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Lincoln Electric WELD-PAK 3200HD User's Manual

1. Regardless of the type of metal being welded in order to get a quality weld it is important that the metal is free of oil paint rust or other contaminant s JOINT TYPES AND POSITIONS Five types of welding joints are Butt Welds Fillet Welds Lap Welds Edge Welds and Corner Welds See Figure B 11 Of these the Butt Weld and Fillet Weld are the two most common welds Butt weld 4 Lap weld Edge weld Fillet weld Corner weld FIGURE B 11 Butt Welds Place two plates side by side leaving a space approx imately one half the thickness of the metal between them in order to get deeper penetration Securely clamp or tack weld the plates at both ends otherwise the heat will cause the plates to move apart See Figure B 12 Now weld the two plates together Weld from left to right if right handed Point the wire electrode down in the crack between the two plates keeping the gun slightly tilted in the direction of travel Watch the molten metal to be sure it distributes itself evenly on both edges and in between the plates This is referred to as the pull technique On thin gauge sheet metal use the push technique See Welding Techniques for GMAW MIG Process WELD PAK 3200HD LINCOLN B 10 LEARNING TO WELD B 10 4 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 In the example shown in Figu
2. WELD PAK 3200HD LINCOLN 5 E 3 TROUBLESHOOTING E 3 Observe all Safety Guidelines detailed throughout this manual PROBLEMS POSSIBLE AREAS OF RECOMMENDED SYMPTOMS MISADJUSTMENT S COURSE OF ACTION FEEDING PROBLEMS No wire feed when gun trigger is 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 voltage 32VDC maximum weld If all recommended possible areas output Check for clogged cable lineror of misadjustment have been contact tip checked and the problem persists Contact your local Lincoln Check for proper size cable liner Authorized Field Service and contact tip Facility PROBLEMS POSSIBLE AREAS OF RECOMMENDED SYMPTOMS MISADJUSTMENT S COURSE OF ACTION GAS FLOW PROBLEMS Low or no gas flow when gun 1 Check gas supply flow regulator trigger is pulled Wire feed weld and gas hoses output and fan operate normally 2 Check gun connection to If all recommended possible areas machine for obstruction or leaky of misadjustment have been seals checked and the problem persists Contact your local Lincoln Authorized Field Service Facility CAUTION 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 W
3. material to protect your skin and that of your helpers from the arc rays Protect other nearby personnel with suitable non flammable screening and or warn them not to watch the arc nor expose themselves to the arc rays or to hot spatter or metal FUMES AND GASES can be dangerous 5 a Welding may produce fumes and gases hazardous to health Avoid breathing these fumes and gases When welding keep your head out of the fume Use enough ventilation and or exhaust at the arc to keep fumes and gases away from the breathing zone When welding with electrodes which require special ventilation such as stainless or hard facing see instructions on container or MSDS or on lead or cadmium plated steel and other metals or coatings which produce highly toxic fumes keep exposure as low as possible and below Threshold Limit Values TLV using local exhaust or mechanical ventilation In confined spaces or in some circumstances outdoors a respirator may be required Additional precautions are also required when welding on galvanized steel Do not weld in locations near chlorinated hydrocarbon vapors coming from degreasing cleaning or spraying operations The heat and rays of the arc can react with solvent vapors to form phosgene a highly toxic gas and other irritating products 5 6 LINCOLN 2 Also see item 1 0 Shielding gases used for arc welding can displace air and cause injury or death Always use enough ventilation
4. TANVd 831N39 011535010 SI HOIHM 3GISNI IHL NO GALNNOW 60 3 LQ 53801 ON INISLV3H 3GIS100 JHL 70 8 cd SACOIC IX T Sx n Ea 000 HOLIMS 80194145 05 40 3015 IN3NOdWWOO JONANDAS SNIH38IATIN ALIAVO 540002 1VOIH19313 di8vorlddv YAHLO HO 1V901 d3d GNNOYS H14V3 OL anis ONIANNOHO ASVO d3 v3d8 LIN94I9 4399141 NNO X6 43395 1109 7035 OL Q31NnOW 1VISOWHSHL TWNOILdO H3IALL HOLILS LOdS 15 ond ueo SIU 921 95 35V L10A HOIH 10 ASN esu Pinoys suosJed Au e syed yono Jou og Buras 910 90 102 19 00 Aq Jamod du 129102511 e 5 gau ejeredo quod ANINYY MY GION31OS Svo ZH09 ASLL HOLIMS 330 15 ONIGNIM Ave YOLOW ZHO9 AS INVH9VIG 9NIHIM GHOOZE XVd Q13M NOTE This diagram is for reference only It may not be accurate for all machines covered by this manual The specific diagram for a particular code is pasted inside the machine on one of the enclosure panels PAK 3200HD LINCOLN E WELD NOTES WELD PAK 3200HD LINCOLN 5 Now Available 12th Edition The Procedure Handbook of Arc Welding With over 500 000 copies of previous edi
5. especially in confined areas to insure breathing air is safe Read and understand the manufacturer s instructions for this equipment and the consumables to be used including the material safety data sheet MSDS and follow your employer s safety practices MSDS forms are available from your welding distributor or from the manufacturer Mar 95 SAFETY 7 WELDING SPARKS can gt cause fire or explosion 6 a Remove fire hazards from the welding area If this is not possible cover them to prevent the welding sparks from starting a fire Remember that welding sparks and hot materials from welding can easily go through small cracks and openings to adjacent areas Avoid welding near hydraulic lines Have a fire extinguisher readily available Where compressed gases are to be used at the job site special precautions should be used to prevent hazardous situations Refer to Safety in Welding and Cutting ANSI Standard Z49 1 and the operating information for the equipment being used When not welding make certain no part of the electrode circuit is touching the work or ground Accidental contact can cause overheating and create a fire hazard Do not heat cut or weld tanks drums or containers until the proper steps have been taken to insure that such procedures will not cause flammable or toxic vapors from substances inside They can cause an explosion even though they have been cleaned For information
6. finished looking welds If you have answered yes to all the above questions GMAW may be the process for you If you have answered no to any of the above questions then you should consider using the FCAW process For FCAW Innershield Process 1 Do want simplicity and portability 2 Will welding be performed outdoors or under windy conditions 3 Do require good all position welding capability 4 Will most welding be performed on 16 gauge and heavier somewhat rusty or dirty materials 5 Weld must be cleaned prior to painting COMMON METALS Most metals found around the farm small shop or home are low carbon steel sometimes referred to as mild steel Typical items made with this type of steel include most sheet metal plate pipe and rolled shapes such as channels and angle irons This type of steel can usually be easily welded without special pre cautions Some steels however contain higher car bon levels or other alloys and are more difficult to weld Basically if a magnet sticks to the metal and you can easily cut the metal with a file chances are good that the metal is mild steel and that you will be able to weld the material In addition aluminum and stainless steel can be welded using the K664 1 Aluminum Welding Kit For further information on identifying various types of steels and other metals and for proper procedures for welding them we again suggest you purchase a copy of New Lessons in Arc Welding
7. opere com os paineis abertos ou guardas removidas OSILDI RALE CHkBEELZVCNEUS CHRRIARRARS Ro e 20 Sel AE Asal HAS WARNING Spanish AVISO DE PRECAUCION French ATTENTION German WARNUNG ATEN O BIR Chinese Qai oe Jung dul jua e os uui ARI ge cal z ue Aie Ao a NM jui ale Ads cuts UI ai l Jai y e Aale Viel Al all LEIA E COMPREENDA AS INSTRUCOES DO FABRICANTE PARA ESTE EQUIPAMENTO E AS PARTES DE USO E SIGA AS PR TICAS DE SEGURANCA DO EMPREGADOR SRM OBUOX HD OHBRBEE lt K RA ETISRIUCESU CL TRHORERMEI HS TFE Uo ET REL BE SUCR Rr de EL AMENER 0 HA zeit ele EFSA BEHE ET Aal veel d illai aui Qui AAL Gail guet Ca L LINCOLN 5 World s Leader in Welding and Cutting P roducts 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
8. Figure B 20 Do not watch the arc itself It is the appearance of the puddle and the ridge where the molten puddle solidifies that indicates correct weld ing speed The ridge should be approximately 3 8 10 mm behind the wire electrode 2 Position gun over joint End of wire may be lightly touching the work 3 Position face shield to protect face and eyes close gun trigger and begin welding Hold the gun so that the contact tip to work distance is about 3 8 to 1 2 inch 10 12 mm Most beginners tend to weld too fast resulting in a thin uneven wormy looking bead They are not watching the molten metal 4 To stop welding release the gun trigger and the pull the gun away from the work after the arc goes out 5 A ball may form at the tip end of the wire after welding For easier restrikes with Innershield wire the ball may be removed by feeding out a few inches of wire and simply bending the wire back and forth until it breaks off Solidifying ridge 6 When no more welding is to be done turn off Molten puddle the machine dg 3 The Correct Electrical Stickout ESO ASSA The electrical stickout ESO is the distance from the end of the contacttip to the end of the wire FIGURE B 20 See Figure B 19 Once the arc has been established maintaining the correct ESO becomes extremely important The ESO should be approximately 3 8 to 1 2 inch 10 to 12 mm long WELD PAK 3200HD LINCOLN B 13 Hel
9. SELF SHIELDED FCAW 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 2 See the Application Guide on the inside of wire feed section door for information on setting the controls 3 Set the Voltage and Wire Speed controls to the settings suggested on the Application Guide for the welding wire and base metal thickness being used The voltage control is marked V and the wire feed speed is marked olo 4 Check that the polarity is correct for the welding wire being used Set the polarity for DC when welding with NR 211 MP Innershield electrode See Work Cable Installation in the INSTALLATION section for instructions on changing polarity 5 When using Innershield electrode the gasless noz zle may be used instead of a gas nozzle to improve visibility of the arc 6 Connect work clamp to metal to be welded Work clamp must make good electrical contact to the work piece The work piece must also be grounded as stated in the Arc Welding Safety Precautions at the beginning of this manual WELDING TECHNIQUES FOR THE SELF SHIELDED FCAW PROCESS Four simple manipulations are of prime importance when welding With complete mastery of the four welding will be easy They are as follows 1 The Correct Welding Position Figure B 18 illustrates the correct welding position for right handed people For left handed
