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IM759
May, 2002
WELD-PAK 3200HD
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:
Ser
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i i SAFETY WARNING CALIFORNIA PROPOSITION 65 WARNINGS 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 other 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
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ii ii SAFETY ELECTRIC SHOCK can ARC RAYS can burn. 4.a. Use a shield with the proper filter and cover kill. plates to protect your eyes from sparks and 3.a. The electrode and work (or ground) circuits the rays of the arc when welding or observing are electrically “hot” when the welder is on. open arc welding. Headshield and filter lens Do not touch these “hot” parts with your bare should conform to ANSI Z87. I standards. skin or wet clothing. Wear dry, hole-free gloves to insulate hands. 4.b. Us
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iii iii SAFETY CYLINDER may explode WELDING SPARKS can cause fire or explosion. if damaged. 6.a. Remove fire hazards from the welding area. 7.a.Use only compressed gas cylinders If this is not possible, cover them to prevent containing the correct shielding gas for the the welding sparks from starting a fire. process used and properly operating Remember that welding sparks and hot regulators designed for the gas and materials from welding can easily go through small cracks pressure used. All hos
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iv iv SAFETY 5. Toujours porter des lunettes de sécurité dans la zone de PRÉCAUTIONS DE SÛRETÉ soudage. Utiliser des lunettes avec écrans lateraux dans les zones où l’on pique le laitier. Pour votre propre protection lire et observer toutes les instruc- tions et les précautions de sûreté specifiques qui parraissent 6. Eloigner les matériaux inflammables ou les recouvrir afin de dans ce manuel aussi bien que les précautions de sûreté prévenir tout risque d’incendie dû aux étincelles. générales su
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v v for selecting a QUALITY product by Lincoln Electric. We want you to take pride in operating this Lincoln Electric Company product Thank You ��� 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
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vi MASTER TABLE OF CONTENTS FOR ALL SECTIONS Page Installation .......................................................................................................Section A Technical Specifications ........................................................................................A-1 Identify and Locate Components...........................................................................A-2 Select Suitable Location .........................................................................
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A-1 A-1 INSTALLATION 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 1 Output Mode Input Voltage Breaker Size Input Amps Power Cord Extension Cord Three Conductor #14 AWG 2 (2.
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A-2 A-2 INSTALLATION Read entire installation section before starting 11. Undercarriage: installation. a) Base b) Gas bottle support base SAFETY PRECAUTIONS c) (2) Gas bottle support brackets WARNING For available options and accessories refer to the ELECTRIC SHOCK can kill. Accessories Section of this manual. � Only qualified personnel should perform 1) this installation. As shipped from the factory, the WELD-PAK 3200HD gun liner is ready to feed .023” (0.6 mm) - � Only personnel that ha
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A-3 A-3 INSTALLATION Work Clamp Installation SELECT SUITABLE LOCATION Attach the work clamp per the following: Locate the welder in a dry location where there is free circulation of clean air into the louvers in the back and 1. Unplug the machine or turn the power switch to the out the front of the unit. A location that minimizes the “OFF” position. amount of smoke and dirt drawn into the rear louvers reduces the chance of dirt accumulation that can block 2. Insert the work cable terminal lug
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A-4 A-4 INSTALLATION Connecting Gun Cable to the WELD-PAK Work Cable Installation 3200HD. Refer to Figure A.2. 1. Refer to Figure A.2. Unplug the machine or turn 1. Open the wire feed section door on the right side of power switch to the OFF “O” position. the WELD-PAK 3200HD. 2. Pass the insulated terminals of the gun trigger con- 2. Pass the end of the work cable that has the termi- trol leads, one at a time, through the Gun Cable nal lug with the smaller hole through the Work and Control Le
