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IM796
Handymig 170i April, 2006
For use with machine Code Numbers 10984
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 PRECAUTIONS CON-
TAINED THROUGHOUT. And,
most importantly, think before you
act and be careful.
OPERATOR鈥橲 MANUAL
Made exclusive for Australia
A Division of Lincoln Electric Company (Aust) Ply Ltd A.B.N. 36 000 040 308
35 Bryant Street, Padstow, NSW2211, Australia
Copyright 漏 2000 Lincoln Global Inc.
i i
SAFETY
WARNING
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.
For more detailed information it is strongly recommended that you purchase a copy of "Safety in Welding and Cutting - ANSI
Standard Z49.1" and WTIA Technical Note 7. All WTIA publications and ANSI/AWS Standards are available from the
Welding Technology Institute of Australia, PO Box 6165 Silverwater NSW 2128. For copies of various Australian Standards
contact your local S.A.A. office.
BE SURE THAT ALL INSTALLATION, OPERATION, MAINTENANCE AND REPAIR PROCEDURES ARE
PERFORMED ONLY BY QUALIFIED INDIVIDUALS.
1.e. In some cases it may be necessary to remove safety
FOR ENGINE guards to perform required maintenance. Remove
powered equipment. guards only when necessary and replace them when the
maintenance requiring their removal is complete.
1.a. Turn the engine off before troubleshooting and maintenance Always use the greatest care when working near moving
work unless the maintenance work requires it to be running. parts.
------------------------------------------------------------------------ ___________________________________________________
1.b. Operate engines in open, well-ventilated 1.f. Do not put your hands near the engine fan. Do not attempt to
areas or vent the engine exhaust fumes override the governor or idler by pushing on the throttle control
outdoors. 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.c. Do not add the fuel near an open flame
welding arc or when the engine is running. 1.h. To avoid scalding, do not remove the
Stop the engine and allow it to cool before radiator pressure cap when the engine is
refueling to prevent spilled fuel from vapor- hot.
izing 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.
____________________________________________________
Oct 鈥?00
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.
____________________________________________________
ii
SAFETY ii
2.i.4 Connect the work cable to the work piece as close as
ELECTRIC AND possible to the area being welded. (This is also a good
MAGNETIC FIELDS practice to eliminate a common problem on welding - a
poor work connection.
may be dangerous
2.i.5 Do not work next to the welding power source.
2.a. Electric current flowing through any conductor causes
ADDITIONAL PRECAUTIONS FOR
localized Electric and Magnetic Fields (EMF). Welding
WELDERS WITH PACEMAKERS
current creates EMF fields around welding cables and
welding machines
2.j. There is no question that the fields in arc welding can interfere
with a pacemakers function. Generally the interference does
2.b. EMF fields may interfere with some pacemakers, and
not permanently damage the pacemaker. Once the wearer
welders having a pacemaker should consult their physician
leaves the arc welding environment or stops welding, the pace-
before welding.
maker returns to normal functioning. The welding arc has little
or no effect on the operation of some pacemakers, especially
2.c. Exposure to EMF fields in welding may have other health
designs that are bi-polar or designed to filter out such interfer-
effects which are now not known.
ence.
2.d. All welders should follow safe practices that minimize their 2.k. For a welder or anyone working around electrical equipment
exposure to electric and magnetic fields (EMF). the selection of a pacemaker is very important. Get a doctor鈥檚
advice about which pacemaker is the least sensitive to inter-
2.e. For welders wearing implanted pacemakers, safe welding ference from welding while still being medically suitable.
practices are particularly important and additional procedures
should be followed by those who have decided to continue to 2.l. In addition to the normal safety precautions, the following addi-
weld. (Hopefully in keeping with a doctor鈥檚 advice). tional procedures should be adopted by welders with pacemak-
ers.
2.f. The following procedures will not eliminate exposure to EMF or
the possibility of arc welding having an effect on a pacemaker, 2.l.1 Use gas welding when the application is suitable.
however if followed, they will significantly reduce exposure to
electric and magnetic fields. Electric and magnetic fields are 2.l.2 Use the lowest current setting appropriate for the applica-
created any time electric current flows through a conductor, tion. Do not exceed 400 amps. Low current (75-200
however it is not clear whether such exposure affects ones amps) direct current (DC) welding should be used if arc
health. welding is necessary. Do not TIG weld with high frequen-
cy.
2.g. Some researchers have reported that exposure to EMF may
cause leukemia or other illnesses. These claims originally 2.l.3 Do not use repeated, short welds. Wait about ten sec-
arose in relation to high voltage electric power lines and are onds between stopping one weld and starting the next.
very much in dispute in the medical and scientific arena, how- When having difficulty starting an electrode, do not re-
ever the best advice is to minimize your exposure to EMF to strike the rod repeatedly.
protect your health should doctors eventually decide there is a
risk. 2.l.4 If you feel light headed, dizzy or faint, immediately stop
welding. Lay the electrode holder down so that it does not
2.h. There are four fundamental facts about EMF: contact the work and move away from any welding being
2.h.1 With direct current (DC), the field strength is relatively performed. Arrange your work in advance so that, if you
constant and does not change. become dizzy and drop the electrode holder it will not fall
on your body or strike the work.
2.h.2 With alternating current (AC), the field strength constant-
ly changes. 2.l.5 Do not work on a ladder or other elevated position or in a
cramped, confined place.
2.h.3 The greater the current flow, i.e. the higher the amps,
the stronger the field created by the current 2.l.6 Do not work alone. Work only in the presence of an indi-
vidual who understands these precautions and the possi-
2.h.4 The closer the conductor or electrical device is to the ble effect welding may have on your pacemaker.
body the greater the exposure to the field.
2.l.7 Do not work near spot welding equipment.
MINIMIZE EXPOSURE TO EMF
2.l.8 If you have a pacemaker and wish to continue arc weld-
2.i. All welders should use the following procedures to minimize ing, discuss this and any other questions you may have
EMF exposure: with your physician and follow his or her advice. The doc-
2.i.1 Route electrode or gun and work cables together. Secure tor may wish to contact the pacemaker manufacturer for a
them with tape if possible. recommendation. As mentioned before, the design of the
pacemaker significantly affects the degree to which it is
2.i.2 Never coil the electrode lead around your body. subject to interference from a welding circuit. Do not rely
on the fact that you know another welder with a pacemak-
2.i.3 Do not place your body between the electrode and work er who has welded for years without experiencing a prob-
cables. If your electrode cable is on your right side the lem.That welder and his or her pacemaker may be quite
work cable should also be on your right side. different from you and your pacemaker.
Oct 鈥?00
iii iii
SAFETY
ARC RAYS can burn.
ELECTRIC SHOCK can
4.a. Use a shield with the proper filter and cover
kill. plates to protect your eyes from sparks and
3.a. The electrode and work (or ground) circuits
the rays of the arc when welding or observing
are electrically 鈥渉ot鈥? when the welder is on. open arc welding. Headshield and filter lens
Do not touch these 鈥渉ot鈥? parts with your bare should conform to ANSI Z87. I standards.
skin or wet clothing. Wear dry, hole-free
gloves to insulate hands. 4.b. Use suitable clothing made from durable flame-resistant
material to protect your skin and that of your helpers from
3.b. Insulate yourself from work and ground using dry insulation. the arc rays.
Make certain the insulation is large enough to cover your full
area of physical contact with work and ground. 4.c. Protect other nearby personnel with suitable, non-flammable
screening and/or warn them not to watch the arc nor expose
In addition to the normal safety precautions, if welding themselves to the arc rays or to hot spatter or metal.
must be performed under electrically hazardous
conditions (in damp locations or while wearing wet
FUMES AND GASES
clothing; on metal structures such as floors, gratings or
scaffolds; when in cramped positions such as sitting,
can be dangerous.
kneeling or lying, if there is a high risk of unavoidable or
accidental contact with the workpiece or ground) use 5.a. Welding may produce fumes and gases
the following equipment: hazardous to health. Avoid breathing these
鈥? Semiautomatic DC Constant Voltage (Wire) Welder. fumes and gases.When welding, keep
鈥? DC Manual (Stick) Welder. your head out of the fume. Use enough
鈥? AC Welder with Reduced Voltage Control. ventilation and/or exhaust at the arc to keep
fumes and gases away from the breathing zone. When
3.c. In semiautomatic or automatic wire welding, the electrode, welding with electrodes which require special
electrode reel, welding head, nozzle or semiautomatic ventilation such as stainless or hard facing (see
welding gun are also electrically 鈥渉ot鈥?. instructions on container or MSDS) or on lead or
cadmium plated steel and other metals or coatings
3.d. Always be sure the work cable makes a good electrical which produce highly toxic fumes, keep exposure as
connection with the metal being welded. The connection low as possible and below Threshold Limit Values (TLV)
should be as close as possible to the area being welded. using local exhaust or mechanical ventilation. In
confined spaces or in some circumstances, outdoors, a
3.e. Ground the work or metal to be welded to a good electrical respirator may be required. Additional precautions are
(earth) ground. also required when welding on galvanized steel.
