Lincoln Electric IM822 User Manual

IM822

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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.

MIG PAK HD

February, 2003

For use with machine Code Number:11062

Date of Purchase:
Serial Number:
Code Number:
Model:
Where Purchased:

Cleveland, Ohio 44117-1199 U.S.A. TEL: [phone] FAX: [phone] WEB SITE: www.lincolnelectric.com

OPERATOR’S MANUAL

Copyright © 2003 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.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.

___________________________________________________

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.

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

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.

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.

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
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.

vapors

to

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.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

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.

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 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.

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 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

for selecting a QUALITY product by Lincoln Electric. We want you

Thank 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 product registration on-line or information on this equipment
always supply the information you have recorded above.

vv

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.

MASTER TABLE OF CONTENTS FOR ALL SECTIONS

Page

Installation.......................................................................................................Section A

Technical Specifications........................................................................................A-1

Identify and Locate Components...........................................................................A-2

Select Suitable Location........................................................................................A-3

Stacking.................................................................................................................A-3

Changing Polarity ..................................................................................................A-3

Gun Installation......................................................................................................A-3

Input Connections..................................................................................................A-3

Gas Connections...................................................................................................A-3

Shielding Gas Connections ...................................................................................A-4

Code Requirements ..............................................................................................A-4

________________________________________________________________________

Operation.........................................................................................................Section B

Safety Precautions ................................................................................................B-1

General Description...............................................................................................B-1

Recommended Processes.....................................................................................B-1

Operation Features and Controls .........................................................................B-1

Design Features ....................................................................................................B-1

Welding Capability.................................................................................................B-2

Limitations..............................................................................................................B-2

Controls and Settings ............................................................................................B-2

Welding Operations...............................................................................................B-2

Shielding Gas ........................................................................................................B-3

Making a Weld and Process Table........................................................................B-4

Cleaning Tip and Gas Nozzle................................................................................B-5

Changing Machine over to Feed Other Wire Sizes,Overload Protection...............B-5

Learning to Weld....................................................................................B-6 thru B-16

________________________________________________________________________

Accessories.....................................................................................................Section C

Accessories...........................................................................................................C-1

Replacement Parts................................................................................................C-1

________________________________________________________________________

Maintenance ....................................................................................................Section D

Safety Precautions ................................................................................................D-1

Items Requiring No Maintenance..........................................................................D-1

Routine Maintenance.............................................................................................D-1

Cleaning the Gun Liner..........................................................................................D-2

Cleaning Components as Required.......................................................................D-2

Component Replacement Procedures ..................................................................D-2

Changing Contact Tip............................................................................................D-2

Changing the Drive Roll.........................................................................................D-2

Gun Assembly Removal........................................................................................D-3

Work Cable Installation..........................................................................................D-3

________________________________________________________________________

Troubleshooting..............................................................................................Section E

Safety Precautions.................................................................................................E-1

How to Use Troubleshooting Guide.......................................................................E-1

Troubleshooting Guide.........................................................................E-2 THRU E-4

________________________________________________________________________

Wiring Diagrams..............................................................................................Section F

Wiring Diagram.....................................................................................................F-1

________________________________________________________________________

Parts Lists....................................................................................................P437 Series

vi

A-1

INSTALLATION

TECHNICAL SPECIFICATIONS – MIG PAK HD

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 70 17

OUTPUT RANGE

Welding Current Range Maximum-Open Circuit Voltage No Load 0 - 450 in/min

DC OUTPUT: 35-88 Amps 29V (0 - 17.7 mm/min)

While welding 0-300 in/min.

(0-11.8 mm/min.)

RECOMMENDED INPUT CABLE AND FUSE SIZES

Fuse or

Output Mode Input Voltage Breaker Size1Input Amps Power Cord Extension Cord

A-1

AT

RATED 120V/60Hz 20 Amp 20 15 Amp, 125V, Three Conductor

OUTPUT Three Prong Plug #12 AWG

(NEMA Type 5-15P) (3.3 mm2) or Larger

Up to 50 Ft. (15.2 mm)

PHYSICAL DIMENSIONS

Height Width Depth Weight

12.8 in 8.8 in 18 in 46 Ibs
325 mm 224 mm 457 mm 20.9 kg

1

If connected to a circuit protected by fuses use Time Delay Fuse marked “D”.

