Lincoln ElectricメーカーWELD-PAK 3200HDの使用説明書/サービス説明書
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WELD-P AK 3200HD OPERA TORS MANUAL IM759 May, 2002 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.
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.
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.
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.
iv SAFETY iv PRÉCAUTIONS DE SÛRETÉ Pour votre propre protection lire et observer toutes les instruc- tions et les précautions de sûreté specifiques qui parraissent dans ce manuel aussi bien que les précautions de sûreté générales suivantes: Sûreté Pour Soudage A L’Arc 1.
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.
vi MASTER T ABLE OF CONTENTS FOR ALL SECTIONS Page Installation .......................................................................................................Section A Technical Specifications .................................................
A-1 WELD PAK 3200HD A-1 Fuse or Output Mode Input Voltage Breaker Size 1 Input Amps Power Cord Extension Cord Three Conductor #14 AWG (2.1 mm 2 ) or Larger RATED 120V/60Hz 20 Amp 20 15 Amp, 125V, Up to 25 Ft. (7.6 mm) Three Prong Plug Three Conductor (NEMA Type 5-15P) #12 AWG (3.
A-2 INST ALLA TION WELD-PAK 3200HD 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 WELD- PAK 3200HD from its carton and remove all packing material around the WELD-PAK 3200HD.
A-3 INST ALLA TION WELD-PAK 3200HD A-3 4 5 8 3 6 7 1 2 + - FIGURE A.2 Work Clamp Installation Attach the work clamp per the following: 1. Unplug the machine or turn the power switch to the “ OFF ” position. 2. Insert the work cable terminal lug with the larger hole through the strain relief hole in the work clamp as shown in Figure A-3.
Work Cable Installation Refer to Figure A.2. 1. Open the wire feed section door on the right side of the WELD-PAK 3200HD. 2. Pass the end of the work cable that has the termi- nal lug with the smaller hole through the Work Cable Access Hole (1) in the case front.
CYLINDER may explode if dam- aged. Keep cylinder upright and chained to support • Keep cylinder away from areas where it may be damaged. • Never lift welder with cylinder attached. • Never allow welding electrode to touch cylinder. • Keep cylinder away from welding or other live electrical circuits.
A-6 INST ALLA TION WELD-PAK 3200HD A-6 INPUT CONNECTIONS Refer to Figure A.6. The WELD-PAK 3200HD has a power input cable located on the rear of the machine. FIGURE A.6 CODE REQUIREMENTS FOR INPUT CONNECTIONS This welding machine must be connected to a power source in accordance with applicable elec- trical codes.
A-7 INST ALLA TION WELD-PAK 3200HD A-7 UNDERCARRIAGE ASSEMBL Y CYLINDER may explode if damaged. • Keep cylinder upright and secured to support. • Keep cylinder away from areas where it may be damaged. • Never lift welder with cylinder attached. • Never allow welding electrode to touch cylinder.
B-1 OPERA TION B-1 WELD-PAK 3200HD Read entire operation section before operating the WELD-P AK 3200HD. 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.
B-2 OPERA TION B-2 Refer to Figure B.1b. 4. Circuit Breaker – Protects machine from damage if maximum output is exceeded. Button will extend out when tripped (Manual reset) Refer to Figure B.1b . 5. Gun Trigger - Activates welding output, wire feed, and gas solenoid operation.
B-3 OPERA TION B-3 FIGURE B.1a FIGURE B.1b WELDING OPERA TIONS SEQUENCE OF OPERA TION Wire Loading Refer to Figures B.2 and B.3. The machine power switch should be turned to the OFF ( “ O ” ) position before working inside the wire feed enclosure.
B-4 OPERA TION B-4 Friction Brake Adjustment With wire spool installed on the spindle shaft and the wing nut loose, turn the spool by hand while slowly tightening the wing nut until a light drag is felt.
B-5 OPERA TION B-5 FIGURE B.6 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 WELD-PAK 3200HD controls.
B-6 OPERA TION B-6 The WELD-PAK 3200HD is suitable for .035" alu- minum wire and .030" stainless wire. Refer to Table B.1 for recommended procedure settings (requires K499 Argon Regulator Kit). TABLE B.1 CHANGING MACHINE OVER T O FEED OTHER WIRE SIZES The WELD-PAK 3200HD is shipped from the factory ready to feed 023 ” -.
B-7 LEARNING T O WELD B-7 LEARNING T O WELD No one can learn to weld simply by reading about it. Skill comes only with practice. The following pages will help the inexperienced operator to understand welding and develop this skill. For more detailed infor- mation, order a copy of “ New Lessons in Arc Welding ” listed at the end of this manual.
B-8 LEARNING T O WELD B-8 The “ arc stream ” is seen in the middle of the picture. This is the electric arc created by the electric current flowing through the space between the end of the wire electrode and the base metal. The temperature of this arc is about 6000 ° F, which is more than enough to melt metal.
B-9 LEARNING T O WELD B-9 WELD-PAK 3200HD For GMAW (MIG) Process 1. Is most of my welding performed on 16 gauge and lighter materials? 2. Can I afford the extra expense, space, and lack of portability required for gas cylinders and gas sup- ply? 3.
