Lincoln Electric IM890 User Manual

Operator’s Manual

RETURN TO MAIN MENU

POWER MIG ®(140, 180 MODELS)

For use with machines having Code Numbers:

11254, 11255, 11256, 11257 and 11444

LINCOLN

ELECTRIC

Save for future reference

Date Purchased

Code: (ex: 10859)

Serial: (ex: U1060512345)

IM890-A | Issue D ate Nov- 13

www.lincolnelectric.com/register

Authorized Service and Distributor Locator:

www.lincolnelectric.com/locator

THANK YOU FOR SELECTING

AT ALL

TIMES.

SPECIAL SITUATIONS

Additional precautionary measures

A QUALITY PRODUCT BY LINCOLN ELEC TRIC.

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.

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.

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.

KEEP YOUR HEAD OUT OF THE FUMES.

DON’T get too close to the arc. Use

corrective lenses if necessary to stay a reasonable distance away from the arc.

READ and obey the Material Safety

Data Sheet (MSDS) and the warning label that appears on all containers of welding materials.

USE ENOUGH VENTILATION or

exhaust at the arc, or both, to keep the fumes and gases from your breathing zone and the general area.

IN A LARGE ROOM OR OUTDOORS, natural ventilation may be

adequate if you keep your head out of the fumes (See below).

USE NATURAL DRAFTS or fans to keep the fumes away from your

face.

If you de velop unusual symptoms, see your supervisor. Perhaps the welding atmosphere and ventilation system should be checked.

WEAR CORRECT EYE, EAR & BODY PROTECTION

PROTECT your eyes and face with welding helmet

properly fitted and with proper grade of filter plate (See ANSI Z49.1).

PROTECT your body from welding spatter and arc

flash with protective clothing including woolen clothing, flame-proof apron and gloves, leather leggings, and high boots.

PROTECT others from splatter, flash, and glare with

protective screens or barriers.

IN SOME AREAS, protection from noise may be

appropriate.

BE SURE protective equipment is in good condition.

Also, wear safety glasses in work area

DO NOT WELD OR CUT containers or materials which previously had

been in contact with hazardous substances unless they are properly cleaned. This is extremely dangerous.

DO NOT WELD OR CUT painted or plated parts unless special

precautions with ventilation have been taken. They can release highly toxic fumes or gases.

PROTECT compressed gas cylinders from excessive heat, mechanical

shocks, and arcs; fasten cylinders so they cannot fall.

BE SURE cylinders are never grounded or part of an electrical circuit. REMOVE all potential fire hazards from welding area. ALWAYS HAVE FIRE FIGHTING EQUIPMENT READY FOR

IMMEDIATE USE AND KNOW HOW TO USE IT.

SECTION A:

Diesel Engines

Gasoline Engines

WARNINGS

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

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.

SAFETY

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.

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.

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

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.

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.

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.

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.

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.

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

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.

between the

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 within applicable OSHA PEL and ACGIH TLV limits 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.

5. b. The operation of welding fume control equipment is affected by various factors including proper use and positioning of the equipment, maintenance of the equipment and the specific welding procedure and application involved. Worker exposure level should be checked upon installation and periodically thereafter to be certain it is within applicable OSHA PEL and ACGIH TLV limits.

5.c. Do not weld in locations near chlorinated hydrocarbon vapors coming from degreasing, cleaning or spraying operations. The heat and rays of the arc can react with solvent vapors to form phosgene, a highly toxic gas, and other irritating products.

3.j. Also see It ems 6.c. and 8.

5.d. Shielding gases used for arc welding can displace air and

injury or death. Always use enough ventilation, especially in confined areas, to insure breathing air is safe.

5.e. 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.f. Also see item 1.b.

iii

cause

SAFETY

WELDING AND CUTTING 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. Remember that welding sparks and hot materials from welding can easily go through small cracks and openings to adjacent areas. Avoid welding near hydraulic lines. Have a fire extinguisher readily available.

6.b. Where compressed gases are to be used at the job site, special precautions should be used to prevent hazardous situations. Refer to “Safety in 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 though they have been “cleaned”. For information, purchase “Recommended Safe Practices for the Preparation for Welding and Cutting of 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.

