Lincoln Electric 170I User Manual

Handymig 170i

A Division of Lincoln Electric Company (Aust) Ply Ltd A.B.N. 36 000 040 308

35 Bryant Street, Padstow, NSW2211, Australia

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IM711

January, 2001

Safety Depends on You

LiquidArc machines are designed and built with safety in mind. However, your overall safety can be increased by proper installation ... and thoughtful operation on your part.

OPERATE OR REPAIR THIS EQUIPMENT WITHOUT READING THIS MANUAL AND THE SAFETY PRECAUTIONS CONTAINED THROUGHOUT.

most importantly, think before you act and be careful.

DO NOT INSTALL,

And,

For use with machine Code Numbers

10843

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

ISO 9001

ANSI RAB

QMS

Designed and Manufactured Under a

Quality Program Certified by ABS Quality Evaluations, Inc.

to ISO 9001 Requirements.

CERTIFICATE NUMBER: 30273

Made exclusive for Australia

OPERATOR’S MANUAL

SAFETY

WARNING

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.

For more detailed information it is strongly recommended that you purchase a copy of "Safety in Welding and Cutting - ANSI Standard Z49.1" and WTIA Technical Note 7. All WTIA publications and ANSI/AWS Standards are available from the Welding Technology Institute of Australia, PO Box 6165 Silverwater NSW 2128. For copies of various Australian Standards contact your local S.A.A. office.

BE SURE THAT ALL INSTALLATION, OPERATION, MAINTENANCE AND REPAIR PROCEDURES ARE PERFORMED ONLY BY QUALIFIED INDIVIDUALS.

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.

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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.

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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.

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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.

1.h. To avoid scalding, do not remove the radiator pressure cap when the engine is hot.

Oct ‘00

____________________________________________________

SAFETY

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 follow safe practices that minimize their exposure to electric and magnetic fields (EMF).

2.e. For welders wearing implanted pacemakers, safe welding practices are particularly important and additional procedures should be followed by those who have decided to continue to weld. (Hopefully in keeping with a doctor’s advice).

2.f. The following procedures will not eliminate exposure to EMF or

the possibility of arc welding having an effect on a pacemaker, however if followed, they will significantly reduce exposure to electric and magnetic fields. Electric and magnetic fields are created any time electric current flows through a conductor, however it is not clear whether such exposure affects ones health.

2.g. Some researchers have reported that exposure to EMF may

cause leukemia or other illnesses. These claims originally arose in relation to high voltage electric power lines and are very much in dispute in the medical and scientific arena, however the best advice is to minimize your exposure to EMF to protect your health should doctors eventually decide there is a risk.

2.h. There are four fundamental facts about EMF:

2.h.1 With direct current (DC), the field strength is relatively

constant and does not change.

2.h.2 With alternating current (AC), the field strength constant-

ly changes.

2.h.3 The greater the current flow, i.e. the higher the amps,

the stronger the field created by the current

2.h.4 The closer the conductor or electrical device is to the

body the greater the exposure to the field.

MINIMIZE EXPOSURE TO EMF

2.i. All welders should use the following procedures to minimize

EMF exposure:

2.i.1 Route electrode or gun and work cables together. Secure

them with tape if possible.

2.i.2 Never coil the electrode lead around your body.

2.i.3 Do not place your body between the electrode and work

cables. If your electrode cable is on your right side the work cable should also be on your right side.

2.i.4 Connect the work cable to the work piece as close as possible to the area being welded. (This is also a good practice to eliminate a common problem on welding - a poor work connection.

2.i.5 Do not work next to the welding power source.

ADDITIONAL PRECAUTIONS FOR WELDERS WITH PACEMAKERS

2.j. There is no question that the fields in arc welding can interfere with a pacemakers function. Generally the interference does not permanently damage the pacemaker. Once the wearer leaves the arc welding environment or stops welding, the pacemaker returns to normal functioning. The welding arc has little or no effect on the operation of some pacemakers, especially designs that are bi-polar or designed to filter out such interference.

2.k. For a welder or anyone working around electrical equipment

the selection of a pacemaker is very important. Get a doctor’s advice about which pacemaker is the least sensitive to interference from welding while still being medically suitable.

2.l. In addition to the normal safety precautions, the following additional procedures should be adopted by welders with pacemakers.

2.l.1 Use gas welding when the application is suitable.

2.l.2 Use the lowest current setting appropriate for the application. Do not exceed 400 amps. Low current (75-200 amps) direct current (DC) welding should be used if arc welding is necessary. Do not TIG weld with high frequency.