10. Wire Loading Refer to Figures B 2 and B 3 The machine power switch should be turned to the OFF position before working inside the wire feed enclosure The welder is shipped from the factory ready to feed 8 200 mm diameter spools with 2 2 56 mm maxi mum width These spools fit on a 2 51 mm diameter spindle that has a built in adjustable friction brake to prevent overrun of the spool and excess slack in the wire 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 FIGURE B 2 Wire Spool Spindle 8 Wire Spool Be sure that this stud engages the hole in the wire spool To Wire Drive Wire Spool must be pushed all the way on the spindle so that the spindle s tab will hold it in place The Wire Spool will rotate clock wise when wire is dereeled Load an 8 200 mm diameter spool on the wire spool spindle shown in Figure B 2 To use 4 100 mm diameter spools the 2 50 mm diameter spindle must be removed See Figure B 3 Remove the wing nut and spacer at the end of the shaft and remove the outside plastic wire spool spin dle The spindle can be stored in the wire feed com partment A 4 100 mm diameter spool is mounted directly on the 5 8 16 mm diameter sha
11. accidental contact with the workpiece or ground use the following equipment Semiautomatic DC Constant Voltage Wire Welder DC Manual Stick Welder AC Welder with Reduced Voltage Control In semiautomatic or automatic wire welding the electrode electrode reel welding head nozzle or semiautomatic welding gun are also electrically hot Always be sure the work cable makes a good electrical connection with the metal being welded The connection should be as close as possible to the area being welded Ground the work or metal to be welded to a good electrical earth ground Maintain the electrode holder work clamp welding cable and welding machine in good safe operating condition Replace damaged insulation Never dip the electrode in water for cooling Never simultaneously touch electrically hot parts of electrode holders connected to two welders because voltage between the two can be the total of the open circuit voltage of both welders When working above floor level use a safety belt to protect yourself from a fall should you get a shock Also see Items 6 c and 8 L ARC RAYS 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 standards 4 b Use suitable clothing made from durable flame resistant 5 b
12. applicable electrical code requirements consult a qualified electrician INSTALLATION Requirements For Rated Output A power cord with a 15 amp 125 volt three prong plug NEMA Type 5 15P is factory installed on the WELD PAK 3200HD Connect this plug to a mating grounded receptacle which is connected to a 20 amp branch circuit with a nominal voltage rating of 115 to 125 volts 60 Hertz AC only The rated output with this installation is 90 amps 19 Volts 2096 duty cycle 2 minutes of every 10 minutes used for welding CAUTION Do not connect the WELD PAK 3200HD to an input power supply with a rated voltage that is greater than 125 volts Do not remove the power cord ground prong WELD PAK 3200HD LINCOLN 7 INSTALLATION A 7 UNDERCARRIAGE ASSEMBLY 10 Tighten Gas Bottle Support Brackets with supplied 1 4 20 wing screws and wing nuts A FIGURE A 7 CYLINDER may explode FS if damaged S 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 Keep cylinder away from welding or other live electrical circuits The undercarriage is not intended for transport ing the Weld Pak 3200HD f the Weld Pak 3200HD is going to be transport ed remove the under carriage Do not lift the Weld Pak 3200HD when a gas bot tle is connected f th
13. cable as straight as practical when welding Do not allow dolly wheels or trucks to run over the cables Keep the cable clean Innershield electrode has proper surface lubrica tion Use only clean rust free electrode Replace contact tip when it becomes worn or the end is fused or deformed WELD PAK 3200HD LINCOLN P B 17 B 18 ASEl dS 02111 821615 ON Wed 509 SUR aqeumnsuog 1482 pue unb 7001 60 ut cgo 0 wun z 9 0 620 1 921615 8719 104 ON Hed Ang pyepuejs 501 3221007 6 0 ut cgo 0 a 9 0 ut 520 1 812025 8719 104 ON Med 61 ut g c 21 7 ug ut g g v899LIN qi Buruadg ON Med passa3ay 5917204 sen 20899 1 1 899 LIN 21 Ul z L qi Buiuadg v629LM ON Utd 8LY9LN ON Med ysnj4 dij 9JZZON Sex 9 ZZON 55915 pajade sdij 3201007 V NOISN31 SNOS SIN 1 05 1004193131 13 001 30 31 IN3IINIVHLLN3 O S31 339N03N3 153 13101514 31N3130 V1 13 3H9NVH8 153 39 0005 31504 31 3108801 1N3ASSLLU3AV LOH ATIV2IH12313 38V 300812313 ONY 1334 51109 0334 05539930 8395181 NNO NO SI 228105 H3M0d SNIGT4M IHL ONINHVM au Ayiqisuodsei APPLICATION CHART B 18 si jquiesse 10 e jo yigessi
14. for welding on heavier steel 14 gauge 2 0 mm for example The recommended electrode for the self shielded process is 035 0 9 mm diameter Lincoln Innershield NR 211 MP on 10 Ib 4 5 kg spools This electrode can be used for all position welding of 20 gauge 1 0 mm through 5 16 8 mm steel Thickness of 1 4 6 mm and 5 16 8 mm require multiple passes This wire can also be used for the welding of galvanized coated sheet metal WELD PAK 3200HD LINCOLN P B 6 OPERATION 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 Shielding Voltage Wire Speed Welding Wire Gas 16 ga 14 ga 12 ga 10 ga 035 Dia 100 Argon 4043 Aluminum Wire 035 Dia 5356 Aluminum Wire 10096 Argon 030 Dia 308L Stainless Steel Wire 98 Argon 2 Oxygen CHANGING MACHINE OVER TO FEED OTHER WIRE SIZES The WELD PAK 3200HD is shipped from the factory ready to feed 023 025 0 6 mm diameter wire To operate the WELD PAK 3200HD with other sizes of wire it is necessary to change the contact tip and change the drive roll over to other sizes Refer to Changing the Contact Tip and Changing the Drive Roll in the MAINTENANCE section for specific infor mation on these procedures WELDING WITH GMAW MIG Shielding Gas When using the GMAW process obtain and
15. install a gas regulator and hose kit K463 for or K499 Argon mixed gas regulator and hose kit 1 For CO open the cylinder very slowly For argon mixed gas open cylinder valve slowly a fraction of a turn When the cylinder pressure gauge pointer stops moving open the valve fully 2 If using a regulator with an adjustable flow meter close the gun trigger and adjust the flow to give 15 20 cubic ft per hour 7 10 l min use 20 25 CFH 10 12 l min when welding out of position or in a drafty location for CO9 For argon mixed gas trigger to release gas pressure and adjust the flow to give 25 30 12 14 l min 3 Keep the cylinder valve closed except when using the WELD PAK 3200HD When finished welding a Close the cylinder valve to stop gas flow b Depress the gun trigger briefly to release the pressure in the gas hose C Turn off the WELD PAK 3200HD WELDING WITH FCAW Innershield When using the FCAW process the correct drive roll and electrode polarity must be used See Work Cable Installation in INSTALLATION section for changing the polarity OVERLOAD PROTECTION Output Overload The WELD PAK 3200HD is equipped with a circuit breaker and a thermostat which protects the machine from damage if maximum output is exceeded The cir cuit breaker button will extend out when tripped The circuit breaker must be manually reset Thermal Protection The WELD PAK
16. may cause part warpage and burn through One way to eliminate these problems is to use the back stepping method illustrated in Figure B 21 Practice The best way of getting practice in the four skills that enable you to maintain 1 Correct welding position 2 Correct way to strike an arc 3 Correct electrical stickout 4 Correct welding speed is to perform the following exercise For the WELD PAK 3200HD use the following Mild Steel 16 gauge or 1 16 inch 1 6 mm Lincolnweld 0 025 L 56 electrode CO Voltage Setting V C Wire Feed Speed 4 Electrode Refer to Figure B 22 1 Learn to strike an arc by positioning the gun over the joint and touching the wire to the work 2 Position face shield to protect face and eyes 3 Depress gun trigger hold gun so contact tip to work distance Is about 3 8 to 1 2 inch 10 to 12 mm and the gun is at proper angle WELD PAK 3200HD LINCOLN B 16 TROUBLESHOOTING WELDS Good welds have excellent appearance To Eliminate Porosity in order of importance Tum on gas supply if used Decrease voltage Increase stickout Increase WFS wire feed speed Decrease drag angle nu Decrease travel speed NOTE Always be sure the joint is free from moisture oil rust paint or other contaminants To Eliminate a Ropy Convex Bead in order of importance CC CET CT V CET Increase vol
17. the gun and cable out straight on a flat surface Loosen the set screw located in the brass connec tor atthe wire feeder end of the cable Pull the liner out 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 connector 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 Gasless Nozzle 8 Screw the gas diffuser onto the end of the gun tube and securely tighten 9 Replace the contacttip and nozzle 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 pastan internal locking rib See Figure D 3 FIGURE DA WELD PAK 3200HD LINCOLN 1 TROUBLESHOOTING 1 HOW U
18. 3200HD has a rated output duty cycle of 2095 If the duty cycle is exceeded a thermal protector will shut off the output until the machine cools to a reasonable operating temperature This is an automatic function of the WELD PAK 3200HD and does not require user intervention The fan continues to run during cooling Electronic Wire Drive Motor Protection The WELD PAK 3200HD has built in protection for wire drive motor overload WELD PAK 3200HD LINCOLN B 7 LEARNING TO 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 THE ARC WELDING CIRCUIT The OPERATORS knowledge of arc welding must go beyond the arc itself The operator must know how to control the arc and this requires a knowledge of the welding circuit and the equipment that provides the electric current used in the arc Figure B 7 illustrates the welding circuit for a typical welding machine The circuit begins where the gun cable is attached to the welding machine Current flows through the gun cable gun and contact tip to the wire and across the arc On the work side of the arc current flows through the base metal to the work cable and back to the welding machine This circuit must be complete for the current to
