Lincoln Electric HANDYMIG 170I manual

Handymig 170i OPERA TOR’S MANUAL IM711 January, 2001 Safety Depends on You LiquidArc machines are 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 READ- ING THIS MANUAL AND THE SAFETY PREC[...]

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. ________________________________________________[...]

SAFETY 2.i.4 Connect the work cable to the work piece as close as possible to the area being welded. (This is also a good practice to eliminate a common problem on welding - a poor work connection. 2.i.5 Do not work next to the welding power source. ADDITIONAL PRECAUTIONS FOR WELDERS WITH PACEMAKERS 2.j. There is no question that the fields in arc [...]

iii SAFETY iii 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 sk[...]

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 National Electrical Code, all local codes and the manufacturer ’ s recommendations. 8.c. Ground the equipment in accordance with the National Electrical Code and [...]

SAFETY v v INSTR UCTIONS FOR ELECTRO- MA GNETIC COMP A TIBILITY Conformance Products displaying the C-Tick mark are in conformity with Australian/New Zealand requirements for Electromagnetic Compatibility (EMC) according to standard (emission) AS/NZS 3652 "Electromagnetic Compatibility – Arc Welding Equipment". Products displaying the C[...]

Thank You for selecting a QUALITY product. We want you to take pride in operating this LiquidArc 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 particular attention to the safety ins[...]

vii vii T ABLE OF CONTENTS Page Installation .......................................................................................................Section A Technical Specifications ........................................................................................A-1 Identify and Locate Components ............................................[...]

viii viii T ABLE OF CONTENTS Page Learning to Weld (Continues) ......................................................................................------ Welding in a Vertical Position ........................................................................B-10 Vertical-up and Overhead Welding .....................................................[...]

A-1 A-1 INST ALLA TION Fuse or Output Mode Input Voltage Breaker Size Input Amps Power Cord RATED 240V/50Hz 25 Super Lag 12.7 15Amp, 240V, Three Pin Plug TECHNICAL SPECIFICA TIONS – Hand ymig 170i INPUT – SINGLE PHASE ONL Y RA TED OUTPUT OUTPUT RECOMMENDED INPUT CABLE AND FUSE SIZES Height Width Depth Weight 305 mm 248 mm 419 mm 25.9 kg PHYSICA[...]

A-2 INST ALLA TION SAFETY PRECA UTIONS • Read entire installation section before starting installation. IDENTIFY AND LOCA TE COMPONENTS If you have not already done so, unpack the Handymig 170i from its carton and remove all packing material around the Handymig 170i. Remove the fol- lowing loose items from the carton (see Figure A.1): 1. Handymig[...]

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 cause ov[...]

A-4 A-4 INST ALLA TION W ork Cable Installation Refer to Figure A.2. 1. Open the wire feed section door on the right side of the Handymig 170i. 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 Ge[...]

A-5 INST ALLA TION BE SURE TO KEEP YOUR FACE AWAY FROM THE VALVE OUTLET WHEN “ CRACKING ” THE VALVE. Never stand directly in front of or behind the flow regulator when opening the cylinder valve. Always stand to one side. 3. Attach the flow regulator to the cylinder valve and tighten the union nut securely with a wrench.. 4. Refer to Figure A.6[...]

A-6 INST ALLA TION ELECTRICAL INPUT CONNECTION FOR RA TED OUTPUT ELECTRIC SHOCK can kill. • Disconnect input power by removing plug from receptacle before working inside Handymig 170i. • Use only grounded receptacle. • Do not touch electrically “ hot ” parts inside Handymig 170i. • Have qualified personnel do the maintenance and trouble[...]

B-1 OPERA TION SAFETY PRECA UTIONS 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 z[...]

B-2 B-2 OPERA TION WELDING CAP ABILITY The Handymig 170i is rated at 130 amps, 20 volts, at 20% duty cycle on a ten minute basis. It is capable of higher output currents at lower duty cycles. . LIMIT A TIONS Arc Gouging cannot be performed with the Handymig 170i. The Handymig 170i is not recommended for pipe thawing or TIG welding. CONTR OLS AND SE[...]

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 spools[...]

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 Handymig 170i controls. Refer to Table B.1 for aluminu[...]

B-6 B-6 OPERA TION The Handymig 170i is suitable for .035"(0.9mm) alu- minum wire and .023" – .035"(0.6-0.9mm) stainless wire. Refer to Table B.1 for recommended procedure settings. (Requires K664-2 Aluminum - Stainless Feeding Kit.) It is important when changing between welding with steel wire and aluminum to exchange feeding comp[...]

Fumes and slag generated from Innershield type electrodes recom- mended for use with this welding machine can be toxic. • Avoid contact with eyes and skin. • Do not take internally. • Keep out of reach of children. • Follow all safety precautions found in this operating manual. B-7 B-7 LEARNING T O WELD W ARNING Electronic Components Hinges[...]

B-8 B-8 LEARNING T O WELD THE SELF-SHIELDED FCA W WELDING ARC Figure B.9 illustrates the action taking place in the self shielded FCAW (Innershield) welding arc. It closely resembles what is actually seen while welding. FIGURE B.9 The “ arc stream ” is seen in the middle of the picture. This is the electric arc created by the electric current f[...]

B-9 B-9 LEARNING T O WELD PROCESS SELECTION By gaining knowledge of the differences between the two processes, you will be able to select the best process for the job you have at hand. In selecting a process, you should consider: For GMAW (MIG) Process 1. Is most of my welding performed on 16 gauge and lighter materials? 2. Can I afford the extra e[...]

