Patriot PBE250, PBE140 Owner's Manual
OWNER'S MANUAL
PBE250 M.I.G. COMBINATION UNIT
CONGRATULATIONS!
YOU HAVE JUST PURCHASED ONE OF THE FINEST
MIG WELDING SYSTEMS AVAILABLE TODAY. THE
PBE250 REPRESENTS FOURTH GENERATION TECHNOLOGICAL ADVANCEMENTS. THIS SYSTEM IS DESIGNED AND ENGINEERED TO PROVIDE YOU WITH
YEARS OF PROFESSIONAL SERVICE.
FOR TECH. SERVICE, CALL 1-610-696-9040
INSTALLATION
OPERATION
MAINTENANCE
FORM WC5369 Rev. 8/00, 5/01
MANUFACTURER’S LIMITED WARRANTY
!
WARNING
This equipment is warranted against defects in materials
and workmanship for a period of two years from the date of
purchase.
EXCEPTION: THE MIG TORCH IS WARRANTED FOR A
PERIOD OF 30 DAYS FROM THE DATE OF PURCHASE.
Should the equipment become defective for such reason,
the Manufacturer will repair it without charge, if it is returned
to the Manufacturer’s factory, freight prepaid. This warranty
does not cover: (1) failure due to normal wear and tear; (2)
consumable parts, such as, but not limited to, torch contact
tips, gas cups and insulating bushings; (3) damage by
accident, force majeure, improper use, neglect, unauthorized repair or alteration; (4) anyone other than the original
purchaser.
THIS LIMITED WARRANTY IS IN LIEU OF ALL OTHER
WARRANTIES, EXPRESS OR IMPLIED. THE MANUFACTURER SHALL NOT BE LIABLE FOR ANY INJURY TO
PERSONS, INCLUDING DEATH; OR LOSS OR DAMAGE
TO ANY PROPERTY, DIRECT OR CONSEQUENTIAL,
INCLUDING, BUT NOT LIMITED TO, LOSS OF USE,
ARISING OUT OF THE USE, OR THE INABILITY TO USE,
THE PRODUCT. THE USER ASSUMES ALL RISK AND
LIABILITY WHATSOEVER IN CONNECTION WITH THE
USE OF THE PRODUCT, AND BEFORE DOING SO,
SHALL DETERMINE ITS SUITABILITY FOR HIS INTENDED USE, AND SHALL ASCERTAIN THE PROPER
METHOD OF USING IT.
SOME STATES DO NOT ALLOW LIMITATIONS ON
HOW LONG AN IMPLIED WARRANTY LASTS, OR THE
EXCLUSIONS OR LIMITATIONS OF INCIDENTAL OR
CONSEQUENTIAL DAMAGES. SO THE ABOVE LIMITATIONS OR EXCLUSIONS MAY NOT APPLY TO YOU. THIS
WARRANTY GIVES YOU SPECIFIC LEGAL RIGHTS, AND
YOU MAY HAVE OTHER RIGHTS WHICH MAY VARY
FROM STATE TO STATE.
ARC WELDING CAN BE INJURIOUS TO OPERATOR AND PERSONS IN THE WORK AREA -——
CONSULT INSTRUCTION MANUAL BEFORE
OPERATING.
ELECTRIC SHOCK can kill.
• Do not touch electrodes or other electrically live parts.
• Insulate yourself from work and ground.
• Install and ground machine in accordance with the National
Electical Code and local code(s). Read Operating Manual
before installing or operating.
• Do not operate with protective covers, panels, or guard
removed.
• Disconnect input power before servicing.
• Only qualified personnel should install, use, or service this
equipment.
ARC RAYS can injure your eyes and burn
skin.
• Wear correct eye, ear, and body protection while welding.
FUMES AND GASES can be dangerous to your
health.
• Use enough ventilation and/or exhaust at the arc.
• Keep your head out of fumes.
• Do not breathe fumes.