19. ELD PAK 3200HD LINCOLN 5 E 4 TROUBLESHOOTING E 4 Observe all Safety Guidelines detailed throughout this manual PROBLEMS POSSIBLE AREAS OF RECOMMENDED SYMPTOMS MISADJUSTMENT S COURSE OF ACTION WELDING PROBLEMS Arc is unstable P oor starting Check for correct input voltage to machine 115vac Check for proper electrode polarity for process Check gun tip for wear or dam age and proper size Replace If all recommended possible areas Check for proper gas and flow of misadjustment have been rate for process For MIG only checked and the problem persists Contact your local Lincoln Check work cable for loose or Authorized Field Service faulty connections Facility Check gun for damage or breaks Check for proper drive roll orien tation and alignment 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 Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed WELD PAK 3200HD LINCOLN F 1 DIAGRAMS ALIHM M X9v18 8 GOO 40109 Qv31 26919 ddd S 1O8AAS 1V914191 T3 30018 HEU 00069 318VO 02 330H9 1 ONIHOV LIV3H N3HM MOQ 1 2 8c L1 3HIn038 SNOLLO3NNOO WANINNT1Y 0311089 ON WOU LNANOdWOO
20. IM759 WELD PAK 3200HD 2007 For use with machine Code Number 10932 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 PRECAUTIONS CONTAINED THROUGHOUT And most importantly think before you act and be careful Date of Purchase Serial Number Code Number Model Where Purchased OPERATORS MANUAL E EE ISO 9001 ANSI RAB DN La y Designed and Manufactured Under a Quality Program Certified by ABS Quality to ISO 9001 Requirements SES LI CO LN Copyright 2002 Lincoln Global Inc World s Leader in Welding and Cutting Products e Sales and Service through Subsidiaries and Distributors Worldwide e Cleveland Ohio 44117 1199 U S A TEL 216 481 8100 FAX 216 486 1751 WEB SITE www lincolnelectric com l A WARNING CALIFORNIA PROPOSITION 65 WARNINGS A Diesel engine exhaust and some of its constituents The engine exhaust from this product contains are known to the State of California to cause can chemicals known to the State of California to cause cer birth defects and other reproductive harm cancer birth defects or othe
21. K 3200HD trigger circuit GAS CONNECTION When using the GMAW process a cylinder of shield ing gas must be obtained For more information about selecting gas cylinders for use with the WELD PAK 3200HD refer to the ACCESSORIES section WELD PAK 3200HD LINCOLN A 5 WARNING CYLINDER may explode if dam aged Keep cylinder upright and chained to support m3 e 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 WARNING BUILDUP OF SHIELDING GAS may harm health or kill Shut off shielding gas supply a 2 when not in use SEE AMERICAN NATIONAL STANDARD Z 49 1 SAFETY IN WELDING AND CUTTING PUB LISHED BY THE AMERICAN WELDING SOCIETY 1 Chain the cylinder to a wall or other stationary sup port to prevent the cylinder from falling over if not using undercarriage Insulate the cylinder from the work circuit and earth ground Refer to Figure A 5 OOQ lt gt Oylinder Valve Flow Regulator E EL Gas Hose x FIGURE A 5 INSTALLATION A 5 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 A WAR
22. MAINTENANCE GUN AND CABLE MAINTENANCE FOR MAGNUM 100L GUN Gun Cable Cleaning Clean cable liner after using approximately 300 165 136 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 out the cable liner from the gas diffuser end CAUTION Excessive pressure at the start may cause the dirt to form a plug Flex the cable over its entire length and again blow out the cable Repeat this procedure until no further dirt comes out Contact Tips Nozzles and Gun Tubes 1 Dirt can accumulate in the contact tip hole and restrict wire feeding After each spool of wire is used remove the contact tip and clean it by push ing a short piece of wire through the tip repeatedly Use the wire as a reamer to remove dirt that may be adhering to the wall of the hole through the tip D 2 2 Replace worn contact tips as required A variable or hunting arc is a typical symptom of a worn con tact tip To install a new tip choose the correct size contact tip for the electrode being used wire size is stenciled on the side of the contacttip and screw it snugly into the gas diffuser 3 Remove spatter from inside of gas nozzle and from tip after each 10 minutes of arc time or as required 4 Be sure the gas nozzle is fully screwed onto the diffuser for gas shielded processes For th
23. NING BE SURE TO KEEP YOUR FACE AWAY FROM THE VALVE OUTLET WHEN CRACKING THE VALVE Never stand directly in front of or behind the flow regulator when opening the cylinder valve Always stand to one side 3 Attach the flow regulator to the cylinder valve and tighten the union nut securely with a wrench NOTE If connecting to 100 CO cylinder make certain the plastic washer is seated in the fitting that attaches to the CO cylinder 4 Refer to Figure A 6 Attach one end of inlet gas hose to the outlet fitting of the flow regulator and tighten the union nut securely with a wrench Connect the other end to the WELD PAK 3200HD Gas Solenoid Inlet Fitting 5 8 18 female threads for CGA 032 fitting Make certain the gas hose is not kinked or twisted WELD PAK 3200HD LINCOLN 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 GAS SOLENOID INLET FITTING POWER INPUT CABLE ll O FIGURE A 6 CODE REQUIREMENTS FOR INPUT CONNECTIONS WARNING This welding machine must be connected to a power source in accordance with applicable elec trical codes The United States National Electrical Code Article 630 B 1990 Edition provides standards for amperage handling capability of supply conduc tors based on duty cycle of the welding source If there is any question about the installation meeting
24. S MANUAL WELD PAK 3200HD LINCOLN A 3 SELECT SUITABLE LOCATION 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 and cause overheating STACKING WELD PAK 3200HD cannot be stacked TILTING Each machine must be placed on a secure level sur face either directly or on either recommended cart The machine may topple over if this procedure is not followed OUTPUT CONNECTIONS Refer to Figure A 2 Work Cable Access Hole Gun Cable and Control Lead Access Hole Connector Block Gun Trigger Lead Connectors Positive and negative output terminals Wire Feed Gearbox Cable Hanger Thumbscrew JO LINCOLN ELECTRIC e Se INSTALLATION 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 3 Fasten securely with the bolt and nut provided FIGURE A 3 Strain Relief Hole Work Cable Work Clamp FIGURE A 2 WELD PAK 3200HD LINCOLN 4 Work Cable Installatio
25. SE 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 Electrical Shock please observe all safety notes and precautions detailed throughout this manual This Troubleshooting Guide is provided to help you locate and repair possible machine malfunctions Simply follow the three step procedure listed below Step 1 LOCATE PROBLEM SYMPTOM Look under the column labeled PROBLEM SYMP TOMS This column describes possible symptoms that the machine may exhibit Find the listing that best describes the symptom that the machine is exhibiting Step 2 POSSIBLE CAUSE The second column labeled POSSIBLE CAUSE lists the obvious external possibilities that may contribute to the machine symptom Step 3 RECOMMENDED COURSE OF ACTION This column provides a course of action for the Possible Cause generally it states to contact your local Lincoln Authorized Field Service Facility If you do not understand or are unable to perform the Recommended Course of Action safely contact your local Lincoln Authorized Field Service Facility CAUTION If for any reason you do not understand the test procedures or are unable to perform the tests repairs safely contact your Local Lincoln Authorize
26. abeza fuera de los humos Utilice ventilaci n o aspiraci n para gases e Gardez la t te l cart des fum es e Utilisez un ventilateur ou un aspira teur pour ter les fum es des zones de travail e Vermeiden Sie das Einatmen von Schweibrauch Sorgen Sie f r gute Be und Entl ftung des Arbeitsplatzes e Mantenha seu rosto da fumaca Use ventilac o exhaust o para remover fumo da zona respirat ria eti ADP5o5UtRic5cuc 9 fsUPBHEILTASESUCFEU CARE 24752 else SUAS MAS sis PARAH 37 amp Turn power off before servicing Desconectar el cable de ali mentaci n de poder de la m quina antes de iniciar cualquier servicio e D branchez le courant avant l entre tien Strom vor Wartungsarbeiten abschalten Netzstrom v llig ff nen Maschine anhalten opere com as tampas removidas Desligue a corrente antes de fazer servico e toque as partes el tricas nuas AVFFVA F EAZLRUP ET BRAY FE e HMDS RK AGS XA Do not operate with panel open or guards off No operar con panel abierto o guardas quitadas N op rez pas avec les panneaux ouverts ou avec les dispositifs de protection enlev s e Anlage nie ohne Schutzgeh use oder Innenschutzverkleidung in Betrieb setzen e Mantenha se afastado das partes moventes
27. amage to this equipment MASTER TABLE OF CONTENTS FOR ALL SECTIONS Page DECIES Section A Technical ee A 1 Identify and Locate A 2 Select Suitable Location cete tee dug tad A 3 Output Connections a EE 6 Code Requirements A 6 lte ee Ee EE A 7 Rm Section B Safety IE D n B 1 General RE le E B 1 Design ER entiere etre B 1 B 2 Welding E B 2 Bill ro a Le EU nne B 2 Coritrols Settings B 2 Welding Operations sie B 3 OVerload Protectio E B 6 to a 7 Application e LEE B 18 LTE Section C un lee EE C 1 Heplacemoent E C 2 Elide Section D Safety Precaltlons uu editione t e n dieci ipe xus D 1 Items Requiring No Maintenance D 1 Routine Maintenance D 1 Gun and Cable Maintenance D 2 Component Replacement Procedures D 3 Changing D 4 Gun Handie cM ED D 4 Troubleshooting Leer eee eren ene Section E Saf
28. anging 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 WELD PAK 3200HD LINCOLN D 3 MAINTENANCE D 3 COMPONENT REPLACEMENT PROCEDURES CHANGING THE CONTACT 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 drive roll has two grooves one for 023 025 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 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 idle arm tensioner Item 2 and lift the idle roll arm Item 3 away from the drive roll Item 1 See Figure D 1 3 Turn the power switch to ON marked 4 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 A CAUTION When inching the welding wire the drive rolls gun connector block and gun contact t
29. asless Nozzle Innershield Only M16418 WELD PAK 3200HD LINCOLN 5 MAINTENANCE MAINTENANCE SAFETY PRECAUTIONS WARNING 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 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 WELD PAK 3200HD Take the unit to an authorized Lincoln Service Center if you experience problems NO maintenance is required In extremely dusty locations dirt may clog the air passages causing the welder to run hot with premature tripping of ther mal protection If so blow dirt out of the welder with low pres sure air at regular intervals to eliminate excessive dirt and dust build up on internal parts 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 if 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 WELD PAK 3200HD LINCOLN D 1 D 2
