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Lincoln Electric WELD-PAK 155 User Manual

Lincoln Electric WELD-PAK 155
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WWEELLDD--PPAAKK 115555
IMT538-C
January, 2010
22801 St. Clair Ave. Cleveland, Ohio 44117-1199 U.S.A.
Tel. (216) 481-8100
WEB SITE: www.lincolnelectric.com
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 thoughtful operation
on your part. DO NOT INSTALL, OPERATE OR REPAIR
THIS EQUIPMENT WITHOUT READING THIS MANUAL
AND THE SAFETY PRECAUTIONS CONTAINED
THROUGHOUT. And, most importantly, think before you act
and be careful.
WELD
-
PA
K
1
5
5
OPERATOR’S MANUAL
MANUAL DE OPERACIÓN
MANUEL DE L’OPÉRATEUR
La Seguridad Depende de Usted
Los equipos de corte y soldadura al arco Lincoln han sido
diseñados y construidos teniendo en cuenta su seguridad.
No obstante, ésta se verá incrementada si la instalación se
realiza correctamente, y si pone atención en el manejo de
los mismos. NO INSTALE, UTILICE O REPARE ESTE
EQUIPO SIN ANTES HABER LEIDO ESTE MANUAL Y LAS
MEDIDAS DE SEGURIDAD QUE CONTIENE. Y, lo más
importante, piense antes de actuar, y tenga mucho cuidado.
La sécurité dépend de vous
Le matériel de soudage et de coupage à l'arc Lincoln est
conçu et construit en tenant compte de la sécurité. Toutefois,
la sécurité en général peut être accrue grâce à une bonne
installation... et à la plus grande prudence de votre part. NE
PAS INSTALLER, UTILISER OU RÉPARER CE MATÉRIEL
SANS AVOIR LU CE MANUEL ET LES MESURES DE
CURITÉ QU'IL CONTIENT. Et, par dessus tout,
réfléchissez avant d'agir et exercez la plus grande prudence.
TABLE OF CONTENTS
Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8
Technical Specification . . . . . . . . . . . . . . . . . . . . . .9
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15
Learn to Weld . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22
Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .39
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .41
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . .45
Wiring Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . .47
Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .48
TABLA DE CONTENIDO
Seguridad . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2
Introducción . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8
Especificaciones Técnicas . . . . . . . . . . . . . . . . . . . . .9
Instalación . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10
Operación . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15
Aprendiendo a Soldar . . . . . . . . . . . . . . . . . . . . . . . . .22
Accesorios . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .39
Mantenimiento . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .41
Localización de averías . . . . . . . . . . . . . . . . . . . . . . .45
Diagramas de cableado . . . . . . . . . . . . . . . . . . . . . . .47
Partes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .48
TABLE DES MATIÈRES
Sécurité .......................................................................2
Introduction..................................................................8
Fiche technique ...........................................................9
Installation ..................................................................10
Fonctionnement...........................................................15
Apprentissage du soudage..........................................22
Accessoires .................................................................39
Entretien ......................................................................41
Dépannage..................................................................45
Schéma de câblage.....................................................47
Pièces..........................................................................48
Date of Purchase:
Serial Number:
Code Number:
Model:
Where Purchased:
Copyright © Lincoln Global Inc.

Table of Contents

Questions and Answers:

Lincoln Electric WELD-PAK 155 Specifications

General IconGeneral
Input Voltage120V
Output Amperage30 - 155 A
Wire Feed Speed50 - 500 IPM
Weight58 lbs
Input Current20 A
Duty Cycle20% at 90 A
Welding ProcessMIG
Wire Size Range0.035 in

Summary

OPERATOR'S MANUAL

Safety Depends on You

General safety principle emphasizing user responsibility for safe operation.

SAFETY

WARNING: ARC WELDING HAZARDS

Highlights the inherent dangers of arc welding and general warnings.

ARC RAYS can burn.

Warns about the specific hazard of arc rays to eyes and skin.

