Lincoln Electric WELD PAK 2000 User manual

IM3051
11/2014
REV01
WELD PAK™ 2000
OPERATOR’S MANUAL
ENGLISH
Lincoln Electric Bester Sp. z o.o.
ul. Jana III Sobieskiego 19A, 58-263 Bielawa, Poland
www.lincolnelectric.eu

English English
I
Declaration of conformity
14
Lincoln Electric Bester Sp. z o.o.
Declares that the welding machine:
WELD PAK™2000
conforms to the following directives:
2006/95/CEE, 2004/108/CEE
and has been designed in compliance with the
following standards:
EN 60974-1, EN 60974-5, EN 60974-10:2007
01.05.2014
PawełLipiński
Operations Director
Lincoln Electric Bester Sp. z o.o., ul. Jana III Sobieskiego 19A, 58-263 Bielawa, Poland
07/11

English English
II
12/05
THANKS! For having chosen the QUALITY of the Lincoln Electric products.
Please Examine Package and Equipment for Damage. Claims for material damaged in shipment must be notified
immediately to the dealer.
For future reference record in the table below your equipment identification information. Model Name, Code &
Serial Number can be found on the machine rating plate.
Model Name:
………………...…………………………….…………………………………………………………………………………………..
Code & Serial number:
………………….……………………………………………….. …………………………………………………….……………..
Date & Where Purchased:
…………………………………………………………………... ……………………….…………………………………………..
ENGLISH INDEX
Technical Specifications .................................................................................................................................................. 1
Electromagnetic Compatibility (EMC) .............................................................................................................................. 2
Safety .............................................................................................................................................................................. 3
Introduction...................................................................................................................................................................... 4
Installation and Operator Instructions .............................................................................................................................. 4
WEEE............................................................................................................................................................................ 13
Spare Parts.................................................................................................................................................................... 13
Electrical Schematic ...................................................................................................................................................... 13
Suggested Accessories ................................................................................................................................................. 13

English English
1
Technical Specifications
WELD PAK™ 2000
NAME INDEX
WELD PAK™2000 K14134-1
INPUT
Input Voltage U1EMC Class Frequency
230 V ± 10%
1 – phase A 50 / 60 Hz
Input Power at Rated Cycle Input Amperes
I1max PF
7,6 kVA @ 20 % Duty Cycle (40°C) 33 A 0,66
RATED OUTPUT
Open Circuit Voltage Duty Cycle 40°C
(based on a 10 min. period) Output Current Output Voltage
GMAW
49 Vdc
100 80 A 18 Vdc
20 180 A 23 Vdc
FCAW-
SS 49 Vdc
100 80 A 18 Vdc
20 180 A 23 Vdc
SMAW
49 Vdc
100 70 A 23,2 Vdc
20 160 A 26,4 Vdc
WELDING CURRENT RANGE
GMAW FCAW-SS SMAW
20 A – 200 A 20 A – 200 A 20 A – 160 A
20 A – 200 A 20 A – 200 A 20 A – 160 A
RECOMMENDED INPUT CABLE AND FUSE SIZES
Fuse (time delayed) or Circuit Breaker Size Power Lead
230 V
D 25 A 3 Conductor, 1,5 mm2
DIMENSIONS AND WEIGHT
Weight Height Width Length
27,5 kg 600 mm 280 mm 800 mm
Protection Rating Operating Temperature Storage Temperature
IP23 from -10 ºC to +40 ºC from -25 ºC o +55 ºC

