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Lincoln Electric IM784 - page 1
PRO 100 OPERA TOR’S MANUAL IM784 April, 2004 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 T ...
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Lincoln Electric IM784 - page 2
FOR ENGINE powered equipment. 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. ________________________________________________ ...
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Lincoln Electric IM784 - page 3
ii SAFETY ii ARC RA YS can burn. 4.a. Use a shield with the proper filter and cover plates to protect your eyes from sparks and the rays of the arc when welding or observing open arc welding. Headshield and filter lens should conform to ANSI Z87. I standards. 4.b. Use suitable clothing made from durable flame-resistant material to protect your skin ...
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Lincoln Electric IM784 - page 4
FOR ELECTRICALL Y powered equipment. 8.a. Turn off input power using the disconnect switch at the fuse box before working on the equipment. 8.b. Install equipment in accordance with the U.S. National Electrical Code, all local codes and the manufacturer’s recommendations. 8.c. Ground the equipment in accordance with the U.S. National Electrical C ...
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Lincoln Electric IM784 - page 5
iv SAFETY iv PRÉCAUTIONS DE SÛRETÉ Pour votre propre protection lire et observer toutes les instructions et les précautions de sûreté specifiques qui parraissent dans ce manuel aussi bien que les précautions de sûreté générales suiv- antes: Sûreté Pour Soudage A L’Arc 1. Protegez-vous contre la secousse électrique: a. Les circuits ? ...
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Lincoln Electric IM784 - page 6
Thank You for selecting a QUALITY product by Lincoln Electric. We want you to take pride in operating this Lincoln Electric Company product ••• as much pride as we have in bringing this product to you! Read this Operators Manual completely before attempting to use this equipment. Save this manual and keep it handy for quick reference. Pay par ...
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Lincoln Electric IM784 - page 7
vi vi T ABLE OF CONTENTS Page Installation .......................................................................................................Section A Technical Specifications ........................................................................................A-1 Identify and Locate Components .............................................. ...
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Lincoln Electric IM784 - page 8
A-1 PRO 100 A-1 INST ALLA TION Fuse or Output Mode Input Voltage Breaker Size Input Amps Power Cord Extension Cord RATED 115V/60Hz 20 Amp 20 15 Amp, 125V, Three Conductor Three Prong Plug #14 AWG (NEMA Type 5-15P) (2.1 mm 2 ) or Larger 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- ...
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Lincoln Electric IM784 - page 9
A-2 INST ALLA TION PRO 100 A-2 Read entire installation section before starting installation. SAFETY PRECAUTIONS IDENTIFY AND LOCA TE COMPONENTS If you have not already done so, unpack the PRO 100 from its carton and remove all packing material around the PRO 100. Remove the following loose items from the carton (see Figure A.1): 1. PRO 100 2. Gun ...
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Lincoln Electric IM784 - page 10
A-3 INST ALLA TION PRO 100 A-3 SELECT SUIT ABLE LOCA TION Locate the welder in a dry location where there is free circulation of clean air into the louvers in the back and out the front of the unit. A location that minimizes the amount of smoke and dirt drawn into the rear louvers reduces the chance of dirt accumulation that can block air passages ...
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Lincoln Electric IM784 - page 11
A-4 INST ALLA TION PRO 100 A-4 Connecting Gun Cable to the PRO 100 1. Refer to Figure A.2. Unplug the machine or turn power switch to the OFF “ O ” position. 2. Pass the insulated terminals of the gun trigger con- trol leads, one at a time, through the Gun Cable and Control Lead Access Slot (2) in the case front. The leads are to be routed unde ...
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Lincoln Electric IM784 - page 12
2 . With the cylinder securely installed, remove the cylinder cap. Stand to one side away from the out- let and open the cylinder valve very slightly for an instant. This blows away any dust or dirt which may have accumulated in the valve outlet. BE SURE TO KEEP YOUR FACE AWAY FROM THE VALVE OUTLET WHEN “CRACKING” THE VALVE. Never stand directl ...
