RETURN TO MAIN MENU
IM784
PRO 100 April, 2004
For use with machine Code Number 10970
Safety Depends on You
Lincoln arc welding and cutting
equipment is designed and built
with safety in mind. However, your
overall safety can be increased by
proper installation ... and thought-
ful operation on your part. DO
NOT INSTALL, OPERATE OR
REPAIR THIS EQUIPMENT
WITHOUT READING THIS
MANUAL AND THE SAFETY
PRO 1
00
PRECAUTIONS CONTAINED
THROUGHOUT. And, most
importantly, think before you act
and be careful.
OPERATOR’S MANUAL
Copyright © 2004 Lincoln Global Inc.
� World's Leader in Welding and Cutting Products �
� 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
i i
SAFETY
WARNING
CALIFORNIA PROPOSITION 65 WARNINGS
The engine exhaust from this product contains
Diesel engine exhaust and some of its constituents
chemicals known to the State of California to cause
are known to the State of California to cause can-
cancer, birth defects, or other reproductive harm.
cer, birth defects, and other reproductive harm.
The Above For Gasoline Engines
The Above For Diesel Engines
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 you
purchase a copy of “Safety in Welding & Cutting - ANSI Standard Z49.1� from the American Welding Society, P.O. Box
351040, Miami, Florida 33135 or CSA Standard W117.2-1974. A Free copy of “Arc Welding Safety� booklet E205 is available
from the Lincoln Electric Company, 22801 St. Clair Avenue, Cleveland, Ohio 44117-1199.
BE SURE THAT ALL INSTALLATION, OPERATION, MAINTENANCE AND REPAIR PROCEDURES ARE
PERFORMED ONLY BY QUALIFIED INDIVIDUALS.
FOR ENGINE 1.h. To avoid scalding, do not remove the
radiator pressure cap when the engine is
powered equipment. hot.
1.a. Turn the engine off before troubleshooting and maintenance
work unless the maintenance work requires it to be running.
____________________________________________________
1.b. Operate engines in open, well-ventilated
areas or vent the engine exhaust fumes
outdoors.
ELECTRIC AND
MAGNETIC FIELDS
____________________________________________________
may be dangerous
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 before 2.a. Electric current flowing through any conductor causes
refueling to prevent spilled fuel from vaporiz- localized Electric and Magnetic Fields (EMF). Welding
ing on contact with hot engine parts and current creates EMF fields around welding cables and
igniting. Do not spill fuel when filling tank. If welding machines
fuel is spilled, wipe it up and do not start
engine until fumes have been eliminated. 2.b. EMF fields may interfere with some pacemakers, and
____________________________________________________ welders having a pacemaker should consult their physician
1.d. Keep all equipment safety guards, covers and devices in before welding.
position and in good repair.Keep hands, hair, clothing and
tools away from V-belts, gears, fans and all other moving 2.c. Exposure to EMF fields in welding may have other health
parts when starting, operating or repairing equipment. effects which are now not known.
____________________________________________________
2.d. All welders should use the following procedures in order to
1.e. In some cases it may be necessary to remove safety
minimize exposure to EMF fields from the welding circuit:
guards to perform required maintenance. Remove
guards only when necessary and replace them when the
2.d.1. Route the electrode and work cables together - Secure
maintenance requiring their removal is complete.
them with tape when possible.
Always use the greatest care when working near moving
parts.
2.d.2. Never coil the electrode lead around your body.
___________________________________________________
1.f. Do not put your hands near the engine fan.
2.d.3. Do not place your body between the electrode and
Do not attempt to override the governor or
idler by pushing on the throttle control rods work cables. If the electrode cable is on your right
while the engine is running. side, the work cable should also be on your right side.
2.d.4. Connect the work cable to the workpiece as close as
possible to the area being welded.
___________________________________________________
1.g. To prevent accidentally starting gasoline engines while 2.d.5. Do not work next to welding power source.
turning the engine or welding generator during maintenance
work, disconnect the spark plug wires, distributor cap or
magneto wire as appropriate. Mar �95
ii ii
SAFETY
ARC RAYS can burn.
ELECTRIC SHOCK can
4.a. Use a shield with the proper filter and cover
kill. plates to protect your eyes from sparks and
3.a. The electrode and work (or ground) circuits
the rays of the arc when welding or observing
are electrically “hot� when the welder is on. open arc welding. Headshield and filter lens
Do not touch these “hot� parts with your bare should conform to ANSI Z87. I standards.
skin or wet clothing. Wear dry, hole-free
gloves to insulate hands. 4.b. Use suitable clothing made from durable flame-resistant
material to protect your skin and that of your helpers from
3.b. Insulate yourself from work and ground using dry insulation. the arc rays.
Make certain the insulation is large enough to cover your full
area of physical contact with work and ground. 4.c. Protect other nearby personnel with suitable, non-flammable
screening and/or warn them not to watch the arc nor expose
In addition to the normal safety precautions, if welding themselves to the arc rays or to hot spatter or metal.
must be performed under electrically hazardous
conditions (in damp locations or while wearing wet
FUMES AND GASES
clothing; on metal structures such as floors, gratings or
scaffolds; when in cramped positions such as sitting,
can be dangerous.
kneeling or lying, if there is a high risk of unavoidable or
accidental contact with the workpiece or ground) use 5.a. Welding may produce fumes and gases
the following equipment: hazardous to health. Avoid breathing these
� Semiautomatic DC Constant Voltage (Wire) Welder. fumes and gases.When welding, keep
� DC Manual (Stick) Welder. your head out of the fume. Use enough
� AC Welder with Reduced Voltage Control. ventilation and/or exhaust at the arc to keep
fumes and gases away from the breathing zone. When
3.c. In semiautomatic or automatic wire welding, the electrode, welding with electrodes which require special
electrode reel, welding head, nozzle or semiautomatic ventilation such as stainless or hard facing (see
welding gun are also electrically “hot�. instructions on container or MSDS) or on lead or
cadmium plated steel and other metals or coatings
3.d. Always be sure the work cable makes a good electrical which produce highly toxic fumes, keep exposure as
connection with the metal being welded. The connection low as possible and below Threshold Limit Values (TLV)
should be as close as possible to the area being welded. using local exhaust or mechanical ventilation. In
confined spaces or in some circumstances, outdoors, a
3.e. Ground the work or metal to be welded to a good electrical respirator may be required. Additional precautions are
(earth) ground. also required when welding on galvanized steel.
5.b. Do not weld in locations near chlorinated hydrocarbon vapors
3.f. Maintain the electrode holder, work clamp, welding cable and
coming from degreasing, cleaning or spraying operations.
welding machine in good, safe operating condition. Replace
The heat and rays of the arc can react with solvent vapors to
damaged insulation.
form phosgene, a highly toxic gas, and other irritating
products.
3.g. Never dip the electrode in water for cooling.
5.c. Shielding gases used for arc welding can displace air and
3.h. Never simultaneously touch electrically “hot� parts of
cause injury or death. Always use enough ventilation,
electrode holders connected to two welders because voltage
especially in confined areas, to insure breathing air is safe.
between the two can be the total of the open circuit voltage
of both welders.
5.d. Read and understand the manufacturer’s instructions for this
equipment and the consumables to be used, including the
3.i. When working above floor level, use a safety belt to protect
material safety data sheet (MSDS) and follow your
yourself from a fall should you get a shock.
employer’s safety practices. MSDS forms are available from
your welding distributor or from the manufacturer.
3.j. Also see Items 6.c. and 8.
5.e. Also see item 1.b.
Mar �95
iii iii
SAFETY
WELDING SPARKS can CYLINDER may explode
cause fire or explosion. if damaged.
6.a. Remove fire hazards from the welding area.
7.a. Use only compressed gas cylinders
If this is not possible, cover them to prevent
containing the correct shielding gas for the
the welding sparks from starting a fire.
process used and properly operating
Remember that welding sparks and hot
regulators designed for the gas and
materials from welding can easily go through small cracks
pressure used. All hoses, fittings, etc. should be suitable for
and openings to adjacent areas. Avoid welding near
the application and maintained in good condition.
hydraulic lines. Have a fire extinguisher readily available.
7.b. Always keep cylinders in an upright position securely
6.b. Where compressed gases are to be used at the job site,
chained to an undercarriage or fixed support.
special precautions should be used to prevent hazardous
situations. Refer to “Safety in Welding and Cutting� (ANSI
7.c. Cylinders should be located:
Standard Z49.1) and the operating information for the
� Away from areas where they may be struck or subjected to
equipment being used.
physical damage.