B-10 LEARNING T O WELD B-10 WELD-PAK 3200HD FIGURE B.12 Penetration Unless a weld penetrates close to 100% of the metal thickness, a butt weld will be weaker than the material welded together.
B-1 1 LEARNING T O WELD B-1 1 WELD-PAK 3200HD FIGURE B.16 Vertical-down Welding Refer to Figure B.17 Vertical-down welds are applied at a fast pace. These welds are therefore shallow and narrow and, as such, are excellent for sheet metal. Vertical-down welds may be applied to 5/32 ” (3.
B-12 LEARNING T O WELD B-12 WELD-PAK 3200HD ARC RAYS can burn eyes and skin. When using an open arc process, it Is necessary to use correct eye, head and body protection. Protect yourself and others, read “ ARC RAYS can burn ” at the front of this manual.
B-13 LEARNING T O WELD B-13 WELD-PAK 3200HD Helpful Hints 1. For general welding, it is not necessary to weave the arc, neither forward or backward nor sideways.
B-14 LEARNING T O WELD B-14 WELD-PAK 3200HD MACHINE SET UP FOR THE GMA W (MIG) PROCESS 1. See PROCESS GUIDELINES in the OPERATION section for selection of welding wire and shielding gas, and for range of metal thicknesses that can be welded.
B-15 LEARNING T O WELD B-15 WELD-PAK 3200HD FIGURE B.24 3. The Correct Electrical Stickout (ESO) The electrical stickout (ESO) is the distance from the end of the contact tip to the end of the wire. See Figure B.24. Once the arc has been established, maintaining the correct ESO becomes extremely important.
B-16 LEARNING T O WELD B-16 TROUBLESHOOTING WELDS Good welds have excellent appearance. To Eliminate Porosity (in order of importance): 1. Turn on gas supply, if used 2. Decrease voltage. 3. Increase stickout. 4. Increase WFS (wire feed speed). 5. Decrease drag angle.
B-17 LEARNING T O WELD B-17 Proper Gun Handling Most feeding problems are caused by improper han- dling of the gun cable or electrodes. 1. Do not kink or pull the gun around sharp corners 2. Keep the gun cable as straight as practical when welding. 3.
B-18 APPLICA TION CHART B-18 WELD-PAK 3200HD.
C-1 ACCESSORIES C-1 OPTIONAL ACCESSORIES 1. K664-2 Aluminum Feeding Kit — This kit required for welding with .035 Aluminum wire. Included with this kit are a drive roll, liner and con- tact tip. It is important when changing between welding with steel wire and aluminum to exchange these components due to the lubri- cant applied to steel wire.
C-2 ACCESSORIES C-2 REPLACEMENT P ARTS Complete Gun and Cable Assembly L8311-5 (K530-4) Contact Tip .025 ” (0.6 mm) S19726-1 Contact Tip .030 ” (0.8 mm) S19726-2 Contact Tip .035 ” (0.9 mm) S19726-3 Contact Tip-Tapered .025 ” (0.6 mm) S20278-1 Contact Tip-Tapered .
MAINTENANCE SAFETY PRECAUTIONS ELECTRIC SHOCK can kill. • Disconnect input power by removing plug from receptacle before working inside WELD-PAK 3200HD. Use only grounded receptacle. Do not touch elec- trically “ hot ” parts inside WELD-PAK 3200HD.
D-2 MAINTENANCE D-2 WELD-PAK 3200HD 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.
D-3 MAINTENANCE D-3 WELD-PAK 3200HD 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.
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.
E-1 TROUBLESHOOTING E-1 WELD-PAK 3200HD If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed.
E-2 TROUBLESHOOTING E-2 WELD-PAK 3200HD If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed.
E-3 TROUBLESHOOTING E-3 WELD-PAK 3200HD If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed.
E-4 TROUBLESHOOTING E-4 WELD-PAK 3200HD If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed.
F-1 DIAGRAMS F-1 WELD-PAK 3200HD S1 SWITCH D1 D3 D2 D4 204 204 204 203 203 203 C1 59,000 f 40V 203 204 - + GUN CABLE CONDUCTOR BLOCK TO WORK ELECTRICAL SYMBOLS PER E1537 CAVITY NUMBERING SEQUENCE ( COMPONENT SIDE OF BOARD ) 539 541 T1 GUN TRIGGER THERMOSTAT 208 5K WIRE SPEED R2 (W) (B) N.
NOTES WELD-PAK 3200HD.
Now A vailable...12th Edition The Procedure Handbook of Arc Welding With over 500,000 copies of previous editions published since 1933, the Procedure Handbook is considered by many to be the “ Bible ” of the arc welding industry. This printing will go fast so don ’ t delay.
W ARNING A VISO DE PRECAUCION A TTENTION W ARNUNG A TEN ÇÃ O 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.
W ARNING A VISO DE PRECAUCION A TTENTION W ARNUNG A TEN ÇÃ O Spanish French German Portuguese Japanese Chinese Korean Arabic LEIA E COMPREENDA AS INSTRUÇÕES DO F ABRICANTE P ARA ESTE EQUIPAMENTO E AS P ARTES DE USO, E SIGA AS PRÁTICAS DE SEGURANÇA DO EMPREGADOR.
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