROCESS GUIDELINES in the OPERATIONsection for selection of welding wire and shieldinggas, and for range of metal thicknesses that can bewelded.

2. See the Application Guide on the inside of wirefeed section door for information on setting thecontrols.

3. Set the “Voltage” and “Wire Speed” controls to thesettings suggested on the Application Guide for thewelding wire and base metal thickness being used.The voltage control is marked “V” and the wire feedspeed is marked ‘’olo.’’

4. Check that the polarity is correct for the weldingwire being used. Set the polarity for DC(+) whenwelding with the GMAW (MIG) process. See WorkCable Installation in the INSTALLATION section forinstructions for changing polarity.

5. Check that the gas nozzle and proper size linerand contact tip are being used and that the gassupply is turned on. If adjustable, set for 15 to 20cubic feet per hour (7 to 10 l/min.) under normalconditions, increase to as high as 35 CFH (17I/min.) under drafty (slightly windy) conditions.

6. Connect work clamp to metal to be welded. Workclamp must make good electrical contact to thework piece. The work piece must also be groundedas stated in the “Arc Welding Safety Precautions”at the beginning of this manual.

WELDING TECHNIQUES FOR THE GMAW(MIG) PROCESS

Four simple manipulations are of prime importancewhen welding. With complete mastery of the four,welding will be easy. They are as follows:

1. The Correct Welding PositionFigure B.23 illustrates the correct welding positionfor right handed people. (For left handed people, itis the opposite.)

When GMAW (MIG) welding on sheet metal, it isimportant to use the “forehand” push technique.

Hold the gun (of the gun and cable assembly) inyour right hand and hold the shield with your lefthand. (Left handers simply do the opposite.)

FIGURE B.23

When using the GMAW process on light gauge mater-ial, weld from right to left (if you are right handed).This results in a colder weld and has less tendency forburn through.

2. The Correct Way To Strike An Arc

ARC RAYS can burn eyes and skin.

When using an open arc process, itIs necessary to use correct eye,head and body protection.

Protect yourself and others, read“ARC RAYS can burn” at the frontof this manual.

1. Be sure the work clamp makes good electrical con-tact to the work.

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

3. Position face shield to protect face and eyes, closegun trigger, and begin welding. Hold the gun sothat the contact tip to work distance is about 3/8 to1/2 inch (10 – 12 mm).

4. To stop welding, release the gun trigger and pullthe gun away from the work after the arc goes out.

5. A ball may form at the tip end of the wire afterwelding. For easier restrikes, the ball may beremoved by feeding out a few inches of wire andcutting off the end of the wire with wire cutters.

6. When no more welding is to be done, close thevalve on the gas cylinder, momentarily operate thegun trigger to release gas pressure, then turn offthe machine.

WARNING


WELD-PAK 3200HD

FIGURE B.24

3. The Correct Electrical Stickout (ESO)The electrical stickout (ESO) is the distance fromthe end of the contact tip to the end of the wire.See Figure B.24.

Once the arc has been established, maintainingthe correct ESO becomes extremely important.The ESO should be approximately 3/8 to 1/2 inch(10 to 12 mm) long.

The easiest way to tell whether the ESO is the cor-rect length is by listening to its sound. The correctESO has a distinctive “crackling” sound, very muchlike eggs frying in a pan. A long ESO has a hollow,blowing or hissing sound. If the ESO is too short,you may stick the contact tip or nozzle to the weldpuddle and/or fuse the wire to the contact tip.

4. The Correct Welding SpeedThe important thing to watch while welding is thepuddle of molten metal right behind the arc. SeeFigure B.25. Do not watch the arc itself. It is theappearance of the puddle and the ridge where themolten Puddle solidifies that indicates correct weld-ing speed. The ridge should be approximately 3/8”(10 mm) behind the wire electrode.

Most beginners tend to weld too fast, resulting in athin, uneven, “wormy” looking bead. They are notwatching the molten metal.

FIGURE B.25

Helpful Hints

1. For general welding, it is not necessary to weavethe arc, neither forward or backward nor sideways.Weld along at a steady pace. You will find it easier.

2. When welding on thin plate, you will find that youwill have to increase the welding speed, whereaswhen welding on heavy plate, it is necessary to gomore slowly in order to get good penetration.

3. When welding sheet metal 16 gauge (1.5 mm) andlighter, heat buildup may cause part warpage andburn through. One way to eliminate these problemsis to use the back-stepping method illustrated inFigure B.21.

Practice

The best way of getting practice in the four skills thatenable you to maintain:

1. Correct welding position

2. Correct way to strike an arc

3. Correct electrical stickout

4. Correct welding speed

is to perform the following exercise.

