Lincoln Electric IM563 User Manual
IM563-A
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For use with machine Code Numbers
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.
NOT INSTALL, OPERATE OR
REPAIR THIS EQUIPMENT
WITHOUT READING THIS
MANUAL AND THE SAFETY
PRECAUTIONS CONTAINED
THROUGHOUT.
importantly, think before you act
and be careful.
And, most
DO
PRO 155
April, 2001
10023 thru 10026,10134,10208 and 10684
PRO
Date of Purchase:
Serial Number:
Code Number:
Model:
Where Purchased:
ISO 9001
Designed and Manufactured Under a
Quality Program Certified by
ABS Quality Evaluations, Inc.
to ISO 9001 Requirements.
CERTIFICATE NUMBER: 30273
Cleveland, Ohio 44117-1199 U.S.A. TEL: 216.481.8100 FAX: 216.486.1751 WEB SITE: www.lincolnelectric.com
ANSI RAB
QMS
OPERATOR’S MANUAL
Copyright © 2001 Lincoln Global Inc.
• World's Leader in Welding and Cutting Products •
• Sales and Service through Subsidiaries and Distributors Worldwide •
i
SAFETY
i
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 Above For Diesel 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.
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 Gasoline Engines
FOR ENGINE
powered equipment.
1.a. Turn the engine off before troubleshooting and maintenance
work unless the maintenance work requires it to be running.
____________________________________________________
1.b.Operate engines in open, well-ventilated
areas or vent the engine exhaust fumes
outdoors.
____________________________________________________
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.
____________________________________________________
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.
____________________________________________________
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.
___________________________________________________
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.
___________________________________________________
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
PRO 155
ii
SAFETY
ii
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.
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.
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.
5.b.
Do not weld in locations near chlorinated hydrocarbon
coming from degreasing, cleaning or spraying operations.
The heat and rays of the arc can react with solvent vapors
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.
vapors
Mar ‘95
to
PRO 155
iii
SAFETY
iii
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.
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
been “cleaned”. For information, purchase “Recommended
Safe Practices for the
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.
Sparks and spatter are thrown from the welding arc. Wear oil
6.f.
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.
Remember that welding sparks and hot
though
they have
Preparation
for Welding and Cutting of
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.
PRO 155
Mar ‘95
iv
SAFETY
iv
PRÉCAUTIONS DE SÛRETÉ
Pour votre propre protection lire et observer toutes les instructions et les précautions de sûreté specifiques qui parraissent
dans ce manuel aussi bien que les précautions de sûreté
générales 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.
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 phosg
ment 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.
éne (gas forte-
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-inflammables.
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.
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 branchéà
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 sûretéà leur
place.
PRO 155
Mar. ‘93
Thank You
vv
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
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:
and Equipment For Damage Immediately
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.
PRO 155
vi
vi
MASTER TABLE OF CONTENTS FOR ALL SECTIONS
Page
Installation.......................................................................................................Section A
Technical Specifications........................................................................................A-1
Safety Precautions.................................................................................................A-2
Identify and Locate Components...........................................................................A-2
Select Suitable Location........................................................................................A-3
Output Connections...............................................................................................A-3
Gun Installation......................................................................................................A-4
Gas Connection (Optional)....................................................................................A-5
Electrical Input Connections..................................................................................A-6
Line Cord Connection ...........................................................................................A-6
Operation.........................................................................................................Section B
Safety Precautions ................................................................................................B-1
General Description...............................................................................................B-2
Design Features and Advantages...................................................................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
Proper Gun Handling...........................................................................................B-17
Application Chart .................................................................................................B-18
Accessories.....................................................................................................Section C
Accessories...........................................................................................................C-1
Mig Conversion......................................................................................................C-1
Maintenance ....................................................................................................Section D
Safety Precautions ................................................................................................D-1
Routine Maintenance.............................................................................................D-1
Gun and Cable Maintenance.................................................................................D-2
Component Replacement Procedures ..................................................................D-2
Ghanging Drive Roll ..............................................................................................D-3
Changing Liner......................................................................................................D-4
Gun Handle Parts..................................................................................................D-4
Troubleshooting..............................................................................................Section E
How to Use Troubleshooting Guide.......................................................................E-1
Troubleshooting Guide.............................................................................E-2 thru E-4
Wiring Diagrams..............................................................................................Section F
PRO 155 Wiring Diagram ......................................................................................F-1
PRO 155 Parts Manual....................................................................P262, P202E Series
PRO 155
A-1
INSTALLATION
TECHNICAL SPECIFICATIONS – PRO 155
INPUT – SINGLE PHASE ONLY
Standard Voltage/Frequency Input Current
230V/60Hz 20 Amps - Rated Output
208V/60Hz 22 Amps - Rated output
RATED OUTPUT
Input Voltage
230V 30% 130 20
208V 25% 130 20
Duty Cycle Amps Volts at Rated Amps
OUTPUT
A-1
Welding
Rated DC Output: 30 - 155 amps 33 50-400 IPM (1.3-10.2 m/min)
Current Range Maximum Open Circuit Voltage Wire Speed Range
RECOMMENDED INPUT CABLE AND FUSE SIZES
Type 75°C Wire Grounding Wire
Fuse or in Conduit, Copper Copper Cond.
