Lincoln Electric IM810 manual

P ro-MIG 175 OPERA TOR’S MANUAL IM810 July, 2005 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 thought- ful operation on your part. DO NOT INSTALL, OPERATE OR REPAIR THIS EQUIPMENT WITHOUT READING THIS MANUAL A[...]

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-ventilatedareas or vent the engine exhaust fumes outdoors. _________________________________________________[...]

ii SAFETY ii ARC RA YS 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[...]

FOR ELECTRICALL Y powered equipment. 8.a. Turn off input power using the disconnect switch at the fuse box before working on the equipment. 8.b. Install equipment in accordance with the U.S. National Electrical Code, all local codes and the manufacturer’s recommendations. 8.c. Ground the equipment in accordance with the U.S. National Electrical C[...]

iv SAFETY iv PRÉCAUTIONS DE SÛRETÉ Pour votre propre protection lire et observer toutes les instructions et les précautions de sûreté specifiques qui parraissent dans ce manuel aussi bien que les précautions de sûreté générales suiv- antes: Sûreté Pour Soudage A L’Arc 1. Protegez-vous contre la secousse électrique: a. Les circuits ?[...]

v v Thank You for selecting a QUALITY product by Lincoln Electric. We want you to take pride in operating this Lincoln Electric Company product ••• as much pride as we have in bringing this product to you! Read this Operators Manual completely before attempting to use this equipment. Save this manual and keep it handy for quick reference. Pay[...]

vi vi T ABLE OF CONTENTS Page Installation .......................................................................................................Section A Technical Specifications ........................................................................................A-1 Safety Precautions...........................................................[...]

A-1 A-1 INST ALLA TION Fuse or Output Mode Input Voltage Breaker Size Input Amps Power Cord RATED 230V/60Hz 40 Super Lag 20/22 50 Amp, 250V, 208V/60Hz Three-Prong Plug (NEMA Type 6-50P) TECHNICAL SPECIFICA TIONS – Pro-MIG 175 INPUT – SINGLE PHASE ONL Y RA TED OUTPUT OUTPUT RECOMMENDED INPUT CABLE AND FUSE SIZES Height Width Depth Weight 12.0 in[...]

A-2 A-2 INST ALLA TION SAFETY PRECAUTIONS Read entire installation section before starting installation. IDENTIFY AND LOCA TE COMPONENTS If you have not already done so, unpack the Pro-MIG 175 from its carton and remove all packing material around the Pro-MIG 175. Remove the following loose items from the carton (see Figure A.1): 1. Pro-MIG 175 2. [...]

A-3 A-3 INST ALLA TION SELECT SUIT ABLE LOCA TION 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 caus[...]

A-4 A-4 INST ALLA TION Work Cable Installation Refer to Figure A.2. 1. Open the wire feed section door on the right side of the Pro-MIG 175. 2. Pass the end of the work cable that has the termi- nal lug with the smaller hole through the Work Cable Access Hole (1) in the case front. 3. Route the cable under and around the back of the Wire Feed Gearb[...]

A-5 A-5 INST ALLA TION Pro-MIG 175 2 . With the cylinder securely installed, remove the cylinder cap. Stand to one side away from the out- let and open the cylinder valve very slightly for an instant. This blows away any dust or dirt which may have accumulated in the valve outlet. BE SURE TO KEEP YOUR FACE AWAY FROM THE VALVE OUTLET WHEN “CRACKIN[...]

A-6 A-6 INST ALLA TION Line Cord Connection A 3 conductor line cord with a 50 amp, 250 volt, three- prong plug (NEMA Type 6-50P) is factory installed. Connect this plug to a mating grounded receptacle which is connected to an appropriate power supply per the U.S. National Electric Code and any applica- ble local codes. CONNECT TO A SYSTEM GROUNDING[...]

B-1 B-1 OPERA TION Read entire operation section before operating the Pro-MIG 175. 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 ventila[...]

Pro-MIG 175 Pro-MIG 175 3 2 1 4 B-2 B-2 OPERA TION ● No external shielding gas is required when used with Lincol .035 ” (0.9 mm) Innershield NR ® -211- MP electrode. ● Spindle accommodates both 8 in. (200 mm) diame- ter and 4 in. (100 mm) diameter spools of wire. WELDING CAP ABILITY The Pro-MIG 175 is rated at 130 amps, 20 volts, at 30% duty[...]

B-3 B-3 OPERA TION WELDING OPERA TIONS SEQUENCE OF OPERA TION Wire Loading Refer to Figure B.2 and B.3. The machine power switch should be turned to the OFF ( “ O ” ) position before working inside the wire feed enclosure. The machine is shipped from the factory ready to feed 8 ” (200 mm) diameter spools [2.2 ” (56 mm) max. width]. These sp[...]

B-4 B-4 OPERA TION Wire Threading Refer to Figure B.4 1 . Release the Spring Loaded Pressure Arm (1) rotate the Idle Roll Arm (2) away from the Wire Feed Drive Roll (3). Ensure that the groove size in the feeding position on the drive roll matches the wire size being used. See Maintenance section for further information. 2 . Carefully detach the en[...]

B-5 B-5 OPERA TION Making A Weld 1. See “ Process Guidelines ” in this section for selec- tion of welding wire and shielding gas and for range of metal thicknesses that can be welded. 2. See the Application chart on the inside of the wire feed compartment door for information on setting the Pro-MIG 175 controls. Refer to Table B.1 for aluminum [...]

