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IM759
WELD-PAK 3200HD |
May, 2002 |
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For use with machine Code Number:10932 |
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Safety Depends on You
Lincoln arc welding and cutting equipment is designed and built with safety in mind. However, your overall safety can be increased by proper installation ... and thoughtful operation on your part. DO NOT INSTALL, OPERATE OR REPAIR THIS EQUIPMENT WITHOUT READING THIS MANUAL AND THE SAFETY PRECAUTIONS CONTAINED THROUGHOUT. And, most importantly, think before you act and be careful.
Date of Purchase:
Serial Number:
Code Number:
Model:
Where Purchased:
OPERATORS MANUAL
ISO 9001
ANSI RAB
QMS
Designed and Manufactured Under a
Quality Program Certified by
ABS Quality Evaluations, Inc.
to ISO 9001 Requirements.
CERTIFICATE NUMBER: 30273
Copyright © 2002 Lincoln Global Inc.
•World's Leader in Welding and Cutting Products •
•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
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SAFETY
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WARNING
CALIFORNIA PROPOSITION 65 WARNINGS
Diesel engine exhaust and some of its constituents are known to the State of California to cause cancer, birth defects, and other reproductive harm.
The engine exhaust from this product contains chemicals known to the State of California to cause 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 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 & 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.
FOR ENGINE powered equipment.
1.a. Turn the engine off before troubleshooting and maintenance work unless the maintenance work requires it to be running.
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1.b.Operate engines in open, well-ventilated areas or vent the engine exhaust fumes
outdoors.
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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 spilled fuel from vaporizing 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.
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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.
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1.e. In some cases it may be necessary to remove safety 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.
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1.f. Do not put your hands 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.
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1.g. 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.
1.h. To avoid scalding, do not remove the radiator pressure cap when the engine is hot.
ELECTRIC AND MAGNETIC FIELDS may be dangerous
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
2.b. EMF fields may interfere with some pacemakers, and welders having a pacemaker should consult their physician before welding.
2.c. Exposure to EMF fields in welding may have other health effects which are now not known.
2.d. All welders should use the following procedures in order to minimize exposure to EMF fields from the welding circuit:
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.
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.
2.d.4. Connect the work cable to the workpiece as close as possible to the area being welded.
2.d.5. Do not work next to welding power source.
Mar ‘95
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SAFETY |
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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 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.
3.c. In semiautomatic or automatic wire welding, the electrode, electrode reel, welding head, nozzle or semiautomatic welding gun are also electrically “hot”.
3.d. 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.
3.e. Ground the work or metal to be welded to a good electrical (earth) ground.
3.f. Maintain the electrode holder, work clamp, welding cable and welding machine in good, safe operating condition. Replace damaged insulation.
3.g. Never dip the electrode in water for cooling.
3.h. 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.
3.i. When working above floor level, use a safety belt to protect yourself from a fall should you get a shock.
3.j. Also see Items 6.c. and 8.
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. I standards.
4.b. Use suitable clothing made from durable flame-resistant material to protect your skin and that of your helpers from the arc rays.
4.c. 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.
5.b. 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.c. Shielding gases used for arc welding can displace air and cause injury or death. Always use enough ventilation, especially in confined areas, to insure breathing air is safe.
5.d. 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.
5.e. Also see item 1.b.
Mar ‘95
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SAFETY
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WELDING SPARKS can
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.
6.b. 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.
6.c. 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.
6.d. 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, purchase “Recommended 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).
6.e. Vent hollow castings or containers before heating, cutting or welding. They may explode.
6.f. 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.
6.g. 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 circuits. This can create fire hazards or overheat lifting chains or cables until they fail.
6.h. Also see item 1.c.
CYLINDER may explode
if damaged.
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.
7.b. Always keep cylinders in an upright position securely chained to an undercarriage or fixed support.
7.c. Cylinders should be located:
•Away from areas where they may be struck or subjected to physical damage.
•A safe distance from arc welding or cutting operations and any other source of heat, sparks, or flame.
7.d. Never allow the electrode, electrode holder or any other electrically “hot” parts to touch a cylinder.
7.e. Keep your head and face away from the cylinder valve outlet when opening the cylinder valve.
7.f. Valve protection caps should always be in place and hand tight except when the cylinder is in use or connected for use.
7.g. Read and follow the instructions on compressed gas cylinders, associated equipment, and CGA publication P-l,
“Precautions for Safe Handling of Compressed Gases in Cylinders,” 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.
8.b. Install equipment in accordance with the U.S. National Electrical Code, all local codes and the manufacturer’s recommendations.