5.b. Do not weld in locations near chlorinated hydrocarbon vapors
3.f. Maintain the electrode holder, work clamp, welding cable and
coming from degreasing, cleaning or spraying operations.
welding machine in good, safe operating condition. Replace
The heat and rays of the arc can react with solvent vapors to
damaged insulation.
form phosgene, a highly toxic gas, and other irritating prod-
ucts.
3.g. Never dip the electrode in water for cooling.
5.c. Shielding gases used for arc welding can displace air and
3.h. Never simultaneously touch electrically 鈥渉ot鈥? parts of
cause injury or death. Always use enough ventilation,
electrode holders connected to two welders because voltage
especially in confined areas, to insure breathing air is safe.
between the two can be the total of the open circuit voltage
of both welders.
5.d. Read and understand the manufacturer鈥檚 instructions for this
equipment and the consumables to be used, including the
3.i. When working above floor level, use a safety belt to protect
material safety data sheet (MSDS) and follow your
yourself from a fall should you get a shock.
employer鈥檚 safety practices. MSDS forms are available from
your welding distributor or from the manufacturer.
3.j. Also see Items 6.c. and 8.
5.e. Also see item 1.b.
Mar 鈥?95
SAFETY
iv iv
WELDING SPARKS can CYLINDER may explode
cause fire or explosion. if damaged.
6.a. Remove fire hazards from the welding area.
7.a. Use only compressed gas cylinders
If this is not possible, cover them to prevent
containing the correct shielding gas for the
the welding sparks from starting a fire.
process used and properly operating
Remember that welding sparks and hot
regulators designed for the gas and
materials from welding can easily go through small cracks
pressure used. All hoses, fittings, etc. should be suitable for
and openings to adjacent areas. Avoid welding near
the application and maintained in good condition.
hydraulic lines. Have a fire extinguisher readily available.
7.b. Always keep cylinders in an upright position securely
6.b. Where compressed gases are to be used at the job site,
chained to an undercarriage or fixed support.
special precautions should be used to prevent hazardous
situations. Refer to 鈥淪afety in Welding and Cutting鈥? (ANSI
7.c. Cylinders should be located:
Standard Z49.1) and the operating information for the
鈥? Away from areas where they may be struck or subjected to
equipment being used.
physical damage.
6.c. When not welding, make certain no part of the electrode
鈥? A safe distance from arc welding or cutting operations and
circuit is touching the work or ground. Accidental contact
any other source of heat, sparks, or flame.
can cause overheating and create a fire hazard.
7.d. Never allow the electrode, electrode holder or any other
6.d. Do not heat, cut or weld tanks, drums or containers until the
electrically 鈥渉ot鈥? parts to touch a cylinder.
proper steps have been taken to insure that such procedures
will not cause flammable or toxic vapors from substances
7.e. Keep your head and face away from the cylinder valve outlet
inside. They can cause an explosion even though they have
when opening the cylinder valve.
been 鈥渃leaned鈥?. For information, purchase 鈥淩ecommended
Safe Practices for the Preparation for Welding and Cutting of
7.f. Valve protection caps should always be in place and hand
Containers and Piping That Have Held Hazardous
tight except when the cylinder is in use or connected for
Substances鈥?, AWS F4.1 from the American Welding Society
use.
(see address above).
7.g. Read and follow the instructions on compressed gas
6.e. Vent hollow castings or containers before heating, cutting or
cylinders, associated equipment, and CGA publication P-l,
welding. They may explode.
鈥淧recautions for Safe Handling of Compressed Gases in
Cylinders,鈥? available from the Compressed Gas Association
6.f. Sparks and spatter are thrown from the welding arc. Wear oil
1235 Jefferson Davis Highway, Arlington, VA 22202.
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.
FOR ELECTRICALLY
Always wear safety glasses with side shields when in a
welding area.
powered equipment.
6.g. Connect the work cable to the work as close to the welding
8.a. Turn off input power using the disconnect
area as practical. Work cables connected to the building
switch at the fuse box before working on
framework or other locations away from the welding area
the equipment.
increase the possibility of the welding current passing
through lifting chains, crane cables or other alternate cir-
8.b. Install equipment in accordance with the National
cuits. This can create fire hazards or overheat lifting chains
Electrical Code, all local codes and the manufacturer鈥檚
or cables until they fail.
recommendations.
6.h. Also see item 1.c.
8.c. Ground the equipment in accordance with the National
Electrical Code and the manufacturer鈥檚 recommendations.
Mar 鈥?95
v
v
SAFETY
The size of the surrounding area to be considered will depend on
INSTRUCTIONS FOR ELECTRO- the structure of the building and other activities that are taking
MAGNETIC COMPATIBILITY place. The surrounding area may extend beyond the boundaries of
the premises.
Conformance
Methods of Reducing Emissions
Products displaying the C-Tick mark are in conformity with
Australian/New Zealand requirements for Electromagnetic
Mains Supply
Compatibility (EMC) according to standard (emission) AS/NZS
3652 "Electromagnetic Compatibility 鈥? Arc Welding
Welding equipment should be connected to the mains supply
Equipment".
according to the manufacturer鈥檚 recommendations.If interference
occurs, it may be necessary to take additional precautions such as
Products displaying the CE mark are in conformity with
filtering the mains supply. Consideration should be given to shield-
European Community Council Directive 89/336/EEC require-
ing the supply cable of permanently installed welding equipment in
ments for EMC by implementing EN50199 "Electromagnetic
metallic conduit or equivalent. Shielding should be electrically con-
Compatibility (EMC) 鈥? Product standard for arc welding equip-
tinuous throughout its length. The shielding should be connected to
ment".
the welding power source so that good electrical contact is main-
tained between the conduit and the welding power source enclo-
Products are:
sure.
鈥? For use with other Lincoln Electric/LiquidArc equipment.
鈥? Designed for industrial and professional use.
Maintenance of the Welding Equipment
Introduction The welding equipment should be routinely maintained according
to the manufacturer鈥檚 recommendations. All access and service
All electrical equipment generates small amounts of electromagnet-
doors and covers should be closed and properly fastened when the
ic emission. Electrical emission may be transmitted through power
welding equipment is in operation. The welding equipment should
lines or radiated through space, similar to a radio transmitter. When
not be modified in any way except for those changes and adjust-
emissions are received by other equipment, electrical interference
ment covered in the manufacturer鈥檚 instructions. In particular, the
may result. Electrical emissions may effect many kinds of electrical
spark gaps of arc initiation and stabilizing devices should be adjust-
equipment: other nearby welding equipment, radio and TV trans-
ed and maintained according to the manufacturer鈥檚 recommenda-
mitters and receivers, numerical controlled machines, telephone
tions.
systems, computers, etc. Be aware that interference may result
and extra precautions may be required when a welding power
Welding Cables
source is used in a domestic establishment.
The welding cables should be kept as short as possible and should
Installation and Use be positioned close together, running at or close to the floor level.
The purchaser/user is responsible for installing and using the weld-
Equipotential Bonding
ing equipment according to the manufacturer鈥檚 instructions. If elec-
Bonding of all metallic components in the welding installation and
tromagnetic disturbances are detected then it shall be the responsi-
adjacent to it should be considered. However, metallic components
bility of the purchaser/user of the welding equipment to resolve the
bonded to the work piece will increase the risk that the operator
situation with the technical assistance of the manufacturer. In some
could receive a shock by touching these metallic components and
cases this remedial action may be as simple as earthing (ground-
the electrode at the same time. The operator should be insulated
ing) the welding circuit (see note below). In other cases it could
from all such bonded metallic components.
involve constructing an electromagnetic screen enclosing the
power source and the work complete with associated input filters.