Input Voltage Breaker Size Input Amps Power Cord Cond. AWG Size AWG Size
208V/60Hz 40 Amp 22 50 Amp, 250V, 8 AWG 10
Three Prong Plug
(NEMA Type 6-50P)
230V/60Hz 40 Amp 20 50 Amp, 250V, 8 AWG 10
Three Prong Plug
(NEMA Type 6-50P)
PHYSICAL DIMENSIONS
Height Width Depth Weight
12.0 in 9.75 in 16.5 in 57 Ibs
305 mm 248 mm 419 mm 25.9 kg
PRO 155
A-2
PR
O 155
1
2
4
5
6
7
8
E
3
9
INSTALLATION
A-2
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 PRO 155 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 PRO 155 power switch is to be in the
OFF (“O”) position when installing work
cable and gun and when connecting power
cord to input power.
For available options and accessories refer to accessories section.
(1)
The gun is ready to feed 0.045" (1.2 mm)
Innershield wire.
FIGURE A.1
IDENTIFY AND LOCATE
COMPONENTS
If you have not already done so, unpack the PRO 155
from its carton and remove all packing material
around the PRO 155. Remove the following loose
items from the carton (see Figure A.1):
1. PRO 155
2. Gun and cable assembly
3. Literature and miscellaneous including:
a) This operating manual
b) 10 extra .045" contact tips
c) Hex key wrench for removal of drive roll.
4. 10 ft (3,0 m) work cable.
5. Work clamp.
6. Sample 10 lb. spool of Innershield .045" (1.2 mm)
NR-211-MP electrode.
(1)
7. Handshield with filter plate and lens.
8. Instructional video.
9. 8” Spool Adapter (2” Spindle) for mounting 10 lb.
Spools. (May be installed)
PRO 155
A-3
PRO 155
3
WELDING AMP RANGE
30-155
4
5
8
3 6
7
1
2
+
-
SCREW
PLASTIC HANDLE
WORK CABLE
BACKING PLATE & NUT
INSTALLATION
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
PRO 155’s cannot be stacked.
TILTING
Each machine must be placed on a secure, level surface, either directly or on the recommended utility cart.
The machine may topple over if this procedure is not
followed.
OUTPUT CONNECTIONS
Refer to Figure A.2.
1. Work Cable Access Hole.
Work Clamp Installation
Attach the work clamp per the following: Refer to
Figure A-3.
FIGURE A.3
1. Remove the screw, pressure plate and backing nut
from clamp.
2. Remove plastic handle from same side of clamp by
pulling steadily on handle until it slides off clamp.
3. Insert the work cable terminal lug with the larger
hole through the hole in the end of the plastic handle. Slide plastic handle several inches further onto
cable to allow easy and clear access to terminal
lug.
2. Gun Cable and Control Lead Access Hole.
3. Connector Block.
4. Gun Trigger Lead Connectors.
5. Positive (+) and negative (–) output terminals.
WELDING AMP RANGE
E
THE LINCOLN ELECTRIC COMPANY CLEVELAND, OHIO USA
4. Secure work cable to clamp by inserting screw
5. Slide plastic handle back onto clamp and into origi-
FIGURE A.2
through hole in clamp, attaching cable lug on inside
of clamp, and installing pressure plate and backing
nut. make sure pressure plate is installed such that
it prevents nut from turning. tighten screw securely.
nal position.
PRO 155
A-4
1
2
4
3
INSTALLATION
A-4
Work Cable Installation
Refer to Figure A.2.
1. Open the wire feed section door on the right side of
the PRO 155.
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.2. As
delivered, the PRO 155 is connected for negative
electrode polarity. This is the appropriate configuration for the Innershield process. To complete
installation, use the provided wing nut to connect
the work cable’s terminal lug to the positive (+) output terminal (5) located above the Wire Feed
Gearbox (6). Make sure that both wing nuts are
tight.
For GMAW Only: Refer to Figure A.4. To wire for
5.
positive polarity (required for the MIG process),
connect the short cable attached to the connector
block (1) to the positive (+) output terminal (4) and
the work cable (3) to the negative (–) terminal (2).