30. d Field Service Facility for technical troubleshooting assistance before you proceed WELD PAK 3200HD LINCOLN E 2 PROBLEMS SYMPTOMS TROUBLESHOOTING Observe all Safety Guidelines detailed throughout this manual RECOMMENDED COURSE OF ACTION POSSIBLE AREAS OF MISADJUSTMENT S OUTPUT PROBLEMS Major physical or electrical damage None is evident No wire feed weld output or gas flow when gun trigger is pulled Fan applied to the machine 115vac does NOT operate No wire feed weld output or gas Contact your local Authorized Field Service Facility Make sure correct voltage is Make certain that power switch is in the ON position Make sure circuit breaker inside wire drive compartment is reset 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 Check for obstructions in air flow Check Gun Trigger connec tions See Installation section Gun trigger may be faulty E 2 If all recommended possible areas of misadjustment have been checked and the problem persists Contact your local Lincoln Authorized Field Service Facility CAUTION 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
31. ding and cutting CSA Standard W 117 2 1974 jamais enrouler le c ble lectrode autour de n importe quelle PR CAUTIONS DE S RET POUR partie du corps LES MACHINES SOUDER Un coup d arc peut tre plus s v re qu un coup de soliel TRANSFORMATEUR ET REDRESSEUR donc a Utiliser un bon masque avec un verre filtrant appropri ainsi qu un verre blanc afin de se prot ger les yeux du rayonnement de l arc et des projections quand on soude ou quand on regarde l arc Porter des v tements convenables afin de prot ger la peau de soudeur et des aides contre le rayonnement de l arc Prot ger l autre personnel travaillant proximit au soudage l aide d crans appropri s et non inflamma bles Des gouttes de laitier en fusion sont mises de l arc de soudage Se prot ger avec des v tements de protection libres de l huile tels que les gants en cuir chemise paisse pantalons sans revers et chaussures montantes LINCOLN 2 Relier la terre le chassis du poste conformement au code de l lectricit et aux recommendations du fabricant Le dis positif de montage ou la piece souder doit tre branch une bonne mise la terre Autant que possible l installation et l entretien du poste seront effectu s par un lectricien qualifi Avant de faires des travaux l interieur de poste la debrancher l interrupteur la boite de fusibles Garder tous les couvercles et disposi
32. e Innershield process the gasless nozzle should be screwed onto the diffuser 5 To remove gun tube from gun remove gas nozzle or gasless nozzle and remove diffuser from gun 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 place against the gun end cable connector Unscrew gun tube from cable connector To install 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 more than one turn the gun tube until its axis is perpendicular to the flat sides of the cable connec tor and pointed in the direction of the trigger Tighten the locking nut so as to maintain the proper relationship between the gun tube and the cable connector Replace the gun handle trigger and dif fuser Replace the gas nozzle or gasless nozzle CONFIGURATION OF COMPONENTS IN WIRE FEEDING SYSTEM Contact Tip Cable Liner Drive Roll S19726 3 035 0 9mm Components shipped with WELD PAK 3200HDe S24221 1 035A 0 9mm e FOr 0 025 wire feeding use the included S 19726 1 contact tip K664 2 035 0 9mm Aluminum or Stainless Kit e If 030 Solid wire feeding is desired obtain an 5 19726 2 Contact Tip M16291 6 035 0 9mm M18971 1 035 0 9mm KP 665 035 2 Smooth grooves Small 023 025 0 6mm Large 030 0 8mm M19631 Itis important when ch
33. e Weld Pak 3200HD is going to be moved or lifted remove the gas bottle Refer to Figure A 7 Note The following instructions assume a gas bottle is going to be used If a gas bottle is not going to be used skip steps 5 and steps 7 10 Remove both sheet metal screws 1 from case 2 Align undercarriage base 2 with side mount screw holes as shown Make sure the two caster mount ing holes are located in front of the machine 3 Replace sheet metal screws removed in step 1 making sure to secure undercarriage to the Weld Pak 3200HD 1 4 Use both supplied black round head screws to secure door side of the Weld Pak 3200HD 3 to undercarriage 5 Attach Gas Bottle Support Base to rear of undercar riage using supplied 1 4 20 fasteners 4 6 Attach the supplied fixed casters to the rear of the undercarriage assembly 5 7 Attach the supplied swivel caster to the front of the undercarriage with the supplied 5 16 acorn nuts 8 Attach both Gas Bottle Support Brackets 6 as shown 9 Insert gas bottle if available WELD PAK 3200HD LINCOLN B 1 OPERATION B 1 Read entire operation section before operating the WELD PAK 3200HD 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 o
34. e must be plugged into a receptacle which is grounded per any national local or other applicable electrical codes The WELD PAK 3200 HD power switch is to be in the OFF position when installing work cable and gun and when connecting power cord to input power IDENTIFY AND LOCATE 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 Remove the following loose items from the carton see Figure A 1 1 WELD PAK 3200HD 2 Gun and cable assembly 3 Literature and miscellaneous including a This operating manual b extra 023 025 0 6 mm contact tips 3 extra 035 09mm contact tips d Hex key wrench for removal of drive roll 4 10 ft 3 0 m work cable 5 Work clamp 6 Sample spool of 025 0 6 mm L 56 MIG wire 7 Sample spool of 035 09mm NR 211 MP Innershield Flux Cored Wire 8 Handshield with filter plate and lens 9 Adjustable mixed Gas Regulator amp Hose 10 Mig Nozzle Assembly INSTALLATION 11 Undercarriage a Base b Gas bottle support base 2 Gas bottle support brackets For available options and accessories refer to the Accessories Section of this manual As shipped from the factory the WELD PAK 3200HD gun liner is ready to feed 023 0 6 mm 035 0 9 mm wire The contact tip is sized for 023 025 0 6 mm wire feeding FIGURE A 1 OPERATOR
35. erformed with the WELD PAK 3200HD The WELD PAK 3200HD is not recom mended for pipe thawing or TIG welding CONTROLS AND SETTINGS Refer to Figure B 1a 1 Control Power ON OFF Switch When the power is on the fan motor will run and air will be exhausted out the louvers in the front of the machine The weld ing output and wire feeder OFF remain off until the gun trigger is pressed 2 Wire Speed Control ON Controls the wire feed speed from 50 300 in min 1 3 7 6 m min The control can be preset on the dial to the setting specified on the WELDPAK3200HD Application Chart located on the inside of the wire feed section door WIRE SPEED 3 Voltage Control A 4 posi tion tap selector switch gives full range adjustment of power source output voltage Do not switch while welding ARC VOLTS 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 Releasing the trigger deactivates welding and simultaneously activates the burnback function so that the welding wire does not stick in the weld puddle WELD PAK 3200HD LINCOLN P B 3 OPERATION B 3 WIRE SPEED 9 o ARC VOLTS D oN LK B 2 DO NOT SWITCH WHEN WELDING FIGURE B 1b WELDING OPERATIONS SEQUENCE OF OPERATION
36. ety sas 1 How to Use Troubleshooting E 1 Troubleshooting Guilde ucc ettet mnt entere teen etas E 2 THRU E 4 Wiring Diagrams ss nnne nnne nennen nnn nnn na Section F SP 195 T Witing oen iere aree ees t tra prete ste Eben te F 1 Parts LISS pee casses valent P442 Series P202 E vi n INSTALLATION m TECHNICAL SPECIFICATIONS WELD PAK 3200HD INPUT SINGLE PHASE ONLY Standard Voltage Frequency Input Current 120V 60Hz 20 Amps Rated Output RATED OUTPUT Duty Cycle Amps Volts at Rated Amperes 20 Duty Cycle 90 19 OUTPUT Welding Current Range Maximum Open Circuit Voltage 50 300 in min 25 135 Amps 29V 1 3 7 6 m min RECOMMENDED INPUT CABLE AND FUSE SIZES Fuse or Three Conductor 14 AWG 2 1 mm or Larger 120V 60Hz 15 Amp 125V Up to 25 Ft 7 6 mm Three Prong Plug Three Conductor NEMA Type 5 15P 12 AWG 3 3 mm or Larger Up to 50 Ft 15 2 mm PHYSICAL DIMENSIONS 11f connected to a circuit protected by fuses use Time Delay Fuse marked D WELD PAK 3200HD LINCOLN 5 A 2 Read entire installation section before starting installation SAFETY PRECAUTIONS WARNING e ELECTRIC SHOCK can kill Only qualified personnel should perform this installation Only personnel that have read and under stood the WELD PAK 3200 HD Operating Manual should install and operate this equipment Machin
37. f 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 2 Observe all safety information throughout this manual GENERAL DESCRIPTION The WELD PAK 3200HD is a complete semiautomatic constant voltage DC wire feeder power source arc welder It has been designed for workshop hobby automotive and light maintenance Included is a tap switch controlled single phase constant voltage trans former rectifier power source and a wire feeder weld ing gun for feeding 023 025 0 6 mm through 030 0 8 mm solid steel electrode and 035 0 9 mm Innershield NR 211 MP flux cored wire The WELD PAK 3200HD is ideally suited for individu als having access to 120 volt AC input power and wanting the ease of use quality and dependability of both gas metal arc welding or GMAW also known as MIG welding and the Innershield electrode process self shielded flux cored or FCAW The WELD PAK 3200HD is a rugged and reliable machine that has been designed for dependable service and long life RECOMMENDED PROCESSES The WELD PAK 3200HD can be used for welding mild steel using the Gas Metal Arc Welding GMAW or MIG Metal Inert Gas single pass process which requires a supply of shielding gas or the flux cored a
38. flow This machine s welding circuit has a voltage output of 32 volts DC maximum This voltage is quite low and is only present when the gun triggers depressed To weld the work clamp must be tightly connected to clean base metal Remove paint rust dirt or oil as necessary and connect the work clamp as close as possible to the area you wish to weld This helps pre vent current from going through an unwanted path Avoid allowing the welding circuit to pass through hinges bearings electronic components or similar devices that can be damaged See Figure B 8 Always disconnect electrical devices before welding upon them Electronic Components Bearings FIGURE B 8 LEARNING TO WELD B 7 WARNING Fumes and slag generated from 3 Innershield type electrodes recom mended for use with this welding machine can be toxic Avoid contact with eyes and skin Do not take internally Keep out of reach of children Follow all safety precautions found in this operating manual The gun and cable assembly is held by the operator who guides the automatically fed wire along the joint maintaining a contact tip to work distance of about 3 8 to 1 2 inch 10 12 mm This is called electrical stick out This electrical stickout ESO must be properly maintained by the operator The electric arc is made in the gap between the work and the tip end of a small diameter wire When the power source is properly set the arc gap