2.l.3 Do not use repeated, short welds. Wait about ten seconds between stopping one weld and starting the next. When having difficulty starting an electrode, do not restrike the rod repeatedly.

2.l.4 If you feel light headed, dizzy or faint, immediately stop welding. Lay the electrode holder down so that it does not contact the work and move away from any welding being performed. Arrange your work in advance so that, if you become dizzy and drop the electrode holder it will not fall on your body or strike the work.

2.l.5 Do not work on a ladder or other elevated position or in a cramped, confined place.

2.l.6 Do not work alone. Work only in the presence of an individual who understands these precautions and the possible effect welding may have on your pacemaker.

2.l.7 Do not work near spot welding equipment.

2.l.8 If you have a pacemaker and wish to continue arc welding, discuss this and any other questions you may have with your physician and follow his or her advice. The doctor may wish to contact the pacemaker manufacturer for a recommendation. As mentioned before, the design of the pacemaker significantly affects the degree to which it is subject to interference from a welding circuit. Do not rely on the fact that you know another welder with a pacemaker who has welded for years without experiencing a problem.That welder and his or her pacemaker may be quite different from you and your pacemaker.

Oct ‘00

iii

SAFETY

iii

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.

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.

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 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.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.

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.

vapors

Mar ‘95

SAFETY

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 National Electrical Code, all local codes and the manufacturer’s recommendations.

8.c. Ground the equipment in accordance with the National Electrical Code and the manufacturer’s recommendations.

Mar ‘95

SAFETY

INSTRUCTIONS FOR ELECTROMAGNETIC COMPATIBILITY

Conformance

Products displaying the C-Tick mark are in conformity with Australian/New Zealand requirements for Electromagnetic Compatibility (EMC) according to standard (emission) AS/NZS 3652 "Electromagnetic Compatibility – Arc Welding Equipment".

Products displaying the CE mark are in conformity with European Community Council Directive 89/336/EEC requirements for EMC by implementing EN50199 "Electromagnetic Compatibility (EMC) – Product standard for arc welding equipment".

Products are:

• For use with other Lincoln Electric/LiquidArc equipment.

• Designed for industrial and professional use.

Introduction

All electrical equipment generates small amounts of electromagnetic emission. Electrical emission may be transmitted through power lines or radiated through space, similar to a radio transmitter. When emissions are received by other equipment, electrical interference may result. Electrical emissions may effect many kinds of electrical equipment: other nearby welding equipment, radio and TV transmitters and receivers, numerical controlled machines, telephone systems, computers, etc. Be aware that interference may result and extra precautions may be required when a welding power source is used in a domestic establishment.

Installation and Use

The purchaser/user is responsible for installing and using the welding equipment according to the manufacturer’s instructions. If electromagnetic disturbances are detected then it shall be the responsibility of the purchaser/user of the welding equipment to resolve the situation with the technical assistance of the manufacturer. In some cases this remedial action may be as simple as earthing (grounding) the welding circuit (see note below). In other cases it could involve constructing an electromagnetic screen enclosing the power source and the work complete with associated input filters. In all cases electromagnetic disturbances must be reduced to the point where they are no longer troublesome.

Note: The welding circuit may or may not be earthed for safety reasons according to national codes. Changing the earthing arrangements should only be authorized by a person who is competent to assess whether the changes increase the risk of injury, eg. by allowing parallel welding current return paths which may damage the earth circuits of other equipment.

Assessment of Area

Before installing welding equipment the purchaser/user shall make an assessment of potential problems in the surrounding area.

The following shall be taken into account:

• Other supply cables, control cables, signalling and telephone cables above, below and adjacent to the welding equipment;

• Radio and television transmitters and receivers;

• Computer and other control equipment;

• Safety critical safety equipment, eg. guarding of industrial

equipment;

• The health of people around, eg. the use of pacemakers and hearing aids;

• Equipment used for calibration or measurement;

• The immunity of other equipment in the environment. The

purchaser/user shall ensure that other equipment being used in the environment is compatible. This may require additional protection measures;

• The time of the day that welding or other activities are to be carried out.

The size of the surrounding area to be considered will depend on the structure of the building and other activities that are taking place. The surrounding area may extend beyond the boundaries of the premises.