Refer to Figure B.22.

1. Learn to strike an arc by positioning the gun overthe joint and touching the wire to the work.

2. Position face shield to protect face and eyes.

3. Depress gun trigger, hold gun so contact tip towork distance Is about 3/8 to 1/2 inch (10 to 12mm) and the gun is at proper angle.

Contact Tip

Wire Electrode

ESO

Molten puddle

Base metalWeld metal ridge

Mild Steel 16 gauge or 1/16 inch(1.6 mm)

Electrode Lincolnweld 0.025 L-56electrode

CO2Voltage Setting “V” C

Wire Feed Speed “o|o” 4

For the WELD-PAK 3200HD, use the following:


TROUBLESHOOTING WELDS

Good welds have excellent appearance.

To Eliminate Porosity (in order of importance):

1. Turn on gas supply, if used2. Decrease voltage.3. Increase stickout.4. Increase WFS (wire feed speed).5. Decrease drag angle.6. Decrease travel speed.NOTE: Always be sure the joint is free from moisture,oil, rust, paint or other contaminant's.

To Eliminate a Ropy Convex Bead(in order of importance):

1. Increase voltage.2. Decrease stickout.3. Decrease WFS (wire feed speed.4. Decrease travel speed.5. Decrease drag angle.6. Check for correct gas, if used.

To Reduce Spatter (in order of importance):

1. Increase voltage.2. Increase drag angle.3. Decrease stickout.4. Increase WFS (wire feed speed).5. Decrease travel speed.6. Check for correct gas, if used.

To Correct Poor Penetration (in order of impor-tance):1. Decrease stickout.2. Increase WFS (wire feed speed).3. Increase voltage.4. Decrease speed.5. Decrease drag angle.6. Check for correct gas, if used.

If Arc Blow Occurs (in order of importance):NOTE: Try different ground connection locationsbefore adjusting procedures.1. Decrease drag angle.2. Increase stickout.3. Decrease voltage.4. Decrease WFS (wire feed speed.5. Decrease travel speed.

To Eliminate Stubbing* (in order of importance):

1. Increase voltage2. Decrease WFS (wire feed speed)3. Decrease stickout4. Increase drag angle * Stubbing occurs when the electrode drives through

the molten puddle and hits the bottom plate tendingto push the gun up.

WELD-PAK 3200HD


Proper Gun Handling

Most feeding problems are caused by improper han-dling of the gun cable or electrodes.1. Do not kink or pull the gun around sharp corners2. Keep the gun cable as straight as practical when

welding.3. Do not allow dolly wheels or trucks to run over the

cables.4. Keep the cable clean.5. Innershield electrode has proper surface lubrica-

tion. Use only clean, rust-free electrode.6. Replace contact tip when it becomes worn or the

end is fused or deformed.

WELD-PAK 3200HD

B-18APPLICATION CHARTB-18

WELD-PAK 3200HD

C-1ACCESSORIESC-1

OPTIONAL ACCESSORIES

1. K664-2 Aluminum Feeding Kit — This kitrequired for welding with .035 Aluminum wire.Included with this kit are a drive roll, liner and con-tact tip. It is important when changing betweenwelding with steel wire and aluminum toexchange these components due to the lubri-cant applied to steel wire. Failure to do so mayresult in contaminated welds when welding alu-minum.

2. KP665-045C Drive Roll – Optional — Knurleddrive roll for feeding .035 (0.9 mm) diameter flux-cored electrode.

3. K520 Utility Cart — Designed to transport theLincoln 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.

4. K586-1 Deluxe Adjustable Gas Regulator &Hose KitAccommodates CO2 or mixed Gas Cylinders.

WELD-PAK 3200HD

C-2ACCESSORIESC-2

REPLACEMENT PARTS

Complete Gun and Cable AssemblyL8311-5 (K530-4)

Contact Tip .025” (0.6 mm)S19726-1

Contact Tip .030” (0.8 mm)S19726-2

Contact Tip .035” (0.9 mm)S19726-3

Contact Tip-Tapered .025” (0.6 mm)S20278-1



Liner .023 - .030” (0.6 - 0.8 mm)M16291-2

Liner .030 - .035” (0.8 - 0.9 mm)M16291-6

Liner .035/.045” (0.9/1.2 mm)M16291-1

Gas DiffuserS19728

Gas NozzleM16294

Gas Nozzle-Tip Recessed 3/8” (9.5 mm) Opening I.D.M16684

Gas Nozzle-Tip Recessed 1/2” (12.7 mm) Opening I.D.M16684-1

Gas Nozzle-Tip Recessed 5/8” (15.9 mm) Opening I.D.M16684-2

Spot Welding NozzleM17846

Gasless Nozzle (Innershield Only)M16418

WELD-PAK 3200HD

MAINTENANCE

SAFETY PRECAUTIONS

ELECTRIC SHOCK can kill.• Disconnect input power by removing

plug from receptacle before workinginside WELD-PAK 3200HD. Use onlygrounded receptacle. Do not touch elec-trically “hot” parts inside WELD-PAK3200HD.