Earthing of the workpiece
In all cases electromagnetic disturbances must be reduced to the
point where they are no longer troublesome. Where the workpiece is not bonded to earth for electrical safety,
nor connected to earth because of its size and position, eg. ship鈥檚
Note: The welding circuit may or may not be earthed for safety rea-
hull or building steelwork, a connection bonding the workpiece to
sons according to national codes. Changing the earthing arrange-
earth may reduce emissions in some, but not all instances. Care
ments should only be authorized by a person who is competent to
should be taken to prevent the earthing of work pieces increasing
assess whether the changes increase the risk of injury, eg. by
the risk of injury to users, or damage to other electrical equipment.
allowing parallel welding current return paths which may damage
Where necessary, the connection of the workpiece to earth should
the earth circuits of other equipment.
be made by direct connection to the workpiece, but in some coun-
Assessment of Area tries where direct connection is not permitted, the bonding should
be achieved by suitable capacitance, selected according to national
Before installing welding equipment the purchaser/user shall make regulations.
an assessment of potential problems in the surrounding area.
Screening and Shielding
The following shall be taken into account:
Selective screening and shielding of other cables and equipment in
鈥? Other supply cables, control cables, signalling and telephone the surrounding area may alleviate problems of interference.
cables above, below and adjacent to the welding equipment; Screening of the entire welding installation may be considered for
special applications.
鈥? Radio and television transmitters and receivers;
Portions of the preceding text are extracted from:
鈥? Computer and other control equipment;
鈥? Australian/New Zealand standard AS/NZS 3652. Permission to
鈥? Safety critical safety equipment, eg. guarding of industrial reproduce has been granted by Standards Australia and
equipment; Standards New Zealand. For further explanation, readers should
be referred to the standard itself.
鈥? The health of people around, eg. the use of pacemakers and
鈥? British Standards Institution standard BS EN 50199:1995.
hearing aids;
Reproduced with permission of BSI under license number
鈥? Equipment used for calibration or measurement;
2000SK0631. Complete standards can be obtained from BSI
鈥? The immunity of other equipment in the environment. The Customer Services, 389 Chiswick High Road, London W4 4AL.
purchaser/user shall ensure that other equipment being used United Kingdom. (Tel +44 (0) 20 8996 9001).
in the environment is compatible. This may require additional Copyright of above text is property of Standards Australia,
protection measures; Standards New Zealand and British Standards Institution.
Permission to reproduce the text must be obtained.
鈥? The time of the day that welding or other activities are to be
JAN 鈥?01
carried out.
vi vi
for selecting a QUALITY product by Lincoln Electric. We want you
Thank You to take pride in operating this Lincoln Electric Company product
鈥⑩?⑩?? as much pride as we have in bringing this product to you!
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.
Please record your equipment identification information below for future reference. This information can be
found on your machine nameplate.
Product _________________________________________________________________________________
Model Number ___________________________________________________________________________
Code Number or Date Code_________________________________________________________________
Serial Number____________________________________________________________________________
Date Purchased___________________________________________________________________________
Where Purchased_________________________________________________________________________
Whenever you request replacement parts or information on this equipment, always supply the information you
have recorded above. The code number is especially important when identifying the correct replacement parts.
On-Line Product Registration
- Register your machine with Lincoln Electric either via fax or over the Internet.
鈥? For faxing: Complete the form on the back of the warranty statement included in the literature packet
accompanying this machine and fax the form per the instructions printed on it.
鈥? For On-Line Registration: Go to our WEB SITE at www.lincolnelectric.com. Choose 鈥淨uick Links鈥? and then
鈥淧roduct Registration鈥?. Please complete the form and submit your registration.
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 instructions we have provided for your protection.
The level of seriousness to be applied to each is explained below:
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.
vii
vii
TABLE OF CONTENTS
Page
Installation .......................................................................................................Section A
Technical Specifications ........................................................................................A-1
Identify and Locate Components ...........................................................................A-2
Select Suitable Location ........................................................................................A-3
Stacking ..........................................................................................................A-3
Tilting...............................................................................................................A-3
Output Connections ...............................................................................................A-3
Work Clamp Installation ..................................................................................A-3
Work Cable Installation ...................................................................................A-4
Gun Installation......................................................................................................A-4
Connecting Gun Cable to the Handymig 170i.................................................A-4
Gas Connection .....................................................................................................A-4
Input Connections..................................................................................................A-5
Electrical Input Connection for Rated Output ........................................................A-6
Line Cord Connection .....................................................................................A-6
Operation .........................................................................................................Section B
Safety Precautions ................................................................................................B-1
General Description ...............................................................................................B-1
Recommended Processes ..............................................................................B-1
Optional Features and Controls ......................................................................B-1
Design Features and Advantages .........................................................................B-1
Welding Capability .................................................................................................B-2
Limitations..............................................................................................................B-2
Controls and Settings ............................................................................................B-2
Welding Operations ...............................................................................................B-3
Sequence of Operations .................................................................................B-3
Wire Loading ..............................................................................................B-3
Friction Brake Adjustments ........................................................................B-3
Wire Threading...........................................................................................B-4
Making a Weld ...........................................................................................B-5
Cleaning Tip and Nozzle ............................................................................B-5
Process Guidelines................................................................................................B-5
Changing Over to Feed Other Wire Sizes .............................................................B-6
Welding with GMAW..............................................................................................B-6
Welding with FCAW...............................................................................................B-6
Application Chart.................................................................................................B-7
Handymig 170i
viii
viii
TABLE OF CONTENTS
Page
Maintenance ....................................................................................................Section D
Safety Precautions ................................................................................................D-1
Routine Maintenance.............................................................................................D-1
Wire Feed Compartment.................................................................................D-1
Fan Motor........................................................................................................D-1
Wire Reel Spindle ...........................................................................................D-1
Gun and Cable................................................................................................D-1
Gun Cable Cleaning................................................................................D-1
Contact Tips, Nozzles, and Gun Tubes ..................................................D-1
Component Replacement Procedures ..................................................................D-2
Changing the Contact Tip ...............................................................................D-2
Changing Drive Roll ........................................................................................D-2
Changing Liner................................................................................................D-3
Gun Handle Parts ...........................................................................................D-3
Ground Test Procedure .........................................................................................D-4
Troubleshooting ..............................................................................................Section E
Safety Precautions.................................................................................................E-1
How to Use Troubleshooting Guide.......................................................................E-1
Troubleshooting Guide.............................................................................E-2 thru E-4
Wiring Diagrams ..............................................................................................Section F
Handymig 170i Wiring Diagram .............................................................................F-1
Handymig 170i Parts ............................................................................P463,P202,P189
Handymig 170i
A-1 A-1
INSTALLATION
TECHNICAL SPECIFICATIONS 鈥? Handymig 170i
INPUT 鈥? SINGLE PHASE ONLY
Standard Voltage/Frequency AS1966.1
240V/50Hz Rated Input Current
12.7 Amps
RATED OUTPUT
Duty Cycle Amps Volts at Rated Amperes
20% 130 20
OUTPUT
Welding Current Range Maximum Open Circuit Voltage Auxiliary Power
Rated DC Output: 30 鈥? 170 amps 33 N/A
RECOMMENDED INPUT CABLE AND FUSE SIZES
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
PHYSICAL DIMENSIONS
Height Width Depth Weight
305 mm 248 mm 419 mm 25.9 kg
Handymig 170i
A-2 A-2
INSTALLATION
FIGURE A.1
SAFETY PRECAUTIONS
鈥? Read entire installation section before starting
1
installation.
2
WARNING WELD
ING
25-125AMP RA
NGE
Hand
ymig
ELECTRIC SHOCK can kill. 170i
鈥? Only qualified personnel should perform
this installation.
鈥? Only personnel that have read and under-
stood the Handymig 170i Operating
Manual should install and operate this
equipment.
4
鈥? Machine must be plugged into a receptacle
which is grounded per any national, local
or other applicable electrical codes.
3
鈥? The Handymig 170i power switch is to be
in the OFF (鈥淥鈥?) position when installing
work cable and gun and when connecting
power cord to input power.