6.c. When not welding, make certain no part of the electrode
� A safe distance from arc welding or cutting operations and
circuit is touching the work or ground. Accidental contact
any other source of heat, sparks, or flame.
can cause overheating and create a fire hazard.
7.d. Never allow the electrode, electrode holder or any other
6.d. Do not heat, cut or weld tanks, drums or containers until the
electrically “hot� parts to touch a cylinder.
proper steps have been taken to insure that such procedures
will not cause flammable or toxic vapors from substances
7.e. Keep your head and face away from the cylinder valve outlet
inside. They can cause an explosion even though they have
when opening the cylinder valve.
been “cleaned�. For information, purchase “Recommended
Safe Practices for the Preparation for Welding and Cutting of
7.f. Valve protection caps should always be in place and hand
Containers and Piping That Have Held Hazardous
tight except when the cylinder is in use or connected for
Substances�, AWS F4.1 from the American Welding Society
use.
(see address above).
7.g. Read and follow the instructions on compressed gas
6.e. Vent hollow castings or containers before heating, cutting or
cylinders, associated equipment, and CGA publication P-l,
welding. They may explode.
“Precautions for Safe Handling of Compressed Gases in
Cylinders,� available from the Compressed Gas Association
6.f. Sparks and spatter are thrown from the welding arc. Wear oil
1235 Jefferson Davis Highway, Arlington, VA 22202.
free protective garments such as leather gloves, heavy shirt,
cuffless trousers, high shoes and a cap over your hair. Wear
ear plugs when welding out of position or in confined places.
FOR ELECTRICALLY
Always wear safety glasses with side shields when in a
powered equipment.
welding area.
6.g. Connect the work cable to the work as close to the welding
8.a. Turn off input power using the disconnect
area as practical. Work cables connected to the building
switch at the fuse box before working on
framework or other locations away from the welding area
the equipment.
increase the possibility of the welding current passing
through lifting chains, crane cables or other alternate cir-
8.b. Install equipment in accordance with the U.S. National
cuits. This can create fire hazards or overheat lifting chains
Electrical Code, all local codes and the manufacturer’s
or cables until they fail.
recommendations.
6.h. Also see item 1.c.
8.c. Ground the equipment in accordance with the U.S. National
Electrical Code and the manufacturer’s recommendations.
Mar �95
iv iv
SAFETY
zones où l’on pique le laitier.
PRÉCAUTIONS DE SÛRETÉ
6. Eloigner les matériaux inflammables ou les recouvrir afin de
Pour votre propre protection lire et observer toutes les instructions
prévenir tout risque d’incendie dû aux étincelles.
et les précautions de sûreté specifiques qui parraissent dans ce
manuel aussi bien que les précautions de sûreté générales suiv-
7. Quand on ne soude pas, poser la pince à une endroit isolé de
antes:
la masse. Un court-circuit accidental peut provoquer un
échauffement et un risque d’incendie.
Sûreté Pour Soudage A L’Arc
1. Protegez-vous contre la secousse électrique:
8. S’assurer que la masse est connectée le plus prés possible
de la zone de travail qu’il est pratique de le faire. Si on place
a. Les circuits à l’électrode et à la piéce sont sous tension
la masse sur la charpente de la construction ou d’autres
quand la machine à souder est en marche. Eviter toujours
endroits éloignés de la zone de travail, on augmente le risque
tout contact entre les parties sous tension et la peau nue
de voir passer le courant de soudage par les chaines de lev-
ou les vétements mouillés. Porter des gants secs et sans
age, câbles de grue, ou autres circuits. Cela peut provoquer
trous pour isoler les mains.
des risques d’incendie ou d’echauffement des chaines et des
b. Faire trés attention de bien s’isoler de la masse quand on
câbles jusqu’� ce qu’ils se rompent.
soude dans des endroits humides, ou sur un plancher
metallique ou des grilles metalliques, principalement dans
9. Assurer une ventilation suffisante dans la zone de soudage.
les positions assis ou couché pour lesquelles une grande
Ceci est particuliérement important pour le soudage de tôles
partie du corps peut être en contact avec la masse.
galvanisées plombées, ou cadmiées ou tout autre métal qui
c. Maintenir le porte-électrode, la pince de masse, le câble
produit des fumeés toxiques.
de soudage et la machine à souder en bon et sûr état
defonctionnement.
10. Ne pas souder en présence de vapeurs de chlore provenant
d.Ne jamais plonger le porte-électrode dans l’eau pour le
d’opérations de dégraissage, nettoyage ou pistolage. La
refroidir.
chaleur ou les rayons de l’arc peuvent réagir avec les vapeurs
e. Ne jamais toucher simultanément les parties sous tension
du solvant pour produire du phosgéne (gas fortement toxique)
des porte-électrodes connectés à deux machines à souder
ou autres produits irritants.
parce que la tension entre les deux pinces peut être le
total de la tension à vide des deux machines.
11. Pour obtenir de plus amples renseignements sur la sûreté,
f. Si on utilise la machine à souder comme une source de
voir le code “Code for safety in welding and cutting� CSA
courant pour soudage semi-automatique, ces precautions
Standard W 117.2-1974.
pour le porte-électrode s’applicuent aussi au pistolet de
soudage.
2. Dans le cas de travail au dessus du niveau du sol, se protéger
contre les chutes dans le cas ou on recoit un choc. Ne jamais
PRÉCAUTIONS DE SÛRETÉ POUR
enrouler le câble-électrode autour de n’importe quelle partie
LES MACHINES À SOUDER À
du corps.
TRANSFORMATEUR ET À
3. Un coup d’arc peut être plus sévère qu’un coup de soliel,
REDRESSEUR
donc:
a. Utiliser un bon masque avec un verre filtrant approprié
ainsi qu’un verre blanc afin de se protéger les yeux du ray- 1. Relier à la terre le chassis du poste conformement au code de
onnement de l’arc et des projections quand on soude ou l’électricité et aux recommendations du fabricant. Le dispositif
quand on regarde l’arc. de montage ou la piece à souder doit être branché à une
b. Porter des vêtements convenables afin de protéger la bonne mise à la terre.
peau de soudeur et des aides contre le rayonnement de
l‘arc. 2. Autant que possible, I’installation et l’entretien du poste seront
c. Protéger l’autre personnel travaillant à proximité au effectués par un électricien qualifié.
soudage à l’aide d’écrans appropriés et non-inflammables.
3. Avant de faires des travaux à l’interieur de poste, la debranch-
4. Des gouttes de laitier en fusion sont émises de l’arc de er à l’interrupteur à la boite de fusibles.
soudage. Se protéger avec des vêtements de protection libres
de l’huile, tels que les gants en cuir, chemise épaisse, pan- 4. Garder tous les couvercles et dispositifs de sûreté à leur
talons sans revers, et chaussures montantes. place.
5. Toujours porter des lunettes de sécurité dans la zone de
soudage. Utiliser des lunettes avec écrans lateraux dans les
Mar. �93
v v
for selecting a QUALITY product by Lincoln Electric. We want you
Thank You to take pride in operating this Lincoln Electric Company product
•â?¢â?? as much pride as we have in bringing this product to you!
Please Examine Carton and Equipment For Damage Immediately
When this equipment is shipped, title passes to the purchaser upon receipt by the carrier. Consequently, Claims
for material damaged in shipment must be made by the purchaser against the transportation company at the
time the shipment is received.
Please record your equipment identification information below for future reference. This information can be
found on your machine nameplate.
Product _________________________________________________________________________________
Model Number ___________________________________________________________________________
Code Number or Date Code_________________________________________________________________
Serial Number____________________________________________________________________________
Date Purchased___________________________________________________________________________
Where Purchased_________________________________________________________________________
Whenever you request replacement parts or information on this equipment, always supply the information you
have recorded above. The code number is especially important when identifying the correct replacement parts.
On-Line Product Registration
- Register your machine with Lincoln Electric either via fax or over the Internet.
� For faxing: Complete the form on the back of the warranty statement included in the literature packet
accompanying this machine and fax the form per the instructions printed on it.
� For On-Line Registration: Go to our WEB SITE at www.lincolnelectric.com. Choose “Quick Links� and then “Prod-
uct Registration�. Please complete the form and submit your registration.
Read this Operators Manual completely before attempting to use this equipment. Save this manual and keep it
handy for quick reference. Pay particular attention to the safety instructions we have provided for your protection.
The level of seriousness to be applied to each is explained below:
WARNING
This statement appears where the information must be followed exactly to avoid serious personal injury or
loss of life.