6.f. Sparks and spatter are thrown from the welding arc. Wear oil 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.

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.

6.I. Read and follow NFPA 51B “ Standard for Fire Prevention During Welding, Cutting and Other Hot Work”, available from NFPA, 1 Batterymarch Park, PO box 9101, Quincy, Ma 022690-9101.

6.j. Do not use a welding power source for pipe thawing.

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

Refer to

http://www.lincolnelectric.com/safety

for additional safety information.

Welding Safety Interactive Web Guide for mobile devices

SAFETY

ELECTROMAGNETIC

COMPATIBILITY (EMC)

CONFORMANCE

Products displaying the CE mark are in conformity with European Community Council Directive of 3 May 1989 on the approximation of the laws of the Member States relating to electromagnetic compatibility (89/336/EEC). It was manufactured in conformity with a national standard that implements a harmonized standard: EN 60974-10 Electromagnetic Compatibility (EMC) Product Standard for Arc Welding Equipment. It is for use with other Lincoln Electric equipment. It is 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 affect many kinds of electrical equipment; other nearby welding equipment, radio and TV reception, 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 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 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. In other cases it could involve construction of 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 access whether the changes will increase the risk of injury, e.g., by allowing parallel welding current return paths which may damage the earth circuits of other equipment.

ASSESSMENT OF AREA

Before installing welding equipment the user shall make an assessment of potential electromagnetic problems in the surrounding area. The following shall be taken into account:

a. other supply cables, control cables, signaling and telephone cables;

above, below and adjacent to the welding equipment;

b. radio and television transmitters and receivers;

c. computer and other control equipment;

d. safety critical equipment, e.g., guarding of industrial equipment;

e. the health of the people around, e.g., the use of pacemakers and

hearing aids;

f. equipment used for calibration or measurement

g. the immunity of other equipment in the environment. The user shall

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

h. the time of 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 of 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 adjustments covered in the manufacturers instructio ns. In particular, the spark gaps of arc striking 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 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, not connected to earth because of its size and position, e.g., ships 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 the work piece 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 a direct connection to the work piece, 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 contained in EN 60974-10: “Electromagnetic

Compatibility (EMC) product standard for arc welding equipment.”

viii

TABLE OF CONTENTS

Page

––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––

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

Technical Specifications.................................................................................A-1, A-2

Safety Precautions.................................................................................................A-3

Location...........................................................................................................A-3

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

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

Identify and Locate Components...........................................................................A-4

________________________________________________________________________________

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

Safety and Product Description.............................................................................B-1

Controls and Settings.....................................................................................B-2, B-3

Drive Roll and Wire Guides Table .........................................................................B-4

Setting Up and Making a Flux-Cored Weld.............................................B-5 thru B-7

Setting Up and Making a MIG Weld and Install Shielding Gas..............B-8 thru B-11

Setting Up and Making a Aluminum Weld...........................................................B-12

________________________________________________________________________

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

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

Utility Carts ....................................................................................................C-2, C-3

________________________________________________________________________

viii

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

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

Wire Feed Compartment, Fan Motor, Wire Reel Maintenance .............................D-1

Gun And Cable Maintenance ................................................................................D-2

Overload Protection...............................................................................................D-2

Component Replacement Procedures ..................................................................D-3

________________________________________________________________________

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

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

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

Troubleshooting Guide.............................................................................E-2 thru E-4

________________________________________________________________________

Wiring Diagram and Dimension Print............................................................Section F

________________________________________________________________________

Parts Lists................................................................................................P-533, P-202-E

________________________________________________________________________

A-1

INSTALLATION

A-1

TECHNICAL SPECIFICATIONS

180 Amp units

(K2472-1 180T, K2473-1 180C)

INPUT – SINGLE PHASE ONLY

Standard Voltage/Frequency Input Current

230 V 60 Hz 20 Amps @ rated output 208 V 60 Hz 20 Amps @ rated output

RATED OUTPUT

Voltage/Duty

230 V 30% 130 Amps 20 208 V 30% 130 Amps 17

Cycle Current Voltage at Rated Amperes

OUTPUT

Welding

Current Range Open Circuit Voltage Wire Speed Range

30-180 Amps 34 V 50 - 500 in/min.

