Lincoln Electric IM756-A User Manual

IM756-A

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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 thoughtful 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.

HANDY MIG

August, 2005

For use with machine Code Number:10919, 11205

ISO 9001

Designed and Manufactured Under a

Quality Program Certified by ABS Quality Evaluations, Inc.

to ISO 9001 Requirements.

CERTIFICATE NUMBER: 30273

Cleveland, Ohio 44117-1199 U.S.A. TEL: 216.481.8100 FAX: 216.486.1751 WEB SITE: www.lincolnelectric.com

ANSI RAB

QMS

OPERATOR’S MANUAL

• World's Leader in Welding and Cutting Products •

• Sales and Service through Subsidiaries and Distributors Worldwide •

SAFETY

WARNING

CALIFORNIA PROPOSITION 65 WARNINGS

Diesel engine exhaust and some of its constituents are known to the State of California to cause cancer, birth defects, and other reproductive harm.

The Above For Diesel Engines

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.

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 available from the Lincoln Electric Company, 22801 St. Clair Avenue, Cleveland, Ohio 44117-1199.

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

The engine exhaust from this product contains chemicals known to the State of California to cause cancer, birth defects, or other reproductive harm.

The Above For Gasoline Engines

FOR ENGINE powered equipment.

1.a. Turn the engine off before troubleshooting and maintenance work unless the maintenance work requires it to be running.

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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, coversand 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.

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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.

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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.

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

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 use the following procedures in order to minimize exposure to EMF fields from the welding circuit:

2.d.1.

Route the electrode and work cables together - Secure them with tape when possible.

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

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

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

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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.

2.d.4. Connect the work cable to the workpiece as close as possible to the area being welded.

2.d.5. Do not work next to welding power source.

Mar ‘95

SAFETY

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.

Mar ‘95

vapors

iii

SAFETY

iii

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

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

Mar ‘95

SAFETY

PRÉCAUTIONS DE SÛRETÉ

Pour votre propre protection lire et observer toutes les instructions et les précautions de sûreté specifiques qui parraissent dans ce manuel aussi bien que les précautions de sûreté générales suivantes:

Sûreté Pour Soudage A L’Arc

1. Protegez-vous contre la secousse électrique:

a. Les circuits à l’électrode et à la piéce sont sous tension

quand la machine à souder est en marche. Eviter toujours tout contact entre les parties sous tension et la peau nue ou les vétements mouillés. Porter des gants secs et sans trous pour isoler les mains.

b. Faire trés attention de bien s’isoler de la masse quand on

soude dans des endroits humides, ou sur un plancher metallique ou des grilles metalliques, principalement dans

les positions assis ou couché pour lesquelles une grande partie du corps peut être en contact avec la masse.

c. Maintenir le porte-électrode, la pince de masse, le câble

de soudage et la machine à souder en bon et sûr état defonctionnement.

d.Ne jamais plonger le porte-électrode dans l’eau pour le

refroidir.

e. Ne jamais toucher simultanément les parties sous tension

des porte-électrodes connectés à deux machines à souder parce que la tension entre les deux pinces peut être le total de la tension à vide des deux machines.

f. Si on utilise la machine à souder comme une source de

courant pour soudage semi-automatique, ces precautions pour le porte-électrode s’applicuent aussi au pistolet de soudage.

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. Eloigner les matériaux inflammables ou les recouvrir afin de prévenir tout risque d’incendie dû aux étincelles.

7. Quand on ne soude pas, poser la pince à une endroit isolé de la masse. Un court-circuit accidental peut provoquer un échauffement et un risque d’incendie.

8. S’assurer que la masse est connectée le plus prés possible de la zone de travail qu’il est pratique de le faire. Si on place la masse sur la charpente de la construction ou d’autres endroits éloignés de la zone de travail, on augmente le risque de voir passer le courant de soudage par les chaines de levage, câbles de grue, ou autres circuits. Cela peut provoquer des risques d’incendie ou d’echauffement des chaines et des câbles jusqu’à ce qu’ils se rompent.

9. Assurer une ventilation suffisante dans la zone de soudage. Ceci est particuliérement important pour le soudage de tôles galvanisées plombées, ou cadmiées ou tout autre métal qui produit des fumeés toxiques.

10. Ne pas souder en présence de vapeurs de chlore provenant d’opérations de dégraissage, nettoyage ou pistolage. La chaleur ou les rayons de l’arc peuvent réagir avec les vapeurs du solvant pour produire du phosgéne (gas fortement toxique) ou autres produits irritants.

