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PRO 155

OPERATOR’S MANUAL

IM563-A

April, 2001

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 thought-
ful 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.

For use with machine Code Numbers

10023; 10024; 10025;

,10134,10208 and 10684

PRO

• 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

• World's Leader in Welding and Cutting Products •

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

ISO 9001

CERTIFICATE NUMBER: 30273

Designed and Manufactured Under a

Quality Program Certified by

ABS Quality Evaluations, Inc.

to ISO 9001 Requirements.

QMS

ANSI RAB

Copyright © 2001 Lincoln Global Inc.

This manual covers equipment which is no
longer in production by The Lincoln Electric Co.
Specifications and availability of optional
features may have changed.

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Summary of Contents for PRO 155

Page 1: ...0023 10024 10025 10134 10208 and 10684 PRO 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 World s Leader in Welding and Cutting Products Date of Purchase Serial Number Code Number Model Where Purchased ISO 9001 CERTIFICATE NUMBER 30273 Designed and Manufactured Under a Quality Prog...

Page 2: ...MAKER 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 av...

Page 3: ...ectrical 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 welde...

Page 4: ...o 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 We...

Page 5: ...priés 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 El...

Page 6: ...re the information must be followed to avoid minor personal injury or damage to this equipment CAUTION 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 rec...

Page 7: ... 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...

Page 8: ...ICAL SPECIFICATIONS PRO 155 INPUT SINGLE PHASE ONLY RATED OUTPUT OUTPUT RECOMMENDED INPUT CABLE AND FUSE SIZES Height Width Depth Weight 12 0 in 9 75 in 16 5 in 57 Ibs 305 mm 248 mm 419 mm 25 9 kg PHYSICAL DIMENSIONS Standard Voltage Frequency Input Current 230V 60Hz 20 Amps Rated Output 208V 60Hz 22 Amps Rated output Input Voltage Duty Cycle Amps Volts at Rated Amps 230V 30 130 20 208V 25 130 20 ...

Page 9: ... NR 211 MP electrode 7 Handshield with filter plate and lens 8 Instructional video 9 8 Spool Adapter 2 Spindle for mounting 10 lb Spools May be installed ELECTRIC SHOCK can kill Only qualified personnel should perform this installation Only personnel that have read and under stood the PRO 155 Operating Manual should install and operate this equipment Machine must be plugged into a receptacle which...

Page 10: ...s Work Clamp Installation Attach the work clamp per the following Refer to Figure A 3 FIGURE A 3 PRO 155 3 WELDING AMP RANGE WELDING AMP RANGE 30 155 E THE LINCOLN ELECTRIC COMPANY CLEVELAND OHIO USA 4 5 8 3 6 7 1 2 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 c...

Page 11: ... 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 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 thumbscre...

Page 12: ... 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 GAS CONNECTION OPTIONAL When using the GMAW process a K610 2 MIG con version 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...

Page 13: ...ecuring 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 This welding machine must be connected to power source in accordance with applicable elec trical codes The United States National Electrical Code Article 630 B 1990 Edition provides standards f...

Page 14: ... 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 contain ers ARC RAYS can burn eyes and skin Wear eye ear and body protec tion Observe all safety information throughout this manual...

Page 15: ...ermo stat and a circuit breaker Quality wire drive with electronic overload protec tion Quick Release idle roll pressure arm is easily adjusted Reversible dual groove drive roll Drive roll will feed 045 1 2 mm diameter wire No external shielding gas is required when used with Lincoln Innershield 045 1 2 mm NR 211 MP electrode Accommodates 4 100 mm diameter spool of wire Will accommodate 8 200 mm d...

Page 16: ...ot be depressed to load or unload the wire spool FIGURE B 2 Load an 8 200 mm diameter spool on the wire spool spindle shown in Figure B 2 To use 4 100 mm diameter spools the 2 50 mm diameter spindle must be removed See Figure B 3 Remove the wing nut and spacer at the end of the shaft and remove the outside plastic wire spool spin dle The spindle can be stored in the wire feed com partment A 4 100 ...

Page 17: ...he idle roll pressure adjustment wing nut is facto ry set to approximately five full turns from where the wing nut first engages the threads of the pres sure arm 1 If feeding problems occur because the wire is flattened excessively turn the pressure adjustment counter clockwise to reduce distortion of the wire Slightly less pressure may be required when using 0 023 0 025 0 6 mm wire If the drive r...

Page 18: ...top welding release the gun trigger and then pull the gun away from the work after the arc goes out 10 When no more welding is to be done close valve on gas cylinder if used momentarily operate gun trigger to release gas pressure and turn off the PRO 155 Cleaning Tip And Nozzle Clean the contact tip and nozzle to avoid arc bridging between the nozzle and contact tip which can result in a shorted n...