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Lincoln Electric IM784 - page 13
A-6 INST ALLA TION PRO 100 A-6 INPUT CONNECTIONS FIGURE A.6 Refer to Figure A.6. The PRO 100 has a power input cable located on the rear of the machine. CODE REQUIREMENTS FOR INPUT CONNECTIONS This welding machine must be connected to power source in accordance with applicable elec- trical codes. The National Electrical Code provides standards for ...
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Lincoln Electric IM784 - page 14
B-1 OPERA TION B-1 PRO 100 Read entire operation section before operating the PRO 100. 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 ven ...
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Lincoln Electric IM784 - page 15
B-2 OPERA TION B-2 ● No external shielding gas is required when used with Lincoln Innershield .035 ” (0,9 mm) NR ® -211- MP electrode. ● Accommodates 4 ” (100 mm) diameter spool of wire. Will accommodate 8 ” (200 mm) diameter with optional spindle. WELDING CAP ABILITY The PRO 100 is rated at 88 amps, 18 volts, at 20% duty cycle on a ten ...
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Lincoln Electric IM784 - page 16
B-3 OPERA TION B-3 FIGURE B.1a FIGURE B.1b WELDING OPERA TIONS SEQUENCE OF OPERA TION 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. The machine is shipped from the factory ready to feed 4 ” (100 mm) diameter spools. A 4" (100 ...
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Lincoln Electric IM784 - page 17
Gun Handle Gas Diffuser/ Contact Tip Gas Nozzle FIGURE B.5 B-4 OPERA TION 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 and coast of the spool. 2. To tighten the brake turn the wing nut c ...
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Lincoln Electric IM784 - page 18
B-5 OPERA TION B-5 Making A Weld 1. See “ Process Guidelines ” in this section for selec- tion of welding wire and shielding gas and for range of metal thicknesses that can be welded. 2. See the Application chart on the inside of the wire feed compartment door for information on setting the PRO 100 controls. Refer to Table B.1 for alu- minum an ...
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Lincoln Electric IM784 - page 19
B-6 OPERA TION B-6 The PRO 100 is suitable for .035" aluminum wire and .030" stainless wire. Refer to Table B.1 for recom- mended procedure settings. (Requires K610-1 MIG Conversion Kit and K664-2 Aluminum - Stainless Feeding Kit.) It is important when changing between welding with steel wire and aluminum to exchange feeding components du ...
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Lincoln Electric IM784 - page 20
B-7 APPLICA TION CHART B-7 PRO 100 ...
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Lincoln Electric IM784 - page 21
C-1 ACCESSORIES C-1 OPTIONAL ACCESSORIES 1. K520 Utility Cart — Designed to transport the Lin- coln family of small welders. Has provisions for mounting a single gas cylinder. Has front casters and large rear wheels. Handle height is easily adjustable. Bottom tray provided for tools and accessories. Easy assembly required; takes less than 15 minu ...
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Lincoln Electric IM784 - page 22
D-1 MAINTENANCE D-1 PRO 100 MAINTENANCE SAFETY PRECAUTIONS 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 MA ...
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Lincoln Electric IM784 - page 23
D-2 MAINTENANCE D-2 GUN AND CABLE MAINTENANCE FOR MAGNUM™ 100L GUN Gun Cable Cleaning Clean cable liner after using approximately 300 lbs (136 kg) of solid wire or 50 lbs (23 kg) of flux-cored wire. Remove the cable from the wire feeder and lay it out straight on the floor. Remove the contact tip from the gun. Using low pressure air, gently blow ...
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Lincoln Electric IM784 - page 24
D-3 MAINTENANCE D-3 COMPONENT REPLACEMENT PROCEDURES CHANGING THE CONT ACT TIP 1. Refer to Figure D.2. Remove the gas nozzle from 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. CHANGING DRIVE ROLL The dri ...