MIG PAK HD

A-2

INSTALLATION

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 Machine 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 Machine 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 machine
from its carton and remove all packing material
around the machine. The following items are shipped
loose. (see Figure A.1):

2

1

OPERATOR'SMANUAL

For use with machines having Code Numbers:00000

Safety Depends on You

Lincolnarc weldingandcutting
equipmentisdesigned andbuilt
withsafetyinmind. However,your
overallsafetycan beincreasedby
properinstallation...andthoughtful
operationonyour part.DO NOT
INSTALL,OPERATEOR REPAIR
THISEQUIPMENT WITHOUT
READINGTHISMANUALANDTHE
SAFETT PRECAUTIONS
CONTAINEDTHROUGHOUT.And,
mostimportantly,think beforeyou
act and be careful.

World's Leader in Welding and Cutting Products Premier Manufacturer of Industrial Motors

Sales and Service through Subsidiaries and Distributors Worldwide

22801 St. Clair Ave. Cleveland, ohio 44117-1199 U.S.A. Tel. [phone]

5

FIGURE A.1

IM000

October 1998

4

A-2

3

6

1. MIG PAK HD with work clamp, Gun and cable
assembly attached.

2. This operator’s manual

3. Two contact tips for .035(0.9mm) diameter wire.

4. Three contact tips for .025(0.6mm) diameter wire.

5. Gas Nozzle.

6. Chipping hammer and brush.

7. Starter spool of .035” (0.9mm) NR211-MP flux

cored wire.

8. Starter spool of .025” (0.6mm) solid mig wire.

9. Gas regulator and hose with hose clamps.

10. Handshield with filter plate and lens.

For available options and accessories refer to the
Accessories Section of this manual.

7

8

10

9

MIG PAK HD

GAS INLET FITTING

POWER INPUT CABLE

A-3

WORK CABLE

WORK CABLE

GUN CABLE

GUN CABLE

WORK CABLE

WORK CABLE

GUN CABLE

GUN CABLE

INSTALLATION

A-3

SELECT SUITABLE LOCATION

Place the machine on a secure, level surface or rec­ommended undercarriage. The machine may topple
over if this procedure is not followed. To minimize over
heating, locate the welder in a dry location where there
is free circulation of clean air. Do not place on com­bustible surfaces.

STACKING

Machines cannot be stacked.

CHANGING POLARITY

1. For Negative Polarity Welding (DC-): Refer to

Figure A.2. As delivered, the machine is wired for
Negative polarity with the gun cable connected to
the Negative (-) output terminal and the work cable
to the Positive (+) output terminal. Make sure that
both thumbscrews are tight. This is the typical con­figuration for Flux Cored Welding (FCAW).

WORK CABLE

FIGURE A.2

GUN CABLE

GUN CABLE

WORK CABLE

INPUT CONNECTIONS

(FIGURE A.4)

Refer to Figure A.4.
The machine has two input connections, the power

input cable and the gas inlet fitting. The power input
cable and gas inlet fitting are located on the rear.

GAS CONNECTION

When using the MIG process, a cylinder of shielding
gas (appropriate for the metal being welded) must be
obtained.

WARNING

2.For Positive Polarity Welding (DC+): Refer to
Figure A.3. To wire for Positive polarity, connect
the gun cable to the Positive (+) output terminal and
the work cable to the Negative (-) terminal. This is
the typical configuration for the Metal Inert Gas
(MIG) process. Make sure that both thumbscrews
are tight.

(FIGURE A.3)

WORK CABLE

GUN CABLE

GUN CABLE

WORK CABLE

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.

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” PUB-

LISHED BY THE AMERICAN WELDING SOCIETY.