READ AND UNDERSTAND THE
MANUFACTURER’S INSTRUCTIONS AND
YOUR EMPLOYER’S SAFETY PRACTICES.
See American National Standard Z49.1, “Safety in
Welding and Cutting”, published by the American
Welding Society, 2501 N.W. 7th St., Miami, Florida
33125; OSHA Safety and Health Standards, 29 CFR
1910 available from U.S. Dept. of Labor, Wash.,
D.C. 20210.
INTRODUCTION ........................................................................... 1
DESCRIPTION, SPECIFICATIONS .............................................. 2
CHECK LIST (CONTENTS) .......................................................... 3
INSTALLATION & ELECTRICAL REQUIREMENTS .................... 3
OPERATION ................................................................................. 7
MAINTENANCE .......................................................................... 12
TROUBLE SHOOTING CHART .................................................. 14
CONNECTING TIG PACK OR SPOOL GUN ............................. 19
LINER INSTALLATION ............................................................... 20
PARTS BREAKDOWN - MIG TORCH ........................................ 21
OPTIONS - TIG PACK OR SPOOL GUN ................................... 23
Systematics, Inc. West Chester, PA. 19380
TABLE OF CONTENTS
INTRODUCTION
The Systematics PBE250 is a com-
bination welding power source, wire
feed unit, MIG torch and accessory
package, and is designed to meet the
requirements of the metal fabrication industries. The PBE250 produces fusion welds by the Gas Metal
Arc Welding process (GMAW or MIG),
on steel and aluminum up to "3/8"
thick, using .023" through .045"
steel wire and .025" through 3/64"
aluminum wire with the optional
MHG7-C spool gun. (optional liners
must be purchased to cover given
wire sizes). Heavier sections can
be easily welded using slightly
different techniques.
FEED
ROLLS
MIG
TORCH
SHIELDING GAS
WORK
FIG. 1. SCHEMATIC OF M.I.G. PROCESS
POWER SOURCE
SHORT ARC OR DIP TRANSFER
WIRE SPOOL
+
REVERSE
POLARITY
(STD.)
_
The number of controls on the unit
have been reduced to assist inexperienced operators to learn MIG
welding. This facilitates rapid
set up for welding various thicknesses of material requiring various heat inputs. The VOLTAGE
control adjusts the welding voltage
and the WIRE SPEED control adjusts
the speed of the wire feed motor.
THE MIG PROCESS
AS APPLIED TO THE PBE250
The MIG process uses a bare,
consumable electrode in the form of
spooled wire, which is fed by a
controllable speed feed unit
through the cable and torch to the
weld. The emerging wire and the
weld are shielded by a stream of
CO2, Argon, or a mixture of the two,
which prevents oxidation of the
molten weld puddle. The gas shield
enables high quality welds to be
made without the use of flux,
eliminating the need for slag or
flux removal after the weld is
completed.
The consumable electrode wire is
melted and transferred to the weld
puddle by any of three arc modes;
short arc transfer, globular transfer, or spray arc transfer. The
PBE250 is capable of performing all
modes.
Short arc transfer occurs at 12 to
22 arc volts (voltage while welding), depending on wire size. Welding commences as the arc is struck
and a weld pool is formed. The tip
of the electrode wire dips into the
pool and causes a short circuit.
The short circuit current flow
causes a rapid temperature rise in
the electrode wire and the end of
the wire is melted off. An arc is
immediately formed between the tip
of the wire and the weld pool,
maintaining the electrical circuit
and producing sufficient heat to
keep the weld pool fluid. The
electrode continues to feed and
again dips into the pool.
ELECTRODE
WORK
FIG. 2. SHORT ARC TRANSFER
This sequence of events is repeated up to 200 times per second.
Short arc transfer is suitable for
positional welding. The heat input
to the workpiece is kept to a
minimum which limits distortion and
makes possible the welding of thin
sheet material.