39. ft and held in place with the previously removed hardware Also 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 Wire Spindle Shaft Wing Nut gt and Spacer To Wire Drive WELD PAK 3200HD LINCOLN BA 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 Tighten the wing nut an additional 1 4 turn Note When properly adjusted the brake should pro vide only enough drag to prevent overrun of the spool and excess slack in the wire Too much drag may result in wire feeding problems and may cause pre mature wear of wire drive system components Wire Threading Refer to Figure B 4 1 Release the Spring Loaded Pressure Arm 1 rotate the Idle Roll Arm 2 away from the Wire Feed Drive Roll 3 Ensure that the groove size in the feeding position on the drive roll matches the wire size being used 2 Carefully detach the end of the wire from the spool To prevent the spool from unwinding maintain tension on the wire until after step 5 3 Cut the bent portion of wire off and straighten the first 4 100 mm 4 Thread the wire through the In going guide tube 4 over the drive roll 3 and into the out going guide tube 5 5 Close the idle roll arm 2 and latch the spring
40. i cant applied to steel wire Failure to do so may result in contaminated welds when welding alu minum KP665 045C Drive Roll Optional Knurled drive roll for feeding 035 0 9 mm diameter flux cored electrode ACCESSORIES e 3 K520 Utility Cart Designed to transport the Lincoln 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 minutes K586 1 Deluxe Adjustable Gas Regulator amp Hose Kit Accommodates CO or mixed Gas Cylinders WELD PAK 3200HD LINCOLN 5 C 2 REPLACEMENT PARTS Complete Gun and Cable Assembly L8311 5 K530 4 Contact Tip 025 0 6 mm 519726 1 Contact 030 0 8 mm 519726 2 Contact 035 0 9 519726 3 Contact Tip Tapered 025 0 6 mm S20278 1 Contact Tip Tapered 030 0 8 mm S20278 2 Contact Tip Tapered 035 0 9 mm S20278 3 Liner 023 030 0 6 0 8 mm M16291 2 Liner 030 035 0 8 0 9 mm M16291 6 ACCESSORIES c2 Liner 035 045 0 9 1 2 mm M16291 1 Gas Diffuser S19728 Gas Nozzle M16294 Gas Nozzle Tip Recessed 3 8 9 5 mm Opening LD M16684 Gas Nozzle Tip Recessed 1 2 12 7 mm Opening LD M16684 1 Gas Nozzle Tip Recessed 5 8 15 9 mm Opening LD M16684 2 Spot Welding Nozzle M17846 G
41. ing out of position run stringer beads Don t whip break the arc move out of the puddle or move too fast in any direction Use Wire Feed Speed WFS in the low portion of the range The general technique and proper gun angle is illustrated in Figure B 16 Generally keep the electrode nearly perpendicular to the joint as illustrated The maximum angle above per pendicular may be required if porosity becomes a problem WELD PAK 3200HD LINCOLN B 11 1 A PROPER GUN ANGLE FOR GMAW PROCESS FOR FCAW PROCESS WELDING IN THE VERTICAL UP POSITION WELDING IN THE VERTICAL UP POSITION FIGURE B 16 PROPER GUN ANGLE 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 9 mm and lighter material Use stringer beads and tip the gun in the direction of travel so the arc force helps hold the molten metal in the joint Move as fast as possible consistent with desired bead shape The important thing is to continue lowering the entire arm as the weld is made so the angle of the gun does not change Move the electrode wire fast enough that the slag does not catch up with the arc Vertical down welding gives thin shallow welds It should not be used on heavy material where large welds are required FIGURE B 17 LEARNING TO WELD MACHINE SET UP FOR THE
42. ip 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 8 Push a length of straightened welding wire through the wire feeder guide tubes and adjust the position of the drive roll so that the groove is centered on the wire Make certain the set screw is located on the flat portion of the shaft and tighten FIGURE D 1 WELD PAK 3200HD LINCOLN D 4 MAINTENANCE D 4 1 1 4 31 8 mm Liner Trim Length Gas Diffuser 9 Gas Nozzle or Brass Cable Y Ph Set Screw Liner Assembly Liner bushing to be sealed tight against brass cable connector FIGURE D 2 Liner trim length CHANGING LINER NOTICE The variation in cable lengths prevents the interchangeability of liners Once a liner has been cut for a particular gun it should not be installed in anoth er gun unless it can meet the liner cutoff length requirement Refer to Figure D 2 1 Remove the gas nozzle from the gun by unscrew ing counter clockwise 2 Remove the existing contact tip from the gun by unscrewing counter clockwise 3 Remove the gas diffuser from the gun tube by unscrewing counter clockwise 4 Lay
43. is maintained automatically Arc welding is a manual skill requiring a steady hand good physical condition and good eyesight The oper ator controls the welding arc and therefore the quali ty of the weld made THE SELF SHIELDED FCAW WELDING ARC Figure B 9 illustrates the action taking place in the self shielded FCAW Innershield welding arc It closely resembles what is actually seen while welding Burning of core materials inside wire electrode results in shield of gas Ge Arc Stream Cored Wire Protective Slag Metal Weld FIGURE B 9 WELD PAK 3200HD LINCOLN P B 8 LEARNING TO 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 The arc is very bright as well as hot and cannot be looked at with the naked eye without risking painful injury The very dark lens specifically designed for arc welding must be used with the hand or face shield whenever viewing the arc The arc melts the base metal and actually digs into it much as water through a nozzle on a garden hose digs into the earth The molten metal forms a molten pool or crater and tends to flow away from the arc As it moves away from the arc it cools and solidifies The function of the Innershield cored wi
44. la zone de soudage Utiliser des lunettes avec crans lateraux dans les zones o l on pique le laitier Eloigner les mat riaux inflammables ou les recouvrir afin de pr venir tout risque d incendie d aux tincelles Quand on ne soude pas poser la pince une endroit isol de la masse Un court circuit accidental peut provoquer un chauffement et un risque d incendie S assurer que la masse est connect e le plus pr s possible de la zone de travail qu il est pratique de le faire Si on place la masse sur la charpente de la construction ou d autres endroits loign s de la zone de travail on augmente le risque de voir passer le courant de soudage par les chaines de lev age c bles de grue ou autres circuits Cela peut provoquer des risques d incendie ou d echauffement des chaines et des c bles jusqu ce qu ils se rompent Assurer une ventilation suffisante dans la zone de soudage Ceci est particuli rement important pour le soudage de t les galvanis es plomb es ou cadmi es ou tout autre m tal qui produit des fume s toxiques Ne pas souder en pr sence de vapeurs de chlore provenant d op rations de d graissage nettoyage ou pistolage La chaleur ou les rayons de l arc peuvent r agir avec les vapeurs du solvant pour produire du phosg ne gas forte ment toxique ou autres produits irritants Pour obtenir de plus amples renseignements sur la s ret voir le code Code for safety in wel
45. loaded pressure arm 1 in place Rotate the spool counterclockwise if required in order to take up extra slack in the wire 6 The idle roll pressure adjustment wing nut is factory set to approximately five full turns from where the wing nut first engages the threads of the pressure arm 1 If feeding problems occur because the wire is flatened excessively turn the pressure adjust ment 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 drive roll slips while feeding wire the pressure should be increased until the wire feeds properly 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 OPERATION The Wire Drive Feed Roll can accommodate two wire sizes by flipping the wire drive feed roll over FIGURE B 4 Refer to Figure B 5 Remove gas nozzle and con tact tip from end of gun the WELD PAK 3200HD ON 1 Straighten the gun cable assembly Depress the gun trigger switch and feed welding wire through the gun and cable Point gun away from yourself and others while feeding wire Release gun trigger after wire appears at end of gun Turn the WELD PAK 3200HD OFF O Replace contact tip and gas nozzle Refer
46. mmable Entfernen Sie brennbarres Material e Mantenha inflam veis bem guarda dos EA R m 282 SC AIX ule O ALL Aal Wear eye ear and body protection Prot jase los ojos los o dos y el cuerpo Prot gez vos yeux vos oreilles et votre corps Tragen Sie Augen Ohren und K r perschutz Use protec o para a vista ouvido e corpo HAUSHERMRELTTF KA E CHE ez 119 Sol STE SES AIR s due le Lily vues pis aua g 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 UNFALLVERH TUNGSVORSCHRIFTEN DES ARBEITGEBERS SIND EBENFALLS ZU BEACHTEN Keep your head out of fumes Use ventilation or exhaust to remove fumes from breathing zone Los humos fuera de la zona de res piraci n e Mantenga la c
47. mues eu jo ed siu synse1 ay paye sejqeueA pue jquiesse uoneonqey esneseg jenuen eui SNOILYVO3Hd AL3JVS UO uonoes eui pue 519 uo eui puejsjepun pue pea eg 310049 3A00H9 dIN LL HN CT3IHSH3NNI 6 0 gen JUIM 13319 01105 8 0 060 SS3NX9IHL 13318 TWANVIN 338 751919319 g NTIOONIT eui 0607 620 112150 190 1590 104 3015 3A0089 TIVWS 3UIM 13315 01108 970 620 202 02 S2 08 6 G29 10 029 202 02 52 uofiy 08 6 92 10 029 5 9 SNIGT3IHS SONILLAS 13318 SS3TNIVIS 404 9NIQOT3M 803 SONILLAS 415492905 d3402 Xf 13 5831819 2 03802 074 31819 diAl LLZ g HN Q 13IHSU3NNI 60 ui seg 96 1 el DM N102NIT 3uIM 1331S 01108 vig 90 060 96 1 ef DM N102NI1 34IM 13319 01105 WIG 970 ur 620 3HIM 9 013 NTIOONII WELD PAK 3200HD LINCOLN E 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 lubr