IDENTIFY AND LOCATE 5
6
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 170i
2. Gun and cable assembly(1)
3. Literature and miscellaneous includes:
a) This operating manual
b) A separate .030" (0.8 mm) contact tip
c) Hex key wrench for removal of drive roll.
4. 10 ft (3,0 m) work cable.
5. Work clamp.
6. Adjustable mixed-Gas Regulator & Hose.
The gun is ready to feed .023" 鈥? .025" (0.6 mm)
(1)
diameter wire.
Handymig 170i
A-3
INSTALLATION
A-3
6. Wire Feed Gearbox.
SELECT SUITABLE LOCATION
7. Cable Hanger.
Locate the welder in a dry location where there is free
circulation of clean air into the louvers in the back and
8. Thumbscrew.
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.
Work Clamp Installation
STACKING
Attach the work clamp per the following: Refer to
Figure A-3.
Handymig 170i鈥檚 cannot be stacked.
TILTING
Each machine must be placed on a secure, level sur-
face, either directly or on the recommended cart. The
machine may topple over if this procedure is not fol-
lowed.
OUTPUT CONNECTIONS FIGURE A.3
Refer to Figure A.2. 1. Insert the work cable terminal lug with the larger
hole through the strain relief hole in the work clamp
1. Work Cable Access Hole. as shown above.
2. Gun Cable and Control Lead Access Hole. 2. Fasten securely with the bolt and nut provided.
3. Connector Block.
4. Gun Trigger Lead Connectors.
5. Positive (+) and negative (鈥?) output terminals.
FIGURE A.2
4
E
5
WELDING AMP RANGE
30-70
+
8
Handymig 170i
-
6
3 7
1 2
Handymig 170i
A-4
A-4 INSTALLATION
Work Cable Installation
NOTE: If .045" or 1.2 mm) Innershield flux-cored wire
Refer to Figure A.2. is to be used, the appropriate Innershield kit is
required.
1. Open the wire feed section door on the right side of
the Handymig 170i.
Connecting Gun Cable to the Handymig
2. Pass the end of the work cable that has the termi- 170i.
nal lug with the smaller hole through the Work
Cable Access Hole (1) in the case front. 1. Refer to Figure A.2. Unplug the machine or turn
power switch to the OFF 鈥淥鈥? position.
3. Route the cable under and around the back of the
Wire Feed Gearbox (6). 2. Pass the insulated terminals of the gun trigger con-
trol leads, one at a time, through the Gun Cable
4. For GMAW Only: Refer to Figure A.2. As deliv- and Control Lead Access Slot (2) in the case front.
ered, the machine is connected for positive elec- The leads are to be routed up the inside of the
trode polarity. This is the appropriate configuration case front, behind the gas line.
for the GMAW (MIG) process. To complete installa-
tion, use the provided wing nut to connect the work 3. Insert the connector on the gun conductor cable
cable鈥檚 terminal lug to the negative (鈥?) output ter- through the Gun Cable Access Hole (2) in the
minal (5) located above the Wire Feed Gearbox Handymig 170i case front. Make sure the connec-
(6). Make sure that both wing nuts are tight. tor is all the way in the brass connector block to
obtain proper gas flow. If the gun connector will not
5. For Innershield Only: Refer to Figure A.4. To wire fully insert, unscrew the thumbscrew on the con-
for negative polarity (required for the Innershield nector block a few turns. Rotate the connector so
process), connect the short cable attached to the control leads are on the underside and tighten the
connector block (1) to the negative (鈥?) output termi- Thumbscrew on the connector block.
nal (2) and the work cable (3) to the positive (+) ter-
minal (4). 4. Connect the gun trigger control lead terminals to
the two insulated 1/4" (6,4 mm) tab terminal con-
FIGURE A.4 nector bushings located above the 鈥淕un Trigger
Connection鈥? decal in the wire feed section (4).
Either lead can go to either connector.
4
CAUTION
3
2 If the gun trigger switch being used is other than
that supplied, the switch must be a normally open,
momentary switch. The terminals of the switch
1 must be insulated from the welding circuit.
Malfunction of the Handymig 170i may result if
this switch shorts to the Handymig 170i welding
output circuit or is common to any electrical cir-
cuit other than the Handymig 170i trigger circuit.
GAS CONNECTION
GUN INSTALLATION The Handymig 170i is supplied with a mixed gas
Regulator and a 3m gas hose. A cylinder of an appro-
As shipped from the factory, the Handymig 170i gun is priate shielding gas must be obtained from your gas
ready to feed .023" 鈥? .025"(.6mm) solid wire. If .030"- distributor.
.035鈥? (0.8-.09 mm) solid wire is to be used, change the
contact tip to the appropriate size. If .035鈥? Flux-cored
wire is to be used, change the contact tip and nozzle
to the appropriate types and orient the drive roll to the
appropriate groove size
Handymig 170i
A-5
INSTALLATION
A-5
WARNING WARNING
BE SURE TO KEEP YOUR FACE AWAY FROM THE
VALVE OUTLET WHEN 鈥淐RACKING鈥? THE VALVE.
CYLINDER may explode if dam-
Never stand directly in front of or behind the flow
aged. Keep cylinder upright and
regulator when opening the cylinder valve. Always
chained to support
stand to one side.
鈥? Keep cylinder away from areas
where it may be damaged. 3. Attach the flow regulator to the cylinder valve and
tighten the union nut securely with a wrench..
鈥? Never lift welder with cylinder
attached.
鈥? Never allow welding electrode to
touch cylinder.
4. Refer to Figure A.6. Attach one end of inlet gas
鈥? Keep cylinder away from welding hose to the outlet fitting of the flow regulator and
tighten the union nut securely with a wrench.
Connect the other end to the Handymig 170i Gas
WARNING Solenoid Inlet Fitting (5/8-18 female threads 鈥? for
or other live electrical circuits. CGA 鈥? 032 fitting). Make certain the gas hose is
not kinked or twisted.
BUILDUP OF SHIELDING GAS may
5. Reinstall case side before connecting input power.
harm health or kill.
鈥? Shut off shielding gas supply
when not in use.
INPUT CONNECTIONS
FIGURE A.6
1. Chain the cylinder to a wall or other stationary sup-
port to prevent the cylinder from falling over.
Insulate the cylinder from the work circuit and earth
ground. Refer to Figure A.5.
FIGURE A.5
Cylinder Valve
Flow Regulator GAS SOLENOID
INLET FITTING
POWER INPUT
CABLE
Gas Hose
Refer to Figure A.6.
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.
Handymig 170i
A-6 A-6
INSTALLATION
ELECTRICAL INPUT CONNECTION
FOR RATED OUTPUT
WARNING
ELECTRIC SHOCK can kill.
鈥? Disconnect input power by
removing plug from receptacle
before working inside Handymig
170i.
鈥? Use only grounded receptacle.
鈥? Do not touch electrically 鈥渉ot鈥?
parts inside Handymig 170i.
鈥? Have qualified personnel do the
maintenance and troubleshooting
work.
Line Cord Connection
A three conductor line cord with a 15 amp, 240 volt,
three pin plug is factory installed. Connect this plug to
a mating grounded receptacle which is connected to
an appropriate power supply per the Wiring Rules and
any applicable local codes.
WARNING
鈥? This welding machine must be connected to a
power source in accordance with applicable
electrical codes.
鈥? If there is any question about the installation
meeting applicable electrical code requirements,
consult a qualified electrician.
Handymig 170i
B-1
OPERATION
B-1
SAFETY PRECAUTIONS GENERAL DESCRIPTION
The Handymig 170i is a complete semiautomatic con-
WARNING stant voltage DC portable arc welder. Included is a
tap-switch controlled, single phase constant voltage
ELECTRIC SHOCK can kill. transformer/rectifier power source and a wire feeder
with welding gun for feeding .023" (0.6 mm) through
鈥? Do not touch electrically live
.030" (0.8 mm) solid steel electrode. Optional kits are
parts or electrode with skin or
available for .035" (0.9 mm) and .045" (1.2 mm)
wet clothing. Insulate yourself
Innershield庐 NR-211-MP.
from work and ground.