Systematics, Inc. West Chester, PA. 19380 1
GLOBULAR TRANSFER
Globular transfer occurs at the
intermediate range of 22 to 24 arc
volts, depending on wire size. As
the name implies, the transfer
takes place in the form of irregularly shaped globules. Globular
transfer is useful in cases where a
lower heat input than that of true
spray is required.
ELECTRODE GAS NOZZLE
SHIELDING GAS
WORK
FIG. 3. GLOBULAR TRANSFER
SPRAY TRANSFER
Spray transfer occurs at 22 to 32
arc volts, depending on wire size.
The length of the arc is held
constant by the voltage available.
The higher voltage and current
causes the electrode wire to melt
off before touching the workpiece.
The molten metal crosses the gap to
the workpiece in a spray form.
Spray transfer is used in the downhand position and provides higher
deposition rates than short arc
transfer or globular transfer.
Welder controls are simple and
clearly marked. The output voltage
is controlled by a twelve position
tap switch, providing 4 TIG and 8
MIG voltage selections. Wire feed
speed is controlled by the wire
speed potentiometer.
SPECIFICATIONS
PART NUMBER: PBE250
INPUT POWER REQUIREMENTS:
Voltage 208/230
Phase single phase
Frequency 50/60 hertz
Current 33/30
OUTPUT POWER @ 60% Duty Cycle:
- 200 Amps
@ 35% - 250 Amps
DUTY CYCLE TIME PERIOD:
10 minutes
OPEN CIRCUIT VOLTAGE:
18 - 42 volts DC
ARC VOLTAGE: 14 - 28 volts DC
WELD CURRENT RANGE:
30 - 250 amps
WIRE TYPES: mild steel,
Recommended (for steel) ER70S-6
stainless steel, aluminum,
bronze, flux cored,
flux cored - gasless
ELECTRODE GAS NOZZLE
SHIELDING GAS
WORK
FIG. 4. SPRAY TRANSFER
DESCRIPTION
The PBE250 consists of a combina-
tion MIG welding power source and
wire feed unit, a MIG torch with 10
foot cable, a ten foot work cable
with clamp, a twenty foot power
input cable, a gas regulator flowmeter, a torch accessory kit,
and a built-in cylinder rack and
industrial wheel kit.
2 Systematics, Inc. West Chester, PA. 19380
WIRE SIZES: .023" - .045" steel,
3/64" aluminum,
(.023" - 3/64" alum. w/spool gun)
.030" - .035" bronze,
.030" - .045" flux cored
(gas shielded or gasless)
Recommended Size:Aluminum .035
Others .030
SHIELDING GASES:
For Steel CO2 or Argon/CO2 mix
Recommended (for steel) 75% Argon/
25% CO2
For Aluminum, Bronze Argon
For Stainless Steel
Argon/2% Oxygen
For Flux cored CO2 or
Argon/CO2 mix
SPECIFICATIONS (Cont.)
WIRE FEED SPEED RANGE:
50 - 800 inches per minute
DIMENSIONS:
Height 34 in.
Width 14-1/2 in.
Depth 34-1/2 in.
Weight 175 lbs.
TORCH SPECIFICATIONS
NECK ANGLE: 60 degrees
LEAD LENGTH: 10 feet
ITEMS REQUIRED FOR MIG WELDING
WHICH ARE NOT PROVIDED WITH THE
PBE250
1. Full cover welding helmet with
proper colored lens (shade 9 to
11 depending on operator’s preference).
2. Proper shielding gas and cylin-
der.
3. Leather welding gloves.
4. 208 or 230 volt 40 amp single
phase AC power.
OVERALL LENGTH: 10 feet
COOLING METHOD: gas (air)
RATING - DUTY CYCLE:
With Argon/CO2 gas 150 amps @ 100%
With CO2 gas 200 amps @ 100%
CHECK LIST
THE SYSTEMATICS PBE250 INCLUDES THE
FOLLOWING:
1- Combination Power Source/Wire
Feeder
1- Cylinder Rack/Industrial Wheel
Kit-Factory installed
1- 15TG10 MIG Torch with adjustable
nozzle
1- 20 foot Power Input Cable
1- 10 foot Work Cable and Clamp
1- MP250PK-1 Parts Kit
1- GR-FM Gas Regulator/Flowmeter
5. Other personal protective
equipment which may vary to
match the welding being performed.