Methods of Reducing Emissions

Mains Supply

Welding equipment should be connected to the mains supply according to the manufacturer’s recommendations.If interference occurs, it may be necessary to take additional precautions such as filtering the mains supply. Consideration should be given to shielding the supply cable of permanently installed welding equipment in metallic conduit or equivalent. Shielding should be electrically continuous throughout its length. The shielding should be connected to the welding power source so that good electrical contact is maintained between the conduit and the welding power source enclosure.

Maintenance of the Welding Equipment

The welding equipment should be routinely maintained according to the manufacturer’s recommendations. All access and service doors and covers should be closed and properly fastened when the welding equipment is in operation. The welding equipment should not be modified in any way except for those changes and adjustment covered in the manufacturer’s instructions. In particular, the spark gaps of arc initiation and stabilizing devices should be adjusted and maintained according to the manufacturer’s recommendations.

Welding Cables

The welding cables should be kept as short as possible and should be positioned close together, running at or close to the floor level.

Equipotential Bonding

Bonding of all metallic components in the welding installation and adjacent to it should be considered. However, metallic components bonded to the work piece will increase the risk that the operator could receive a shock by touching these metallic components and the electrode at the same time. The operator should be insulated from all such bonded metallic components.

Earthing of the workpiece

Where the workpiece is not bonded to earth for electrical safety, nor connected to earth because of its size and position, eg. ship’s hull or building steelwork, a connection bonding the workpiece to earth may reduce emissions in some, but not all instances. Care should be taken to prevent the earthing of work pieces increasing the risk of injury to users, or damage to other electrical equipment. Where necessary, the connection of the workpiece to earth should be made by direct connection to the workpiece, but in some countries where direct connection is not permitted, the bonding should be achieved by suitable capacitance, selected according to national regulations.

Screening and Shielding

Selective screening and shielding of other cables and equipment in the surrounding area may alleviate problems of interference. Screening of the entire welding installation may be considered for special applications.

Portions of the preceding text are extracted from:

• Australian/New Zealand standard AS/NZS 3652. Permission to reproduce has been granted by Standards Australia and Standards New Zealand. For further explanation, readers should be referred to the standard itself.

• British Standards Institution standard BS EN 50199:1995. Reproduced with permission of BSI under license number 2000SK0631. Complete standards can be obtained from BSI Customer Services, 389 Chiswick High Road, London W4 4AL. United Kingdom. (Tel +44 (0) 20 8996 9001).

Copyright of above text is property of Standards Australia, Standards New Zealand and British Standards Institution. Permission to reproduce the text must be obtained.

JAN ‘01

Thank You

vivi

for selecting a QUALITY product. We want you to take pride in operating this LiquidArc product ••• as much pride as we have in bringing this product to you!

Please Examine Carton

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 or information on this equipment always supply the information you have recorded above.

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:

and Equipment For Damage Immediately

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.

vii

TABLE OF CONTENTS

Page

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

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

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

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

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

Tilting...............................................................................................................A-3

Output Connections...............................................................................................A-3

Work Clamp Installation..................................................................................A-3

Work Cable Installation...................................................................................A-4

Gun Installation......................................................................................................A-4

Connecting Gun Cable to the Handymig 170i.................................................A-4

Gas Connection.....................................................................................................A-4

Input Connections..................................................................................................A-5

Electrical Input Connection for Rated Output ........................................................A-6

Line Cord Connection .....................................................................................A-6

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

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

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

Recommended Processess............................................................................B-1

Optional Features and Controls......................................................................B-1

Design Features and Advantages .........................................................................B-1

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

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

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

Welding Operations...............................................................................................B-3

Sequence of Operations .................................................................................B-3

Wire Loading..............................................................................................B-3

Friction Brake Adjustments........................................................................B-3

Wire Threading...........................................................................................B-4

Making a Weld ...........................................................................................B-5

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

Process Guidelines................................................................................................B-5

Changing Over to Feed Other Wire Sizes.............................................................B-6

Welding with GMAW..............................................................................................B-6

Welding with FCAW...............................................................................................B-6

Learning to Weld .......................................................................................................B-7

Overload Protection...............................................................................................B-7

Output Overload..............................................................................................B-7

Thermal Protection..........................................................................................B-7

Electronic Wire Drive Motor Protection...........................................................B-7

Learning to Weld....................................................................................................B-7

The Arc-Welding Circuit..................................................................................B-7

The Self-Shielded FCAW Welding Arc............................................................B-8

The GMAW (MIG) Welding Arc.......................................................................B-8

Process Selection ...........................................................................................B-9

For GMAW (MIG) Process.........................................................................B-9

For FCAW (Innershield) Process...............................................................B-9