鈥? Always wear dry insulating
It is ideally suited for individuals having access to 240
gloves.
volts 50 Hz AC input power and want the ease of use,
quality and dependability of both gas metal arc weld-
ing or GMAW (also known as MIG welding) and the
FUMES AND GASES can be Innershield 庐 process (self-shielded flux-cored or
dangerous. FCAW). A convenient chart is mounted inside the wire
feed section door for setting welding procedures for 24
鈥? Keep your head out of fumes.
gauge (.60 mm) through 5/16" (8.0 mm) mild steel.
鈥? Use ventilation or exhaust to
The machine is rugged and reliable and has designed
remove fumes from breathing
for dependable service and long life.
zone.
RECOMMENDED PROCESSES
WELDING SPARKS can The Handymig 170i can be used for welding mild steel
cause fire or explosion. using the GMAW, single pass, process which requires
a supply of shielding gas or it can be used with the
鈥? Keep flammable material away.
self-shielded, Innershield庐 process (FCAW).
鈥? Do not weld on closed contain-
ers. OPERATIONAL FEATURES AND
CONTROLS
The Handymig 170i has the following controls as stan-
dard: Power ON/OFF Switch, Voltage Control, Wire
Speed Control, Trigger Switch, and a Circuit Breaker.
ARC RAYS can burn eyes
and skin.
DESIGN FEATURES AND
鈥? Wear eye, ear and body protec- ADVANTAGES
tion.
鈥? 鈥淐old electrode鈥? until gun trigger is pressed for an
added measure of safety.
鈥? Overload protection 鈥? incorporates both a thermo-
stat and a circuit breaker.
鈥? Quality wire drive with electronic overload protection.
See additional warning information at
鈥? 鈥淨uick Release鈥? idle roll pressure arm is easily
front of this operator鈥檚 manual.
adjusted.
鈥? Reversible, dual groove drive roll, shipped ready to
feed .023"/.025" (0.6 mm) diameter wire. The drive
roll is easily reversed to feed .030" (0.8 mm) diame-
ter solid wire and .035" (0.9 mm) flux-cored diameter
wire. Optional drive roll included in .045" (1.2 mm)
Innershield庐 welding kit must be installed to feed
.045" (1.2 mm) flux-cored wire.
鈥? No external shielding gas is required when used with
Liquid Arc steelcore 71T-GS electrode.
鈥? Spindle accommodates both 8 in. (200 mm) diameter
and 4 in. (100 mm) diameter spools of wire.
Handymig 170i
B-2 B-2
OPERATION
WELDING CAPABILITY
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. .
FIGURE B.1a
LIMITATIONS
Arc Gouging cannot be performed with the Handymig
170i. The Handymig 170i is not recommended for pipe
thawing or TIG welding.
CONTROLS AND SETTINGS
Refer to Figure B.1a.
1. Power ON/OFF Switch 鈥?
When the power is on the
fan motor will run and air will
be exhausted out the louvers
in the front of the machine.
ON
The welding output and wire
feeder remain off until the
gun trigger is pressed.
OFF
2. Wire Speed Control 鈥?
Controls the wire feed speed
from 50 鈥? 400 in/min (1.2 鈥?
10.2 m/min). The control can
be preset on the dial to the
FIGURE B.1b
setting specified on the
WIRE SPEED
Handymig 170i Application
Chart located on the inside
of the wire feed section door.
4
3. Voltage Control 鈥? A 5-posi-
tion tap selector switch gives
full range adjustment of +
ARC VOLTS
power source output voltage. -
Do not switch while welding.
4. Circuit Breaker 鈥? Protects machine from damage if
maximum output is exceeded. Button will extend
out when tripped (Manual reset).Refer to Figure
B.1b.
Handymig 170i
B-3 B-3
OPERATION
FIGURE B.3
WELDING OPERATIONS
SEQUENCE OF OPERATION
Wire Loading Wire Spindle Shaft
4" Wire Spool
Refer to Figure B.2 and B.3.
The machine power switch should be turned to the
OFF (鈥淥鈥?) position before working inside the wire feed
enclosure.
The machine is shipped from the factory ready to feed
8鈥? (200 mm) diameter spools [2.2鈥? (56 mm) max. Wing Nut
and Spacer
width]. These spools fit on a 2鈥? (50 mm) diameter
To wire drive
spindle that has a built-in adjustable friction brake to
prevent overrun of the spool and excess slack in the
wire.
Note:When loading and removing the 8鈥? Spools make
sure that the wing nut (inside the wire spool spindle Note: The brake should be adjusted with a spool of
hub) is turned 90掳 from the wire spool spindle locking wire installed. When properly adjusted it should
tab. If the wing nut is positioned in line with the locking move freely but not coast.
tab, the tab cannot be depressed to load or unload
CAUTION
FIGURE B.2
the wire spool. Some spools can have the start wire protruding
from the side of the spool. This must be insulated
8鈥? Wire Spool
Wire Spool Spindle
from internal metal components otherwise electri-
cal grounding faults will result and the machine
will be seriously damaged.
Friction Brake Adjustments
1. With wire spool installed, check free movement
and coast of the spool.
Be sure that this stud engages
the hole in the wire spool.
2. To tighten the brake turn the wing nut clockwise in
1/4 turn increments until coasting stops.
To Wire Drive
3. To loosen the brake turn the wing nut counter-
Wire Spool must be pushed all the way on the spindle so that the
clockwise in 1/4 turn increments until the wire spool
spindle鈥檚 tab will hold it in place. The Wire Spool will rotate clock-
moves freely without coasting.
wise when wire is dereeled.
Load an 8鈥? (200 mm) diameter spool on the wire spool
spindle shown in Figure B.2.
To use 4鈥? (100 mm) diameter spools, the 2鈥? (50 mm)
diameter spindle must be removed (See Figure B.3).
Remove the wing nut and spacer at the end of the
shaft and remove the outside plastic wire spool spin-
dle. The spindle can be stored in the wire feed com-
partment. A 4鈥? (100 mm) diameter spool is mounted
directly on the 5/8鈥? (16 mm) diameter shaft and held in
place with the previously removed hardware. Also
make certain the start end of the wire, which may pro-
trude through the side of the spool does not contact
any metallic case parts.
Handymig 170i
B-4 B-4
OPERATION
FIGURE B.4
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 2
wire size being used. See Maintenance section for
further information.
1
2. Carefully detach the end of the wire from the
spool. To prevent the spool from unwinding, main- 4
5
tain tension on the wire until after step 5.
3 The Wire Drive Feed Roll can
accommodate two wire sizes by
3. Cut the bent portion of wire off and straighten the
flipping the wire drive feed roll
first 4鈥? (100 mm). over.
4. Thread the wire through the incoming guide tube
(4), over the drive roll (3), and into the outgoing
guide tube (5).
8. Turn the Handymig 170i ON (鈥淚鈥?).
5. Close the idle roll arm and latch the spring loaded
pressure arm (2) in place. Rotate the spool coun-
terclockwise if required to take up extra slack in
9. Straighten the gun cable assembly.
the wire.
6. The idle roll pressure adjustment wing nut is nor-
mally set for mid-position on the pressure arm
10. Depress the gun trigger switch and feed welding
threads. If feeding problems occur because the
wire through the gun and cable. (Point gun away
wire is flattened excessively, turn the pressure
from yourself and others while feeding wire.)
adjustment counter-clockwise to reduce distortion
Release gun trigger after wire appears at end of
of the wire. Slightly less pressure may be required
gun.
when using 0.023 鈥? 0.025鈥? (0,6 mm) wire. If the
6. drive roll slips while feeding wire, the pressure
should be increased until the wire feeds properly.
11. Turn the Handymig 170i OFF (鈥淥鈥?).
WARNING
FIGURE B.5
When inching the welding wire, the drive rolls, the
gun connector block and the gun contact tip are
electrically energized relative to work and ground
and remain energized for several seconds after
the gun trigger is released.
Gun Handle
------------------------------------------------------------------------
7. Refer to Figure B.5. Remove gas nozzle and con-
Gas Diffuser/
tact tip from end of gun. Contact Tip
Gas Nozzle
12. Replace contact tip and gas nozzle.
13. Refer to Figure B-6. Cut the wire off 3/8鈥? 鈥? 1/2鈥? (10
鈥? 12 mm) from the end of the tip. The Handymig
170i is now ready to weld.