INSTALLATION
POSITIONING THE UNIT
Locate the unit adjacent to the
welding area and position it so
there is adequate clearance all
around for ventilation and maintenance.
ELECTRICAL SUPPLY
Ensure that there is a 208 or 230
volt, single phase, 40 amp electri-
cal supply within easy reach of the
unit. The input cable supplied is 20
feet long. A 50 foot cable is an
optional extra. Attach a suitable
plug making sure the green wire is
attached to the ground terminal of
the wall plug. All wiring should be
performed by a qualified electrician.
1- Nozzle, 1/2 in. orifice (in-
stalled on MIG torch)
1- Contact Tip, for .030 in. wire
(installed on MIG torch)
1- ER70S-6-30-3, Sample Spool of
.030 Steel Wire
Systematics, Inc. West Chester, PA. 19380 3
230V INPUT SELECTION
1. Factory selected no change is
needed.
208V INPUT SELECTION
1. Remove the top cover.
(continued on following page)
CONTACTOR SWITCH
CONNECT "208"
WIRE FOR
OPERATION ON
208 VOLT INPUT
CONNECT
"230" WIRE FOR
OPERATION ON
230 VOLT INPUT.
2. Rapidly open and close the cyl-
inder valve. This will purge
dust and foreign matter from the
valve.
CAUTION
Take care to point the
valve outlet away from
yourself or other people,
as escaping high pressure
gas may be dangerous.
FRONT OF
MACHINE
FIG. 5. INPUT VOLTAGE SELECTIONS
2. Locate the contactor switch,
which is mounted on top of the
main power transformer(See Figure 5).
CAUTION
MAKE SURE POWER SOURCE IS
UNPLUGGED BEFORE MAKING INPUT SELECTION CHANGE-OVER.
3. Attached to the power source’s
contactor is one (2) two position plug which allows easy
selection of input voltages of
either 208 or 230 volts.
3. Attach the gas regulator - flowmeter supplied with this unit,
to the cylinder valve using a
suitable wrench.
NOTE
If this unit is to be used
with 100% CO2 shielding
gas, an optional gas regulator coupler is required.
FLOW TUBE
INDICATES
FLOW RATE
IN C.F.H.
GAUGE -
INDICATES
TANK
PRESSURE
GAS FLOW
ADJUSTING
KNOB
4. Remove the one (1) plug labeled
230V and connect the one (1) plug
labeled 208V.
5. Reattach the top cover of the
machine. Voltage input selection is now complete.
SHIELDING GAS CONNECTIONS
1. Place a cylinder of the appropriate shielding gas in the rack
at the rear of the machine and
secure it with the chain provided. See recommended gases on
page 2.
4 Systematics, Inc. West Chester, PA. 19380
OUTLET
FITTING
TO
WELDING
MACHINE
FIG. 6. GAS FLOW ADJUSTMENT
INLET
FITTING
TO
TANK
4. Fit the gas hose from the welding
machine to the regulator outlet
fitting and tighten it with a
suitable wrench. Open the cylinder valve.
SHIELDING GAS CONNECTIONS (Cont.)
5. Check that the gas regulator is
properly adjusted. When welding
steel, the gas flow rate is 30
CFH. When welding aluminum, the
gas flow rate is 40 CFH.
NOTE
The PBE250 must be turned
"ON" and the MIG torch
trigger depressed, before
the gas flow rate can be
adjusted.
TORCH CONNECTION
1. Open the access door of the
machine to its fullest extent.
2. Back out the thumb screw located
on the drive assembly mounting
bracket inside the machine. Insert the MIG torch into the torch
panel mount on the front panel
and TIGHTEN THE THUMB SCREW.