8.c. Ground the equipment in accordance with the U.S. National Electrical Code and the manufacturer’s recommendations.
Mar ‘95
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SAFETY
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PRÉCAUTIONS DE SÛRETÉ
Pour votre propre protection lire et observer toutes les instructions et les précautions de sûreté specifiques qui parraissent dans ce manuel aussi bien que les précautions de sûreté générales suivantes:
Sûreté Pour Soudage A L’Arc
1.Protegez-vous contre la secousse électrique:
a.Les circuits à l’électrode et à la piéce sont sous tension quand la machine à souder est en marche. Eviter toujours tout contact entre les parties sous tension et la peau nue ou les vétements mouillés. Porter des gants secs et sans trous pour isoler les mains.
b.Faire trés 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 couché pour lesquelles une grande partie du corps peut être en contact avec la
masse.
c.Maintenir le porte-électrode, la pince de masse, le câble de soudage et la machine à souder en bon et sûr état defonctionnement.
d.Ne jamais plonger le porte-électrode dans l’eau pour le refroidir.
e.Ne jamais toucher simultanément les parties sous tension des porte-électrodes connectés à deux machines à souder parce que la tension entre les deux pinces peut être le total de la tension à vide des deux machines.
f.Si on utilise la machine à souder comme une source de courant pour soudage semi-automatique, ces precautions pour le porte-électrode s’applicuent aussi au pistolet de soudage.
2.Dans le cas de travail au dessus du niveau du sol, se protéger contre les chutes dans le cas ou on recoit un choc. Ne jamais enrouler le câble-électrode autour de n’importe quelle partie du corps.
3.Un coup d’arc peut être plus sévère qu’un coup de soliel, donc:
a.Utiliser un bon masque avec un verre filtrant approprié
ainsi qu’un verre blanc afin de se protéger les yeux du rayonnement de l’arc et des projections quand on soude ou quand on regarde l’arc.
b.Porter des vêtements convenables afin de protéger la peau de soudeur et des aides contre le rayonnement de l‘arc.
c.Protéger l’autre personnel travaillant à proximité au
soudage à l’aide d’écrans appropriés et non-inflamma- bles.
4.Des gouttes de laitier en fusion sont émises de l’arc de soudage. Se protéger avec des vêtements de protection libres de l’huile, tels que les gants en cuir, chemise épaisse, pantalons sans revers, et chaussures montantes.
5.Toujours porter des lunettes de sécurité dans la zone de soudage. Utiliser des lunettes avec écrans lateraux dans les zones où l’on pique le laitier.
6.Eloigner les matériaux inflammables ou les recouvrir afin de prévenir tout risque d’incendie dû aux étincelles.
7.Quand on ne soude pas, poser la pince à une endroit isolé de la masse. Un court-circuit accidental peut provoquer un échauffement et un risque d’incendie.
8.S’assurer que la masse est connectée le plus prés 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 éloignés de la zone de travail, on augmente le risque de voir passer le courant de soudage par les chaines de levage, câbles de grue, ou autres circuits. Cela peut provoquer des risques d’incendie ou d’echauffement des chaines et des câbles jusqu’à ce qu’ils se rompent.
9.Assurer une ventilation suffisante dans la zone de soudage. Ceci est particuliérement important pour le soudage de tôles galvanisées plombées, ou cadmiées ou tout autre métal qui produit des fumeés toxiques.
10.Ne pas souder en présence de vapeurs de chlore provenant d’opérations de dégraissage, nettoyage ou pistolage. La chaleur ou les rayons de l’arc peuvent réagir avec les vapeurs du solvant pour produire du phosgéne (gas fortement toxique) ou autres produits irritants.
11.Pour obtenir de plus amples renseignements sur la sûreté, voir le code “Code for safety in welding and cutting” CSA
Standard W 117.2-1974.
PRÉCAUTIONS DE SÛRETÉ POUR LES MACHINES À SOUDER À TRANSFORMATEUR ET À REDRESSEUR
1.Relier à la terre le chassis du poste conformement au code de l’électricité et aux recommendations du fabricant. Le dispositif de montage ou la piece à souder doit être branché à une bonne mise à la terre.
2.Autant que possible, I’installation et l’entretien du poste seront effectués par un électricien qualifié.
3.Avant de faires des travaux à l’interieur de poste, la debrancher à l’interrupteur à la boite de fusibles.
4.Garder tous les couvercles et dispositifs de sûreté à leur place.
Mar. ‘93
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Thank You
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for selecting a QUALITY product by Lincoln Electric. We want you to take pride in operating this Lincoln Electric Company product
••• as much pride as we have in bringing this product to you!