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A-5 A-5 INSTALLATION 2. With the cylinder securely installed, remove the WARNING cylinder cap. Stand to one side away from the out- CYLINDER may explode if dam- let and open the cylinder valve very slightly for an aged. Keep cylinder upright and instant. This blows away any dust or dirt which may chained to support have accumulated in the valve outlet. � Keep cylinder away from areas where it may be damaged. WARNING � Never lift welder with cylinder attached. BE SURE TO KEEP YOUR FACE AWAY FR
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A-6 A-6 INSTALLATION Requirements For Rated Output INPUT CONNECTIONS A power cord with a 15 amp, 125 volt, three prong Refer to Figure A.6. plug (NEMA Type 5-15P) is factory installed on the WELD-PAK 3200HD. Connect this plug to a mating The WELD-PAK 3200HD has a power input cable grounded receptacle which is connected to a 20 amp located on the rear of the machine. branch circuit with a nominal voltage rating of 115 to 125 volts, 60 Hertz, AC only. The rated output with this installation is
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A-7 A-7 INSTALLATION 10. Tighten Gas Bottle Support Brackets with supplied UNDERCARRIAGE ASSEMBLY 1/4"-20 wing screws and wing nuts. WARNING FIGURE A.7 CYLINDER may explode if damaged. 3 � 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. 6 7 � Keep cylinder away from welding or other live electrical circuits. � The undercarriage is not intended f
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B-1 B-1 OPERATION Read entire operation section before GENERAL DESCRIPTION operating the WELD-PAK 3200HD. The WELD-PAK 3200HD is a complete semiautomatic constant-voltage DC wire feeder / power source arc welder. It has been designed for workshop, hobby, WARNING automotive and light maintenance. Included is a tap- switch controlled, single phase constant voltage trans- ELECTRIC SHOCK can kill. former / rectifier power source and a wire feeder weld- ing gun for feeding .023 - .025” (0.6 mm) throu
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B-2 B-2 OPERATION ● No external shielding gas is required when used Refer to Figure B.1b. ® with Lincoln Innershield .035” (0.9 mm) NR-211- 4. Circuit Breaker – Protects machine from damage if MP electrode. maximum output is exceeded. Button will extend out when tripped (Manual reset) Refer to Figure B.1b. ● Accommodates both 4” (100 mm) diameter and 8” (200 mm) diameter spools of wire. 5. Gun Trigger - Activates welding output, wire feed, and gas solenoid operation. Releasing the trigger WELDI
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B-3 B-3 OPERATION 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 2 tab, the tab cannot be depressed to load or unload the 1 wire spool. FIGURE B.2 3 DO NOT SWITCH WHEN WELDING Wire Spool Spindle 8” Wire Spool FIGURE B.1a Be sure that this stud engages the hole in the wire spool. To Wire Drive Wire Spool must be pushed all the
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B-4 B-4 OPERATION 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. 2 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 1 result in wire feeding problems, and may cause pre- 4 5 mature wear of wire drive system compo
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B-5 B-5 OPERATION 6. Refer to Figure B.7. Connect work clamp to metal to be welded. Work clamp must make good elec- trical contact to the workpiece. The workpiece must also be grounded as stated in “Arc Welding Contact Tip Safety Precautions” in the beginning of this manu- al. 7. Position gun over joint. End of wire may be lightly Wire Electrode touching the work. 3/8" – 1/2" Electrical Stickout 8. Lower welding helmet, close gun trigger, and begin welding. Hold the gun so the contact tip to wor
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B-6 B-6 OPERATION The WELD-PAK 3200HD is suitable for .035" alu- 2. If using a regulator with an adjustable flow meter, minum wire and .030" stainless wire. Refer to Table close the gun trigger and adjust the flow to give 15 B.1 for recommended procedure settings (requires – 20 cubic ft per hour (CFH) (7 – 10 I/min) [use 20 K499 Argon Regulator Kit). – 25 CFH (10 – 12 I/min) when welding out of position or in a drafty location for CO ]. For argon 2 TABLE B.1 mixed gas, trigger to release gas pr