CAUTION
This statement appears where the information must be followed to avoid minor personal injury or damage to
this equipment.
vi vi
TABLE OF CONTENTS
Page
Installation .......................................................................................................Section A
Technical Specifications ........................................................................................A-1
Identify and Locate Components ...........................................................................A-2
Select Suitable Location ........................................................................................A-3
Output Connections ...............................................................................................A-3
Input Connections..................................................................................................A-6
Code Requirements ..............................................................................................A-6
Operation .........................................................................................................Section B
Safety Precautions ................................................................................................B-1
General Description ...............................................................................................B-2
Design Features and Advantages...................................................................B-2
Welding Capability ..........................................................................................B-2
Limitations .......................................................................................................B-2
Controls and Settings......................................................................................B-2
Welding Operations ...............................................................................................B-3
Overload Protection ...............................................................................................B-6
Application Chart ...................................................................................................B-7
Accessories .....................................................................................................Section C
Accessories ...........................................................................................................C-1
Replacement Parts ................................................................................................C-1
Maintenance ....................................................................................................Section D
Safety Precautions ................................................................................................D-1
Items Requiring No Maintenance ..........................................................................D-1
Routine Maintenance.............................................................................................D-1
Gun and Cable Maintenance.................................................................................D-2
Configuration of Components in Wire Feeding System.........................................D-2
Component Replacement Procedures ..................................................................D-3
Troubleshooting ..............................................................................................Section E
Safety Precautions.................................................................................................E-1
How to Use Troubleshooting Guide.......................................................................E-1
Troubleshooting Guide.............................................................................E-2 thru E-4
Wiring Diagrams ..............................................................................................Section F
PRO 100 Wiring Diagram ......................................................................................F-1
PRO 100 Parts Manual................................................................P464 Series & P202-E
A-1 A-1
INSTALLATION
TECHNICAL SPECIFICATIONS � PRO 100
INPUT � SINGLE PHASE ONLY
Standard Voltage/Frequency Input Current
115V/60Hz 20 Amps - Rated Output
115V/60Hz 15 Amps - CSA Rated output
RATED OUTPUT
Duty Cycle Current Voltage
20% Duty Cycle 88Amps 18V
20% Duty Cycle � CSA Rated Output 62Amps 20V
OUTPUT
Welding Current Range Maximum Open Circuit Voltage Wire Speed Range
Rated DC Output: 30 - 100 amps 32V 50 - 300 IPM
(1.3 - 7.6 m/min)
RECOMMENDED INPUT CABLE AND FUSE SIZES
Fuse or
Output Mode Input Voltage Breaker Size Input Amps Power Cord Extension Cord
Three Conductor
RATED 115V/60Hz 20 Amp 20 15 Amp, 125V,
#14 AWG
Three Prong Plug
(2.1 mm2) or Larger
(NEMA Type 5-15P)
Up to 25 Ft. (7.6 mm)
CSA 115V/60Hz 15 Amp 12 15 Amp, 125V, Three Conductor
Three Prong Plug #12 AWG
(NEMA Type 5-15P) (3.3 mm2) or Larger
Up to 50 Ft. (15.2 mm)
PHYSICAL DIMENSIONS
Height Width Depth Weight
12.0 in 9.75 in 16.5 in 47 Ibs
305 mm 248 mm 419 mm 21.4 kg
PRO 100
A-2 A-2
INSTALLATION
Read entire installation section before starting FIGURE A.1
installation.
SAFETY PRECAUTIONS
1 2
WARNING
ELECTRIC SHOCK can kill.
PRO
100
� Only qualified personnel should perform
this installation.
� Only personnel that have read and under-
stood the PRO 100 Operating Manual
should install and operate this equipment.
� Machine must be plugged into a receptacle
which is grounded per any national, local
or other applicable electrical codes.
� The PRO 100 power switch is to be in the
4
OFF (“O�) position when installing work
cable and gun and when connecting power
cord to input power.
3
IDENTIFY AND LOCATE
COMPONENTS
If you have not already done so, unpack the PRO 100
from its carton and remove all packing material 5 6
around the PRO 100. Remove the following loose
items from the carton (see Figure A.1):
1. PRO 100
2. Gun and cable assembly(1)
3. Literature and miscellaneous including:
a) This operating manual 8
7
b) Extra .035" contact tip
c) Hex key wrench for removal of drive roll.
4. 10 ft (3,0 m) work cable.
5. Work clamp.
6. Sample spool of Innershield .035" (0,9 mm)
NR-211-MP electrode.
7. Handshield with filter plate and lens.
8. Instructional video.
For available options and accessories refer to the
Accessories Section of this manual.
The gun is ready to feed 0.035" (0,9 mm) Inner-
(1)
shield wire.
PRO 100
A-3 A-3
INSTALLATION
SELECT SUITABLE LOCATION 6. Wire Feed Gearbox.
7. Cable Hanger.
Locate the welder in a dry location where there is free
circulation of clean air into the louvers in the back and
8. Thumbscrew.
out the front of the unit. A location that minimizes the
amount of smoke and dirt drawn into the rear louvers
Work Clamp Installation
reduces the chance of dirt accumulation that can block
air passages and cause overheating.
Attach the work clamp per the following:
1. Unplug the machine or turn the power switch to the
STACKING
“OFF� position.
PRO 100’s cannot be stacked.
2. Insert the work cable terminal lug with the larger
hole through the strain relief hole in the work clamp
as shown in Figure A-3.
TILTING
3. Fasten securely with the bolt and nut provided.
Each machine must be placed on a secure, level sur-
face, either directly or on a recommended undercar-
riage. The machine may topple over if this procedure
FIGURE A.3
is not followed.
OUTPUT CONNECTIONS Strain Relief Hole
Work Cable
Refer to Figure A.2. Nut & Bolt
1. Work Cable Access Hole.
2. Gun Cable and Control Lead Access Hole.
Work Clamp
3. Connector Block.
4. Gun Trigger Lead Connectors.
5. Positive (+) and negative (�) output terminals.
FIGURE A.2
4
5
DO NOT SWITCH
+
WHEN WELDING
PRO 100 8
-
3 6 7
1 2
PRO 100
A-4 A-4
INSTALLATION
Work Cable Installation
Connecting Gun Cable to the PRO 100
Refer to Figure A.2.
1. Refer to Figure A.2. Unplug the machine or turn
power switch to the OFF “O� position.
1. Open the wire feed section door on the right side of
the PRO 100.
2. Pass the insulated terminals of the gun trigger con-
trol leads, one at a time, through the Gun Cable
2. Pass the end of the work cable that has the termi-
and Control Lead Access Slot (2) in the case front.
nal lug with the smaller hole through the Work
The leads are to be routed under the Wire Feed
Cable Access Hole (1) in the case front.
Gearbox (6) and through the Cable Hanger (7) on
the inner panel.
3. Route the cable under and around the back of the
Wire Feed Gearbox (6).
3. Insert the connector on the gun conductor cable
through the Gun Cable Access Hole (2) in the
4. For Innershield Only: Refer to Figure A.2. As
PRO 100 case front. Make sure the connector is all
delivered, the PRO 100 is connected for negative
the way in the brass connector block. Unscrew
electrode polarity. This is the appropriate configu-
thumbscrew on the connector block a few turns if
ration for the Innershield process. To complete
gun connector will not insert fully. Rotate the con-
installation, use the provided wing nut to connect
nector so control leads are on the underside and
the work cable’s terminal lug to the positive (+) out-
tighten the Thumbscrew (8) in the connector block.
put terminal (5) located above the Wire Feed Gear-
box (6). Make sure that both wing nuts are tight.
4. Connect the gun trigger control lead terminals to
5. For GMAW Only: Refer to Figure A.4. To wire for the two insulated 1/4" (6,4 mm) tab terminal con-
positive polarity (required for the MIG process), nector bushings located above the “Gun Trigger
connect the short cable attached to the connector Connection� decal in the wire feed section (4).
block (1) to the positive (+) output terminal (4) and Either lead can go to either connector. Form the
the work cable (3) to the negative (�) terminal (2). leads so that they are as close as possible to the
inside panel.
FIGURE A.4
CAUTION
4
If the gun trigger switch being used is other than
3 that supplied with the PRO 100, the switch must
2 be a normally open, momentary switch. The termi-
nals of the switch must be insulated from the
welding circuit. Malfunction of the PRO 100 may
1 result if this switch shorts to the PRO 100 welding
output circuit or is common to any electrical cir-
cuit other than the PRO 100 trigger circuit.
GAS CONNECTION (OPTIONAL)
When using the GMAW process, a K610-1 MIG con-
version kit and a cylinder of carbon dioxide (CO2) or
argon-carbon dioxide mixed shielding gas must be
obtained. For more information about the K610-1 MIG
GUN INSTALLATION
Conversion Kit for use with the PRO 100, refer to the
ACCESSORIES section.