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Lincoln Electric IM784 - page 25
D-4 MAINTENANCE D-4 PRO 100 CHANGING LINER NOTICE: The variation in cable lengths pre- vents the interchangeability of liners. Once a liner has been cut for a particular gun, it should not be installed in another gun unless it can meet the liner cutoff length requirement. Refer to Figure D.2. 1. Remove the gas nozzle from the gun by unscrewing coun ...
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Lincoln Electric IM784 - page 26
D-5 MAINTENANCE D-5 PRO 100 GUN HANDLE P ARTS 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 ha ...
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Lincoln Electric IM784 - page 27
E-1 TROUBLESHOOTING E-1 PRO 100 This Troubleshooting Guide is provided to help you locate and remedy possible prob- lems with machine setup or operation. Sim- ply follow the three-step procedure listed below. Step 1. LOCATE PROBLEM (SYMPTOM). Look under the column labeled “ PROBLEM (SYMPTOMS) ” . This column describes pos- sible symptoms that t ...
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Lincoln Electric IM784 - page 28
E-2 TROUBLESHOOTING E-2 PRO 100 Observe Safety Guidelines detailed in the beginning of this manual. TROUBLESHOOTING GUIDE PROBLEMS (SYMPTOMS) Major physical or electrical damage is evident. No wire feed, weld output or gas flow when gun trigger is pulled. Fan does NOT operate. No wire feed, weld output or gas flow when gun trigger is pulled. Fan op ...
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Lincoln Electric IM784 - page 29
E-3 TROUBLESHOOTING E-3 PRO 100 TROUBLESHOOTING GUIDE Observe Safety Guidelines detailed in the beginning of this manual. PROBLEMS (SYMPTOMS) No wire feed when gun trigger is pulled. Fan runs, gas flows and machine has correct open circuit voltage (32vcd maximum) – weld output. POSSIBLE AREAS OF MISADJUSTMENT(S) 1. If the wire drive motor is runn ...
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Lincoln Electric IM784 - page 30
E-4 TROUBLESHOOTING E-4 PRO 100 Observe Safety Guidelines detailed in the beginning of this manual. TROUBLESHOOTING GUIDE 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. CAUTION PROB ...
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Lincoln Electric IM784 - page 31
F-1 DIAGRAMS F-1 PRO 100 S1 SWITCH D1 D3 D2 D4 204 204 204 203 203 203 C1 59,000 mf 40V 203 204 - + GUN CABLE CONDUCTOR BLOCK TO WORK ELECTRICAL SYMBOLS PER E1537 CAVITY NUMBERING SEQUENCE ( COMPONENT SIDE OF BOARD ) 539 541 T1 213 GUN TRIGGER THERMOSTAT 208 5K WIRE SPEED R2 (W) (B) N.C. N.C. COMPONENT VIEWED FROM REAR. ON-OFF N.C. 209 WINDING 24V ...
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Lincoln Electric IM784 - page 32
NOTES PRO 100 ...
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Lincoln Electric IM784 - page 33
W ARNING A VISO DE PRECAUCION A TTENTION W ARNUNG A TENÇÃO Spanish French German Portuguese Japanese Chinese Korean Arabic READ AND UNDERST AND THE MANUF ACTURER’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 F ABRICANTE PARA EL U ...
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Lincoln Electric IM784 - page 34
W ARNING A VISO DE PRECAUCION A TTENTION W ARNUNG A TENÇÃO Spanish French German Portuguese Japanese Chinese Korean Arabic LEIA E COMPREENDA AS INSTRUÇÕES DO F ABRICANTE PARA ESTE EQUIP AMENTO E AS P ARTES DE USO, E SIGA AS PRÁTICAS DE SEGURANÇA DO EMPREGADOR. ● Keep your head out of fumes. ● Use ventilation or exhaust to remove fumes fro ...
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Lincoln Electric IM784 - page 35
• Sales and Service through Subsidiaries and Distributors Worldwide • Cleveland, Ohio 44117-1199 U.S.A. TEL: 216.481.8100 FAX: 216.486.1751 WEB SITE: www.lincolnelectric.com • World's Leader in Welding and Cutting Products • ...
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