11. Pour obtenir de plus amples renseignements sur la sûreté, voir le code “Code for safety in welding and cutting” CSA Standard W 117.2-1974.

2. Dans le cas de travail au dessus du niveau du sol, se protéger contre les chutes dans le cas ou on recoit un choc. Ne jamais enrouler le câble-électrode autour de n’importe quelle partie du corps.

3. Un coup d’arc peut être plus sévère qu’un coup de soliel, donc:

a. Utiliser un bon masque avec un verre filtrant approprié

ainsi qu’un verre blanc afin de se protéger les yeux du rayonnement de l’arc et des projections quand on soude ou quand on regarde l’arc.

b. Porter des vêtements convenables afin de protéger la

peau de soudeur et des aides contre le rayonnement de l‘arc.

c. Protéger l’autre personnel travaillant à proximité au

soudage à l’aide d’écrans appropriés et non-inflammables.

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.

PRÉCAUTIONS DE SÛRETÉ POUR LES MACHINES À SOUDER À TRANSFORMATEUR ET À REDRESSEUR

1. Relier à la terre le chassis du poste conformement au code de l’électricité et aux recommendations du fabricant. Le dispositif de montage ou la piece à souder doit être branché à une bonne mise à la terre.

2. Autant que possible, I’installation et l’entretien du poste seront effectués par un électricien qualifié.

3. Avant de faires des travaux à l’interieur de poste, la debrancher à l’interrupteur à la boite de fusibles.

4. Garder tous les couvercles et dispositifs de sûreté à leur place.

Mar. ‘93

for selecting a QUALITY product by Lincoln Electric. We want you

Thank You

to take pride in operating this Lincoln Electric Company product

••• as much pride as we have in bringing this product to you!

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 received.

Please record your equipment identification information below for future reference. This information can be found on your machine nameplate.

Product _________________________________________________________________________________

Model Number ___________________________________________________________________________

Code Number or Date Code_________________________________________________________________

Serial Number____________________________________________________________________________

Date Purchased___________________________________________________________________________

Where Purchased_________________________________________________________________________

Whenever you request replacement parts or information on this equipment, always supply the information you have recorded above. The code number is especially important when identifying the correct replacement parts.

On-Line Product Registration

- Register your machine with Lincoln Electric either via fax or over the Internet.

• For faxing: Complete the form on the back of the warranty statement included in the literature packet accompanying this machine and fax the form per the instructions printed on it.

• For On-Line Registration: Go to our

“Product Registration”. Please complete the form and submit your registration.

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:

WEB SITE at www.lincolnelectric.com. Choose “Quick Links” and then

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.

MASTER TABLE OF CONTENTS FOR ALL SECTIONS

Page

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

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

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

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

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

Changing Polarity ..................................................................................................A-3

Gun Installation......................................................................................................A-3

Input Connections..................................................................................................A-3

Gas Connections ...................................................................................................A-3

Shielding Gas Connections ...................................................................................A-4

Code Requirements ..............................................................................................A-4

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

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

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

Recommended Processes.....................................................................................B-1

Operation Features and Controls .........................................................................B-1

Design Features ....................................................................................................B-1

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

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

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

Welding Operations ...............................................................................................B-2

Shielding Gas ........................................................................................................B-3

Making a Weld and Process Table........................................................................B-4

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

Changing Machine over to Feed Other Wire Sizes,Overload Protection...............B-5

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Accessories.....................................................................................................Section C

Accessories ...........................................................................................................C-1

Replacement Parts................................................................................................C-1

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

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

Items Requiring No Maintenance ..........................................................................D-1

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

Cleaning the Gun Liner..........................................................................................D-2

Cleaning Components as Required.......................................................................D-2

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

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

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

Gun Assembly Removal........................................................................................D-3

Work Cable Installation..........................................................................................D-3

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Troubleshooting..............................................................................................Section E

Safety Precautions.................................................................................................E-1

How to Use Troubleshooting Guide.......................................................................E-1

Troubleshooting Guide.........................................................................E-2 THRU E-4

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Wiring Diagrams..............................................................................................Section F

Wiring Diagram .....................................................................................................F-1

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Parts Lists ....................................................................................................P437 Series

A-1

INSTALLATION

TECHNICAL SPECIFICATIONS – HANDY MIG

INPUT – SINGLE PHASE ONLY

Standard Voltage/Frequency Input Current

120V/60Hz 20 Amps - Rated Output

RATED OUTPUT

Duty

Cycle Amps Volts at Rated Amperes

20% Duty Cycle 70 17

OUTPUT RANGE

Welding Current Range Maximum-Open Circuit Voltage No Load 0 - 450 in/min

DC OUTPUT: 35-88 Amps 29V (0 - 17.7m/min)

While welding 0-300 in/min.