As shipped from the factory, the PRO 100 gun is
ready to feed 0.035� (0,9 mm) wire. If .023" � .025"
(0,6 mm) or .030" (0.8 mm) wire is to be used for the
GMAW (MIG) process, see the MAINTENANCE sec-
tion for proper configuration of feeding components
and installation details.
PRO 100
A-5 A-5
INSTALLATION
WARNING
2. With the cylinder securely installed, remove the
CYLINDER may explode if dam-
cylinder cap. Stand to one side away from the out-
aged. Keep cylinder upright and
let and open the cylinder valve very slightly for an
chained to support
instant. This blows away any dust or dirt which may
� Keep cylinder away from areas
have accumulated in the valve outlet.
where it may be damaged.
� Never lift welder with cylinder
attached. WARNING
� Never allow welding electrode to
BE SURE TO KEEP YOUR FACE AWAY FROM THE
touch cylinder.
VALVE OUTLET WHEN “CRACKING� THE VALVE.
� Keep cylinder away from welding Never stand directly in front of or behind the flow
or other live electrical circuits. regulator when opening the cylinder valve. Always
stand to one side.
WARNING
3. Attach the flow regulator to the cylinder valve and
tighten the union nut securely with a wrench..
BUILDUP OF SHIELDING GAS may
harm health or kill.
NOTE: If connecting to 100% CO2 cylinder, insert
� Shut off shielding gas supply regulator adapter (provided with MIG Conversion
when not in use. Kit for the PRO 100) between regulator and cylin-
der valve. If adapter is equipped with a plastic
� SEE AMERICAN NATIONAL
washer, be sure it is seated for connection to the
STANDARD Z-49.1, “SAFETY IN
CO2 cylinder.
WELDING AND CUTTING� PUB-
LISHED BY THE AMERICAN
4. Refer to Figure A.6. Attach one end of inlet gas
WELDING SOCIETY.
hose to the outlet fitting of the flow regulator and
tighten the union nut securely with a wrench. Con-
nect the other end to the PRO 100 Gas Solenoid
1. Chain the cylinder to a wall or other stationary sup-
Inlet Fitting (5/8-18 female threads � for CGA �
port to prevent the cylinder from falling over. Insu-
032 fitting). Make certain the gas hose is not
late the cylinder from the work circuit and earth
kinked or twisted.
ground. Refer to Figure A.5.
FIGURE A.5
Cylinder Valve
Flow Regulator
Gas Hose
PRO 100
A-6 A-6
INSTALLATION
Requirements For Rated Output
INPUT CONNECTIONS
A power cord with a 15 amp, 125 volt, three prong
FIGURE A.6
plug (NEMA Type 5-15P) is factory installed on the
PRO 100. Connect this plug to a mating grounded
receptacle which is connected to a 20 amp branch cir-
cuit with a nominal voltage rating of 115 to 125 volts,
60 Hertz, AC only.
The rated output with this installation is 88 amps, 18
Volts, 20% duty cycle (2 minutes of every 10 minutes
OPTIONAL GAS
used for welding).
SOLENOID INLET FITTING
POWER INPUT
CABLE
CAUTION
Do not connect the PRO 100 to an input power
supply with a rated voltage that is greater than 125
volts.
Do not remove the power cord ground prong.
Requirements For CSA Rated Output
Refer to Figure A.6.
A line cord with a 15 amp, 125 volt, three-prong plug
The PRO 100 has a power input cable located on the (NEMA Type 5-15P) is factory installed. Connect this
rear of the machine. plug to a mating grounded receptacle which is con-
nected to a 15 amp branch circuit with a nominal volt-
age rating of 115 volts to 125 volts, 60 hertz, AC only.
CODE REQUIREMENTS FOR INPUT With this installation, the PRO 100 can be used at an
CONNECTIONS output of 62 amps, 20 volts, 20% duty cycle.
WARNING
This welding machine must be connected to
power source in accordance with applicable elec-
trical codes.
The National Electrical Code provides standards
for amperage handling capability of supply con-
ductors based on duty cycle of the welding
source.
If there is any question about the installation
meeting applicable electrical code requirements,
consult a qualified electrician.
PRO 100
B-1 B-1
OPERATION
Read entire operation section before
operating the PRO 100.
WARNING
ELECTRIC SHOCK can kill.
� Do not touch electrically live
parts or electrode with skin or
wet clothing. Insulate yourself
from work and ground.
� Always wear dry insulating
gloves.
FUMES AND GASES can be
dangerous.
� Keep your head out of fumes.
� Use ventilation or exhaust to
remove fumes from breathing
zone.
WELDING SPARKS can
cause fire or explosion.
� Keep flammable material away.
� Do not weld on closed contain-
ers.
ARC RAYS can burn eyes
and skin.
� Wear eye, ear and body protec-
tion.
Observe all safety information throughout
this manual.
PRO 100
B-2 B-2
OPERATION
G No external shielding gas is required when used
GENERAL DESCRIPTION
with Lincoln Innershield .035� (0,9 mm) NR®-211-
The PRO 100 is a compact lightweight DC wire feed- MP electrode.
er/power source. It has been designed for workshop,
G Accommodates 4� (100 mm) diameter spool of
hobby, and light maintenance. It is capable of general
wire. Will accommodate 8� (200 mm) diameter with
purpose welding with self-shielded flux-cored (Inner-
optional spindle.
shield®) wire. When combined with the optional K610-
1 MIG Conversion Kit, the PRO 100 is suitable for
GMAW (MIG) welding applications.
WELDING CAPABILITY
The PRO 100 is ideally suited for individuals having The PRO 100 is rated at 88 amps, 18 volts, at 20%
access to 115 volt AC input power, and wanting the duty cycle on a ten minute basis. CSA rated output at
ease of use, quality and dependability of both the 62 amps at 20 volts at 20% duty cycle. It is capable of
Innershield electrode process (self-shielded flux-cored higher output currents at lower duty cycles.
or FCAW) and gas metal arc welding or GMAW (also
known as MIG welding). The PRO 100 is a rugged
LIMITATIONS
and reliable machine that has been designed for
dependable service and long life.
Arc Gouging cannot be performed with the PRO 100.
The PRO 100 is not recommended for pipe thawing or
RECOMMENDED PROCESSES TIG welding.
The PRO 100 can be used for welding mild steel using
CONTROLS AND SETTINGS
the self shielded, Innershield electrode process
(FCAW) or it can be used for the GMAW, single pass,
Refer to Figure B.1a.
process which requires a supply of shielding gas and
the K610-1 MIG Conversion Kit. The PRO 100 is con-
1. Power ON/OFF Switch �
figured for use with the FCAW process as delivered
When the power is on the
from the factory.
fan motor will run and air will
be exhausted out the louvers
OFF
OPERATIONAL FEATURES AND in the front of the machine.
CONTROLS The welding output and wire
feeder remain off until the
The PRO 100 has the following controls as standard: gun trigger is pressed.
ON
Power ON/OFF Switch, Voltage Control, Wire Speed
Control, Trigger Switch, and a Circuit Breaker. 2. Wire Speed Control � Con-
trols the wire feed speed
from 50 � 300 in /min (1.3 �
DESIGN FEATURES AND 7.6 m/min). The control can
ADVANTAGES be preset on the dial to the
WIRE SPEED
setting specified on the PRO
G Operates on 115 volt input . 100 Application Chart locat-
ed on the inside of the wire
G “Cold electrode� until gun trigger is pressed for an
feed section door.
added measure of safety.
G Overload protection � incorporates both a thermo- 3. Voltage Control � A 4-posi-
stat and a circuit breaker. tion tap selector switch gives
full range adjustment of
G Quality wire drive with electronic overload protec-
ARC VOLTS
power source output voltage.
tion.
Do not switch while welding.
G “Quick Release� idle roll pressure arm is easily
adjusted.
Refer to Figure B.1b.
G Reversible, dual groove drive roll. Drive roll will
feed .023 � .025� (0.6 mm) and .030" and .035"
4. Circuit Breaker � Protects machine from damage if
(0.8 mm and 0.9 mm) diameter wire.
maximum output is exceeded. Button will extend
out when tripped (Manual reset).
PRO 100
B-3 B-3
OPERATION
FIGURE B.1a
Wire Spindle Shaft
4" Wire Spool
2
1
3
DO NOT SWITCH
WHEN WELDING
Wing Nut
PRO 100 and Spacer
To wire drive
FIGURE B.2
To use 8" (200 mm) diameter spools, the 2" (51 mm)
diameter M15445 spindle must be used. Remove the
spacer and wing nut at the end of the shaft. Insert
FIGURE B.1b
spindle as shown in figure B.3. Reattach spacer and
wing nut.