RECOMMENDED INPUT CABLE AND FUSE SIZES

Input Voltage/Frequency Fuse or Breaker Size

230 V 60 Hz 40 Amp Super Lag 20 50 Amp, 250 V,

Input Amps Power Cord

Three Prong Plug

(NEMA Type 6-50P)

PHYSICAL DIMENSIONS

Height Width Depth Weight

14.0 in 10.15 in 18.6 in 66 Ibs 357 mm 258 mm 472 mm 30 kg

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

(1.3 - 12.7 m/min.)

140 Amp units

(K2470-1 140T, K2471-1 140C)

INPUT – SINGLE PHASE ONLY

Standard Voltage/Frequency Input Current

120 V / 60 Hz 20 Amps @ rated output

RATED OUTPUT

Cycle Current Voltage at Rated Amperes

Duty

20% Duty Cycle 90 Amps 19.5

OUTPUT

Welding

Current Range Open Circuit Voltage Wire Speed Range

30-140 Amps 33 V 50 - 500 in/min.

RECOMMENDED INPUT CABLE AND FUSE SIZES

Input Voltage/Frequency Fuse or Breaker Size

120 V 60 Hz 20 Amp 20 15 Amp, 125 V,

1,2

Input Amps Power Cord Extension Cord

Three Prong Plug (4mm2) or Larger (NEMA Type 5-15P) up to 50 ft.(15.2m)

PHYSICAL DIMENSIONS

Height Width Depth Weight

14.0 in 10.15 in 18.6 in 58 Ibs 357 mm 258 mm 472 mm 26.3 kg

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

(1.3 - 12.7 m/min.)

3 Conductor # 12 AWG

POWER MIG (140, 180 MODELS)

A-2

INSTALLATION

A-2

TECHNICAL SPECIFICATIONS

180 Amp units

(K2668-1 180C)

INPUT – SINGLE PHASE ONLY

Standard Voltage/Frequency Input Current

240 V 50 Hz

1 eff

1 max

20 Amps

10.7 Amps

RATED OUTPUT

Voltage/Duty

240 V 25% 131 Amps 20

Cycle Current Voltage at Rated Amperes

OUTPUT

Welding

Current Range Open Circuit Voltage Wire Speed Range

30 - 180 Amps 34 V 50 - 500 in/min.

RECOMMENDED INPUT CABLE AND FUSE SIZES

Input Voltage/Frequency Fuse or Breaker Size

240 V 50 Hz 40 Amp Super Lag 20 15 Amp, 240 V,

Input Amps Power Cord

PHYSICAL DIMENSIONS

Height Width Depth Weight

14.0 in 10.15 in 18.6 in 66 Ibs 357 mm 258 mm 472 mm 30 kg

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

1.3 - 12.7 ( m/min.)

Three Pin Plug

Requirements For Maximum Output

In order to utilize the maximum output capability of the machine, a branch circuit capable of 25 amps at 120 volts, 60 Hertz is required.

POWER MIG (140, 180 MODELS)

A-3

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 POWER MIG 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 POWER MIG power switch is to be in the OFF (“O”) position when installing work cable and gun and when connecting power cord to input power.

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.

A-3

STACKING

POWER MIG (140, 180 MODELS) cannot be stacked.

TILTING

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

POWER MIG (140, 180 MODELS)

A-4

INSTALLATION

A-4

IDENTIFY AND LOCA TE COMPONENTS

INCLUDED COMPONENTS

• Wire Feeder Welder.

• Work Cable & Clamp.

• Magnum 100L Welding Gun.