• 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 WELD-PAK3200HD. Take the unit to an authorized Lincoln ServiceCenter if you experience problems. NO maintenance isrequired.

In extremely dusty locations, dirt may clog the air passagescausing the welder to run hot with premature tripping of ther-mal protection. If so, blow dirt out of the welder with low pres-sure air at regular intervals to eliminate excessive dirt and dustbuild-up on internal parts.

WIRE FEED COMPARTMENT1. When necessary, vacuum accumulated dirt from gearbox

and wire feed section.

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

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

FAN MOTORHas lifetime lubrication — requires no maintenance.

WIRE REEL SPINDLERequires no maintenance. Do not lubricate shaft.

D-1MAINTENANCED-1

WELD-PAK 3200HD

WARNING

D-2MAINTENANCED-2

WELD-PAK 3200HD

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 theInnershield® process, the gasless nozzle shouldbe screwed 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.Tighten 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.

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

Components shipped with S19726-3 M16291-6 KP665-035WELD-PAK 3200HD• .035” (0.9mm) .035” (0.9mm) 2 Smooth grooves

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

K664-2 .035 (0.9mm) S24221-1 M18971-1 M19631Aluminum or Stainless Kit* .035A (0.9mm) .035” (0.9mm)

• F0r 0.025 wire feeding use the included S19726-1 contact tip.

• If .030 Solid wire feeding is desired obtain an S19726-2 Contact Tip.

* It is important when changing between welding with steel wire and aluminum to exchange feeding components due to the lubricant applied to steel wire. Failure to do so may result in contaminated welds when welding aluminum.

CAUTION

D-3MAINTENANCED-3

WELD-PAK 3200HD

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 idle arm tensioner Item 2, andlift the idle roll arm, Item 3, away from the drive roll, Item1. (See Figure D.1)

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.

3

2

1

FIGURE D.1

CAUTION

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

D-4MAINTENANCED-4

8. Screw the gas diffuser onto the end of the gun tubeand securely tighten.

9. Replace the contact tip and nozzle.

WELD-PAK 3200HD

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

Gas Diffuser

Gas Nozzle orGasless NozzleSet Screw Brass Cable

Connector

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

FIGURE D.2Liner trim length

CHANGING LINER

NOTICE: The variation in cable lengths prevents theinterchangeability of liners. Once a liner has been cutfor a particular gun, it should not be installed in anoth-er gun unless it can meet the liner cutoff lengthrequirement. Refer to Figure D.2.

1. Remove the gas nozzle from the gun by unscrew-ing counter-clockwise.

2. Remove the existing contact tip from the gun byunscrewing counter-clockwise.

3. Remove the gas diffuser from the gun tube byunscrewing counter-clockwise.

4. Lay the gun and cable out straight on a flat surface.Loosen the set screw located in the brass connec-tor at the wire feeder end of the cable. Pull the linerout of the cable.

5. Insert a new untrimmed liner into the connector endof the cable. Be sure the liner bushing is stenciledappropriately for the wire size being used.

6. Fully seat the liner bushing into the connector.Tighten the set screw on the brass cable connector.At this time, the gas diffuser should not be installedonto the end of the gun tube.

7. With the gas nozzle and diffuser removed from thegun tube, be sure the cable is straight, and thentrim the liner to the length shown in the Figure D.2.Remove any burrs from the end of the liner.

E-1TROUBLESHOOTINGE-1

WELD-PAK 3200HD

If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact yourLocal Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed.

CAUTION

This Troubleshooting Guide is provided to help youlocate and repair possible machine malfunctions.Simply follow the three-step procedure listed below.

Step 1. LOCATE PROBLEM (SYMPTOM).Look under the column labeled “PROBLEM (SYMP-TOMS)”. This column describes possible symptomsthat the machine may exhibit. Find the listing thatbest describes the symptom that the machine isexhibiting.

Step 2. POSSIBLE CAUSE.The second column labeled “POSSIBLE CAUSE” liststhe obvious external possibilities that may contributeto the machine symptom.

Step 3. RECOMMENDED COURSE OF ACTIONThis column provides a course of action for thePossible Cause, generally it states to contact yourlocal Lincoln Authorized Field Service Facility.