Common Metals..............................................................................................B-9

Joints Types and Positions .............................................................................B-9

Butt Welds..................................................................................................B-9

Penetration...............................................................................................B-10

Fillet Welds...............................................................................................B-10

Handymig 170i

viii

TABLE OF CONTENTS

Page

Learning to Weld (Continues)......................................................................................------

Welding in a Vertical Position........................................................................B-10

Vertical-up and Overhead Welding.........................................................B-10

Vertical-down Welding ............................................................................B-11

Machine Set Up for the Self-Shielded FCAW Process .................................B-11

Welding Techniques for the Self-Shielded FCAW Process ..........................B-11

The Correct Welding Position .................................................................B-11

The Correct Way to Strick an Arc............................................................B-12

The Correct Electrical Stick Out..............................................................B-12

The Correct Welding Speed....................................................................B-12

Helpful Hints..................................................................................................B-13

Practice.........................................................................................................B-13

Machine Set Up for the GMAW (MIG) Process.............................................B-14

Welding Techniques for the GMAW (MIG) Process......................................B-14

The Correct Welding Position .................................................................B-14

The Correct Way to Strick an Arc............................................................B-14

The Correct Electrical Stick Out..............................................................B-15

The Correct Welding Speed....................................................................B-15

Helpful Hints..................................................................................................B-15

Practice.........................................................................................................B-15

Troblreshooting Welds..................................................................................B-16

To Eliminate Porosity.............................................................................B-16

To Eliminate a Ropy Convex Bead........................................................B-16

To Reduce Spatter.................................................................................B-16

To Correct Poor Penetration..................................................................B-16

If Arc Blow Occurs..................................................................................B-16

To Eliminate Stubbing............................................................................B-16

Proper Gun Handling .............................................................................B-17

Application Chart.....................................................................................................B-18

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

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

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

Wire Feed Compartment.................................................................................D-1

Fan Motor........................................................................................................D-1

Wire Reel Spindle...........................................................................................D-1

Gun and Cable................................................................................................D-1

Gun Cable Cleaning................................................................................D-1

Contact Tips, Nozzles, and Gun Tubes..................................................D-1

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

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

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

Changing Liner................................................................................................D-3

Gun Handle Parts ...........................................................................................D-3

Ground Test Procedure.........................................................................................D-4

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

Handymig 170i Wiring Diagram .............................................................................F-1

Handymig 170i Parts ............................................................................P390,P202,P189

Handymig 170i

A-1

INSTALLATION

TECHNICAL SPECIFICATIONS – Handymig 170i

INPUT – SINGLE PHASE ONLY

A-1

Standard

Voltage/Frequency AS1966.1

240V/50Hz Rated Input Current

12.7 Amps

RATED OUTPUT

Duty

Cycle Amps Volts at Rated Amperes

20% 130 20

OUTPUT

Welding

Rated DC Output: 30 – 170 amps 33 N/A

Current Range Maximum Open Circuit Voltage Auxiliary Power

RECOMMENDED INPUT CABLE AND FUSE SIZES

Fuse or

Output Mode Input Voltage Breaker Size Input Amps Power Cord

RATED 240V/50Hz 25 Super Lag 12.7 15Amp, 240V,

Three Pin Plug

PHYSICAL DIMENSIONS

Height Width Depth Weight

305 mm 248 mm 419 mm 25.9 kg

Handymig 170i

A-2

WELDING AMP

25-125

INSTALLATION

A-2

SAFETY PRECAUTIONS

• Read entire installation section before starting installation.

WARNING

ELECTRIC SHOCK can kill.

• Only qualified personnel should perform this installation.

• Only personnel that have read and understood the Handymig 170i 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 Handymig 170i 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

WELDIN

G AMP

-1

Handymig 170i

FIGURE A.1

ANGE

If you have not already done so, unpack the Handymig 170i from its carton and remove all packing material around the Handymig 170i. Remove the following loose items from the carton (see Figure A.1):

1. Handymig 170i

2. Gun and cable assembly

(1)

3. Literature and miscellaneous includes: a) This operating manual b) A separate .030" (0.8 mm) contact tip c) Hex key wrench for removal of drive roll.

4. 10 ft (3,0 m) work cable.

5. Work clamp.

6. Adjustable mixed-Gas Regulator & Hose.

(1)

The gun is ready to feed .023" – .025" (0.6 mm) diameter wire.