• .030” -.045” (0.8 - 1.1mm) Knurled Drive Roll (Installed on Machine)

.030

.045

• .025” -.035” (0.6 - 0.9mm) Inner Wire guide

• .035” -.045” (0.9 - 1.1mm) Inner Wire Guide

(Installed on Machine)

• Outer Wire Guide (Installed on Machine)

INNER WIRE GUIDE .025-.035 (.6-.9mm)

INNER WIRE GUIDE .035-.045 (.9-1.1mm)

OUTER WIRE GUIDE

• Black Flux-cored Gasless Gun Nozzle (Installed on

Welding Gun)

• 3 .035” (0.9mm) Contact Tips (1 installed on the welding gun).

• 3 .025” (0.6mm) Contact Tips.

.035

.025

• Spool of .035” (0.9 mm) diameter NR-211MP

Innershield Flux-cored Wire.

• Spool of .025” (0.6 mm) diameter L-56 MIG Wire.

NR-211 MP

• .025”-.030” (0.6 - 0.8mm)

• .035” (0.9mm)

Smooth Drive Roll

L-56 MIG

WIRE

• Brass MIG Gas Gun Nozzle

• 2”(51mm) Spindle Adapter (For 8”(203mm) Reel of wire)

• Regulator

• Gas Hose

• Learn to Weld (LTW1 Manual)

• DVD

REGULATOR

GAS HOSE

2" SPINDLE ADAPTER (FOR 8" REEL OF WIRE)

"LEARN TO WELD"

LTW1

DVD

POWER MIG (140, 180 MODELS)

B-1

OPERATION

B-1

Read entire operation section before operating the POWER MIG.

WARNING

ELECTRIC SHOCK can kill.

• Do not touch electrically live parts or electrode with skin or wet clothing. Insulate yourself from work and ground.

• Always wear dry insulating gloves.

FUMES AND GASES can be dangerous.

• Keep your head out of fumes.

• Use ventilation or exhaust to remove fumes from breathing zone.

WELDING SPARKS can cause fire or explosion.

• Keep flammable material away.

• Do not weld on closed containers.

ARC RAYS can burn eyes and skin.

• Wear eye, ear and body protection.

PRODUCT DESCRIPTION (PRODUCT CAPABILITIES)

These small portable wire feed welders are capable of MIG welding on steel, stainless steel, and aluminum. They are also capable of flux-cored welding on mild steel.

MIG welding stands for Metal Inert Gas welding and requires a separate bottle of shielding gas to protect the weld until it cools. Appropriate shielding gas based on the type of material you are welding can be purchased separately from your local welding gas distributor. MIG welding is ideal for welding on thinner and clean materials when a very clean excellent cosmetic looking weld is required. An example would be automotive body panels.

Flux-cored Welding does not require separate shielding gas to protect the weld since the welding wire has special additives known as flux to protect the weld until it cools. Flux-cored welding is ideal for medium to thicker material and if welding on painted or rusty steel. Flux-cored welding is also ideal in outdoor applications where windy conditions might blow the MIG shielding gas away from the weld. Flux-cored welding produces a good looking weld but does not produce an excellent weld appearance as MIG welding does.

Your machine includes the necessary items to weld with either the MIG or the flux-cored welding process on steel. To weld on stainless steel optional stainless steel welding wire can be purchased separately. This machine can weld aluminum using .035”(0.9mm) diameter 4043 aluminum welding wire. Since aluminum welding wire is soft an optional aluminum spool gun is recommended for best results. A welding Procedure Decal is located inside machine door to help provide suggested settings for welding.

Observe all safety information throughout this manual.

------------------------------------------------------------

POWER MIG (140, 180 MODELS)

COMMON WELDING ABBREVIATIONS

GMAW (MIG)

• Gas Metal Arc Welding

FCAW (Innershield or Outershield)

• Flux Core Arc Welding

B-2

CONTROLS AND SETTINGS

This machine has the following controls:

OPERATION

B-2

See Figure B.1

1. POWER SWITCH – Turns power on and off to the

machine.

2. ARC VOLTAGE CONTROL – This knob sets the output voltage of the machine. Along with wire feed speed (WFS) this control sets a weld procedure. Refer to the procedure decal on the inside wire drive compartment door to set a correct welding procedure based on type of material and thickness being welded.

3. WIRE FEED SPEED CONTROL (WFS) – The knob sets the speed that the machine feeds wire. Along with arc voltage this control sets a weld procedure. Refer to the procedure decal on the inside wire drive compartment door to set a correct welding procedure based on type of material and thickness being welded.