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 & Number _____________________________________
Code & 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:
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 damage to this equipment.
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MASTER TABLE OF CONTENTS FOR ALL SECTIONS
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Installation ....................................................................................................... |
Section A |
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Technical Specifications ........................................................................................ |
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Identify and Locate Components........................................................................... |
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Select Suitable Location ........................................................................................ |
A-3 |
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Output Connections............................................................................................... |
A-3 |
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Input Connections.................................................................................................. |
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Code Requirements .............................................................................................. |
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Undercarriage Assembly ....................................................................................... |
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Operation ......................................................................................................... |
Section B |
Safety Precautions ................................................................................................ |
B-1 |
General Description ............................................................................................... |
B-1 |
Design Features.............................................................................................. |
B-1,B-2 |
Welding Capability ................................................................................................. |
B-2 |
Limitations.............................................................................................................. |
B-2 |
Controls and Settings ............................................................................................ |
B-2 |
Welding Operations ............................................................................................... |
B-3 |
Overload Protection............................................................................................... |
B-6 |
Learning to Weld.................................................................................................... |
B-7 |
Application Chart ................................................................................................. |
B-18 |
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Accessories ..................................................................................................... |
Section C |
Optional Accessories............................................................................................. |
C-1 |
Replacement Parts ................................................................................................ |
C-2 |
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Maintenance .................................................................................................... |
Section D |
Safety Precautions ................................................................................................ |
D-1 |
Items Requiring No Maintenance .......................................................................... |
D-1 |
Routine Maintenance............................................................................................. |
D-1 |
Gun and Cable Maintenance................................................................................. |
D-2 |
Component Replacement Procedures .................................................................. |
D-3 |
Changing Liner ...................................................................................................... |
D-4 |
Gun Handle Parts.................................................................................................. |
D-4 |
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Troubleshooting .............................................................................................. |
Section E |
Safety Precautions................................................................................................. |
E-1 |
How to Use Troubleshooting Guide....................................................................... |
E-1 |
Troubleshooting Guide......................................................................... |
E-2 THRU E-4 |
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Wiring Diagrams .............................................................................................. |
Section F |
SP-135T Wiring Diagram ....................................................................................... |
F-1 |
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Parts Lists .....................................................................................P442 Series, P202-E
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INSTALLATION |
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A-1 |
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TECHNICAL SPECIFICATIONS – WELD-PAK 3200HD |
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INPUT – SINGLE PHASE ONLY |
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Standard Voltage/Frequency |
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Input Current |
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120V/60Hz |
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20 Amps - Rated Output |
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RATED OUTPUT |
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Duty Cycle |
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20% Duty Cycle |
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90 |
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OUTPUT |
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Welding Current Range |
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Maximum-Open Circuit Voltage |
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50 - 300 in/min |
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25-135 Amps |
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29V |
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(1.3 - 7.6 m/min) |
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RECOMMENDED INPUT CABLE AND FUSE SIZES |
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Fuse or |
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Output Mode |
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Input Voltage |
Breaker Size1 |
Input Amps |
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Power Cord |
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Extension Cord |
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Three Conductor |
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#14 AWG |
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(2.1 mm2) or Larger |
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RATED |
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120V/60Hz |
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20 Amp |
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15 Amp, 125V, |
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Up to 25 Ft. (7.6 mm) |
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Three Prong Plug |
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Three Conductor |
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#12 AWG |
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(3.3 mm2) or Larger |
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Up to 50 Ft. (15.2 mm) |
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PHYSICAL DIMENSIONS |
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Weight |
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12.0 in |
9.75 in |
16.5 in |
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48 Ibs |
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305 mm |
248 mm |
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21.8 kg |
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1If connected to a circuit protected by fuses use Time Delay Fuse marked “D”.
WELD PAK 3200HD
A-2 |
INSTALLATION |
A-2 |
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Read entire installation section before starting installation.
SAFETY PRECAUTIONS
WARNING
ELECTRIC SHOCK can kill.
•Only qualified personnel should perform this installation.
•Only personnel that have read and understood the WELD-PAK 3200 HD Operating Manual should install and operate this equipment.
•Machine 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 (“O”) 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 WELDPAK 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(1)
3.Literature and miscellaneous including:
a)This operating manual
b)3 extra .023"-.025” (0.6 mm) contact tips
c)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 & Hose.
10.Mig Nozzle Assembly
11.Undercarriage:
a)Base
b)Gas bottle support base
c)(2) Gas bottle support brackets
For available options and accessories refer to the Accessories Section of this manual.