SAFETY

ELECTRIC AND MAGNETIC FIELDS may be dangerous

Alerts users to potential dangers from EMF and health effects.

SAFETY

WELDING SPARKS can cause fire or explosion.

Warns about fire and explosion risks from welding sparks.

SAFETY

ELECTRIC SHOCK can kill.

Emphasizes the severe risk of electric shock and fatality.

SAFETY

FUMES AND GASES can be dangerous.

Alerts to the health hazards posed by welding fumes and gases.

SAFETY

CYLINDER may explode if damaged.

Warns about the explosion risk associated with damaged gas cylinders.

General Safety Warnings

Provides general warnings and cautions for safe operation.

INTRODUCTION

Safety Precautions

Summarizes key safety warnings relevant to the introduction.

General Description

Provides an overview of the WELD-PAK 155 features and purpose.

TECHNICAL SPECIFICATIONS

Input and Output Ratings

Details electrical input and output specifications, including voltage and current.

Physical Dimensions

Lists the physical size and weight of the WELD-PAK 155.

Recommended Cable and Fuse Sizes

Provides guidance on appropriate input cable and fuse sizes.

INSTALLATION

IDENTIFY AND LOCATE COMPONENTS

Guides users on unpacking and identifying included parts.

INSTALLATION

LOCATION

Advises on proper placement of the welder for safe operation.

WORK CLAMP INSTALLATION

Details the procedure for attaching the work clamp.

WORK CABLE INSTALLATION

Explains how to connect the work cable to the machine.

INSTALLATION

GUN INSTALLATION

Provides instructions for installing the welding gun assembly.

INSTALLATION

INPUT POWER CONNECTIONS

Explains how to connect the machine to the power source.

INSTALLATION

GAS CONNECTION (OPTIONAL)

Describes how to connect shielding gas for optional processes.

WARNING

Safety warning regarding gas cylinders during installation.

OPERATION

Controls and Settings

Explains the function of each control and setting on the WELD-PAK.

Overload and Thermal Protection

Details the machine's protective mechanisms against overload and overheating.

OPERATION

WIRE LOADING

Guides on how to load welding wire spools onto the machine.

OPERATION

WIRE LOADING

Continues instructions for loading wire, including spool types.

FRICTION BRAKE ADJUSTMENT

Explains how to adjust the spool friction brake for proper wire feeding.

WIRE THREADING

Details the process of threading the welding wire through the machine.

OPERATION

Wire Drive Feed Roll Adjustment

Instructions for adjusting the wire drive roll for optimal feeding.

WARNING

Safety warning regarding electrical hazards during wire feed operation.

OPERATION

MAKING A WELD

Step-by-step guide on how to perform a weld.

CLEANING TIP AND NOZZLE

Maintenance instructions for keeping the gun tip and nozzle clean.

OPERATION

The Correct Welding Position

Explains the proper gun position for effective welding.

CLEANING TIP AND NOZZLE

Provides ongoing maintenance advice for the gun tip and nozzle.

OPERATION

PROCESS GUIDELINES

Offers guidance on selecting and using different welding processes.

WARNING

Safety warning related to changing between steel and aluminum wire.

CHANGING MACHINE OVER TO FEED OTHER WIRE SIZES

Instructions for reconfiguring the machine for different wire types.

OPERATION

LEARNING TO WELD

Introduces the basics of learning welding skills.

THE ARC-WELDING CIRCUIT

Explains the fundamental principles of the arc welding circuit.

OPERATION

WARNING

Safety warning about toxic fumes from Innershield electrodes.

THE SELF-SHIELDED FCAW WELDING ARC

Explains the FCAW welding arc process and its characteristics.

OPERATION

THE GMAW (MIG) WELDING ARC

Explains the GMAW (MIG) welding arc process and its requirements.

OPERATION

PROCESS SELECTION

Helps users choose between GMAW and FCAW processes based on needs.

OPERATION

For FCAW (Innershield) Process

Provides specific guidelines for using the FCAW process.

COMMON METALS

Information on welding common types of metals.