FITTING AND THREADING THE ELECTRODE
WIRE - ALWAYS USE ER70S-6 WELDING
WIRE WHEN WELDING STEEL.
1. Remove the wire spool clip from
the spool hub.
2. Unpack the spool of welding wire
from its protective packaging.
3. Place the spool of ER70S-6 welding wire onto the hub. The wire
is fed off the bottom of the
spool.
CAUTION
Look for wire protruding
from the center of the
spool. The protruding wire
is electrically HOT during
welding and must not touch
the machine. Cut this wire
flush with the spool.
4. Replace the spool clip on the
hub.
TORCH
PANEL
MOUNT
MIG
TORCH
THUMB
SCREW
DRIVE
ROLL
FIG. 7. TORCH CONNECTION
PRESSURE
ROLLS
DRIVE
ASSEMBLY
MOUNTING
BRACKET
INLET
GUIDE
5. Unlatch the pressure roll arm
and swing it open.
6. Make sure the double v-groove
drive roll is installed to match
the wire size. To change the
wire size setting, remove the
drive roll, turn it over and
reinstall it on the shaft.
"B" SIDE FACING IN FOR
.023" - .035" STEEL WIRES
"C" SIDE FACING IN FOR
.040" - .045" STEEL WIRES
AND 3/64" ALUMINUM WIRES
FIG. 8. DOUBLE GROOVE DRIVE ROLL
(continued on following page)
Systematics, Inc. West Chester, PA. 19380 5
FITTING AND THREADING THE ELECTRODE
WIRE (Cont.)
7. Release the wire from the spool
and trim off the kinked end with
wire cutters. The wire must be
straight when it enters the
inlet guide.
8. Thread the electrode wire
through the inlet guide, over
the feed roll and into the outlet
guide. Ensure that the wire
locates in the feed roll groove.
Do not allow the wire on the
spool to loosen.
9. Close and relatch the pressure
roll arm.
10.Stretch the torch cable straight
out in front of the machine
making sure there are no kinks.
Remove the nozzle and contact
tip from the torch.
11.Turn "ON" the circuit breaker on
the front of the machine. The
cooling fan will start and the
"ON" indicator light will illuminate. Set the TIG/MIG VOLTAGE
control switch to "MIG 3" and the
WIRE SPEED control to "5". Pull
the trigger on the MIG torch.
The wire feed system will start
and wire will be fed through the
cable liner and torch. If the
wire does not feed, or appears to
slip, tighten the pressure roll
arm adjusting nut. Feed the wire
until it protrudes from the
front of the torch approximately
six inches.
12.Install the contact tip over the
protruding wire and tighten it
firmly using a proper size
wrench. Make sure the tip is the
correct size for the wire being
used.
13.Install the nozzle on the torch.
For steel, the contact tip
should be flush or stick out up
to 1/16 inch beyond the end of
the nozzle. For aluminum, the
contact tip should be recessed
1/8 to 1/4 inch inside the
nozzle. Using wire cutters,
trim off the wire so the stickout
is approximately 1/4 inch for
steel or 1 inch for aluminum.
For aluminum, the end of the wire
should be bent over so it does
not JAM into the work. This is
called a "scratch start".
14.For steel welding only, spray
anti-spatter compound inside
the nozzle and on the outside of
the contact tip. For aluminum or
stainless steel welding, NO
anti-spatter compound can be
used as it will contaminate the
weld.
1/4"
STICK-OUT
1"
STICK-OUT
CAUTION
Keep hands and face away
from the front of the torch
and do not allow the wire to
contact the Work. The wire
is electrically HOT when
the torch trigger is actuated.
6 Systematics, Inc. West Chester, PA. 19380
FOR STEEL:
CONTACT TIP
FLUSH WITH NOZZLE
FIG. 9. WIRE STICKOUT - STEEL, ALUMINUM
FOR ALUMINUM:
CONTACT TIP
RECESSED 1/8" - 1/4"
Loading...