See Figure B.2

4. GUN TRIGGER – Depress the trigger to activates

the wire drive to feed wire and energizes the output of the machine. Depress the trigger to weld and release the trigger to stop welding.

FIGURE B.1

FIGURE B.2

5. WELDING GUN – Delivers wire and welding cur-

rent to the weld. a. Gun Liner – wire travels through the liner from

the wire drive. The gun liner will feed .025” to .035” (0.6mm to 0.9mm) wire. The 180A machine can weld with .045”(1.1mm) wire if an optional .045”(1.1mm) liner is installed in the gun.

b. Contact Tip – provides electrical contact to the

wire.

c. Nozzle – When flux-cored welding the black noz-

zle protects the mounting threads on the gun. When MIG welding the brass nozzle funnels the shielding gas to the weld.

6. WORK CLAMP & CABLE – Clamps to the work piece being welded and completes the electrical welding circuit.

7. GUN TRIGGER CONNECTOR RECEPTACLE –

Plug the 4 pin gun trigger connector into this receptacle.

.035"(0.9mm)

NR-211-MP

WIRE SPOOL

POWER MIG (140, 180 MODELS)

B-3

OPERATION

B-3

See Figure B.3

8. WELDING GUN CONNECTOR BUSHING &

THUMBSCREW – Provides electrical power to the

welding gun. The thumbscrew holds the welding gun into the connector block. (Front of Machine, Side Door and Wire Drive Cover have been removed for clarity of Items 8 and 9).

9. OUTPUT TERMINALS –These connections allow to change the welding polarity of the machine depending on whether you are MIG welding or fluxcored welding.

See Figure B.4

10. WIRE SPOOL SPINDLE AND BRAKE – Holds a

4”(102mm) diameter spool. Use the 2”(51mm) spindle adapter included with the machine to use 8”(203mm) diameter spools. The thumbscrew sets the brake friction to prevent the spool from over rotating when the trigger is released.

FIGURE B.3

FIGURE B.4

2"(51mm) SPINDLE ADAPTER (FOR 8"(20mm) REEL OF WIRE)

( 4"(102mm) REEL OF WIRE)

See Figure B.5

11. WIRE DRIVE & COMPONENTS – Feeds wire

from the wire spool through the drive and through the welding gun to the weld.

a. Top and Bottom Drive Roll – Drives the wire

through the drive system. The drive roll has a groove to match the specific wire type and diameter. Refer to Table B.1 for available drive rolls.

b. Inner & Outer Wire Guide – Guides the wire

between the Top and Bottom Drive Roll and through the wire drive. The inner guide has a groove to match a particular wire diameter. Refer to Table B.1 for available wire guides.

c. Drive Roll Tension Thumbscrew – Turning

clockwise increases the force on the drive rolls and turning counterclockwise decreases the force.

FIGURE B.5

TOP DRIVE ROLL PRESSURE ARM

TENSION ADJUSTOR DOWN

INNER WIRE GUIDE REMOVED

LOWER DRIVE ROLL REMOVED

WIRE SPOOL .035" (0.9mm)

NR-211-MP

OUTER WIRE GUIDE REMOVED

POWER MIG (140, 180 MODELS)

B-4

OPERATION

TABLE B.1

DRIVE ROLL AND WIRE GUIDES

B-4

Wire Diameter &

Type

.025”(0.6mm) MIG wire .030”(0.8mm) MIG wire

.035”(0.9mm) MIG wire .030”(0.8mm) flux-cored .035”(0.9mm) flux-cored .045”(1.1mm) flux-cored

12. CIRCUIT BREAKER – If the rated input current of the machine is exceeded this circuit breaker will trip. Press to reset.