Handymig 170i
B-5
B-5 OPERATION
FIGURE B.7
FIGURE B.6
Contact Tip
GUN CABLE
Wire Electrode
3/8" 鈥? 1/2" Contact Tip To Work Distance
(10-12 mm) (CTWD)
WORKPIECE
ARC
Making A Weld
1. See 鈥淧rocess Guidelines鈥? in this section for selec- WORK CLAMP
10. When no more welding is to be done, close valve
tion of welding wire and shielding gas and for
on gas cylinder (if used), momentarily operate gun
range of metal thicknesses that can be welded.
trigger to release gas pressure, and turn off the
Handymig 170i.
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
Cleaning Tip And Nozzle
aluminum and stainless wire.
Clean the contact tip and nozzle to avoid arc bridging
between the nozzle and contact tip which can result in
3. Set the Voltage (鈥淰鈥?) and Wire Speed (鈥渙lo鈥欌??) con-
a shorted nozzle, poor welds and an overheated gun.
trols to the settings suggested for the welding wire
Hint: Anti-stick spray or gel, available from a welding
and base metal thickness being used, refer to
supply distributor, may reduce buildup and aid in spat-
3. Applications chart on the inside of the wire drive
ter removal.
compartment door.
4. Check that the polarity is correct for the welding
PROCESS GUIDELINES
wire being used and that the gas supply, if
required, is turned on.
The Handymig 170i can be used for welding mild steel
using the GMAW, single pass, process which requires
5. When using Innershield electrode, remove the gas
a supply of shielding gas or it can be used for the self-
nozzle and install the gasless nozzle. This will
shielded, Innershield庐 process (FCAW).
improve visibility of the arc and protect the gas dif-
fuser from weld spatter. Refer to the MAINTE-
The recommended gases and electrodes for GMAW
NANCE section for details on nozzle replacement.
are welding grade CO2 gas or an argon-CO2 blended
gas (75 to 80% argon and 25 to 20% CO2) and .025"
6. Refer to Figure B.7. Connect work clamp to metal
(0.6 mm) diameter Liquid Arc S6 mild-steel welding
to be welded. Work clamp must make good elec-
wire, supplied on 12-1/2 lb (5 kg) spools. The blended
trical contact to the workpiece. The workpiece
gas is recommended for welding on heavier steel, 14
must also be grounded as stated in 鈥淎rc Welding
gauge (2.0 mm), for example.
Safety Precautions鈥? in the beginning of this manu-
al.
The recommended electrode for the self-shielded
process is Liquid Arc steelcore 71T-GS on 10 lb (4.5
7. Position gun over joint. End of wire may be lightly
kg) spools. This electrode is available as .035" (0.9
touching the work.
mm) and .045" (1.2 mm) NR-211-MP for all position
welding of 18 gauge (1.2 mm) through 5/16" (8.0 mm)
8. Lower welding helmet, close gun trigger, and
steel. Thickness of 1/4" (6.4 mm) and 5/16" (7.9 mm)
begin welding. Hold the gun so the contact tip to
require multiple passes. both wire sizes can also be
work distance is about 3/8 inch (10 mm).
used for the welding of galvanized coated sheet
metal.
9. To stop welding, release the gun trigger and then
pull the gun away from the work after the arc goes
out.
Handymig 170i
B-6 B-6
OPERATION
鈥? Depress the gun trigger briefly to release the
The Handymig 170i is suitable for .035"(0.9mm) alu-
pressure in the gas hose.
minum wire and .023"鈥?.035"(0.6-0.9mm) stainless
wire. Refer to Table B.1 for recommended procedure
鈥? Turn off the Handymig 170i.
settings. (Requires K664-2 Aluminum - Stainless
Feeding Kit.)
WELDING WITH FCAW (Innershield)
When using the FCAW process, the correct drive roll
CAUTION and electrode polarity must be used. See Work Cable
Installation in INSTALLATION section for changing the
It is important when changing between welding
polarity.
with steel wire and aluminum to exchange feeding
Use optional Innershield welding kit K549-1 (for 0.9
components due to the lubricant applied to steel
mm) or K549-2 (for 1.2 mm), as appropriate.
wire. Failure to do so may result in contaminated
welds when welding aluminum.
鈥? K549-1 0.9mm (.035鈥?) Innershield庐 Welding Kit鈥?
------------------------------------------------------------------------
Includes a contact tip, a gasless nozzle and a 0.9-
TABLE B.1 鈥? Handymig 170i
1.2mm cable liner to permit the Magnum鈩? 100L gun
and cable to use 0.9mm diameter flux-cored elec-
Voltage/Wire Speed
Shielding trode. The fitting on the end of the liner is stencilled
Process Welding Wire Gas 22 ga 16 ga 12 ga 1/8鈥? 3/16鈥? 1/4鈥?
with the maximum rated wire size (.045鈥?/1.2mm).
.035 Dia(0.9mm 100% Argon A-4.5 B-6.5 D-8.5 D-10 E-10 E10*
Also included is a spool of 0.9mm Innershield庐 NR-
4043 Aluminum
211-MP.
Wire
18 ga 16 ga 14 ga 12 ga 10 ga
MIG DC+
.030 Dia 98% Argon/ A-2 B-3 C-5 D-7 E-10 鈥? K549-2 1.2mm (.045鈥?) Innershield庐 Welding Kit鈥?
308L Stainless 2% Oxygen
Includes a contact tip, a gasless nozzle and a 0.9-
Steel Wire
1.2mm cable liner to permit Magnum鈩? 100L gun
NOTES:
and cable to use 1.2mm diameter flux-cored elec-
* Test assembly preheated to 250掳F(121掳C)
trode. The fitting on the end of the liner is stencilled
with the maximum rated wire size (.045鈥?/1.2mm).
Also included is a spool of 1.2mm Innershield庐 NR-
CHANGING MACHINE OVER TO 211-MP and a knurled drive roll.
FEED OTHER WIRE SIZES
Several changes are needed to convert the unit for
operation with the Innershield (FCAW) process. The
The Handymig 170i is shipped from the factory ready
K549-1 or K549-2 Innershield Kits include all the nec-
to feed 0.023鈥? 鈥? .025" (0.6 mm) diameter wire. To
essary accessories for this conversion and are provid-
operate the Handymig 170i with other sizes of wire, it
ed for this purpose. The following conversions should
maybe necessary to change the contact tip, change
be made using the contents of this kit:
drive roll and gun liner configuration. Refer to the
MAINTENANCE section, for component configuration
鈥? Change the output polarity to DC(-). See 鈥淲ork
and replacement procedures.
Cable Installation鈥? in Installation Section for details.
WELDING WITH GMAW (MIG)
鈥? Install proper drive roll for wire size selected. See
鈥淐hanging Drive Roll鈥? in Maintenance Section for
Shielding Gas
details.
When using the GMAW process, install a gas regula-
tor and hose kit.
鈥? Install the proper gun liner and tip for the wire size
selected. See 鈥淐omponent Replacement鈥? in the
鈥? For CO2, open the cylinder very slowly. For argon-
Maintenance Section for details.
mixed gas, open cylinder valve slowly a fraction of
a turn. When the cylinder pressure gauge pointer
鈥? Remove gas nozzle (if installed) and install gasless
stops moving, open the valve fully.
nozzle. To remove, simply unscrew.
鈥? If using a regulator with an adjustable flow meter,
close the gun trigger and adjust the flow to give 15
鈥? Load wire into machine and thread into gun and
鈥? 20 cubic ft per hour (CFH) (7 鈥? 10 I/min) [use 20
cable per 鈥淲elding Wire Loading鈥? section.
鈥? 25 CFH (10 鈥? 12 I/min) when welding out of posi-
tion or in a drafty location.
鈥? Keep the cylinder valve closed, except when using
the Handymig 170i. When finished welding:
鈥? Close the cylinder valve to stop gas flow.
Handymig 170i
B-7
B-7 APPLICATION CHART
Handymig 170i
D-1 D-1
MAINTENANCE
GUN AND CABLE
SAFETY PRECAUTIONS
MAINTENANCE
WARNING
FOR MAGNUM鈩? 100L GUN
ELECTRIC SHOCK can kill.
Gun Cable Cleaning
Clean cable liner after using approximately 300 lbs
鈥? Disconnect input power by
(136 kg) of solid wire or 50 lbs (23 kg) of flux-cored
removing plug from receptacle
wire. Remove the cable from the wire feeder and lay it
before working inside Handymig
out straight on the floor. Remove the contact tip from
170i. Use only grounded recepta-
the gun. Using low pressure air, gently blow out the
cle. Do not touch electrically
cable liner from the gas diffuser end.
