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Lincoln WELD-PAK 3200HD User Manual

Lincoln WELD-PAK 3200HD
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WELD-PAK 3200HD
IMT786-A
February, 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.
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
CURI QU'IL CONTIENT. Et, par dessus tout,
réfléchissez avant d'agir et exercez la plus grande prudence.
TABLA DE CONTENIDO
Seguridad . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2
Especificaciones Técnicas . . . . . . . . . . . . . . . . . . . . .8
Instalación . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9
Operación . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18
Accesorios . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .31
Mantenimiento . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .33
Localización de averías . . . . . . . . . . . . . . . . . . . . . . .39
Diagramas de cableado . . . . . . . . . . . . . . . . . . . . . . .41
Partes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .42
TABLE DES MATIÈRES
Sécurité....................................................................2
Fiche technique .......................................................8
Installation ...............................................................9
Fonctionnement .......................................................18
Accessoires..............................................................31
Entretien...................................................................33
Dépannage ..............................................................39
Schéma de câblage.................................................41
Pièces ......................................................................42
Date of Purchase:
Serial Number:
Code Number:
Model:
Where Purchased:
Copyright © Lincoln Global Inc.
For use with machines having Code Number:
Para el uso con las máguinas que tienen números de código:
Pour l’usage avec des machines ayant des muméros de code:
}
10972
TABLE OF CONTENTS
Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2
Technical Specification . . . . . . . . . . . . . . . . . . . . . .8
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18
Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .31
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .33
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . .39
Wiring Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . .41
Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .42

Questions and Answers:

Lincoln WELD-PAK 3200HD Specifications

General IconGeneral
BrandLincoln
ModelWELD-PAK 3200HD
CategoryWelding System
LanguageEnglish

Summary

Safety

Electrically Powered Equipment Safety

Safety instructions for electrically powered equipment installation and grounding.

Safety

Electric and Magnetic Fields Safety

Information on potential dangers of electric and magnetic fields (EMF) during welding.

Safety

Welding Sparks Fire and Explosion Hazards

Precautions against fire and explosion hazards caused by welding sparks and hot materials.

Safety

Electric Shock Hazards

Warnings and procedures to prevent fatal electric shock hazards during welding operations.

Safety

Fumes and Gases Health Hazards

Health hazards associated with welding fumes and gases, and necessary precautions.

Safety

Gas Cylinder Safety Precautions

Safety warnings regarding compressed gas cylinders and precautions to prevent damage or explosion.

Technical Specifications

Input Single Phase

Details regarding the single-phase power input requirements for the machine.

Rated Output Specifications

Performance specifications of the welding machine's rated output.

Recommended Input Cable and Fuse Sizes

Recommended input cable and fuse sizes for the machine's rated output.

Physical Dimensions

Physical dimensions and weight of the welding equipment.

Installation

Installation Safety Precautions

Critical safety precautions to follow before and during the installation process.

Identify and Locate Components

Instructions for identifying and locating all components included with the welding machine.

Installation

Select Suitable Location

Guidance on selecting an appropriate and safe location for the welding machine.

Output Connections

Instructions for connecting the output terminals and cables to the machine.

Installation

Work Clamp Installation

Detailed steps for correctly attaching the work clamp to the welding machine.

Work Cable Installation

Procedures for routing the work cable through the machine's housing and connecting it.

Installation

Gun Installation

Instructions for installing the welding gun, including contact tip and nozzle setup.

Connecting Gun Cable

Steps for connecting the welding gun's cable assembly to the main unit.

Installation

Gas Connection

Guidelines for connecting a gas cylinder for welding processes requiring shielding gas.

Installation

Gas Cylinder Safety During Installation

Critical safety warnings regarding gas cylinder handling and installation.

Installation

Code Requirements for Input Connections

Electrical code requirements for connecting the welding machine to the power supply.

Installation

Undercarriage Assembly

Instructions for assembling the undercarriage, including casters and bottle support.

Operation

Operation Safety Precautions

Essential safety precautions to follow while operating the welding equipment.

General Description

A general overview of the WELD-PAK 3200HD's features and intended uses.

Operation

Recommended Processes

Recommended welding processes and wire types for optimal performance.

Operational Controls

Description of the standard controls available on the WELD-PAK 3200HD.

Operation

Welding Capability

Details on the welding machine's amperage, voltage, and duty cycle capabilities.

Controls and Settings

Guidance on operating controls and setting the machine for different welding parameters.

Operation

Welding Sequence of Operation

Step-by-step instructions for performing a welding operation.

Wire Loading

Procedures for loading wire spools onto the machine's wire feed system.

Operation

Wire Threading

Step-by-step guide on how to thread the welding wire through the gun and feeder.

Operation

Making a Weld

Detailed guide on how to make a weld using the machine.

Work Clamp Connection

Instructions on connecting the work clamp to the workpiece for proper welding.

Operation

Process Guidelines

Guidelines for selecting welding wire, shielding gas, and appropriate settings for various materials.

Operation

Suggested Settings Table

A table providing suggested welding settings for different processes, wires, and metal thicknesses.

Operation

Overload Protection

Information on the machine's overload protection mechanisms, including circuit breakers and thermal cutoffs.

Operation

Suggested Settings for Welding

Suggested welding settings for stainless steel, aluminum, and wire drive roll orientation.

Accessories

Optional Accessories

Description of optional accessories available for the welding machine.

Accessories

Replacement Parts

A list of common replacement parts for the welding gun and machine.

Maintenance

Maintenance Safety Precautions

Critical safety precautions to follow before performing any maintenance on the equipment.

Routine Maintenance

Routine maintenance procedures for the power source and wire feed compartments.

Wire Feed Compartment Maintenance

Maintenance instructions for the wire feed compartment, including cleaning and lubrication.

Maintenance

Gun and Cable Maintenance

Procedures for cleaning and maintaining the welding gun and its cable.

Contact Tips, Nozzles, and Gun Tubes

Instructions for cleaning and replacing contact tips, nozzles, and gun tubes.

Maintenance

Wire Feeding System Component Configuration

Details on the configuration of components within the wire feeding system.

Maintenance

Component Replacement Procedures

Step-by-step procedures for replacing common components like contact tips and drive rolls.

Changing the Contact Tip

Instructions on how to safely remove and replace the contact tip.

Changing the Drive Roll

Detailed steps for reversing or replacing the drive roll for different wire sizes.

Maintenance

Changing the Liner

Procedures for replacing the wire liner in the gun cable assembly.

Maintenance

Gun Handle Parts

Instructions on how to disassemble the gun handle to access internal parts.

Troubleshooting

No Wire Feed, Weld Output, or Gas Flow (Fan Not Operating)

Troubleshooting steps when the fan does not operate, and there is no wire feed, weld output, or gas flow.

No Wire Feed, Weld Output, or Gas Flow (Fan Operating)

Troubleshooting steps when the fan operates normally but there is no wire feed, weld output, or gas flow.

No Wire Feed (Other Functions Normal)

Troubleshooting steps when wire feed fails, but other functions appear normal.

Troubleshooting

Low or No Gas Flow (Other Functions Normal)

Troubleshooting steps for low or no gas flow while other functions are normal.

Unstable Arc and Poor Starting

Steps to troubleshoot an unstable arc and poor starting conditions during welding.

Wiring Diagram

Parts

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