Pro-MIG 175 B-6 B-6 OPERA TION The Pro-MIG 175 is suitable for .035" aluminum wire and .023" – .035" stainless wire. Refer to Table B.1 for recommended procedure settings. (Requires K586-1 regulator kit and K664-2 Aluminum - Stainless Feeding Kit.) It is important when changing between welding with steel wire and aluminum to exchan[...]

B-7 B-7 APPLICA TION CHART Pro-MIG 175[...]

C-1 C-1 ACCESSORIES OPTIONAL ACCESSORIES 1. K549-1 .035" (0.9 mm) Innershield® Welding Kit — Includes a contact tip, a gasless nozzle and a .030/.035 (.8/.9mm) cable liner to permit the Magnum ™ 100L gun and cable to use .035" (0.9 mm) diameter flux-cored electrode. The fitting on the end of the liner is stenciled with the maximum ra[...]

C-2 C-2 ACCESSORIES INNERSHIELD (FCA W) CONVERSION Several changes are needed to convert the unit for operation with the Innershield (FCAW) process. The K549-1 Innershield Kit includes all the necessary accessories for this conversion and is provided for this purpose. The following conversions should be made using the contents of this kit: 1. Chang[...]

MAINTENANCE SAFETY PRECAUTIONS ELECTRIC SHOCK can kill. • Disconnect input power by removing plug from receptacle before working inside Pro-MIG 175. Use only grounded receptacle. Do not touch electrically “hot” parts inside Pro-MIG 175. • Have qualified personnel do the mainte- nance and trouble shooting work. ROUTINE MAINTENANCE POWER SOUR[...]

D-2 D-2 MAINTENANCE GUN AND CABLE MAINTENANCE FOR MAGNUM™ 100L GUN Gun Cable Cleaning Clean cable liner after using approximately 300 lbs (136 kg) of solid wire or 50 lbs (23 kg) of flux-cored wire. Remove the cable from the wire feeder and lay it out straight on the floor. Remove the contact tip from the gun. Using low pressure air, gently blow [...]

D-3 D-3 MAINTENANCE COMPONENT REPLACEMENT PROCEDURES CHANGING THE CONT ACT TIP 1. Refer to Figure D.2. Remove the gas nozzle from the gun by unscrewing counter-clockwise. 2. Remove the existing contact tip from the gun by unscrewing counter-clockwise. 3. Insert and hand tighten desired contact tip. 4. Replace gas nozzle. CHANGING DRIVE ROLL (Refer [...]

D-4 D-4 MAINTENANCE 8. Screw the gas diffuser onto the end of the gun tube and securely tighten. 9. Replace the contact tip and nozzle. GUN HANDLE P ARTS The gun handle consists of two halves that are held together with a collar on each end. To open up the handle, turn the collars approximately 60 degrees counter-clockwise until the collar reaches [...]

Pro-MIG 175 E-1 TROUBLESHOOTING E-1 If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed. CAUTION This Troubleshooting Guide is provided to help you locate and repair poss[...]

E-2 E-2 TROUBLESHOOTING PROBLEMS (SYMPTOMS) Major physical or electrical damage is evident. No wire feed, weld output or gas flow when gun trigger is pulled. Fan does NOT operate. No wire feed, weld output or gas flow when gun trigger is pulled. Fan operates normally. POSSIBLE CAUSE None Contact your local Authorized Field Service Facility. 1. Make[...]

Pro-MIG 175 E-3 E-3 TROUBLESHOOTING PROBLEMS (SYMPTOMS) No wire feed when gun trigger is pulled. Fan runs, gas flows and machine has correct open circuit voltage (33 vcd maximum) – weld output. POSSIBLE CAUSE 1. If the wire drive motor is running make sure that the correct drive rolls are installed in the machine. 2. Check for clogged cable liner[...]

Pro-MIG 175 E-4 E-4 TROUBLESHOOTING If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your LOCAL AUTHORIZED LINCOLN ELECTRIC FIELD SERVICE FACILITY for assistance before you proceed. CAUTION PROBLEMS (SYMPTOMS) Arc is unstable – Poor starting POSSIBLE CAUSE 1. Check for correct [...]

F-1 F-1 WIRING DIAGRAMS W IRIN G DIA GR A M W ARNING HIGH VOLTAGE can kill Only qualified perso ns should install, use or service this machine. Do not operate with covers removed. Disconnect input power by unplugging po we r cord before servicing. Do n ot t ouch el ect ri ca lly l iv e par ts B M20143 ELECTRICAL S YMBOLS PER E153 7 CAVITY NUMBERING[...]

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W ARNING A VISO DE PRECAUCION A TTENTION W ARNUNG A TENÇÃO Spanish French German Portuguese Japanese Chinese Korean Arabic READ AND UNDERST AND THE MANUF ACTURER’S INSTRUCTION FOR THIS EQUIPMENT AND THE CONSUMABLES TO BE USED AND FOLLOW YOUR EMPLOYER’S SAFETY PRACTICES. SE RECOMIENDA LEER Y ENTENDER LAS INSTRUCCIONES DEL F ABRICANTE PARA EL U[...]

W ARNING A VISO DE PRECAUCION A TTENTION W ARNUNG A TENÇÃO Spanish French German Portuguese Japanese Chinese Korean Arabic LEIA E COMPREENDA AS INSTRUÇÕES DO F ABRICANTE PARA ESTE EQUIP AMENTO E AS P ARTES DE USO, E SIGA AS PRÁTICAS DE SEGURANÇA DO EMPREGADOR. ● Keep your head out of fumes. ● Use ventilation or exhaust to remove fumes fro[...]

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