Page 19: ...e 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 CO2 For argon mixed gas trigger to release gas pressure and turn off the adjust the flow to give 25 30 CFH 12 14 I min 3 Keep the cylinder valve closed except when using the PRO 155 When finished welding a Close the...

Page 20: ...his helps pre vent current from going through an unwanted path Avoid allowing the welding circuit to pass through hinges bearings electronic components or similar devices that can be damaged See Figure B 8 Always disconnect electrical devices before welding upon them Fumes and slag generated from Innershield type electrodes recom mended for use with this welding machine can be toxic Avoid contact ...

Page 21: ...tective slag on top of the weld during cooling After running a weld bead the slag may be removed with a chipping hammer and wire brush This improves appearance and allows for inspection of the finished weld Since machine size and output characteristics limit the size and type of wire electrode which can be used Lincoln 0 035 0 9 mm NR 211 MP Innershield elec trode is recommended for Self Shielded ...

Page 22: ...paint rust or other contaminants MACHINE SET UP FOR THE SELF SHIELDED FCAW PROCESS 1 See PROCESS GUIDELINES in the OPERATION section for selection of welding wire and shielding gas and for range of metal thicknesses that can be welded 2 See the Application Guide on the inside of wire feed section door for information on setting the controls 3 Set the Voltage and Wire Speed controls to the settings...

Page 23: ...SO is the distance from the end of the contact tip to the end of the wire See Figure B 12 Once the arc has been established maintaining the correct ESO becomes extremely important The ESO should be approximately 3 8 to 1 2 inch 10 to 12 mm long The easiest way to tell whether the ESO is the cor rect length is by listening to its sound The correct ESO has a distinctive crackling sound very much lik...

Page 24: ...nd touching the wire to the work 2 Position face shield to protect face and eyes 3 Depress gun trigger hold gun so contact tip to work distance is about 3 8 to 1 2 inch 10 to 12 mm and the gun is at proper angle 4 After you strike the arc practice the correct electri cal stickout Learn to distinguish it by its sound 5 When you are sure that you can hold the correct electrical stickout with a smoot...

Page 25: ...our welding will be easy They are as follows 1 The Correct Welding Position Figure B 16 illustrates the correct welding position for right handed people For left handed people it is the opposite When GMAW MIG welding on sheet metal it is important to use the forehand push technique Hold the gun of the gun and cable assembly in your right hand and hold the shield with your left hand Left handers si...

Page 26: ...g the molten metal FIGURE B 18 Helpful Hints 1 For general welding it is not necessary to weave the arc neither forward or backward nor sideways Weld along at a steady pace You will find it easier 2 When welding on thin plate you will find that you will have to increase the welding speed whereas when welding on heavy plate it is necessary to go more slowly in order to get good penetration 3 When w...

Page 27: ...ly clamp or tack weld the plates at both ends otherwise the heat will cause the plates to move apart See Figure B 20 Now weld the two plates together Weld from left to right if right handed Point the wire electrode down in the crack between the two plates keeping the gun slightly tilted in the direction of travel Watch the molten metal to be sure it distributes itself evenly on both edges and in b...

Page 28: ...ortion of the range The general technique and proper gun angle is illustrated in Figure B 24 Generally keep the electrode nearly perpendicular to the joint as illustrated The maximum angle above per pendicular may be required if porosity becomes a problem FIGURE B 24 Vertical down Welding Refer to Figure B 25 Vertical down welds are applied at a fast pace These welds are therefore shallow and narr...

Page 29: ...ease voltage 2 Increase drag angle 3 Decrease stickout 4 Increase WFS wire feed speed 5 Decrease travel speed 6 Check for correct gas if used To Correct Poor Penetration in order of impor tance 1 Decrease stickout 2 Increase WFS wire feed speed 3 Decrease voltage 4 Increase speed 5 Decrease drag angle 6 Check for correct gas if used If Arc Blow Occurs in order of importance NOTE Try different grou...

Page 30: ... kink or pull the gun around sharp corners 2 Keep the gun cable as straight as practical when welding 3 Do not allow dolly wheels or trucks to run over the cables 4 Keep the cable clean 5 Innershield electrode has proper surface lubrica tion Use only clean rust free electrode 6 Replace contact tip when it becomes worn or the end is fused or deformed ...

Page 31: ...B 18 PRO 155 B 18 APPLICATION CHART ...

Page 32: ...coln family of small welders Has provisions for mounting a single gas cylinder Has front casters and large rear wheels Handle height is easily adjustable Bottom tray provided for tools and accessories Easy assembly required takes less than 15 minutes 2 K664 2 Aluminum Feeding Kit This kit required for welding with 035 Aluminum wire This kit may also be used for feeding 030 stainless wire Included ...

Page 33: ...rts inside Do not attempt to perform service in the power source fixed side of the PRO 155 Take the unit to an authorized Lincoln Service Center if you experi ence problems NO maintenance is required WIRE FEED COMPARTMENT 1 When necessary vacuum accumulated dirt from gearbox and wire feed section 2 Occasionally inspect the incoming guide tube and clean inside diameter is necessary 3 Motor and gear...