B-10 B-10 LEARNING T O WELD FIGURE B.12 Penetration Unless a weld penetrates close to 100% of the metal thickness, a butt weld will be weaker than the material welded together. In the example shown in Figure B.13, the total weld is only half the thickness of the material thus the weld is only approximately half as strong as the metal. FIGURE B.13 F[...]

B-11 B-11 LEARNING T O WELD FIGURE B.16 Vertical-down Welding Refer to Figure B.17 Vertical-down welds are applied at a fast pace. These welds are therefore shallow and narrow and, as such, are excellent for sheet metal. Vertical-down welds may be applied to 5/32 ” (3.9 mm) and lighter material. Use stringer beads and tip the gun in the direction[...]

B-12 B-12 LEARNING T O WELD ARC RAYS can burn eyes and skin. When using an open arc process, it Is necessary to use correct eye, head and body protection. Protect yourself and others, read “ ARC RAYS can burn ” at the front of this manual. • The Correct Way To Strike An Arc • Be sure the work clamp makes good electrical contact to the work.[...]

B-13 B-13 LEARNING T O WELD Mild Steel 16 gauge or 1/16 inch (1.6 mm) Electrode 0.035" (0.9 mm) Steelcore 71T-GS Innershield Wire Voltage Setting “ V ” A Wire Feed Speed “ o|o ” 1.5 For the Handymig 170i, use the following: Helpful Hints • For general welding, it is not necessary to weave the arc, neither forward or backward nor side[...]

B-14 B-14 LEARNING T O WELD MA CHINE SET UP FOR THE GMA W (MIG) PROCESS • See PROCESS GUIDELINES in the OPERATION section for selection of welding wire and shielding gas, and for range of metal thicknesses that can be welded. • See the Application Guide on the inside of wire feed section door for information on setting the controls. • Set the[...]

Helpful Hints • For general welding, it is not necessary to weave the arc, neither forward or backward nor sideways. Weld along at a steady pace. You will find it easier. • When welding on thin plate, you will find that you will have to increase the welding speed, whereas when welding on heavy plate, it is necessary to go more slowly in order t[...]

B-16 B-16 LEARNING T O WELD • After you strike the arc, practice the correct electri- cal stickout. Learn to distinguish it by its sound. • When you are sure that you can hold the correct electrical stickout, with a smooth “ crackling ” arc, start moving. Look at the molten puddle constantly, • Run beads on a flat plate. Run them parallel[...]

B-17 B-17 LEARNING T O WELD Proper Gun Handling Most feeding problems are caused by improper han- dling of the gun cable or electrodes. • Do not kink or pull the gun around sharp corners • Keep the gun cable as straight as practical when welding. • Do not allow dolly wheels or trucks to run over the cables. • Keep the cable clean. • Inner[...]

B-18 B-18 APPLICA TION CHART Handymig 170i[...]

D-1 GUN AND CABLE MAINTENANCE FOR MA GNUM ™ 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 out the cable [...]

D-2 D-2 MAINTENANCE COMPONENT REPLA CEMENT PR OCEDURES CHANGING THE CONT A CT 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 The [...]

GUN HANDLE P AR TS 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 a stop. Then pull the collar off the gun handle. If the collars are diffi- cult to turn, position the gun handle against a corner, plac[...]

D-4 D-4 GR OUND TEST PROCEDURE WARNING ELECTRIC SHOCK can kill WARNING: This procedure is only suitable for applica- tions using DC mega testers up to 500V. Note: This procedure is for ‘ machines as built ’ many modifications could have taken place over the life of a particular machine, so details of this procedure may need to be ‘ adjusted ?[...]

E-1 E-1 TR OUBLESHOO TING This Troubleshooting Guide is provided to help you locate and repair possible machine malfunctions. Simply follow the three-step procedure listed below. Step 1. LOCATE PROBLEM (SYMPTOM). Look under the column labeled “ PROBLEM (SYMPTOMS) ” . This column describes pos- sible symptoms that the machine may exhibit. Find t[...]

E-2 E-2 TR OUBLESHOO TING Observe Safety Guidelines detailed in the beginning of this manual. TR OUBLESHOO TING GUIDE PROBLEMS (SYMPT OMS) 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 operat[...]

E-3 E-3 TR OUBLESHOO TING TR OUBLESHOO TING GUIDE Observe Safety Guidelines detailed in the beginning of this manual. PROBLEMS (SYMPT OMS) 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 AREAS OF MISADJUSTMENT(S) 1. If the wire drive motor is runnin[...]

E-4 E-4 TR OUBLESHOO TING Observe Safety Guidelines detailed in the beginning of this manual. TR OUBLESHOO TING GUIDE If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your LOCAL AUTHORIZED LIQUID ARC FIELD SERVICE FACILITY for assistance before you proceed. CA UTION PROBLEMS (SYM[...]

F-1 F-1 WIRING DIA GRAMS Handymig 170i WIRING DIA GRAM: Code 10842 Handymig 170i WIRING DIA GRAM 10/00 NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual. The specific diagram for a particular code is pasted inside the machine on one of the enclosure panels. Handymig 170i[...]

W ARNING A VISO DE PRECA UCION A TTENTION W ARNUNG A TEN ÇÃ O Spanish French German Portuguese Japanese Chinese Korean Arabic READ AND UNDERST AND THE MANUFACTURER’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 P ARA E[...]

W ARNING A VISO DE PRECA UCION A TTENTION W ARNUNG A TEN ÇÃ O Spanish French German Portuguese Japanese Chinese Korean Arabic LEIA E COMPREENDA AS INSTRUÇÕES DO F ABRICANTE P ARA 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[...]

A Division of Lincoln Electric Company (Aust) Ply Ltd A.B.N. 36 000 040 308 Copyright © 2000 Lincoln Global Inc. 35 Bryant Street, Padstow, NSW2211, Australia[...]