1)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
2 1 
4
6
3
7
5
9
8
WELD-PAK 3200HD
A-3 |
INSTALLATION |
A-3 |
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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 surface, either directly or on either recommended cart. The machine may topple over if this procedure is not followed.
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
Nut & Bolt
OUTPUT CONNECTIONS
Refer to Figure A.2.
Work Clamp
1.Work Cable Access Hole.
2.Gun Cable and Control Lead Access Hole.
3.Connector Block.
4.Gun Trigger Lead Connectors.
5.Positive (+) and negative (–) output terminals.
6.Wire Feed Gearbox.
7.Cable Hanger.
8.Thumbscrew.
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3 |
6 |
7 |
1 2
FIGURE A.2
WELD-PAK 3200HD
A-4 |
INSTALLATION |
A-4 |
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Work Cable Installation
Refer to Figure A.2.
1.Open the wire feed section door on the right side of the WELD-PAK 3200HD.
2.Pass the end of the work cable that has the terminal 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), connect 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 configuration for the GMAW (MIG) process use the provided 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.
4
3
2 
1
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.
Connecting Gun Cable to the WELD-PAK 3200HD.
1.Refer to Figure A.2. Unplug the machine or turn power switch to the OFF “O” position.
2.Pass the insulated terminals of the gun trigger control 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 connector 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 underside and tighten the Thumbscrew (8) in the connector block.
4.Connect the gun trigger control lead terminals to the two insulated 1/4" (6.4 mm) tab terminal connector 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 insulated 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-PAK 3200HD trigger circuit.
GAS CONNECTION
When using the GMAW process, a cylinder of shielding 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
A-5 |
INSTALLATION |
A-5 |
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WARNING
CYLINDER may explode if damaged. Keep cylinder upright and chained to support
• Keep cylinder away from areas where it may be damaged.
•Never lift welder with cylinder attached.
•Never allow welding electrode to touch cylinder.
•Keep cylinder away from welding or other live electrical circuits.
WARNING
BUILDUP OF SHIELDING GAS may harm health or kill.
• Shut off shielding gas supply when not in use.
•SEE AMERICAN NATIONAL STANDARD Z-49.1, “SAFETY IN WELDING AND CUTTING” PUBLISHED BY THE AMERICAN WELDING SOCIETY.
1.Chain the cylinder to a wall or other stationary support 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.
Flow Regulator |
Cylinder Valve |
Gas Hose |
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FIGURE A.5
2.With the cylinder securely installed, remove the cylinder cap. Stand to one side away from the outlet 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.
WARNING
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% CO2 cylinder, make certain the plastic washer is seated in the fitting that attaches to the CO2 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
A-6 |
INSTALLATION |
A-6 |
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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
FIGURE A.6
CODE REQUIREMENTS FOR INPUT CONNECTIONS
WARNING
This welding machine must be connected to a power source in accordance with applicable electrical codes.
The United States National Electrical Code (Article 630-B, 1990 Edition) provides standards for amperage handling capability of supply conductors based on duty cycle of the welding source.
If there is any question about the installation meeting applicable electrical code requirements, consult a qualified electrician.
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, 20% 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
A-7 |
INSTALLATION |
A-7 |
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UNDERCARRIAGE ASSEMBLY
WARNING
CYLINDER may explode
if damaged.
• Keep cylinder upright and secured to support.
•Keep cylinder away from areas where it may be damaged.
•Never lift welder with cylinder attached.
•Never allow welding electrode to touch cylinder.
•Keep cylinder away from welding or other live electrical circuits.
•The undercarriage is not intended for transporting the Weld-Pak 3200HD.
•If the Weld-Pak 3200HD is going to be transported, remove the under-carriage.
•Do not lift the Weld-Pak 3200HD when a gas bottle is connected.
•If the 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.
1.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 mounting holes are located in front of the machine.
3.Replace sheet metal screws removed in step 1 making sure to secure undercarriage to the WeldPak 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 undercarriage 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.
10.Tighten Gas Bottle Support Brackets with supplied 1/4"-20 wing screws and wing nuts.
FIGURE A.7
3 
6
7 
2 
1 
4 
5 
WELD-PAK 3200HD
B-1 |
OPERATION |
B-1 |
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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 of 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 containers.
ARC RAYS can burn eyes and skin.
• Wear eye, ear and body protection.
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 tapswitch controlled, single phase constant voltage transformer / rectifier power source and a wire feeder welding 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 individuals 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 arc welding (FCAW) process using Innershield® electrode wire. The WELD-PAK 3200HD is configured for use with the FCAW process as delivered from the factory.
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 thermostat and a circuit breaker.
●Quality wire drive with electronic overload protection.
●“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
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