English English
2
Electromagnetic Compatibility (EMC)
01/11
This machine has been designed in accordance with all relevant directives and standards. However, it may still generate
electromagnetic disturbances that can affect other systems like telecommunications (telephone, radio, and television) or
other safety systems. These disturbances can cause safety problems in the affected systems. Read and understand
this section to eliminate or reduce the amount of electromagnetic disturbance generated by this machine.
This machine has been designed to operate in an industrial area. The operator must install and operate
this equipment as described in this manual. If any electromagnetic disturbances are detected the operator
must put in place corrective actions to eliminate these disturbances with, if necessary, assistance from
Lincoln Electric
Before installing the machine, the operator must check the work area for any devices that may malfunction because of
electromagnetic disturbances. Consider the following.
Input and output cables, control cables, and telephone cables that are in or adjacent to the work area and the
machine.
Radio and/or television transmitters and receivers. Computers or computer controlled equipment.
Safety and control equipment for industrial processes. Equipment for calibration and measurement.
Personal medical devices like pacemakers and hearing aids.
Check the electromagnetic immunity for equipment operating in or near the work area. The operator must be sure
that all equipment in the area is compatible. This may require additional protection measures.
The dimensions of the work area to consider will depend on the construction of the area and other activities that are
taking place.
Consider the following guidelines to reduce electromagnetic emissions from the machine.
Connect the machine to the input supply according to this manual. If disturbances occur if may be necessary to take
additional precautions such as filtering the input supply.
The output cables should be kept as short as possible and should be positioned together. If possible connect the
work piece to ground in order to reduce the electromagnetic emissions. The operator must check that connecting
the work piece to ground does not cause problems or unsafe operating conditions for personnel and equipment.
Shielding of cables in the work area can reduce electromagnetic emissions. This may be necessary for special
applications.
WARNING
The Class A equipment is not intended for use in residential locations where the electrical power is provided by the public
low-voltage supply system. There can be potential difficulties in ensuring electromagnetic compatibility in those locations,
due to conducted as well as radio-frequency disturbances.
WARNING
This equipment does not comply with IEC 61000-3-12. If it is connected to a public low voltage system, it is the
responsibility of the installer or user of the equipment to ensure, by consultation with the distribution network operator,
that the equipment may be connected.

English English
3
Safety
01/11
WARNING
This equipment must be used by qualified personnel. Be sure that all installation, operation, maintenance and repair
procedures are performed only by qualified person. Read and understand this manual before operating this equipment.
Failure to follow the instructions in this manual could cause serious personal injury, loss of life, or damage to this
equipment. Read and understand the following explanations of the warning symbols. Lincoln Electric is not responsible
for damages caused by improper installation, improper care or abnormal operation.
WARNING: This symbol indicates that instructions must be followed to avoid serious personal injury,
loss of life, or damage to this equipment. Protect yourself and others from possible serious injury or
death.
READ AND UNDERSTAND INSTRUCTIONS: Read and understand this manual before operating
this equipment. Arc welding can be hazardous. Failure to follow the instructions in this manual could
cause serious personal injury, loss of life, or damage to this equipment.
ELECTRIC SHOCK CAN KILL: Welding equipment generates high voltages. Do not touch the
electrode, work clamp, or connected work pieces when this equipment is on. Insulate yourself from
the electrode, work clamp, and connected work pieces.
ELECTRICALLY POWERED EQUIPMENT: Turn off input power using the disconnect switch at the
fuse box before working on this equipment. Ground this equipment in accordance with local electrical
regulations.
ELECTRICALLY POWERED EQUIPMENT: Regularly inspect the input, electrode, and work clamp
cables. If any insulation damage exists replace the cable immediately. Do not place the electrode
holder directly on the welding table or any other surface in contact with the work clamp to avoid the
risk of accidental arc ignition.
ELECTRIC AND MAGNETIC FIELDS MAY BE DANGEROUS: Electric current flowing through any
conductor creates electric and magnetic fields (EMF). EMF fields may interfere with some
pacemakers, and welders having a pacemaker shall consult their physician before operating this
equipment.
CE COMPLIANCE: This equipment complies with the European Community Directives.
ARTIFICIAL OPTICAL RADIATION: According with the requirements in 2006/25/EC Directive and
EN 12198 Standard, the equipment is a category 2. It makes mandatory the adoption of Personal
Protective Equipments (PPE) having filter with a protection degree up to a maximum of 15, as
required by EN169 Standard.
FUMES AND GASES CAN BE DANGEROUS: Welding may produce fumes and gases hazardous to
health. Avoid breathing these fumes and gases. To avoid these dangers the operator must use
enough ventilation or exhaust to keep fumes and gases away from the breathing zone.
ARC RAYS CAN BURN: 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. Use suitable clothing made from durable
flame-resistant material to protect you skin and that of your helpers. Protect other nearby personnel
with suitable, non-flammable screening and warn them not to watch the arc nor expose themselves to
the arc.
WELDING SPARKS CAN CAUSE FIRE OR EXPLOSION: Remove fire hazards from the welding
area and have a fire extinguisher readily available. Welding sparks and hot materials from the welding
process can easily go through small cracks and openings to adjacent areas. Do not weld on any
tanks, drums, containers, or material until the proper steps have been taken to insure that no
flammable or toxic vapors will be present. Never operate this equipment when flammable gases,
vapors or liquid combustibles are present.
WELDED MATERIALS CAN BURN: Welding generates a large amount of heat. Hot surfaces and
materials in work area can cause serious burns. Use gloves and pliers when touching or moving
materials in the work area.