Handymig 170i

WELDING AMP RANGE 30-70

A-3

INSTALLATION

A-3

SELECT SUITABLE LOCATION

Locate the welder in a dry location where there is free circulation of clean air into the louvers in the back and out the front of the unit. A location that minimizes the amount of smoke and dirt drawn into the rear louvers reduces the chance of dirt accumulation that can block air passages and cause overheating.

STACKING

Handymig 170i’s cannot be stacked.

TILTING

Each machine must be placed on a secure, level surface, either directly or on the recommended cart. The machine may topple over if this procedure is not followed.

OUTPUT CONNECTIONS

6. Wire Feed Gearbox.

7. Cable Hanger.

8. Thumbscrew.

Work Clamp Installation

Attach the work clamp per the following: Refer to Figure A-3.

FIGURE A.3

Refer to Figure A.2.

1. Work Cable Access Hole.

2. Gun Cable and Control Lead Access Hole.

3. Connector Block.

4. Gun Trigger Lead Connectors.

5. Positive (+) and negative (–) output terminals.

FIGURE A.2

1. Insert the work cable terminal lug with the larger hole through the strain relief hole in the work clamp as shown above.

2. Fasten securely with the bolt and nut provided.

Handymig 170i

A-4

INSTALLATION

A-4

Work Cable Installation

Refer to Figure A.2.

1. Open the wire feed section door on the right side of the Handymig 170i.

2. Pass the end of the work cable that has the terminal 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 GMAW Only: Refer to Figure A.2. As deliv- ered, the machine is connected for positive electrode polarity. This is the appropriate configuration for the GMAW (MIG) process. To complete installation, use the provided wing nut to connect the work cable’s terminal lug to the negative (–) output terminal (5) located above the Wire Feed Gearbox (6). Make sure that both wing nuts are tight.

For Innershield Only: Refer to Figure A.4. To wire

5. for negative polarity (required for the Innershield process), connect the short cable attached to the connector block (1) to the negative (–) output terminal (2) and the work cable (3) to the positive (+) terminal (4).

FIGURE A.4

NOTE: If .035" or .045" (0.9 mm or 1.2 mm) Innershield flux-cored wire is to be used, the appropriate Innershield kit is required.

Connecting Gun Cable to the Handymig 170i.

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 control 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, behind the gas line.

3. Insert the connector on the gun conductor cable through the Gun Cable Access Hole (2) in the Handymig 170i case front. Make sure the connector is all the way in the brass connector block to obtain proper gas flow. If the gun connector will not fully insert, unscrew the thumbscrew on the connector block a few turns. Rotate the connector so control leads are on the underside and tighten the Thumbscrew on the connector block.

4. Connect the gun trigger control lead terminals to the two insulated 1/4" (6,4 mm) tab terminal connector bushings located above the “Gun Trigger Connection” decal in the wire feed section (4). Either lead can go to either connector.

CAUTION

If the gun trigger switch being used is other than that supplied, the switch must be a normally open, momentary switch. The terminals of the switch must be insulated from the welding circuit. Malfunction of the Handymig 170i may result if this switch shorts to the Handymig 170i welding output circuit or is common to any electrical circuit other than the Handymig 170i trigger circuit.

GUN INSTALLATION

As shipped from the factory, the Handymig 170i gun is ready to feed .023" – .025"(.6mm) solid wire. If .030" (0.8 mm) solid wire is to be used, change the contact tip to the appropriate size.

GAS CONNECTION

The Handymig 170i is supplied with a mixed gas Regulator and a 3m gas hose. A cylinder of an appropriate shielding gas must be obtained from your gas distributor.

Handymig 170i

A-5

INSTALLATION

A-5

WARNING

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.

WARNING

BUILDUP OF SHIELDING GAS may harm health or kill.

• Shut off shielding gas supply when not in use.

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 the flow regulator to the cylinder valve and tighten the union nut securely with a wrench..

4. Refer to Figure A.6. Attach one end of inlet gas hose to the outlet fitting of the flow regulator and tighten the union nut securely with a wrench. Connect the other end to the Handymig 170i Gas Solenoid Inlet Fitting (5/8-18 female threads — for CGA — 032 fitting). Make certain the gas hose is not kinked or twisted.

5. Reinstall case side before connecting input power.

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 and earth ground. Refer to Figure A.5.

FIGURE A.5

Flow Regulator

Gas Hose

Cylinder Valve

INPUT CONNECTIONS

FIGURE A.6

GAS SOLENOID INLET FITTING

POWER INPUT CABLE

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.

Handymig 170i

Refer to Figure A.6.

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