.025”/.030” (0.6mm/0.8mm)

.035”(0.9mm) Smooth Drive Roll

.030”/.045” (0.8mm/1.1mm)

See Figure B.6

Drive Roll

Smooth Drive Roll

Knurled Drive Roll

Drive Roll Part

Number

KP2529-1

KP2529-2

KP2529-3

Inner Wire Guide

.025”-.035”

(0.6mm-0.9mm)

Steel Wire Guide

.045”(1.1mm)

Wire Guide

Steel

FIGURE B.6

Inner Wire Guide

Part Number

KP2531-1

KP2531-2

13. GAS INLET – Shielding gas connects to this inlet.

POWER MIG (140, 180 MODELS)

B-5

OPERATION

SETTING UP AND MAKING A FLUX-CORED WELD

A. ITEMS NEEDED FOR FLUX CORED

WELDING

1. 035”(0.9mm) Contact Tip

.035

2. .025”-.035”(0.6mm-0.9mm) wire guide

INNER WIRE GUIDE .025-.035 (.6-.9mm)

B-5

7. Work Cable & Clamp

3. Knurled Drive Roll

.030

.045

4. .035”(0.9mm) NR-211MP Flux-Cored Wire

.035 NR-211 MP

5. Black Flux Cored gun nozzle

6. Welding Gun

POWER MIG (140, 180 MODELS)

B-6

OPERATION

B. CONNECT LEADS AND CABLES ON

THE MACHINE

(See Figure B.7)

1. Open the case side door

LOCATE COMPONENTS TO CONNECT TO THE FRONT OF MACHINE

B-6

FIGURE B.7

CASE SIDE DOOR

2. Slide the connector end of the gun and cable through the hole in the machine front and into the gun connector bushing on the wire drive.

3. Make sure the gun connector end is seated fully into the wire drive and tighten the thumbscrew to secure the gun connector.

4. Plug the gun trigger lead connector into the 4 pin gun trigger receptacle on the machine front.

5. Wire Drive Polarity. Flux cored welding requires negative (-) polarity. Connect the short power cable from the wire drive to the negative (-) output terminal and tighten the thumbscrew.

6. Work Lead Connection. Slide the lugged end of the work cable through the hole in the machine front and place on the positive (+) output terminal and tighten thumbscrew.

C. LOAD WIRE SPOOL

(See Figure B.8)

1. Locate the blue labeled 4"(102mm) diameter spool of .035”(0.9mm) NR-211MP flux-cored wire and place onto wire spool spindle. Orient the spool so that the wire feeds off the top of the spool.

2. Secure spool in place by tightening the wing nut against the against the spacer that holds the wire spool on the spindle.

SLIDE CONNECTOR END HERE

(4 PIN) LEAD CONNECTOR

GUN AND CABLE

OPEN LATCH DOOR

TERMINAL END (FITS ON STUD INSIDE SEE FIGURE BELOW)

WORK CLAMP

THUMB SCREW TO TIGHTEN CONNECTOR BUSHING

CONNECTOR END ATTACH

(4 PIN) TRIGGER RECEPTACLE

PLUGGED IN

FIGURE B.8

TOP DRIVE ROLL PRESSURE ARM

TENSION ADJUSTOR DOWN

ALL COMPONENTS SHOWN CONNECTED (FRONT AND SIDE DOOR IS REMOVED FOR CLARITY)

WORK CLAMP

WIRE SPOOL .035" (0.9mm)

SHORT POWER CABLE NEGATIVE "-" OUTPUT TERMINAL

WORK LEAD CONNECTION POSITIVE "+" OUTPUT TERMINAL

3. Open the top drive roll pressure arm by rotating the tension adjustor arm down and pivoting the drive roll pressure arm up.

4. Remove the outer wire guide.

4a. Slide gun out of drive slightly.

5. Remove the lower drive roll and inner wire guide. Install the .025”-.035”(0.6mm-0.9mm) inner wire guide.

7. Install the .030”/.045”(0.8mm/1.1mm) knurled lower drive roll.

8. Carefully unwind and straighten the first six inches of welding wire from the spool. Do not let the end of the wire go to prevent the wire from unspooling.

POWER MIG (140, 180 MODELS)

NR-211-MP

INNER WIRE GUIDE REMOVED

LOWER DRIVE ROLL REMOVED

OUTER WIRE GUIDE REMOVED

+ 39 hidden pages