4 Note: When loading and removing the 8� Spools
make sure that the wing nut (inside the wire spool
spindle hub) is turned 90° from the wire spool spindle
locking tab. If the wing nut is positioned in line with the
locking tab, the tab cannot be depressed to load or
unload the wire spool.
Make certain the start end of the wire, which may pro-
trude through the side of the spool, does not contact
any metallic case parts.
FIGURE B.3
WELDING OPERATIONS Optional
Wire Spool Spindle Locking Tab
SEQUENCE OF OPERATION 8� Wire Spool
Wire Loading
Refer to Figure B.2 AND B3.
The machine power switch should be turned to the
OFF (“O�) position before working inside the wire feed
enclosure. Be sure that this stud engages
the hole in the wire spool.
The machine is shipped from the factory ready to feed
4� (100 mm) diameter spools. A 4" (100 mm) diameter
To Wire Drive
spool is mounted directly on the 5/8" (16 mm) diame-
ter spindle that has a built-in adjustable friction brake Wire Spool must be pushed all the way on the spindle so that the
to prevent overrun of the spool and excess slack in spindle’s tab will hold it in place. The Wire Spool will rotate clock-
wise when wire is dereeled.
the wire. The wing nut at the end of the shaft is used
to adjust the tension on the wire spool.
PRO 100
B-4 B-4
OPERATION
FIGURE B.4
Note: The brake should be adjusted with a spool of
wire installed. When properly adjusted it should
move freely but not coast.
Friction Brake Adjustments
1. With wire spool installed, check free movement
2
and coast of the spool.
2. To tighten the brake turn the wing nut clockwise in
1/4 turn increments until coasting stops.
1
4
5
3. To loosen the brake turn the wing nut counter-
clockwise in 1/4 turn increments until the wire
3 The Wire Drive Feed Roll can
spool moves freely without coasting. accommodate two wire sizes by
flipping the wire drive feed roll
over.
Wire Threading
Refer to Figure B-4
1. Release the Spring Loaded Pressure Arm (1)
7. Refer to Figure B.5. Remove gas nozzle and con-
rotate the Idle Roll Arm (2) away from. the Wire
tact tip from end of gun.
Feed Drive Roll (3). Ensure that the groove size in
the feeding position on the drive roll matches the
8. Turn the PRO 100 ON (“I�).
wire size being used.
9. Straighten the gun cable assembly.
2. Carefully detach the end of the wire from the
spool. To prevent the spool from unwinding,
10. Depress the gun trigger switch and feed welding
maintain tension on the wire until after step 5.
wire through the gun and cable. (Point gun away
from yourself and others while feeding wire.)
3. Cut the bent portion of wire off and straighten the
Release gun trigger after wire appears at end of
first 4� (100 mm).
gun.
4. Thread the wire through the In-going guide tube
11. Turn the PRO 100 OFF (“O�).
(4), over the drive roll (3), and into the out-going
guide tube (5).
12. Replace contact tip and gas nozzle.
5. Close the idle roll arm and latch the spring loaded
13. Refer to Figure B-6. Cut the wire off 3/8� � 1/2� (10
pressure arm (2) in place. Rotate the spool coun-
� 13 mm) from the end of the tip. The PRO 100 is
terclockwise if required in order to take up extra
now ready to weld.
slack in the wire.
WARNING
When inching the welding wire, the drive rolls, the
gun connector block and the gun contact tip are
electrically energized relative to work and ground
and remain energized for several seconds after
the gun trigger is released. FIGURE B.5
6. The idle roll pressure adjustment wing nut is nor-
mally set for mid-position on the pressure arm
threads. If feeding problems occur because the
Gun Handle
wire is flattened excessively, turn the pressure
adjustment counter-clockwise to reduce distortion
of the wire. Slightly less pressure may be required
when using 0.023 � 0.025� (0,6 mm) wire. If the Gas Diffuser/
Contact Tip
drive roll slips while feeding wire, the pressure
should be increaseduntil the wire feeds properly.
Gas Nozzle
PRO 100
B-5 B-5
OPERATION
FIGURE B.6 6. Refer to Figure B.7. Connect work clamp to metal
to be welded. Work clamp must make good elec-
trical contact to the workpiece. The workpiece
must also be grounded as stated in “Arc Welding
Safety Precautions� in the beginning of this manu-
al.
Contact Tip
7. Position gun over joint. End of wire may be lightly
touching the work.
Electrode
8. Lower welding helmet, close gun trigger, and
3/8�-1/2�(10-12mm)Contact
Tip to Work Distance(CTWD) begin welding. Hold the gun so the contact tip to
work distance is about 3/8 inch (10 mm).
9. To stop welding, release the gun trigger and then
Making A Weld pull the gun away from the work after the arc goes
1. See “Process Guidelines� in this section for selec- out.
tion of welding wire and shielding gas and for
range of metal thicknesses that can be welded. 10. When no more welding is to be done, close valve
on gas cylinder (if used), momentarily operate gun
2. See the Application chart on the inside of the wire trigger to release gas pressure, and turn off the
feed compartment door for information on setting PRO 100.
the PRO 100 controls. Refer to Table B.1 for alu-
minum and stainless wire. Cleaning Tip And Nozzle
Clean the contact tip and nozzle to avoid arc bridging
3. Set the Voltage (“Vâ€?) and Wire Speed (“olo’â??) con- between the nozzle and contact tip which can result in
trols to the settings suggested for the welding wire a shorted nozzle, poor welds and an overheated gun.
and base metal thickness being used, refer to Hint: Anti-stick spray or gel, available from a welding
Applications chart on the inside of the wire drive supply distributor, may reduce buildup and aid in spat-
compartment door. ter removal.
4. Check that the polarity is correct for the welding PROCESS GUIDELINES
wire being used and that the gas supply, if
The PRO 100 as shipped, can be used for welding
required, is turned on.
mild steel using the self shielded, Innershield elec-
trode process or it can be used for the GMAW (MIG),
5. When using Innershield electrode, remove the gas
single pass, process which requires a supply of
nozzle and install the gasless nozzle. This will
shielding gas and the K610-1 MIG Conversion Kit.
improve visibility of the arc and protect the gas dif-
fuser from weld spatter. Refer to the MAINTE-
The recommended electrode for the self-shielded
NANCE section for details on nozzle replacement.
process is 0.035� (0,9 mm) diameter Lincoln Inner-
shield NR-211-MP. Requires optional spindle � refer
to Accessories section. This electrode can be used for
FIGURE B.7
all position welding of 20 gauge through 5/16� (1,0 �
8,0 mm) thick steel [multiple passes are required for
1/4� and 5/16� (6,0 and 8,0 mm)].
The recommended gas and electrode for GMAW is
PRO 100
welding grade CO2 gas and 0.025� (0 6 mm) diameter
Lincoln Super Arc L-56 mild-steel welding wire [sup-
GUN CABLE
plied on 12-1/2 Ib (6 kg) spools]. For 14 gauge (2,0
mm) and thinner, CO2 gas is recommended because
it gives equal or better performance than a blended
gas at a lower cost. A mixed gas consisting of 75 to
80% Argon and 20 to 25% CO2 is recommended for
welding on heavier gauge steel, 12 gauge (2,5 mm)
WORKPIECE
ARC for example.
WORK CLAMP
PRO 100
B-6 B-6
OPERATION
The PRO 100 is suitable for .035" aluminum wire and 1. For CO2, open the cylinder very slowly. For argon-
.030" stainless wire. Refer to Table B.1 for recom- mixed gas, open cylinder valve slowly a fraction of
mended procedure settings. (Requires K610-1 MIG a turn. When the cylinder pressure gauge pointer
Conversion Kit and K664-2 Aluminum - Stainless stops moving, open the valve fully.
Feeding Kit.)
2. If using a regulator with an adjustable flow meter,
close the gun trigger and adjust the flow to give 15
CAUTION � 20 cubic ft per hour (CFH) (7 � 10 I/min) [use 20
� 25 CFH (10 � 12 I/min) when welding out of
It is important when changing between welding position or in a drafty location for CO2]. For argon
with steel wire and aluminum to exchange feeding mixed gas, trigger to release gas pressure, and
components due to the lubricant applied to steel turn off the adjust the flow to give 25 � 30 CFH
wire. Failure to do so may result in contaminated (12 � 14 I/min).
welds when welding aluminum.
------------------------------------------------------------------------ 3. Keep the cylinder valve closed, except when using
the PRO 100. When finished welding:
a) Close the cylinder valve to stop gas flow.