English English
4
SAFETY MARK: This equipment is suitable for supplying power for welding operations carried out in
an environment with increased hazard of electric shock.
CYLINDER MAY EXPLODE IF DAMAGED: 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. Always keep cylinders in an upright position securely chained to a fixed support. Do
not move or transport gas cylinders with the protection cap removed. Do not allow the electrode,
electrode holder, work clamp or any other electrically live part to touch a gas cylinder. Gas cylinders
must be located away from areas where they may be subjected to physical damage or the welding
process including sparks and heat sources.
MOVING PARTS ARE DANGEROUS: There are moving mechanical parts in this machine, which can
cause serious injury. Keep your hands, body and clothing away from those parts during machine
starting, operating and servicing.
The manufacturer reserves the right to make changes and/or improvements in design without upgrade at the same time
the operator’s manual.
Introduction
The welding machines WELD PAK™ 2000 enables
welding:
GMAW (MIG/MAG)
FCAW-SS
SMAW (MMA)
The following equipment has been added to WELD
PAK™ 2000:
Bracket with rear wheels, M5 screws (4 units) and
M5 lock nuts (4 units)
Gun for GMAW process – 3m
Work lead – 3m
Gas hose – 2m
For GMAW and FCAW-SS process, the technical
specification describes:
Type of welding wire
Wire diameter
Recommended equipment, which can be bought by
user, was mentioned in the chapter "Accessories".
Installation and Operator Instructions
Read this entire section before installation or operation
of the machine.
Location and Environment
This machine will operate in harsh environments.
However, it is important that simple preventative
measures are followed to assure long life and reliable
operation:
Do not place or operate this machine on a surface
with an incline greater than 15° from horizontal.
Do not use this machine for pipe thawing.
This machine must be located where there is free
circulation of clean air without restrictions for air
movement to and from the air vents. Do not cover
the machine with paper, cloth or rags when
switched on.
Dirt and dust that can be drawn into the machine
should be kept to a minimum.
This machine has a protection rating of IP23. Keep
it dry when possible and do not place it on wet
ground or in puddles.
Locate the machine away from radio controlled
machinery. Normal operation may adversely affect
the operation of nearby radio controlled machinery,
which may result in injury or equipment damage.
Read the section on electromagnetic compatibility in
this manual.
Do not operate in areas with an ambient
temperature greater than 40°C.
Duty cycle and Overheating
The duty cycle of a welding machine is the percentage of
time in a 10 minute cycle at which the welder can
operate the machine at rated welding current.
Example: 60% duty cycle
Welding for 6 minutes. Break for 4 minutes.
Excessive extension of the duty cycle will cause the
thermal protection circuit to activate.
The machine is protected from overheating by a
temperature sensor.