48. n 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 3 Route the cable under and around the back of the Wire Feed Gearbox 6 4 For Innershield Only Refer to Figure A 4 As delivered The machine is connected for negative polarity required for the Innershield process con nect the short cable attached to the connector block 1 to the negative output terminal 2 and the work cable 3 to the positive terminal 4 5 For GMAW Only Refer to Figure A 2 To wire for positive electrode polarity the appropriate configu ration for the GMAW MIG process use the provid ed wing nut to connect the work cable s terminal lug to the negative output terminal 5 located above the Wire Feed Gearbox 6 Make sure that both wing nuts are tight FIGURE A 4 GUN INSTALLATION As shipped from the factory the WELD PAK 3200HD is ready to feed 023 025 0 6 mm solid wire If 030 0 8mm solid wire If 030 0 8 mm solid wire is to be used change the contact tip to the appropriate size NOTE If 035 0 9 mm Innershield flux cored wire is to be used assemble the mig nozzle and 035 tip on to gun and reverse drive roll INSTALLATION 4 Connecting Gun Cable to the WELD PAK 3200HD 1 Refer to Figure A 2 Unpl
49. nded This results in a colder weld and has less tendency for burn through 2 The Correct Way To Strike An Arc ARC RAYS can burn eyes and skin When using an open arc process it Is necessary to use correct eye head and body protection 2 Protect yourself and others read ARC RAYS can burn at the front of this manual 1 Be sure the work clamp makes good electrical con tact to the work 2 Position gun over joint End of wire may be lightly touching the work 3 Position face shield to protect face and eyes close gun trigger and begin welding Hold the gun so that the contact tip to work distance is about 3 8 to 1 2 inch 10 12 mm 4 To stop welding release the gun trigger and pull the gun away from the work after the arc goes out 5 A ball may form at the tip end of the wire after welding For easier restrikes the ball may be removed by feeding out a few inches of wire and cutting off the end of the wire with wire cutters 6 When no more welding is to be done close the valve on the gas cylinder momentarily operate the gun trigger to release gas pressure then turn off the machine WELD PAK 3200HD LINCOLN B 15 Contact Tip Wire Electrode ESO 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 bec
50. near the engine fan Do not attempt to override the governor or idler by pushing on the throttle control rods while the engine is running EN 2 d 3 Do not place your body between the electrode and work cables If the electrode cable is on your right side the work cable should also be on your right side Connect the work cable to the workpiece as close as possible to the area being welded To prevent accidentally starting gasoline engines while turning the engine or welding generator during maintenance work disconnect the spark plug wires distributor cap or magneto wire as appropriate Do not work next to welding power source Mar 95 ILINCOLN SAFETY ELECTRIC SHOCK can kill 3 a The electrode and work or ground circuits are electrically hot when the welder is on Do not touch these hot parts with your bare skin or wet clothing Wear dry hole free gloves to insulate hands 3 b Insulate yourself from work and ground using dry insulation Make certain the insulation is large enough to cover your full area of physical contact with work and ground In addition to the normal safety precautions if welding must be performed under electrically hazardous conditions in damp locations or while wearing wet clothing on metal structures such as floors gratings or scaffolds when in cramped positions such as sitting kneeling or lying if there is a high risk of unavoidable or
51. ns de s ret g n rales suivantes S ret Pour Soudage A L Arc 1 Protegez vous contre la secousse lectrique a Les circuits l lectrode et la pi ce sont sous tension quand la machine souder est en marche Eviter toujours tout contact entre les parties sous tension et la peau nue ou les v tements mouill s Porter des gants secs et sans trous pour isoler les mains Faire tr s attention de bien s isoler de la masse quand on soude dans des endroits humides ou sur un plancher metallique ou des grilles metalliques principalement dans les positions assis ou couch pour lesquelles une grande partie du corps peut tre en contact avec la masse Maintenir le porte lectrode la pince de masse le c ble de soudage et la machine souder en bon et s r tat defonctionnement d Ne jamais plonger le porte lectrode dans l eau pour le refroidir Ne jamais toucher simultan ment les parties sous tension des porte lectrodes connect s deux machines soud er parce que la tension entre les deux pinces peut tre le total de la tension vide des deux machines Si on utilise la machine souder comme une source de courant pour soudage semi automatique ces precautions pour le porte lectrode s applicuent aussi au pistolet de soudage 2 Dans le cas de travail au dessus du niveau du sol se pro t ger contre les chutes dans le cas ou on recoit un choc Ne Toujours porter des lunettes de s curit dans
52. ode characteristics related subjects such as distortion and supplemental information on arc welding applications speeds and costs Practice materials exercises questions and answers are suggested for each lesson 528 pages well illustrated 6 x 9 size bound in simulated gold embossed leather 5 00 postage paid U S A Mainland Need Welding Training The Lincoln Electric Company operates the oldest and most respected Arc Welding School in the United States at its corporate headquarters in Cleveland Ohio Over 100 000 stu dents have graduated Tuition is low and the training is hands on For details write Lincoln Welding School 22801 St Clair Ave Cleveland Ohio 44117 1199 and ask for bulletin ED 80 or call 216 383 2259 and ask for the Welding School Registrar Lincoln Welding School BASIC COURSE 5 weeks of fundamentals 700 00 lo rders of 50 or less before discount or orders outside of North America must be prepaid with charge check or money order in U S Funds Only l IP rices include shipment by 4th Class Book Rate for U S A Mainland Only Please allow up to 4 weeks for delivery lUPS Shipping for North America Only All prepaid orders that request UPS shipment please add 5 00 For order value up to 49 99 10 00 For order value between 50 00 amp 99 99 15 00 For order value between 100 00 amp 149 00 North America inv
53. oiced orders over 50 00 6 credit card orders if UPS is requested it will be invoiced or charged to you atcost Outside U S A Mainland order must be prepaid in U S Funds Please add 2 00 per book for surface mail or 15 00 per book for air parcel postshipment IMETHOD OF PAYMENT Sorry No C O D Orders Name I CHECKONE Aie Please Invoice only if order is over 50 00 FEET ET ER TE TE RTT TT TT TET ET TE TE ET T Check or Money Order Enclosed U S Funds only I Credit Card 2 Telephone 2 2222 Sm Signature as it appears on Charge Card eese LU gt Pp i 2 5 2 Le THIS FORM TO ORDER Order from BOOK DIVISION The Lincoln Electric Company 22801 St Clair Avenue Cleveland Ohio 44117 1199 OR FREE INFORMATIVE CATALOGS Telephone 216 383 2211 or for fastest service FAX this completed form to 216 361 5901 LLincoi Welding School Hes sd Price Code Quantity Cost ED 80 New Lessons in Arc Welding Co Seminar Information Procedure Handbook Twelfth Edition 515 00 PH rt How to Read Shop Drawings 3350 H T 1 Educational Video Information Incentive Management 50 mM J LS A New Approach to Industral Economics 55 00 NA f l Ij ames F Lincoln Arc Welding _____ The AmercanCentuyol onnC Uincom 5 00 AC _____ ____ Foundati
54. omes extremely important The ESO should be approximately 3 8 to 1 2 inch 10 to 12 mm long The easiest way to tell whether the ESO is the cor rect length is by listening to its sound The correct ESO has a distinctive crackling sound very much like eggs frying in a pan A long ESO has a hollow blowing or hissing sound If the ESO is too short you may stick the contact tip or nozzle to the weld puddle and or fuse the wire to the contact tip 4 The Correct Welding Speed The important thing to watch while welding is the puddle of molten metal right behind the arc See Figure B 25 Do not watch the arc itself It is the appearance of the puddle and the ridge where the molten P uddle solidifies that indicates correct weld ing speed The ridge should be approximately 3 8 10 mm behind the wire electrode Most beginners tend to weld too fast resulting in a thin uneven wormy looking bead They are not watching the molten metal mw mee FIGURE B 25 LEARNING TO WELD B 15 Helpful Hints 1 For general welding it is not necessary to weave the arc neither forward or backward nor sideways Weld along ata steady pace You will find it easier 2 When welding on thin plate you will find that you will have to increase the welding speed whereas when welding on heavy plate it is necessary to go more slowly in order to get good penetration 3 When welding sheet metal 16 gauge 1 5 mm and lighter heat buildup
55. on a continuous even flow of shielding gas is needed to protect the molten weld metal from atmospheric contaminant s such as oxygen and nitrogen Shielding gas is supplied through the gun and cable assembly through the gas nozzle and into the welding zone haber Gas nozzle Solid wire Shielding gas electrode Se V Weld metal Base metal FIGURE B 10 When comparing the GMAW and FCAW processes you can see that the principal difference between the two lies in the type of shielding used GMAW uses gas for shielding thus we have Gas Metal Arc Welding FCAW uses the melting or burning of the core ingredi ents for shielding and is thus termed Self Shielded Flux Cored Arc Welding The recommended wire for Gas Metal Arc Welding MIG is Lincolnweld 0 025 0 6 mm L 56 electrode Lincolnweld L 56 is capable of welding a wide range of mild steels in all positions however more skill IS required for out of position welding with the GMAW process PROCESS SELECTION By gaining knowledge of the differences between the two processes you will be able to select the best process for the job you have at hand In selecting a process you should consider WELD PAK 3200HD LINCOLN B 9 LEARNING TO WELD B 9 For GMAW MIG Process 1 Is most of my welding performed on 16 gauge and lighter materials 2 Can afford the extra expense space and lack of portability required for gas cylinders and gas sup ply 3 Do require clean
56. on Book Information Welding Preheat Calculator 53 00 wC 8 SES PipeWelingChats 450 ED amp SS SUB i E d WARNING Spanish AVISO DE PRECAUCION French ATTENTION German WARNUNG ATENCAO Japanese ZS BIR Korean Do not touch electrically live parts or electrode with skin or wet clothing Insulate yourself from work and ground No toque las partes o los electrodos bajo carga con la piel o ropa moja d a Aislese del trabajo y de la tierra Ne laissez ni la peau ni des v te ments mouill s entrer en contact avec des pi ces sous tension Isolez vous du travail et de la terre e Ber hren Sie keine stromf hrenden Teile oder Elektroden mit Ihrem K rper oder feuchter Kleidung Isolieren Sie sich von den Elektroden und dem Erdboden e toque partes el tricas e elec trodos com a pele ou roupa molha da Isole se da e terra e ZEROES ELE E MLMPT APSSAPRBS ATUBHELTFEL KRRR AM GH OA CRM ER Xe uc AU 854 e anc AXE Juill el Quali d pagi aly 34 481 d well t dana ule Yile woe Keep flammable materials away e Mantenga el material combustible fuera del rea de trabajo Gardez l cart de tout mat riel infla