TABLE B.1
b) Depress the gun trigger briefly to release the
Voltage/Wire Speed
Shielding
pressure in the gas hose.
Process Welding Wire Gas 22 ga 16 ga 12 ga 1/8� 3/16� 1/4�
c) Turn off the PRO 100.
.035 Dia(0.9mm 100% Argon A-4.5 C-8.5 D-10 NR* NR* NR*
4043 Aluminum
Wire
16 ga 14 ga 12 ga 10 ga
MIG DC+
.030 Dia 98% Argon/ A-3 C-6 D-7.5 D-7.5
OVERLOAD PROTECTION
308L Stainless 2% Oxygen
Steel Wire
Output Overload
*NR-Not Recommended
The PRO 100 is equipped with a circuit breaker and a
thermostat which protects the machine from damage if
maximum output is exceeded. The circuit breaker but-
CHANGING MACHINE OVER TO ton will extend out when tripped. The circuit breaker
FEED OTHER WIRE SIZES must be manually reset.
The PRO 100 is shipped from the factory ready to
feed 0.035� (0,9 mm) diameter cored wire. To operate Thermal Protection
the PRO 100 with other sizes and types of wire, it The PRO 100 has a rated output duty cycle of 20%. If
maybe necessary to change the contact tip and drive the duty cycle is exceeded, a thermal protector will
roll orientation. Refer to the MAINTENANCE section, shut off the output until the machine cools to a reason-
for component configuration and replacement proce- able operating temperature. This is an automatic func-
dures. tion of the PRO 100 and does not require user inter-
vention. The fan continues to run during cooling.
WELDING WITH GMAW (MIG)
Shielding Gas Electronic Wire Drive Motor Protection
When using the GMAW process, obtain and install the The PRO 100 has built-in protection for wire drive
K610-1 MIG Conversion Kit and a cylinder of carbon motor overload.
dioxide (CO2) or argon-carbon dioxide mixed shield-
ing gas. Refer to the ACCESSORIES section for more
information about installing the K610-1 Kit for use with
the PRO 100. Also see the MAINTENANCE section
for proper contact tip, nozzle liner and drive roll config-
uration.
PRO 100
B-7 B-7
APPLICATION CHART
PRO 100
C-1 C-1
ACCESSORIES
OPTIONAL ACCESSORIES
MIG CONVERSION
1. K520 Utility Cart � Designed to transport the Lin-
Several changes are needed to convert the unit for
coln family of small welders. Has provisions for
operation with the MIG (GMAW) process. The K610-1
mounting a single gas cylinder. Has front casters
MIG Conversion Kit for the PRO 100 includes all the
and large rear wheels. Handle height is easily
necessary accessories for this conversion and is pro-
adjustable. Bottom tray provided for tools and
vided for this purpose. The following conversions
accessories. Easy assembly required; takes less
should be made using the contents of this kit:
than 15 minutes.
1. Install the gas solenoid. Complete instructions are
2. M15445 Spindle � Mounts onto standard spool
included with the kit.
shaft for 4" (100 mm) spools to provide for mount-
ing 8" (200 mm) diameter spools with 2" (51 mm)
2. Change the output polarity to DC(+). See “Work
I.D. and up to 2.2" (56 mm) wide.
Cable Installation� in Installation section for details.
3. K664-2 Aluminum Feeding Kit � This kit recom-
3. Change drive roll orientation (if required) for the
mended for welding with .035 Aluminum wire. This
wire size selected. See “Changing Drive Roll� in
kit may also be used for feeding .030 stainless
Maintenance section for details.
wire. Included with this kit are a drive roll, gun liner
and contact tip. It is important when changing
4. Install the proper gun liner (Note 1) and tip for the
between welding with steel wire and aluminum
wire size selected. See “Component Replacement�
to exchange these components due to the
in Maintenance section for details.
lubricant applied to steel wire. Failure to do so
may result in contaminated welds when weld-
5. Remove gasless nozzle (if installed) and install gas
ing aluminum.
nozzle. To remove, simply unscrew.
See Maintenance section for instructions on
6. Load wire into machine and thread into gun and
installing drive roll, cable liner, contact tip and their
cable per “Welding Wire Loading� section.
proper configuration.
(Note 1) The factory installed gun liner will feed
4. K610-1 MIG Conversion Kit for the PRO 100 �
.025 - .035 (0.6 - 0.9 mm) wire.
Complete kit for use with .025" (0.6 mm) electrode
wire and either CO2 or Argon-mixed gas. Includes
.025-.030" (0.6-0.8 mm) cable liner, two .025" (0.6
mm) contact tips, gas nozzle, 2 lb. spool of .025"
(0.6 mm )Super Arc L-56 electrode, gas regulator,
gas hose, regulator adapter for CO2 cylinders and
gas solenoid assembly, with all necessary hard-
ware and easy instructions for installing gas sole-
noid. Use with .030" (0.8 mm) wire requires addi-
tional .030" (0.8 mm) contact tip and electrode
wire.
See Maintenance section for instructions on flip-
ping over the drive roll, changing the cable liner
and contact tip, and their proper configuration.
PRO 100
D-1 D-1
MAINTENANCE
MAINTENANCE
SAFETY PRECAUTIONS
WARNING
ELECTRIC SHOCK can kill.
� Disconnect input power by removing
plug from receptacle before working
inside PRO 100. Use only grounded
receptacle. Do not touch electrically
“hot� parts inside PRO 100.
� Have qualified personnel do the mainte-
nance and trouble shooting work.
ROUTINE MAINTENANCE
POWER SOURCE COMPARTMENT
No user serviceable parts inside! Do not attempt to perform
service in the power source (fixed) side of the PRO 100. Take
the unit to an authorized Lincoln Service Center if you experi-
ence problems. NO maintenance is required.
WIRE FEED COMPARTMENT
1. When necessary, vacuum accumulated dirt from gearbox
and wire feed section.
2. Occasionally inspect the incoming guide tube and clean
inside diameter is necessary.
3. Motor and gearbox have lifetime lubrication and require no
maintenance.
FAN MOTOR
Has lifetime lubrication � requires no maintenance.
WIRE REEL SPINDLE
Requires no maintenance. Do not lubricate shaft.
PRO 100
D-2 D-2
MAINTENANCE
2. Replace worn contact tips as required. A variable
GUN AND CABLE
or “hunting� arc is a typical symptom of a worn con-
MAINTENANCE
tact tip. To install a new tip, choose the correct size
contact tip for the electrode being used (wire size is
FOR MAGNUMâ„? 100L GUN
stenciled on the side of the contact tip) and screw it
snugly into the gas diffuser.
Gun Cable Cleaning
Clean cable liner after using approximately 300 lbs
3. Remove spatter from inside of gas nozzle and from
(136 kg) of solid wire or 50 lbs (23 kg) of flux-cored
tip after each 10 minutes of arc time or as required.
wire. Remove the cable from the wire feeder and lay it
out straight on the floor. Remove the contact tip from
4. Be sure the gas nozzle is fully screwed onto the
the gun. Using low pressure air, gently blow out the
diffuser for gas shielded processes. For the Inner-
cable liner from the gas diffuser end.
shield ® process, the gasless nozzle should be
screws onto the diffuser.
5. To remove gun tube from gun, remove gas nozzle
Excessive pressure at the start may cause the dirt
or gasless nozzle and remove diffuser from gun
to form a plug.
tube. Remove both collars from each end of the
gun handle and separate the handle halves.
Loosen the locking nut holding the gun tube in
Flex the cable over its entire length and again blow
place against the gun end cable connector.
out the cable. Repeat this procedure until no further
Unscrew gun tube from cable connector. To install
dirt comes out.
gun tube, screw the locking nut on the gun tube as
far as possible. Then screw the gun tube into the
cable connector until it bottoms. Then unscrew (no
Contact Tips, Nozzles, and Gun Tubes
more than one turn) the gun tube until its axis is
1. Dirt can accumulate in the contact tip hole and
perpendicular to the flat sides of the cable connec-
restrict wire feeding. After each spool of wire is
tor and pointed in the direction of the trigger. Tight-
used, remove the contact tip and clean it by push-
en the locking nut so as to maintain the proper
ing a short piece of wire through the tip repeatedly.
relationship between the gun tube and the cable
Use the wire as a reamer to remove dirt that may
connector. Replace the gun handle, trigger and dif-
be adhering to the wall of the hole through the tip.
fuser. Replace the gas nozzle or gasless nozzle.