English English
5
Input Supply Connection
WARNING
Only a qualified electrician can connect the welding
machine to the supply network. Installation had to be
made in accordance with the appropriate National
Electrical Code and local regulations.
Check the input voltage, phase and frequency supplied
to this machine before turning it on. Verify the
connection of ground wires from the machine to the input
source. The welding machine WELD PAK™ 2000 must
be connected to a correctly installed plug-in socket with
an earth pin.
Input voltage is 1x230V, 50/60Hz. For more information
about input supply refer to the technical specification
section of this manual and to the rating plate of the
machine.
Make sure that the amount of mains power available
from the input supply is adequate for normal operation of
the machine. The necessary delayed fuse (or circuit
breaker with "D" characteristic) and cable sizes are
indicated in the technical specification section of this
manual.
WARNING
The welding machine can be supplied from an engine
driven generator of output power at least 30% larger
than input power of the welding machine. Engine driven
generator must have voltage stabilization. Otherwise,
may cause a damage.
See "Technical Specifications" chapter.
WARNING
When powering welder from a generator be sure to turn
off welder first, before generator is shut down, in order to
prevent damage to welder!
Output Connections
Refer to points [8], [9] and [10] of the Figures below.
Controls and Operational Features
1. Power Switch ON/OFF (I/O): Controls the input
power to the machine. Be sure the power source is
connected to the mains supply before turning power
on ("I"). After input power is connected and the
power switch is turned on, the indicator will light up to
indicate the machine is ready to weld.
2. Process Welding’s Switch:
GMAW (MIG/MAG) process
Warning: Can be used to FCAW-
SS process.
SMAW (MMA) process
WARNING
When the machine is switched again on, last welding
process will be recalled.
WARNING
If the push-button is pushed in GMAW process in, the
output terminals will lived.
WARNING
During SMAW process, the output terminals are still
lived.
1
2
6
7
5
4
3
8
9
10
Figure 1
3. Welding Load Voltage / Current Control: Depending
on welding process, this knob controls:
GMAW
process
The welding load voltage and
set by this knob [6] (also during
welding).
SMAW
process
The welding current is set by
this knob [6] (also during
welding).
4. WFS/Hot Start Control: Depending on welding
process, this knob controls:
GMAW
process
Wire feed speed WFS: Value in
percentage of nominal value
wire feed speed.
SMAW
process
HOT START: Value in
percentage of nominal value
welding current during arc start
current. The control is used to
set the level of the increased
current and arc start current is
made easy.
5. Control: Depending on welding process, this knob
controls:
GMAW
process
Inductance: Arc control is
controlled by this knob. If the
value is higher, the arc will be
softer and during welding is less
spatters.
SMAW
process
ARC FORCE: The output
current is temporarily increased
to clear short circuit connections
between the electrode and the
workpiece.

English English
6
6. LED Indicator Power switch: This LED lights
up when the welding machine is ON and is
ready to work
7. Thermal Overload Indicator: It indicates that
the machine is overloaded or that the cooling
is not sufficient.
WARNING
If the welding current exceed 200 A, output power will be
turned off after 5 seconds. It will be indicated by Thermal
Overload Indicator. Output power will be turned on again
after 3 minutes.
8. EURO Socket: For connecting a welding gun (for
GMAW / FCAW-SS process).
9. Positive Output Socket for the Welding
Circuit: For connecting an electrode holder
with lead / work lead.
10. Negative Output Socket for the Welding
Circuit: For connecting an electrode holder
with lead / work lead.
11. Gas Connector: Connection for gas line.
12. Power Lead with Plug (3m): Power lead with plug is
a standard equipment. Connect the power lead with
plug to the main supply before turning power on.
12
11
Figure 2.
13
1415
17
18
16
Figure 3
13. Wire Drive (for GMAW, FCAW-SS process): 2-Roll
wire drive.
14. Welding Wire (for GMAW / FCAW-SS).
15. Spooled Wire (for GMAW / FCAW-SS): The machine
does not include a spooled wire.
16. Wire Spool Support: Maximum 15kg spools. Accepts
plastic, steel and fiber spools onto 51mm spindle.
Also accepts Readi-Reel®type spools onto included
spindle adapter.
17. Shield of Changing Polarity.
18. Terminal Block of Changing Polarity (for GMAW /
FCAW-SS process): This terminal block enables to
set the welding polarity (+ ; -), which will be given at
the welding holder.
WARNING
Positive (+) polarity is set at the factory.
WARNING
Before welding check the polarity for using electrodes
and wires.
If the welding polarity has to be changed, user should:
Switch off the machine.
Determine the wire polarity for the wire to be used.
Consult the electrode data for this information.
Take off the terminal block’s shield [17].
The tip of the wire on the terminal block [18] and
work lead fix as is shown in the Table 1 or
the Table 2.
Put on the terminal block’s shield.
WARNING
The machine must be used with the door completely
closed during welding.
WARNING
Not use handle to move the machine during work.

English English
7
Table 1.
Positive polarity
(factory setting)
Table 2.
Negative polarity