JOINT TYPES AND POSITIONS

Describes different types of welding joints and positions.

OPERATION

Butt Welds

Details the technique for performing butt welds.

Penetration

Explains the importance of weld penetration for strength.

OPERATION

Fillet and Vertical Welding Techniques

Covers techniques for fillet and vertical welding.

Material Thickness Warning

Warns about potential issues when welding thick materials.

OPERATION

Vertical-down Welding

Explains the technique for vertical-down welding.

OPERATION

WELDING TECHNIQUES FOR THE SELF-SHIELDED FCAW PROCESS

Provides detailed techniques for self-shielded FCAW welding.

The Correct Welding Position

Explains the proper gun position for FCAW welding.

OPERATION

The Correct Electrical Stickout (ESO)

Details the importance and method for setting correct electrical stickout.

The Correct Welding Speed

Explains how to achieve the correct welding speed by observing the puddle.

OPERATION

Helpful Hints

Offers useful tips for general welding practice.

Practice

Suggests an exercise for practicing welding techniques.

OPERATION

WELDING TECHNIQUES FOR THE GMAW (MIG) PROCESS

Provides detailed techniques for GMAW (MIG) welding.

The Correct Welding Position

Explains the proper gun position for GMAW (MIG) welding.

OPERATION

The Correct Way To Strike An Arc

Guides users on how to properly initiate a welding arc.

The Correct Electrical Stickout (ESO)

Details the importance and method for setting correct electrical stickout.

OPERATION

The Correct Welding Speed

Explains how to achieve the correct welding speed by observing the puddle.

Helpful Hints

Offers useful tips for general welding practice.

OPERATION

Practice

Suggests an exercise for practicing welding techniques.

OPERATION

Troubleshooting Weld Defects

Guides on identifying and fixing common weld defects like porosity.

OPERATION

Troubleshooting Spatter, Penetration, and Arc Blow

Provides solutions for spatter, poor penetration, and arc blow issues.

Eliminate Stubbing

Explains how to fix stubbing issues during welding.

Proper Gun Handling

Offers advice on correct gun handling to prevent feeding problems.

ACCESSORIES

OPTIONAL ACCESSORIES

Lists optional accessories available for the WELD-PAK.

MIG CONVERSION

Details the MIG conversion process and necessary kits.

ACCESSORIES

CONFIGURATION OF COMPONENTS IN WIRE FEEDING SYSTEM

Explains the configuration of components for different wire feeding systems.

MAINTENANCE

Safety Precautions

Safety guidelines to follow before performing maintenance.

Routine Maintenance Areas

Outlines routine maintenance tasks for different machine compartments.

MAINTENANCE

GUN AND CABLE MAINTENANCE

Instructions for cleaning and maintaining the gun and cable.

Contact Tips, Nozzles, and Gun Tubes

Details maintenance for contact tips, nozzles, and gun tubes.

MAINTENANCE

CHANGING DRIVE ROLL

Step-by-step guide for reversing the drive roll for different wire sizes.

MAINTENANCE

CHANGING LINER

Instructions for replacing the gun liner.

TROUBLESHOOTING

Troubleshooting: No Output/Fan Failure

Addresses issues when there is no output or the fan fails.

Troubleshooting: No Wire Feed / Fan Operates

Addresses issues when there's no wire feed but the fan works.

General Caution

General caution for users performing tests or repairs.

TROUBLESHOOTING

Troubleshooting: Gas Flow and Arc Stability

Solves problems related to gas flow and unstable arc starting.

General Caution

General caution for users performing tests or repairs.

WELD-PAK 155 WIRING DIAGRAM

WARNING

Safety warning regarding operating with covers removed or power connected.

PARTS

OPTIONAL ACCESSORIES

Lists optional parts and accessories.

MIG CONVERSION

Details components for MIG conversion.

FINAL SAFETY INSTRUCTIONS

Read and Understand Manufacturer's Instructions

Stresses the importance of understanding the manual and safety practices.

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