CONFIGURATION OF COMPONENTS IN WIRE FEEDING SYSTEM
Contact Tip Cable Liner Drive Roll
Components shipped with KP2039-3B1 KP1937-3 M16190
PRO 100 .035� (0.9mm) .025 - .035 Large Knurled, Small Smooth groove
(0.6 - 0.9mm) Small .023-.025 (0.6mm)
Large .030/.035� (0.8/0.9mm)
K610-1 .023/.025� (0.6mm) KP2039-1B1 KP1937-2 Use Standard Drive Roll
MIG Conversion Kit� .025� (0.6mm) .030 (0.8mm) Small Smooth Groove
K664-2 .035 (0.9mm) KP2078-1B1 M18971-1 M19631
Aluminum or Stainless Kit* .035A (0.9mm) .035� (0.9mm)
� If .030 Solid wire feeding is desired obtain an KP2039-2B1 Contact Tip.
* It is important when changing between welding with steel wire and aluminum to exchange feeding components due to the lubricant applied to steel wire. Failure
to do so may result in contaminated welds when welding aluminum.
PRO 100
D-3 D-3
MAINTENANCE
8. Push a length of straightened welding wire through
COMPONENT
the wire feeder guide tubes and adjust the position
REPLACEMENT
of the drive roll so that the groove is centered on
PROCEDURES the wire. Make certain the set screw is located on
the flat portion of the shaft and tighten.
CHANGING THE CONTACT TIP
1. Refer to Figure D.2. Remove the gas nozzle from FIGURE D.1
the gun by unscrewing counter-clockwise.
2. Remove the existing contact tip from the gun by
unscrewing counter-clockwise.
3. Insert and hand tighten desired contact tip.
4. Replace gas nozzle.
3
CHANGING DRIVE ROLL
The drive roll has two grooves; one for .023" � .025"
2
(0.6 mm) solid steel electrode and a larger knurled
groove for .030" (0.8 mm) solid and .035" (0.9 mm)
flux-cored steel electrode. As shipped, the drive roll is
1
installed in the .030"/.035" (0.8/0.9 mm) position.
If .023" � .025" (0.6 mm) wire is to be used, the drive
roll must be reversed as follows:
1. Connect the machine to its rated input power per
instructions in Installation section.
2. Release the spring-loaded pressure arm and lift the
idle roll arm away from the drive roll.
3. Turn the power switch to ON (marked “I�).
4. Set the wire speed to minimum and jog the drive
unit with the trigger switch until the drive roll set
screw is facing up.
CAUTION
When inching the welding wire, the drive rolls,
gun connector block, and gun contact tip are
energized relative to work and ground and remain
energized for several seconds after the gun trig-
ger is released.
5. Turn the power switch to OFF (marked “O�).
6. Loosen the drive roll set screw with the 5/64" (2.0
mm) hex wrench supplied.
7. Remove the drive roll, flip over and reinstall with the
.023 � .025" (0.6 mm) groove (the smaller groove)
closest to the gearbox.
PRO 100
D-4 D-4
MAINTENANCE
FIGURE D.2 CHANGING LINER
Liner trim length
NOTICE: The variation in cable lengths pre-
vents the interchangeability of liners. Once
a liner has been cut for a particular gun, it
1-1/4 (31.8 mm)
should not be installed in another gun
Liner Trim Length
unless it can meet the liner cutoff length
requirement. Refer to Figure D.2.
1. Remove the gas nozzle from the gun by
unscrewing counter-clockwise.
Gas Diffuser
2. Remove the existing contact tip from the
gun by unscrewing counter-clockwise.
Gas Nozzle or
Gasless Nozzle
Set Screw Brass Cable
3. Remove the gas diffuser from the gun
Connector
tube by unscrewing counter-clockwise.
4. Lay the gun and cable out straight on a
flat surface. Loosen the set screw locat-
Liner Assembly ed in the brass connector at the wire
(Liner bushing to be sealed tight
feeder end of the cable. Pull the liner out
against brass cable connector)
of the cable.
5. Insert a new untrimmed liner into the
connector end of the cable. Be sure the
liner bushing is stenciled appropriately
for the wire size being used.
6. Fully seat the liner bushing into the con-
nector. Tighten the set screw on the
brass cable connector. At this time, the
gas diffuser should not be installed onto
the end of the gun tube.
7. With the gas nozzle and diffuser
removed from the gun tube, be sure the
cable is straight, and then trim the liner
to the length shown in the Figure D.2.
Remove any burrs from the end of the
liner.
8. Screw the gas diffuser onto the end of
the gun tube and securely tighten.
9. Replace the contact tip and nozzle.
PRO 100
D-5 D-5
MAINTENANCE
GUN HANDLE PARTS
The gun handle consists of two halves that are held
together with a collar on each end. To open up the
handle, turn the collars approximately 60 degrees
counter-clockwise until the collar reaches a stop. Then
pull the collar off the gun handle. If the collars are diffi-
cult to turn, position the gun handle against a corner,
place a screwdriver against the tab on the collar and
give the screwdriver a sharp blow to turn the collar
past an internal locking rib. See Figure D-3.
FIGURE D.3
âž?
Counter-clockwise
PRO 100
E-1 E-1
TROUBLESHOOTING
HOW TO USE TROUBLESHOOTING GUIDE
WARNING
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 and
machine operator and will invalidate your factory warranty. For your safety and to avoid Elec-
trical Shock, please observe all safety notes and precautions detailed throughout this
manual.
__________________________________________________________________________
This Troubleshooting Guide is provided to
Step 2. PERFORM EXTERNAL TESTS.
help you locate and remedy possible prob-
The second column labeled “POSSIBLE
lems with machine setup or operation. Sim-
AREAS OF MISADJUSTMENT(S)� lists the
ply follow the three-step procedure
obvious external possibilities that may con-
listed below.
tribute to the machine symptom. Perform
Step 1. LOCATE PROBLEM (SYMPTOM). these tests/checks in the order listed. In
Look under the column labeled “PROBLEM general, these tests can be conducted with-
(SYMPTOMS)�. This column describes pos- out removing the case wrap-around cover.
sible symptoms that the machine may
Step 3. PERFORM COMPONENT TESTS.
exhibit. Find the listing that best describes
If you have exhausted all of the recom-
the symptom that the machine is exhibiting.
mended tests in Step 2, Consult your Local
Authorized Field Service Facility.
Symptoms are grouped into three main cat-
egories: output problems, function prob-
lems, welding problems.
CAUTION
If for any reason you do not understand the test procedures or are unable to perform
the tests/repairs safely, contact your LOCAL AUTHORIZED LINCOLN ELECTRIC
FIELD SERVICE FACILITY for assistance before you proceed.
_____________________________________________________________________
PRO 100
E-2 E-2
TROUBLESHOOTING
Observe Safety Guidelines
TROUBLESHOOTING GUIDE detailed in the beginning of this manual.
RECOMMENDED
PROBLEMS POSSIBLE AREAS OF
COURSE OF ACTION
(SYMPTOMS) MISADJUSTMENT(S)
OUTPUT PROBLEMS
Major physical or electrical damage None
is evident. Contact your local Authorized Field
Service Facility.
No wire feed, weld output or gas 1. Make sure correct voltage is
flow when gun trigger is pulled. Fan applied to the machine (115vac).
does NOT operate.
2. Make certain that power switch
is in the ON position.
3. Make sure circuit breaker is
Contact your local Lincoln
reset.
Authorized Field Service Facility.
No wire feed, weld output or gas 1. The thermostat may be tripped
flow when gun trigger is pulled. Fan due to overheating. Let machine
operates normally. cool. Weld at lower duty cycle.
2. Check for obstructions in air
flow. Check Gun Trigger connec-
tions. See Installation section.
3. Gun trigger may be faulty.
CAUTION
If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your
LOCAL AUTHORIZED LINCOLN ELECTRIC FIELD SERVICE FACILITY for assistance before you proceed.
PRO 100
E-3 E-3
TROUBLESHOOTING
Observe Safety Guidelines TROUBLESHOOTING GUIDE
detailed in the beginning of this manual.
RECOMMENDED
PROBLEMS POSSIBLE AREAS OF
COURSE OF ACTION
(SYMPTOMS) MISADJUSTMENT(S)
FEEDING PROBLEMS
No wire feed when gun trigger is 1. If the wire drive motor is running
pulled. Fan runs, gas flows and make sure that the correct drive
machine has correct open circuit rolls are installed in the machine.
Contact your local Lincoln
voltage (32vcd maximum) � weld
Authorized Field Service Facility.
output. 2. Check for clogged cable liner or
contact tip.
3. Check for proper size cable liner
and contact tip.