FIGURE A.4
mm) gun liner included in the K610-2 MIG Conversion Kit
must be installed. Also a KP665-035 drive roll must be
used. This drive roll is not part of the K610-2 kit and must
be ordered separately. Refer to the MAINTENANCE section for contact tip and drive roll installation details.
Connecting Gun Cable to the PRO 155
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 up the inside of the
case front and behind the gas line.
3. Insert the connector on the gun conductor cable
through the Gun Cable Access Hole (2) in the
PRO 155 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 above 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.
GUN INSTALLATION
As shipped from the factory, the PRO 155 gun is ready to
feed 0.045” (1.2 mm) wire. If .023" – .025" (0.6 mm) or
.030" (0.8 mm) wire is to be used for the GMAW (MIG)
process, change the contact tip to the appropriate size
and install a gas nozzle included with the K610-2 MIG
Conversion kit. Additionally, the .023 – .030" (0.6 – 0.8
PRO 155
CAUTION
If the gun trigger switch being used is other than
that supplied with the PRO 155, the switch must
be a normally open, momentary switch. The terminals of the switch must be insulated from the
welding circuit. Malfunction of the PRO 155 may
result if this switch shorts to the PRO 155 welding
output circuit or is common to any electrical circuit other than the PRO 155 trigger circuit.
A-5
INSTALLATION
A-5
GAS CONNECTION (OPTIONAL)
When using the GMAW process, a K610-2 MIG conversion kit and a cylinder of carbon dioxide (CO2) or
argon-carbon dioxide mixed shielding gas must be
obtained. For more information about the K610-2 MIG
Conversion Kit for use with the PRO 155, refer to the
ACCESSORIES section.
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.
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% CO
regulator adapter (provided with MIG Conversion
Kit for the PRO 155) between regulator and cylinder valve. If adapter is equipped with a plastic
washer, be sure it is seated for connection to the
CO
cylinder.
2
cylinder, insert
2
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.
Insulate the cylinder from the work circuit and earth
ground. Refer to Figure A.5.
FIGURE A.5
Flow Regulator
Gas Hose
Cylinder Valve
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 PRO 155 Gas
Solenoid Inlet Fitting (5/8-18 female threads — for
CGA — 032 fitting). Make certain the gas hose is
not kinked or twisted.
PRO 155
A-6
INSTALLATION
A-6
ELECTRICAL INPUT CONNECTIONS
FIGURE A.6
OPTIONAL GAS
SOLENOID INLET FITTING
POWER INPUT
CABLE
230 VOLT INPUT CONNECTIONS
also included on the wiring diagram located on the
inside of the case side panel):
1. Disconnect welder from input power and remove
case side.
2. Remove lead marked “H1” from CR1 on the control
P.C. Board.
3. Remvoe tape securing H3 to lead sleeving and
connect H3 to CR1.
4. Insulate unused H1 lead for 300V with electrical
tape and secure to lead sleeving.
5. Reinstall case side before connecting input power.
LINE CORD CONNECTION
WARNING
This welding machine must be connected to
power source in accordance with applicable electrical codes.
The PRO 155 is shipped from the factory connected
for 230 volt input power. If the welder has been
reconnected for 208 volt input power and 230 volt
input is desired, perform the following reconnection
instructions:
WARNING
Make certain that the input power is electrically
disconnected before removing the screws that
hold the case side in place.
1. Disconnect welder from input power and remove
case side panel.
2, Remove lead marked “H3” from CR1 on the control
P.C. Board.
3. Remvoe tape securing H1 lead to lead sleeving
and connect H1 to CR1.
4. Insulate unused H3 lead for 300 volts with electrical tape and secure to lead sleeving.
5. Reinstall case side before connecting input power.
208 VOLT INPUT CONNECTION
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.
A 12/3 AWG (3.3 mm
2
) 3 conductor line cord with a 50
amp, 250 volt, three-prong plug (NEMA Type 6-50P)
is factory installed. Connect this plug to a mating
grounded receptacle which is connected to an appropriate power supply per the U.S. National Electric
Code and any applicable local codes. Refer to
“Technical Specifications” for proper fuse and supply
conductor sizes.
CONNECT TO A SYSTEM
GROUNDING WIRE. SEE
THE UNITED STATES
NATIONAL ELECTRICAL
CODE AND/OR LOCAL
CODES FOR OTHER
DETAILS AND MEANS FOR
PROPER GROUNDING.
CONNECT TO HOT WIRES
OF A THREE-WIRE SINGLE
PHASE SYSTEM OR TO
ONE PHASE OF A TWO OR
THREE PHASE SYSTEM.
To connect the PRO 155 for 208 volt input power, perform the following reconnect instructions (which are
PRO 155
B-1
OPERATION
Read entire operation section before
operating the PRO 155.
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.
B-1
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 protection.
Observe all safety information throughout
this manual.
PRO 155
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