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WELD-PAK 100
B-6
OPERATION
thinner, CO
2
gas is recommended because it gives
equal or better performance than a blended gas at a
lower cost. A mixed gas consisting of 75 to 80% Argon
and 20 to 25% CO
2
is recommended for welding on
heavier gauge [12 gauge (2,5 mm) for example] steel.
The WELD-PAK 100 is suitable for .035" aluminum
wire and .030" stainless wire. Refer to Table B.1 for
recommended procedure settings.
TABLE B.1
CHANGING MACHINE OVER TO
FEED OTHER WIRE SIZES
The WELD-PAK 100 is shipped from the factory ready
to feed 0.035” (0,9 mm) diameter wire. To operate the
WELD-PAK 100 with other sizes of wire, it is neces-
sary to change the contact tip and change the drive
roll over to other sizes. Refer to Changing the Contact
Tip and Changing the Drive Roll, in the MAINTE-
NANCE section, for specific information on these pro-
cedures.
WELDING WITH GMAW (MIG)
Shielding Gas
When using the GMAW process, obtain and install the
K610-1 MIG Conversion Kit and a cylinder of carbon
dioxide (CO
2
) or argon-carbon dioxide mixed shielding
gas. Refer to the ACCESSORIES section for more
information about installing the K610-1 Kit for use with
the WELD-PAK 100.
1. For CO
2
, open the cylinder very slowly. For argon-
mixed gas, open cylinder valve slowly a fraction of
a turn. When the cylinder pressure gauge pointer
stops moving, open the valve fully.
2. If using a regulator with an adjustable flow meter,
close the gun trigger and adjust the flow to give 15
– 20 cubic ft per hour (CFH) (7 – 10 I/min) [use 20
– 25 CFH (10 – 12 I/min) when welding out of
position or in a drafty location for CO
2
]. For argon
mixed gas, trigger to release gas pressure, and
turn off the adjust the flow to give 25 – 30 CFH
(12–14I/min).
3. Keep the cylinder valve closed, except when using
the WELD-PAK 100. When finished welding:
a) Close the cylinder valve to stop gas flow.
b) Depress the gun trigger briefly to release the
pressure in the gas hose.
c) Turn off the WELD-PAK 100.
OVERLOAD PROTECTION
Output Overload
The WELD-PAK 100 is equipped with a circuit breaker
and a thermostat which protects the machine from
damage if maximum output is exceeded. The circuit
breaker button will extend out when tripped. The cir-
cuit breaker must be manually reset.
Thermal Protection
The WELD-PAK 100 has a rated output duty cycle of
20%. If the duty cycle is exceeded, a thermal protector
will shut off the output until the machine cools to a rea-
sonable operating temperature. This is an automatic
function of the WELD-PAK 100 and does not require
user intervention. The fan continues to run during
cooling.
Electronic Wire Drive Motor Protection
The WELD-PAK 100 has built-in protection for wire
drive motor overload.
Shielding
Voltage/Wire Speed
Process Welding Wire Gas 16 ga 14 ga 12 ga 10 ga
MIG DC+ .035 Dia 100% Argon B-5 D-7 D-9 D-9
4043 Aluminum
Wire
MIG DC+ .035 Dia 100% Argon B-5 C-7 D-9 D-10
5356 Aluminum
Wire
MIG DC+ .030 Dia 98% Argon/ A-3 C-6 D-7.5 D-7.5
308L Stainless 2% Oxygen
Steel Wire