------------------------------------------------------------------------

MIG PAK HD

A-4

INSTALLATION

A-4

SHIELDING GAS CONNECTION

(FIGURE A.5)

REGULATOR

HOSE

Refer to Figure A.5.

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 work
ground.

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.

CYLINDER VALVE

GAS CYLINDER

CODE REQUIREMENTS FOR ELECTRI­CAL 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.

CAUTION

Do not connect the machine to an input power
supply with a rated voltage that is greater than 125
volts.

Do not remove the power cord ground prong.

REQUIREMENTS FOR MAXIMUM OUTPUT

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 one end of the inlet gas hose to the outlet fit­ting of the gas cylinder secure with hose clamp.
Connect the other end to the Gas Inlet Fitting on
the machine and secure with hose clamp. Make
certain the gas inlet hose is not kinked or twisted.

4. The machine is supplied with a regulator suitable

for a mixed shielding gas CO
with 100% CO2 a suitable regulator or adapter must
be purchased separately from a welding gas suppli­er. To prevent leakage, if welding with 100% CO2
shielding gas the regulator for carbon dioxide must
have a plastic adapter washer seated in the fitting
that attaches to the cylinder. This adapter is avail­able from your local gas supplier.

2 / Argon. For welding

A line cord with a 15 amp, 125 volt, three-prong plug
(NEMA Type 5-15P) is factory installed on the
machine Connect this plug to a mating grounded
receptacle which is connected to a 20 amp branch cir­cuit with a nominal voltage rating of 115 volts to 125
volts, 60 hertz, AC only. If connected to a circuit pro­tected by fuses, use a time delay fuse marked “D”.
With this installation, the machine can be used at an
output of 70 amps, 17 volts, 20% duty cycle (2 min­utes of every 10 minutes used for welding).

EXTENSION CORD USAGE

If an extension cord is required, use one that is rated
for the application and is 3 conductor #14 AWG (2.1

2

mm

) or larger. The recommended maximum lengths
are 25 ft (7.5 m) if #14 AWG (2.1 mm2) is used and 50
ft (15 m) if #12 AWG (3.3 mm

2

) is used.

MIG PAK HD

B-1

OPERATION

B-1

Read entire operation section before
operating the machine.

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.

GENERAL DESCRIPTION

The machine is a semiautomatic constant voltage DC
arc welder. The machine uses a single phase con­stant voltage transformer, solid state rectifier and a
DC permanent magnet motor for feeding and welding
solid steel electrode and flux-cored electrode.
The machine is ideally suited for individuals having
access to 115 volt AC input power and wanting the
ease of use, quality and dependability of both metal
inert gas (MIG) welding and the Innershield electrode
process (self-shielded flux-cored welding). The
machine will handle reels of wire up to 2 lbs(1 kg).

RECOMMENDED PROCESSES

The machine can be used for welding carbon and low­alloy steel with CO2or argon/CO2mixture shielding

gas. The welder can also be used without gas for the
self-shielded, Innershield electrode process. The
machine is configured for the Flux Cored Arc Welding
process as delivered from the factory.

OPERA TIONAL FEA TURES AND CONTROLS

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.

The machine has the following controls as standard:

• Power ON/OFF Switch

• Heat Range Switch

• 1 – 2 Fine Heat Adjustment Switch

• Wire Speed Control

DESIGN FEATURES AND ADVANTAGES

• Operates on 115 volt input.

• Solid state output control.

• Overload protection - incorporates a thermostat to

protect the welder from overheating caused by mal­functions or overly heavy use.

• Permanent magnet wire drive motor.

• Easy-to-set controls for arc voltage and wire speed.

• Thumbscrew release idle roll pressure arm is easily

adjusted.

• Reversible, dual groove drive roll will feed .023­.035” (0.6- 0.9 mm) diameter wire.

• Accommodates spools of wire up to 4”(102mm)
diameter.

• No external shielding gas is required when used
with Lincoln Innershield .035” (0.9 mm) NR®-211­MP electrode.

• Easy to change polarity.

MIG PAK HD