(0-11.8 m/min.)

RECOMMENDED INPUT CABLE AND FUSE SIZES

Fuse or

Output Mode Input Voltage Breaker Size1Input Amps Power Cord Extension Cord

A-1

RATED 120V/60Hz 20 Amp 20 15 Amp, 125V, Three Conductor

OUTPUT Three Prong Plug #12 AWG

(NEMA Type 5-15P) (3.3 mm2) or Larger

Up to 50 Ft. (15.2 mm)

PHYSICAL DIMENSIONS

Height Width Depth Weight

12.8 in 8.8 in 18 in 46 Ibs 325 mm 224 mm 457 mm 20.9 kg

If connected to a circuit protected by fuses use Time Delay Fuse marked “D”.

HANDY MIG

A-2

Handy Mig 101

IM000

October 1998

For use with machines having Code Numbers:

00000

Safety Depends on You

Lincolnarc weldingandcutting equipmentisdesigned andbuilt withsafetyinmind. However,your overallsafetycan beincreasedby properinstallation...andthoughtful operationonyour part.DO NOT INSTALL,OPERATEOR REPAIR THISEQUIPMENT WITHOUT READINGTHISMANUALANDTHE SAFETT PRECAUTIONS CONTAINEDTHROUGHOUT.And, mostimportantly,think beforeyou act and be careful.

World's Leader in Welding and Cutting Products Premier Manufacturer of Industrial Motors

Sales and Service through Subsidiaries and Distributors Worldwide

22801 St. Clair Ave. Cleveland, ohio 44117-1199 U.S.A. Tel. (216) 481-8100

INSTALLATION

Read entire installation section before starting installation.

SAFETY PRECAUTIONS

WARNING

ELECTRIC SHOCK can kill.

• Only qualified personnel should perform this installation.

• Only personnel that have read and understood the Machine 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 Machine 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

If you have not already done so, unpack the machine from its carton and remove all packing material around the machine. The following items are shipped loose. (see Figure A.1):

A-2

FIGURE A.1

1. HANDY MIG with work clamp, Gun and cable assembly attached.

2. This operating manual

3. Two contact tips for .035(0.9mm) diameter wire.

4. Three contact tips for .025(0.6mm) diameter wire.

5. Gas Nozzle.

6. Chipping hammer and brush.

7. Starter spool of .035” (0.9mm) NR211-MP flux

cored wire.

8. Starter spool of .025” (0.6mm) solid mig wire.

9. Gas regulator and hose with hose clamps.

10. Handshield with filter plate and lens.

For available options and accessories refer to the Accessories Section of this manual.

HANDY MIG

GAS INLET FITTING

POWER INPUT CABLE

A-3

WORK CABLE

GUN CABLE

WORK CABLE

GUN CABLE

INSTALLATION

A-3

SELECT SUITABLE LOCATION

Place the machine on a secure, level surface or recommended undercarriage. The machine may topple over if this procedure is not followed. To minimize over heating, locate the welder in a dry location where there is free circulation of clean air. Do not place on combustible surfaces.

STACKING

Machines cannot be stacked.

CHANGING POLARITY

1. For Negative Polarity Welding (DC-): Refer to

Figure A.2. As delivered, the machine is wired for Negative polarity with the gun cable connected to the Negative (-) output terminal and the work cable to the Positive (+) output terminal. Make sure that both thumbscrews are tight. This is the typical configuration for Flux Cored Welding (FCAW).

FIGURE A.2

INPUT CONNECTIONS

(FIGURE A.4)

Refer to Figure A.4. The machine has two input connections, the power

input cable and the gas inlet fitting. The power input cable and gas inlet fitting are located on the rear.

GAS CONNECTION

When using the MIG process, a cylinder of shielding gas (appropriate for the metal being welded) must be obtained.

2.For Positive Polarity Welding (DC+): Refer to Figure A.3. To wire for Positive polarity, connect the gun cable to the Positive (+) output terminal and the work cable to the Negative (-) terminal. This is the typical configuration for the Metal Inert Gas (MIG) process. Make sure that both thumbscrews are tight.

(FIGURE A.3)

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.

BUILDUP OF SHIELDING GAS may harm health or kill.

• Shut off shielding gas supply when not in use.

• SEE AMERICAN NATIONAL STANDARD Z-49.1, “SAFETY IN WELDING AND CUTTING” PUB-

LISHED BY THE AMERICAN WELDING SOCIETY.

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HANDY MIG

+ 22 hidden pages