Page 34: ...UN Gun Cable Cleaning Clean cable liner after using approximately 300 lbs 136 kg of solid wire or 50 lbs 23 kg of flux cored wire Remove the cable from the wire feeder and lay it out straight on the floor Remove the contact tip from the gun Using low pressure air gently blow out the cable liner from the gas diffuser end Excessive pressure at the start may cause the dirt to form a plug Flex the cab...

Page 35: ... roll set screw is facing up When inching the welding wire the drive rolls gun connector block and gun contact tip are energized relative to work and ground and remain energized for several seconds after the gun trig ger is released 5 Turn the power switch to OFF marked O 6 Loosen the drive roll set screw with the 5 64 2 0 mm hex wrench supplied 7 Remove the drive roll and replace it with the KP66...

Page 36: ...nector Liner Assembly Liner bushing to be sealed tight against brass cable connector FIGURE D 2 Liner trim length CHANGING LINER NOTICE The variation in cable lengths prevents the interchangeability of liners Once a liner has been cut for a particular gun it should not be installed in anoth er gun unless it can meet the liner cutoff length requirement Refer to Figure D 2 1 Remove the gas nozzle fr...

Page 37: ... CAUSE lists the obvious external possibilities that may contribute to the machine symptom Step 3 RECOMMENDED COURSE OF ACTION This column provides a course of action for the Possible Cause generally it states to contact your local Lincoln Authorized Field Service Facility If you do not understand or are unable to perform the Recommended Course of Action safely contact your local Lincoln Authorize...

Page 38: ...de wire drive compartment is reset 1 The thermostat may be tripped due to overheating Let machine cool Weld at lower duty cycle 2 Check for obstructions in air flow Check Gun Trigger connec tions See Installation section 3 Gun trigger may be faulty RECOMMENDED COURSE OF ACTION If all recommended possible areas of misadjustment have been checked and the problem persists Contact your local Lincoln A...

Page 39: ...stand the test procedures or are unable to perform the tests repairs safely contact your LOCAL AUTHORIZED LINCOLN ELECTRIC FIELD SERVICE FACILITY for assistance before you proceed CAUTION PROBLEMS SYMPTOMS Low or no gas flow when gun trigger is pulled Wire feed weld output and fan operate normally Optional MIG Conversion Kit only POSSIBLE AREAS OF MISADJUSTMENT S 1 Verify that gas solenoid is prop...

Page 40: ...tion sec tion 2 Check for proper electrode polarity for process 3 Check gun tip for wear or dam age and proper size Replace 4 Check for proper gas and flow rate for process For MIG only 5 Check work cable for loose or faulty connections 6 Check gun for damage or breaks 7 Check for proper drive roll orien tation and alignment 8 Check liner for proper size RECOMMENDED COURSE OF ACTION If all recomme...

Page 41: ... D 2 1 1 T H E R M O S T A T M 1 8 2 0 2 PRO 155 WIRING DIAGRAM C A S E S I D E B E F O R E C O N N E C T I N G I N P U T P O W E R R E C O N N E C T I O N T O 2 3 0 V I S R E V E R S E D O F A B O V E M A C H I N E S A R E S H I P P E D F R O M F A C T O R Y C O N N E C T E D F O R 2 3 0 V A S S H O W N T O C O N N E C T W E L D E R F O R 2 0 8 V I N P U T D I S C O N N E C T W E L D E R F R O M ...

Page 42: ...NOTES PRO 155 ...

Page 43: ...6 383 2259 and ask for the Welding School Registrar Lincoln Welding School BASIC COURSE 700 00 5 weeks of fundamentals There is a 10 discount on all orders of 50 00 or more for shipment at one time to one location Orders of 50 or less before discount or orders outside of North America must be prepaid with charge check or money order in U S Funds Only Prices include shipment by 4 th Class Book Rate...

Page 44: ...electrically live parts or electrode with skin or wet clothing Insulate yourself from work and ground No toque las partes o los electrodos bajo carga con la piel o ropa moja da Aislese del trabajo y de la tierra Ne laissez ni la peau ni des vête ments mouillés entrer en contact avec des pièces sous tension Isolez vous du travail et de la terre Berühren Sie keine stromführenden Teile oder Elektrode...

Page 45: ...gute Be und Entlüftung des Arbeitsplatzes Mantenha seu rosto da fumaça Use ventilação e exhaustão para remover fumo da zona respiratória Turn power off before servicing Desconectar el cable de ali mentación de poder de la máquina antes de iniciar cualquier servicio Débranchez le courant avant l entre tien Strom vor Wartungsarbeiten abschalten Netzstrom völlig öff nen Maschine anhalten Não opere co...

Page 46: ...s 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 World s Leader in Welding and Cutting Products ...

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