Lincoln Electric IM890 User Manual
Operator’s Manual
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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
© Lincoln Global, Inc. All Rights Reserved.
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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.
ii
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
iv
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.
1
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,
1
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
1
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
1
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
I
I
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,
1
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
1
If connected to a circuit protected by fuses use Time Delay Fuse marked “D”.
1.3 - 12.7 ( m/min.)
Three Pin Plug
2
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
.035
.025
.025
.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
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.
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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
2
3
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.
5c
4
5b
5a
.035"(0.9mm)
5
6
7
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
8
9
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)
.030”/.045” (0.8mm/1.1mm)
See Figure B.6
Drive Roll
Smooth Drive Roll
Knurled Drive Roll
Knurled Drive Roll
Drive Roll Part
Number
KP2529-1
KP2529-2
KP2529-3
KP2529-3
12
Inner Wire Guide
.025”-.035”
(0.6mm-0.9mm)
Steel Wire Guide
.045”(1.1mm)
Wire Guide
Steel
FIGURE B.6
13
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
E
R
F
L
I
W
E
U
R
X
O
-
C
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.
6.
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
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