PROBLEMS POSSIBLE AREAS OF RECOMMENDED
(SYMPTOMS) MISADJUSTMENT(S) COURSE OF ACTION
GAS FLOW PROBLEMS
Low or no gas flow when gun 1. Verify that gas solenoid is prop-
trigger is pulled. Wire feed, weld erly installed. Refer to instruc-
output and fan operate normally. tions included with K610-1 MIG
(Optional MIG Conversion Kit only.) conversion kit.
Contact your local Lincoln
2. Check gas supply, flow regulator Authorized Field Service Facility.
and gas hoses.
3. Check gun connection to
machine for obstruction or leaky
seals.
CAUTION
If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your
LOCAL AUTHORIZED LINCOLN ELECTRIC FIELD SERVICE FACILITY for assistance before you proceed.
PRO 100
E-4 E-4
TROUBLESHOOTING
Observe Safety Guidelines
TROUBLESHOOTING GUIDE
detailed in the beginning of this manual.
PROBLEMS POSSIBLE AREAS OF RECOMMENDED
(SYMPTOMS) MISADJUSTMENT(S) COURSE OF ACTION
WELDING PROBLEMS
Arc is unstable � Poor starting 1. Check for correct input voltage
to machine � 115vac.
2. Check for proper electrode
polarity for process.
3. Check gun tip for wear or dam-
age and proper size � Replace.
Contact your local Lincoln
4. Check for proper gas and flow Authorized Field Service Facility.
rate for process. (For MIG only.)
5. Check work cable for loose or
faulty connections.
6. Check gun for damage or
breaks.
7. Check for proper drive roll orien-
tation and alignment.
8. Check liner for proper size.
CAUTION
If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your
LOCAL AUTHORIZED LINCOLN ELECTRIC FIELD SERVICE FACILITY for assistance before you proceed.
PRO 100
F-1
WIRING DIAGRAM
Do not operate with covers removed.
GAS SOLENOID IS PART OF MIG CONVERSION KIT.
Disconnect input power by unplugging
power cord before servicing
Do not touch electrically live parts
J1
CONTROL P.C. BOARD Only qualified persons should install, use or
H2 LS1
HIGH VOLTAGE service this machine.
can kill
H2
S1
1 2 3 4 6
5 8 9 10
7
ON-OFF H2 N.O.
SWITCH
WIRE SPEED
209 213 208 203
N.C.
N.C.
F1 CR1 5K
214 539
204 THERMOSTAT
541
R2
H1
115V/60HZ (MOUNTED TO
GUN TRIGGER
115V/60HZ GAS
SEC. COIL)
FAN MOTOR SOLENOID
H1 208
24V 213
209
AUXILIARY
WINDING
214
(W)
-
539 WIRE
FEED
541 + MOTOR
(B)
OUTPUT
PRO 100
CIRCUIT
204
203 CHOKE
BREAKER
+
204
DIAGRAMS
S2 TO
204
SELECTOR D1
H1 WORK
SWITCH D2 204
202
X2
59,000 mf
+
X3
X4 C1
N.B. N.D. 40V
X5
N.D.
203
H2 X1 GUN CABLE
T1 N.A.
CONDUCTOR
D4
CASE BLOCK
N.A. DIODES D2 & D4 ARE MOUNTED 203
D3
GROUNDING
ON THE OUTSIDE HEATSINK.
STUD -
203
N.B. DIODES D1 & D3 ARE MOUNTED
ON THE INSIDE HEATSINK, WHICH
IS CLOSEST TO THE CENTER PANEL.
TO EARTH GROUND PER
N.C. COMPONENT VIEWED FROM REAR.
NATIONAL, LOCAL OR J1
OTHER APPLICABLE ELECTRICAL SYMBOLS PER E1537
N.D. BOLTED ALUMINUM CONNECTIONS
12345
ELECTRICAL CODES. REQUIRE T12837 JOINT COMPOUND LEAD COLOR CODE:
(DOW CORNING 340) WHEN REATTACHING.
6 7 8 9 10
B-BLACK
LATCH
W-WHITE
specific diagram for a particular code is pasted inside the machine on one of the enclosure panels.
CAVITY NUMBERING SEQUENCE
8-01G
( COMPONENT SIDE OF BOARD )
NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual. The
F-1
M15732
NOTES
PRO 100
G Do not touch electrically live parts or G Keep flammable materials away. G Wear eye, ear and body protection.
WARNING electrode with skin or wet clothing.
G Insulate yourself from work and
ground.
Spanish
G No toque las partes o los electrodos G Mantenga el material combustible G Protéjase los ojos, los oÃdos y el
AVISO DE bajo carga con la piel o ropa moja- fuera del área de trabajo. cuerpo.
da.
PRECAUCION G Aislese del trabajo y de la tierra.
French G Ne laissez ni la peau ni des vête- G Gardez à l’écart de tout matériel G Protégez vos yeux, vos oreilles et
ments mouillés entrer en contact inflammable. votre corps.
ATTENTION avec des pièces sous tension.
G Isolez-vous du travail et de la terre.
G Berühren Sie keine stromführenden
German G Entfernen Sie brennbarres Material! G Tragen Sie Augen-, Ohren- und Kör-
Teile oder Elektroden mit Ihrem perschutz!
WARNUNG Körper oder feuchter Kleidung!
G Isolieren Sie sich von den Elektro-
den und dem Erdboden!
Portuguese
G Não toque partes elétricas e elec- G Mantenha inflamáveis bem guarda- G Use proteção para a vista, ouvido e
trodos com a pele ou roupa molha- dos. corpo.
ATENÇÃO da.
G Isole-se da peça e terra.
Japanese
Chinese
Korean
Arabic
READ AND UNDERSTAND THE MANUFACTURER’S INSTRUCTION FOR THIS EQUIPMENT AND THE CONSUMABLES TO BE
USED AND FOLLOW YOUR EMPLOYER’S SAFETY PRACTICES.
SE RECOMIENDA LEER Y ENTENDER LAS INSTRUCCIONES DEL FABRICANTE PARA EL USO DE ESTE EQUIPO Y LOS
CONSUMIBLES QUE VA A UTILIZAR, SIGA LAS MEDIDAS DE SEGURIDAD DE SU SUPERVISOR.
LISEZ ET COMPRENEZ LES INSTRUCTIONS DU FABRICANT EN CE QUI REGARDE CET EQUIPMENT ET LES PRODUITS A
ETRE EMPLOYES ET SUIVEZ LES PROCEDURES DE SECURITE DE VOTRE EMPLOYEUR.
LESEN SIE UND BEFOLGEN SIE DIE BETRIEBSANLEITUNG DER ANLAGE UND DEN ELEKTRODENEINSATZ DES HER-
STELLERS. DIE UNFALLVERHÃœTUNGSVORSCHRIFTEN DES ARBEITGEBERS SIND EBENFALLS ZU BEACHTEN.
G Keep your head out of fumes. G Turn power off before servicing. G Do not operate with panel open or
G Use ventilation or exhaust to
WARNING
guards off.
remove fumes from breathing zone.
Spanish
G Los humos fuera de la zona de res- G Desconectar el cable de ali- G No operar con panel abierto o
AVISO DE
piración. mentación de poder de la máquina guardas quitadas.
G Mantenga la cabeza fuera de los antes de iniciar cualquier servicio.
PRECAUCION
humos. Utilice ventilación o
aspiración para gases.
French
G Débranchez le courant avant l’entre- G N’opérez pas avec les panneaux
G Gardez la tête à l’écart des fumées.
G Utilisez un ventilateur ou un aspira- tien. ouverts ou avec les dispositifs de
ATTENTION
protection enlevés.
teur pour ôter les fumées des zones
de travail.
German
G Strom vor Wartungsarbeiten G Anlage nie ohne Schutzgehäuse
G Vermeiden Sie das Einatmen von
abschalten! (Netzstrom völlig öff- oder Innenschutzverkleidung in
Schweibrauch!
WARNUNG
G Sorgen Sie für gute Be- und Entlüf- nen; Maschine anhalten!) Betrieb setzen!
tung des Arbeitsplatzes!
Portuguese
G Não opere com as tampas removidas. G Mantenha-se afastado das partes
G Mantenha seu rosto da fumaça.
G Desligue a corrente antes de fazer
G Use ventilação e exhaustão para moventes.
ATENÇÃO
serviço. G Não opere com os paineis abertos
remover fumo da zona respiratória.
G Não toque as partes elétricas nuas. ou guardas removidas.
Japanese
Chinese
Korean
Arabic
LEIA E COMPREENDA AS INSTRUÇÕES DO FABRICANTE PARA ESTE EQUIPAMENTO E AS PARTES DE USO, E SIGA AS
PRÃTICAS DE SEGURANÇA DO EMPREGADOR.
� World's Leader in Welding and Cutting Products �
� 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
|