鈥渉ot鈥? parts inside Handymig 170i.
CAUTION
鈥? Have qualified personnel do the
maintenance and trouble shoot-
Excessive pressure at the start may cause the dirt
ing work.
to form a plug.
ROUTINE MAINTENANCE
Flex the cable over its entire length and again blow
out the cable. Repeat this procedure until no further
POWER SOURCE COMPARTMENT
dirt comes out.
In extremely dusty locations, dirt may clog the air pas-
sages causing the welder to run hot. Blow dirt out of
the welder with low pressure air at regular intervals to
Contact Tips, Nozzles, and Gun Tubes
eliminate excessive dirt and dust build-up on internal
鈥? Dirt can accumulate in the contact tip hole and
parts.
restrict wire feeding. After each spool of wire is
used, remove the contact tip and clean it by push-
ing a short piece of wire through the tip repeatedly.
WIRE FEED COMPARTMENT
Use the wire as a reamer to remove dirt that may
be adhering to the wall of the hole through the tip.
鈥? When necessary, vacuum accumulated dirt from
gearbox and wire feed section.
鈥? Replace worn contact tips as required. A variable
or 鈥渉unting鈥? arc is a typical symptom of a worn con-
鈥? Occasionally inspect the incoming guide tube and
tact tip. To install a new tip, choose the correct size
clean inside diameter if necessary.
contact tip for the electrode being used (wire size is
stenciled on the side of the contact tip) and screw it
鈥? Motor and gearbox have lifetime lubrication and
snugly into the gas diffuser.
require no maintenance.
鈥? Remove spatter from inside of gas nozzle and from
tip after each 10 minutes of arc time or as required.
FAN MOTOR
鈥? Be sure the gas nozzle is fully screwed onto the
Has lifetime lubrication 鈥? requires no maintenance.
diffuser for gas shielded processes. For the
Innershield庐 process, the gasless nozzle should be
screwed onto the diffuser.
WIRE REEL SPINDLE
Requires no maintenance. Do not lubricate shaft.
Handymig 170i
D-2 D-2
MAINTENANCE
8. Push a length of straightened welding wire through
COMPONENT
the wire feeder guide tubes and adjust the position
REPLACEMENT of the drive roll so that the groove is centered on
PROCEDURES the wire. Make certain the set screw is located on
the flat portion of the shaft and tighten.
CHANGING THE CONTACT 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.
3
4. Replace gas nozzle.
CHANGING DRIVE ROLL
The drive roll has two grooves; one for .023" 鈥? .025"
2
(0.6 mm) solid steel electrode and a larger groove for
.030" (0.8 mm) solid and .035" (0.9 mm) flux-cored
steel electrode. As shipped, the drive roll is installed in
the .023"-.025" (0.6 mm) position.
1
If .030"/.035" (0.8/0.9 mm) wire is to be used, the
drive roll must be reversed as follows:
1. Connect the machine to its rated input power per
instructions in Installation section.
2. Release the spring-loaded pressure arm and lift the
idle roll arm away from the drive roll.
3. Turn the power switch to ON (marked 鈥淚鈥?).
4. Set the wire speed to minimum and jog the drive
unit with the trigger switch until the drive roll set
screw is facing up.
CAUTION
When inching the welding wire, the drive rolls,
gun connector block, and gun contact tip are
energized relative to work and ground and remain
energized for several seconds after the gun trig-
ger is released.
5. Turn the power switch to OFF (marked 鈥淥鈥?).
6. Loosen the drive roll set screw with the 5/64" (2.0
mm) hex wrench supplied.
7. Remove the drive roll, flip over and reinstall with the
.030/.035" (0.8/0.9 mm) groove (the larger groove)
closest to the gearbox.
Handymig 170i
D-3 D-3
MAINTENANCE
1-1/4 (31.8 mm)
Liner Trim Length
Gas Diffuser
Gas Nozzle or
Gasless Nozzle
Set Screw Brass Cable
Connector
Liner Assembly
(Liner bushing to be sealed tight
against brass cable connector)
FIGURE D.2
Liner trim length 8. Screw the gas diffuser onto the end of the gun tube
and securely tighten.
CHANGING LINER
9. Replace the contact tip and nozzle.
NOTICE: The variation in cable lengths prevents the
interchangeability of liners. Once a liner has been cut
for a particular gun, it should not be installed in anoth-
er gun unless it can meet the liner cutoff length GUN HANDLE PARTS
requirement. Refer to Figure D.2.
The gun handle consists of two halves that are held
1. Remove the gas nozzle from the gun by unscrew- together with a collar on each end. To open up the
ing counter-clockwise. handle, turn the collars approximately 60 degrees
counter-clockwise until the collar reaches a stop. Then
2. Remove the existing contact tip from the gun by pull the collar off the gun handle. If the collars are diffi-
unscrewing counter-clockwise. cult to turn, position the gun handle against a corner,
place a screwdriver against the tab on the collar and
3. Remove the gas diffuser from the gun tube by give the screwdriver a sharp blow to turn the collar
unscrewing counter-clockwise. past an internal locking rib. See Figure D-3.
4. Lay the gun and cable out straight on a flat surface.
Loosen the set screw located in the brass connec-
tor at the wire feeder end of the cable. Pull the liner
out of the cable.
5. Insert a new untrimmed liner into the connector end
of the cable. Be sure the liner bushing is stenciled
appropriately for the wire size being used.
鉃?
6. Fully seat the liner bushing into the connector. Counter-clockwise
Tighten the set screw on the brass cable connec-
tor. At this time, the gas diffuser should not be
installed onto the end of the gun tube.
7. With the gas nozzle and diffuser removed from the
gun tube, be sure the cable is straight, and then
trim the liner to the length shown in the Figure D.2.
Remove any burrs from the end of the liner.
Handymig 170i
FIGURE D.3
D-4 D-4
GROUND TEST PROCEDURE
鈥? Welding circuit to auxiliary circuit test: Connect one
WARNING lead of the mega tester to the positive output stud
and the other to the jumper on pins 4 & 5 in the
shorting socket. Apply the test. (Minimum resistance
1M鈥?)
WARNING ELECTRIC SHOCK can kill 鈥? Wire drive test: Connect one lead of the mega tester
to the positive output stud and the other to the drive
roll shaft. Apply the test. (Minimum resistance 1M鈥?)
鈥? Remove all harness shorting plugs and connect all
plug and leads to PCB. Remove all shorting jumpers.
WARNING: This procedure is only suitable for applica-
If any problems are encountered, refer to your near-
tions using DC mega testers up to 500V.
est authorized Liquid Arc Field Service Shop.
Note: This procedure is for 鈥榤achines as built鈥? many
modifications could have taken place over the life of a
particular machine, so details of this procedure may
need to be 鈥榓djusted鈥? to suit these modifications.
For prompt service contact your local authorized Liquid
Arc Field Service shop.
The insulation resistance values listed below are from
Australian Standard AS1966.1.
鈥? Disconnect input power by removing plug from mains
supply.
鈥? Remove welding leads (gun and work lead) from the
machine before any tests are carried out.
鈥? Remove plug from PCB, install a shorting socket into
the harness plug. (The shorting socket is to have pins
4 & 5 jumpered together and all other pins jumpered
together separately and insulated.)
鈥? Connect a shorting jumper across the connections to
the capacitor and from the capacitor to each rectifier
heat sink plate.
鈥? Set power switch to 鈥榦n鈥? position.
鈥? Input circuit test: Connect one lead of the mega tester
to the frame of the machine and the other lead to
both the 鈥榓ctive鈥? & 鈥榥eutral鈥? terminals of the 240V
input plug. Apply the test. (Minimum resistance 1M鈥?)
鈥? Welding circuit test: Connect one lead of the mega
tester to the frame of the machine and the other lead
to the positive output stud. Apply the test. (Minimum
resistance 1M鈥?)
鈥? Auxiliary circuit test: Connect one lead of the mega
tester to the frame of the machine and the other lead
to jumper on pins 4 & 5 in the shorting socket. Apply
the test. (Minimum resistance 1M鈥?)