57. people it is the opposite Hold the gun of the gun and cable assembly in your right hand and hold the shield with your left hand Left handers simply do the opposite When using the FCAW Process weld from left to right if you are right handed This enables you to clearly see what you are doing Left handers do the opposite Tilt the gun toward the direction of travel holding the electrode at an angle as shown in Figure B 18 WELD PAK 3200HD LINCOLN P B 12 LEARNING TO WELD B 12 Contact Tip es Wire Electrode FIGURE B 18 3 8 1 2 10 12 mm Electrical Stickout ESO WARNING 4 ARC RAYS can burn eyes and skin PAURE Boa The easiest way to tell whether the ESO is the cor ZA When using an open arc process it rect length is by listening to its sound The correct Is necessary to use correct eye ESO has a distinctive crackling sound very much head and body protection like eggs frying in a pan A long ESO has a hollow blowing or hissing sound If the ESO is too short you may stick the contact tip or nozzle to the weld puddle and or fuse the wire to the contact tip Protect yourself and others read ARC RAYS can burn at the front of this manual 2 The Correct Way To Strike An Arc 1 Be sure the work clamp makes good electrical contact to the work 4 The Correct Welding Speed The important thing to watch while welding is the puddle of molten metal right behind the arc See
58. pful Hints 1 For general welding it is not necessary to weave the arc neither forward or backward nor sideways Weld along ata steady pace You will find it easier 2 When welding on thin plate you will find that you will have to increase the welding speed whereas when welding on heavy plate it is necessary to go more slowly in order to get good penetration 3 When welding sheet metal 16 gauge 1 5 mm and lighter heat buildup may cause part warpage and burn through One way to eliminate these problems is to use the back stepping method illustrated in Figure B 21 First weld from A to B then from C to A then from D to C then from E to D and so on A C D lt lt Back Stepping FIGURE B 21 Practice The best way of getting practice in the four skills that enable you to maintain 1 Correct welding position 2 Correct way to strike an arc 3 Correct electrical stickout 4 Correct welding speed is to perform the following exercise LEARNING TO WELD For the WELD PAK 3200HD use the following Mild Steel B 13 12 gauge or 1 8 inch 3 0 mm 0 035 0 9 mm NR 211 MP Innershield Wire Voltage Setting V D Wire Feed Speed o o 3 Electrode Refer to Figure B 22 1 Learn to strike an arc by positioning the gun over the joint and touching the wire to the work 2 Position face shield to protect face and eyes 3 Depress gun trigger hold gun so contact tip to wo
59. purchase Hecommended Safe Practices for the Preparation for Welding and Cutting of Containers and Piping That Have Held Hazardous Substances AWS F4 1 from the American Welding Society see address above Vent hollow castings or containers before heating cutting or welding They may explode Sparks and spatter are thrown from the welding arc Wear oil 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 Always wear safety glasses with side shields when in a welding area Connect the work cable to the work as close to the welding area as practical Work cables connected to the building framework or other locations away from the welding area increase the possibility of the welding current passing through lifting chains crane cables or other alternate cir cuits This can create fire hazards or overheat lifting chains or cables until they fail 6 h Also see item 1 c LINCOLN CYLINDER may explode if damaged dh 7 a Use only compressed gas cylinders containing the correct shielding gas for the process used and properly operating regulators designed for the gas and pressure used All hoses fittings etc should be suitable for the application and maintained in good condition Always keep cylinders in an upright position securely chained to an undercarriage or fixed suppo
60. r reproductive harm The Above For Diesel Engines The Above For Gasoline 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 amp 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 powered equipment 1 Turn the engine off before troubleshooting and maintenance work unless the maintenance work requires it to be running 3 om 1 h To avoid scalding do not remove the radiator pressure cap when the engine is hot 1 b Operate engines in open well ventilated areas or vent the engine exhaust fumes outdoors ELECTRIC AND 3 MAGNETIC FIELDS 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 refueling to prevent
61. rc welding FCAW process using Innershield elec trode wire The WELD PAK 3200HD is configured for use with the FCAW process as delivered from the fac tory OPERATIONAL CONTROLS The WELD PAK 3200HD has the following controls as standard Control Power ON OFF Switch Voltage Control Wire Speed Control Trigger Switch and a Circuit Breaker With the optional Spot Stitch Timer Kit installed the following controls are also included Mode switch and Time Control DESIGN FEATURES Operates on 120 volt input no special wiring required Cold electrode until gun trigger is pressed for an added measure of safety Overload protection incorporates both a thermo stat and a circuit breaker Quality wire drive with electronic overload protec tion Quick Release idle roll pressure arm is easily adjusted Reversible dual groove drive roll Drive roll will feed 023 025 0 6 mm and 030 035 0 8 0 9 mm diameter wire WELD PAK 3200HD LINCOLN B 2 OPERATION B 2 No external shielding gas is required when used with Lincoln Innershield 035 0 9 mm NR 211 MP electrode Accommodates both 4 100 mm diameter and 8 200 mm diameter spools of wire WELDING CAPABILITY The WELD PAK 3200HD is rated at 90 amps 19 volts at 2096 duty cycle on a ten minute basis It is capable of higher output currents at lower duty cycles LIMITATIONS Arc Gouging cannot be p
62. re B 13 the total weld is only half the thickness of the material thus the weld is only approximately half as strong as the metal FIGURE B 13 FIGURE B 14 In the example shown in Figure B 14 the joint has been welded so that 10096 penetration could be achieved The weld if properly made is as strong as or stronger than the original metal Fillet Welds When welding fillet welds it is very important to hold the wire electrode at a 45 angle between the two sides or the metal will not distribute itself evenly The gun nozzle is generally formed at an angle to facilitate this See Figure B 15 FIGURE B 15 Welding In The Vertical Position Welding in the vertical position can be done either ver tical up or vertical down Vertical up is used whenever a larger stronger weld is desired Vertical down is used primarily on sheet metal 5 32 3 9 mm and under for fast low penetrating welds WARNING Use of this unit on thicker materials than recom mended may result in poor welds The welds may look good but may just be sitting on top of the plate This is called Cold Casting and will result in weld failure Vertical up And Overhead Welding The problem when welding vertical up is to put the molten metal where it is wanted and make it stay there If too much molten metal is deposited gravity will pull it downwards and make it drip Therefore a certain technique has to be followed When weld
63. re electrode is much more than simply to carry current to the arc The wire core is composed of fluxes and or alloying ingre dients around which a steel sheath has been formed It is simply a stick electrode turned inside out in a con tinuous wire form The cored wire melts in the arc and tiny droplets of molten metal shoot across the arc into the molten pool The wire sheath provides additional filler metal for the joint to fill the groove or gap between the two pieces of base metal The core materials also melt or burn in the arc and perform several functions They make the arc stead ier provide a shield of smoke like gas around the arc to keep oxygen and nitrogen in the air away from the molten metal and provide a flux for the molten pool The flux picks up impurities and forms the protective slag on top of the weld during cooling After running a weld bead the slag may be removed with a chipping hammer and wire brush This improves appearance and allows for inspection of the finished weld Since machine size and output characteristics limit the size and type of wire electrode which can be used Lincoln 0 035 0 9 mm NR 211 MP Innershield elec trode is recommended for Self Shielded Flux Cored Arc Welding THE GMAW MIG WELDING ARC Figure B 10 illustrates the GMAW MIG welding arc Solid wire does not contain fluxes or ingredients to form its own shielding and no slag forms to protect the molten weld metal For this reas
64. rical contact to the workpiece The workpiece must also be grounded as stated in Arc Welding Safety Precautions in the beginning of this manu al 7 Position gun over joint End of wire may be lightly touching the work 8 Lower welding helmet close gun trigger and 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 pull the gun away from the work after the arc goes out 10 When no more welding is to be done close valve on gas oylinder if used momentarily operate gun trigger to release gas pressure and turn off the WELD PAK 3200HD Cleaning Tip And Nozzle Clean the contact tip and nozzle to avoid arc bridging between the nozzle and contact tip which can result in a shorted nozzle poor welds and an overheated gun Hint Anti stick spray or gel available from a welding supply distributor may reduce buildup and aid in spat ter removal PROCESS GUIDELINES The WELD PAK 3200HD can be used for welding mild steel using the GMAW single pass process which requires a supply of shielding gas or it can be used for the self shielded Innershield9 process FCAW The recommended gases and electrodes for GMAW are welding grade CO gas or an argon COo blended gas 75 to 80 argon and 25 to 20 CO and 025 0 6 mm diameter Lincoln L 56 mild steel welding wire supplied on 12 1 2 Ib 5 7 kg spools The blend ed gas is recommended