If you do not understand or are unable to perform theRecommended Course of Action safely, contact yourlocal Lincoln Authorized 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 ElectricalShock, please observe all safety notes and precautions detailed throughout this manual.

__________________________________________________________________________

WARNING


WELD-PAK 3200HD


CAUTION

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 insidewire drive compartment is reset.

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

If all recommended possible areasof misadjustment have beenchecked and the problem persists,Contact your local LincolnAuthorized Field ServiceFacility.

OUTPUT PROBLEMS

Observe all Safety Guidelines detailed throughout this manual


WELD-PAK 3200HD


CAUTION

PROBLEMS(SYMPTOMS)

No wire feed when gun trigger ispulled. Fan runs, gas flows andmachine has correct open circuitvoltage (32VDC 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.


1. Check gas supply, flow regulatorand gas hoses.

2. Check gun connection tomachine for obstruction or leakyseals.



GAS FLOW PROBLEMS



WELD-PAK 3200HD


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

WELD-PAK 3200HD

S1

SWIT

CH

D1

D3

D2

D4

204

204

204

203

203

203

C1

59,0

00 f

40V

203

204

-

+G

UN

CAB

LEC

ON

DU

CTO

RB

LOC

K TO WO

RK

ELEC

TRIC

AL S

YMB

OLS

PER

E15

37

CAV

ITY

NU

MB

ERIN

G S

EQU

ENC

E( C

OM

PON

ENT

SID

E O

F B

OAR

D )

539

541

T1

GU

N T

RIG

GER

THER

MO

STAT

208

5KW

IRE

SPEE

D

R2

(W)

(B)

N.C

.

N.C

. CO

MPO

NEN

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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

WELD-PAK 3200HD

Now Available...12th EditionThe Procedure Handbook of Arc Welding

With over 500,000 copies of previous editions publishedsince 1933, the Procedure Handbook is considered by many to be the “Bible” of the arc welding industry.

This printing wil l go fast so don ’t delay. Place your order now using the coupon below.

The hardbound book contains over 750 pages of weldinginformation, techniques and procedures. Much of this material has never been included in any other book.

A must for al l welders, supervisors, engineers anddesigners. Many welding instructors will want to use the bookas a reference for all students by taking advantage of the lowquantity discount prices which include shipping by4th class parcel post.

$15.00 postage paid U.S.A. Mainland

How To Read Shop Drawings

The book contains the latest information and applicationdata on the American Welding Society Standard WeldingSymbols. Detailed discussion tells how engineers anddraftsmen use the “short-cut” language of symbols to passon assembly and welding information to shop personnel.

Practical exercises and examples develop the reader’s abilityto visualize mechanically drawn objects as they will appearin their assembled form.

187 pages with more than 100 illustrations. Size 8-1/2” x 11”Durable, cloth-covered board binding.


New Lessons in Arc WeldingLessons, simply written, cover manipulatory techniques;

machine and electrode characteristics; related subjects,such as distortion; and supplemental information on arcwelding applications, speeds and costs. Practice materials,exercises, questions and answers are suggested for each lesson.

528 pages, well illustrated, 6” x 9” size, bound in simulated,gold embossed leather.


Need Welding Training?The Lincoln Electric Company operates the oldest and

most respected Arc Welding School in the United States at itscorporate headquarters in Cleveland, Ohio. Over 100,000 stu-dents have graduated. Tuit ion is low and the training is “hands on”

For details write: Lincoln Welding School22801 St. Clair Ave. Cleveland, Ohio 44117-1199.

and ask for bulletin ED-80 or call 216-383-2259 and ask for theWelding School Registrar.

Lincoln Welding SchoolBASIC COURSE $700.00

5 weeks of fundamentalsThere is a 10% discount on all orders of $50.00 or more for shipment at one time to one location.Orders of $50 or less before discount or orders outside of North America must be prepaid with charge, check or money order in U.S. Funds Only.Prices include shipment by 4 thClass Book Rate for U.S.A. Mainland Only. Please allow up to 4 weeks for delivery.UPS Shipping for North America Only. All prepaid orders that request UPS shipment please add:

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Lincoln Welding School Titles: Price Code Quantity Cost(ED-80) New Lessons in Arc Welding $5.00 L

Seminar Information Procedure Handbook “Twelfth Edition” $15.00 PH(ED-45) How to Read Shop Drawings $4.50 H

Educational Video Information Incentive Management $5.00 IM(ED-93) A New Approach to Industrial Economics $5.00 NA

James F. Lincoln Arc Welding The American Century of John C. Lincoln $5.00 ACFoundation Book Information Welding Preheat Calculator $3.00 WC-8

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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 denElektroden 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- undEntlüftung 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

Lincoln Weldpak 3200 HD