Lincoln Electric WELD-PACK 100 PLUS IM546 - Manual (Page 12)

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A-4 INSTALLATION
WELD-PAK 100
Work Cable Installation
Refer to Figure A.2.
1. Open the wire feed section door on the right side of
the WELD-PAK 100.
2. Pass the end of the work cable that has the termi-
nal lug with the smaller hole through the Work
Cable Access Hole (1) in the case front.
3. Route the cable under and around the back of the
Wire Feed Gearbox (6).
4. For Innershield Only: Refer to Figure A.2. As
delivered, the WELD-PAK 100 is connected for
negative electrode polarity. This is the appropriate
configuration for the Innershield process. To com-
plete installation, use the provided wing nut to con-
nect the work cableʼs terminal lug to the positive (+)
output terminal (5) located above the Wire Feed
Gearbox (6). Make sure that both wing nuts are
tight.
5. For GMAW Only: Refer to Figure A.4. To wire for
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
appropriate size. Additionally, the .023 – .030" (0.6 –
0.8 mm) gun liner included in the K610-1 MIG
Conversion Kit must be installed. Refer to the MAIN-
TENANCE section for contact tip installation details.
Connecting Gun Cable to the WELD-PAK
100
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 con-
trol leads, one at a time, through the Gun Cable
and Control Lead Access Slot (2) in the case front.
The leads are to be routed under the Wire Feed
Gearbox (6) and through the Cable Hanger (7) on
the inner panel.
3. Insert the connector on the gun conductor cable
through the Gun Cable Access Hole (2) in the
WELD-PAK 100 case front. Make sure the connec-
tor is all the way in the brass connector block.
Unscrew thumbscrew on the connector block a few
turns if gun connector will not insert fully. Rotate
the connector so control leads are on the under-
side and tighten the Thumbscrew (8) in the con-
nector block.
4. Connect the gun trigger control lead terminals to
the two insulated 1/4" (6,4 mm) tab terminal con-
nector bushings located 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.
If the gun trigger switch being used is other than
that supplied with the WELD-PAK 100, 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 100
may result if this switch shorts to the WELD-PAK
100 welding output circuit or is common to any
electrical circuit other than the WELD-PAK 100
trigger circuit.
GAS CONNECTION (OPTIONAL)
When using the GMAW process, a K610-1 MIG con-
version kit and a cylinder of carbon dioxide (CO
2
) or
argon-carbon dioxide mixed shielding gas must be
obtained. For more information about the K610-1 MIG
Conversion Kit for use with the WELD-PAK 100, refer
to the ACCESSORIES section.
CAUTION
GUN INSTALLATION
As shipped from the factory, the WELD-PAK 100 gun
is ready to feed 0.035” (0,9 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