65. rk distance is about 3 8 to 1 2 inch 10 to 12 mm and the gun is at proper angle 4 After you strike the arc practice the correct electri cal stickout Learn to distinguish it by its sound 5 When you are sure that you can hold the correct electrical stickout with a smooth crackling arc start moving Look at the molten puddle constantly and look at the ridge where the metal solidifies 6 Run beads on a flat plate Run them parallel to the top edge the edge farthest away from you This gives you practice in running straight welds and also gives you an easy way to check your progress The 10th weld will look considerably bet ter than the first weld By constantly checking on your mistakes and your progress welding will soon be a matter of routine Contact m C gt ems CT FIGURE B 22 WELD PAK 3200HD LINCOLN B 14 MACHINE SET UP FOR THE GMAW 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 2 See the Application Guide on the inside of wire feed section door for information on setting the controls 3 Set Voltage and Wire Speed controls to the settings suggested on the Application Guide for the welding wire and base metal thickness being used The voltage control is marked V and the wire feed speed is marked olo 4 Check that the polarity is correct for
66. rt Oylinders should be located Away from areas where they may be struck or subjected to physical damage safe distance from arc welding or cutting operations and any other source of heat sparks or flame Never allow the electrode electrode holder or any other electrically hot parts to touch a cylinder Keep your head and face away from the cylinder valve outlet when opening the cylinder valve Valve protection caps should always be in place and hand tight except when the cylinder is in use or connected for use Read and follow the instructions on compressed gas cylinders associated equipment and CGA publication Precautions for Safe Handling of Compressed Gases in Oylinders available from the Compressed Gas Association 1235 Jefferson Davis Highway Arlington VA 22202 FOR ELECTRICALLY powered equipment 8 a Turn off input power using the disconnect Switch at the fuse box before working on the equipment Install equipment in accordance with the U S National Electrical Code all local codes and the manufacturer s recommendations Ground the equipment in accordance with the U S National Electrical Code and the manufacturer s recommendations Mar 95 SAFETY PR CAUTIONS DE S RET Pour votre propre protection lire et observer toutes les instruc tions et les pr cautions de s ret specifiques qui parraissent dans ce manuel aussi bien que les pr cautio
67. spilled fuel from vaporiz ing on contact with hot engine parts and igniting Do not spill fuel when filling tank If fuel is spilled wipe it up and do not start engine until fumes have been eliminated 2 a Electric current flowing through any conductor causes localized Electric and Magnetic Fields EMF Welding current creates EMF fields around welding cables and welding machines EMF fields may interfere with some pacemakers and welders having a pacemaker should consult their physician before welding 1 d Keep all equipment safety guards covers and devices in position and in good repair Keep hands hair clothing and tools away from V belts gears fans and all other moving parts when starting operating or repairing equipment Exposure to EMF fields in welding may have other health effects which are now not known All welders should use the following procedures in order to In some cases it may be necessary to remove safety nes alle minimize exposure to EMF fields from the welding circuit guards to perform required maintenance Remove guards only when necessary and replace them when the maintenance requiring their removal is complete Always use the greatest care when working near moving parts 2 d 1 Route the electrode and work cables together Secure them with tape when possible 2 d 2 Never coil the electrode lead around your body 1 f Do not put your hands
68. tage Decrease stickout Decrease WFS wire feed speed Decrease travel speed Decrease drag angle uU A Uu FA Check for correct gas if used LEARNING TO WELD B 16 To Reduce Spatter in order of importance RER RTL e e CC Increase voltage Increase drag angle Decrease stickout Increase WFS wire feed speed Decrease travel speed BW FA rH Check for correct gas if used To Correct Poor Penetration in order of impor tance Decrease stickout Increase WFS wire feed speed Increase voltage Decrease speed Decrease drag angle BP WN HR Check for correct gas if used If Arc Blow Occurs in order of importance NOTE Try different ground connection locations before adjusting procedures 1 Decrease drag angle 2 Increase stickout 3 Decrease voltage 4 Decrease WFS wire feed speed 5 Decrease travel speed To Eliminate Stubbing in order of importance 1 Increase voltage 2 Decrease WFS wire feed speed 3 Decrease stickout 4 Increase drag angle Stubbing occurs when the electrode drives through the molten puddle and hits the bottom plate tending to push the gun up WELD PAK 3200HD LINCOLN B 17 LEARNING TO WELD Proper Gun Handling Most feeding problems are caused by improper han dling of the gun cable or electrodes 2 Do not kink or pull the gun around sharp corners Keep the gun
69. the welding wire being used Set the polarity for DC when welding with the GMAW MIG process See Work Cable Installation in the INSTALLATION section for instructions for changing polarity 5 Check that the gas nozzle and proper size liner and contact tip are being used and that the gas supply is turned on If adjustable set for 15 to 20 cubic feet per hour 7 to 10 l min under normal conditions increase to as high as 35 CFH 17 l min under drafty slightly windy conditions 6 Connect work clamp to metal to be welded Work clamp must make good electrical contact to the work piece The work piece must also be grounded as stated in the Arc Welding Safety Precautions atthe beginning of this manual WELDING TECHNIQUES FOR THE GMAW MIG PROCESS Four simple manipulations are of prime importance when welding With complete mastery of the four welding will be easy They are as follows 1 The Correct Welding Position Figure B 23 illustrates the correct welding position for right handed people For left handed people it is the opposite When GMAW MIG welding on sheet metal it is important to use the forehand push technique Hold the gun of the gun and cable assembly in your right hand and hold the shield with your left hand Left handers simply do the opposite LEARNING TO WELD B 14 E __ FIGURE B 23 When using the GMAW process on light gauge mater ial weld from right to left if you are right ha
70. tifs de s ret leur place 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 eee 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 Model Name amp Number Code amp Serial Number Date of Purchase Whenever you request replacement parts for or information on this equipment always supply the information you have recorded above 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 A 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 d
71. tions 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 Place your order now using the coupon below The hardbound book contains over 750 pages of welding information techniques and procedures Much of this material has never been included in any other book A must for all welders supervisors engineers and designers Many welding instructors will want to use the book as a reference for all students by taking advantage of the low quantity discount prices which include shipping by 4th class parcel post 15 00 postage paid U S A Mainland How To Read Shop Drawings The book contains the latest information and application data on the American Welding Society Standard Welding S ymbols Detailed discussion tells how engineers and draftsmen use the short cut language of symbols to pass on assembly and welding information to shop personnel Practical exercises and examples develop the reader s ability to visualize mechanically drawn objects as they will appear in their assembled form 187 pages with more than 100 illustrations Size 8 1 2 x 11 Durable cloth covered board binding 4 50 postage paid U S A Mainland is a 10 discount on all orders of 50 00 or more for shipment at one time to one location New Lessons in Arc Welding Lessons simply written cover manipulatory techniques machine and electr
72. to Figure B 6 Cut the wire off 1 4 3 8 6 10 mm from the end of the tip The WELD PAK 3200HD is now ready to weld Gun Handle Gas Diffuser Contact Gas Nozzle IM FIGURE B 5 WELD PAK 3200HD LINCOLN P Contact Tip Wire Electrode 3 8 1 2 Electrical Stickout 1 FIGURE 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 See the Application chart on the inside of the wire feed compartment door for information on setting the WELD PAK 3200HD controls Refer to Table B 1 for aluminum and stainless wire Set the Voltage V and Wire Speed olo con trols to the settings suggested for the welding wire and base metal thickness being used refer to Applications chart on the inside of the wire drive compartment door Check that the polarity is correct for the welding wire being used and that the gas supply if required is turned on When using Innershield electrode remove the gas nozzle and install the gasless nozzle This will improve visibility of the arc and protect the gas dif fuser from weld spatter Refer to the MAINTE NANCE section for details on nozzle replacement GUN CABLE WORK CLAMP FIGURE B 7 OPERATION B 5 6 Refer to Figure B 7 Connect work clamp to metal to be welded Work clamp must make good elec t
73. ug 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 under the Wire Feed Gearbox 6 and through the Cable Hanger 7 on the inner panel 3 Insert the connector on the gun conductor cable through the Gun Cable Access Hole 2 in the WELD PAK 3200H case front Make sure the con nector is all the way in the brass connector block Unscrew thumbscrew on the connector block a few turns if gun connector will not insert fully Rotate the connector so control leads are on the under side and tighten the Thumbscrew 8 in the con nector block 4 Connect the gun trigger control lead terminals to the two insulated 1 4 6 4 mm tab terminal con nector bushings located below the Gun Trigger Connection decal in the wire feed section 4 Either lead can go to either connector Form the leads so that they are as close as possible to the inside panel CAUTION If the gun trigger switch being used is other than that supplied with the WELD PAK 3200HD the switch must be a normally open momentary switch The terminals of the switch must be insu lated from the welding circuit Malfunction of the WELD PAK 3200HD may result if this switch shorts to the WELD PAK 3200HD welding output circuit or is common to any electrical circuit other than the WELD PA

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