鈥? Input circuit to welding circuit test: Connect one lead
of the mega tester to both the 鈥榓ctive鈥? & 鈥榥eutral鈥? ter-
minals of the 240V input plug and the other to the
positive output stud. Apply the test(s). (Minimum
resistance 10M鈥?)
鈥? Input circuit to auxiliary circuit test: Connect one lead
of the mega tester to both the 鈥榓ctive鈥? & 鈥榥eutral鈥? ter-
minals of the 240V input plug and the other to the
jumper on pins 4 & 5 in the shorting socket. Apply the
test. (Minimum resistance 1M鈥?)
Handymig 170i
E-1
E-1 TROUBLESHOOTING
HOW TO USE TROUBLESHOOTING GUIDE
WARNING
Service and Repair should only be performed by Liquid Arc Factory Trained Personnel.
Unauthorized repairs performed on this equipment may result in danger to the technician and
machine operator and will invalidate your factory warranty. For your safety and to avoid
Electrical Shock, please observe all safety notes and precautions detailed throughout this
manual.
__________________________________________________________________________
Step 2. PERFORM EXTERNAL TESTS.
This Troubleshooting Guide is provided to
The second column labeled 鈥淧OSSIBLE
help you locate and repair possible machine
AREAS OF MISADJUSTMENT(S)鈥? lists the
malfunctions. Simply follow the three-step
obvious external possibilities that may con-
procedure listed below.
tribute to the machine symptom. Perform
Step 1. LOCATE PROBLEM (SYMPTOM). these tests/checks in the order listed. In
Look under the column labeled 鈥淧ROBLEM general, these tests can be conducted with-
(SYMPTOMS)鈥?. This column describes pos- out removing the case wrap-around cover.
sible symptoms that the machine may
Step 3. PERFORM COMPONENT TESTS.
exhibit. Find the listing that best describes
If you have exhausted all of the recom-
the symptom that the machine is exhibiting.
mended tests in Step 2, Consult your Local
Authorized Field Service Facility.
Symptoms are grouped into three main cat-
egories: output problems, function prob-
lems, welding problems.
CAUTION
If for any reason you do not understand the test procedures or are unable to perform
the tests safely, contact your LOCAL AUTHORIZED LIQUID ARC FIELD SERVICE
FACILITY for assistance before you proceed.
_____________________________________________________________________
Handymig 170i
E-2 TROUBLESHOOTING E-2
Observe Safety Guidelines
TROUBLESHOOTING GUIDE detailed in the beginning of this manual.
PROBLEMS POSSIBLE RECOMMENDED
(SYMPTOMS) CAUSE COURSE OF ACTION
OUTPUT PROBLEMS
Major physical or electrical damage None
is evident. Contact your local Authorized Field
Service Facility.
No wire feed, weld output or gas 1. Make sure correct voltage is
flow when gun trigger is pulled. Fan applied to the machine. See
does NOT operate. Installation section, 鈥淓lectrical
Connections鈥?.
2. Make certain that power switch
is in the ON position.
If all recommended possible areas
of misadjustments have been
3. Make sure circuit breaker is
checked and the problem persists,
reset.
contact your local Liquid Arc
Authorized Field Service Facility.
No wire feed, weld output or gas 1. The thermostat may be tripped
flow when gun trigger is pulled Fan due to overheating. Let machine
operates normally. cool. Weld at lower duty cycle.
2. Check for obstructions in air
flow.
3. Check Gun Trigger connections.
See Installation section.
4. Gun trigger may be faulty.
CAUTION
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.
Handymig 170i
E-3
TROUBLESHOOTING
E-3
Observe Safety Guidelines TROUBLESHOOTING GUIDE
detailed in the beginning of this manual.
PROBLEMS POSSIBLE RECOMMENDED
(SYMPTOMS) CAUSE COURSE OF ACTION
FEEDING PROBLEMS
No wire feed when gun trigger is 1. If the wire drive motor is running
If all recommended possible areas
pulled. Fan runs, gas flows and make sure that the correct drive
of misadjustments have been
machine has correct open circuit rolls are installed in the machine.
checked and the problem persists,
voltage (33 vcd maximum) 鈥? weld
contact your local Liquid Arc
output. 2. Check for clogged cable liner or
Authorized Field Service Facility.
contact tip.
3. Check for proper size cable liner
and contact tip.
GAS FLOW PROBLEMS
Low or no gas flow when gun 1. Check gas supply, flow regulator
trigger is pulled. Wire feed, weld and gas hoses.
output and fan operate normally.
2. Check gun connection to
machine for obstruction or leaky
seals.
CAUTION
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.
Handymig 170i
E-4 E-4
TROUBLESHOOTING
Observe Safety Guidelines
TROUBLESHOOTING GUIDE
detailed in the beginning of this manual.
PROBLEMS POSSIBLE RECOMMENDED
(SYMPTOMS) CAUSE COURSE OF ACTION
WELDING PROBLEMS
Arc is unstable 鈥? Poor starting 1. Check for correct input voltage
to machine. See Installation sec-
tion, 鈥淓lectrical Input
Connections鈥?.
2. Check for proper electrode
polarity for process.
3. Check gun tip for wear or dam-
age and proper size 鈥? Replace.
If all recommended possible areas
of misadjustments have been
4. Check for proper gas and flow
checked and the problem persists,
rate for process. (For MIG only.)
contact your local Liquid Arc
Authorized Field Service Facility.
5. Check work cable for loose or
faulty connections.
6. Check gun for damage or
breaks.
7. Check for proper drive roll orien-
tation and alignment.
8. Check liner for proper size.
CAUTION
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.
Handymig 170i
F-1
F-1 WIRING DIAGRAMS
Handymig 170i WIRING DIAGRAM: Code 10984
10/00
Handymig 170i WIRING DIAGRAM
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
NOTES
NOTES
G Do not touch electrically live parts or G Keep flammable materials away. G Wear eye, ear and body protection.
WARNING electrode with skin or wet clothing.
G Insulate yourself from work and
ground.
Spanish
G No toque las partes o los electrodos G Mantenga el material combustible G Prot茅jase los ojos, los o铆dos y el
AVISO DE bajo carga con la piel o ropa moja- fuera del 谩rea de trabajo. cuerpo.
da.
PRECAUCION G Aislese del trabajo y de la tierra.
French G Ne laissez ni la peau ni des v锚te- G Gardez 脿 l鈥櫭ヽart de tout mat茅riel G Prot茅gez vos yeux, vos oreilles et
ments mouill茅s entrer en contact inflammable. votre corps.
ATTENTION avec des pi猫ces sous tension.
G Isolez-vous du travail et de la terre.
G Ber眉hren Sie keine stromf眉hrenden
German G Entfernen Sie brennbarres Material! G Tragen Sie Augen-, Ohren- und K枚r-
Teile oder Elektroden mit Ihrem perschutz!
WARNUNG K枚rper oder feuchter Kleidung!
G Isolieren Sie sich von den
Elektroden und dem Erdboden!
Portuguese
G N茫o toque partes el茅tricas e elec- G Mantenha inflam谩veis bem guarda- G Use prote莽茫o para a vista, ouvido e
trodos com a pele ou roupa molha- dos. corpo.
ATEN脟脙O da.
G Isole-se da pe莽a e terra.
Japanese
Chinese
Korean
Arabic
READ AND UNDERSTAND THE MANUFACTURER鈥橲 INSTRUCTION FOR THIS EQUIPMENT AND THE CONSUMABLES TO BE
USED AND FOLLOW YOUR EMPLOYER鈥橲 SAFETY PRACTICES.
SE RECOMIENDA LEER Y ENTENDER LAS INSTRUCCIONES DEL FABRICANTE PARA EL USO DE ESTE EQUIPO Y LOS
CONSUMIBLES QUE VA A UTILIZAR, SIGA LAS MEDIDAS DE SEGURIDAD DE SU SUPERVISOR.
LISEZ ET COMPRENEZ LES INSTRUCTIONS DU FABRICANT EN CE QUI REGARDE CET EQUIPMENT ET LES PRODUITS A
ETRE EMPLOYES ET SUIVEZ LES PROCEDURES DE SECURITE DE VOTRE EMPLOYEUR.
LESEN SIE UND BEFOLGEN SIE DIE BETRIEBSANLEITUNG DER ANLAGE UND DEN ELEKTRODENEINSATZ DES HER-
STELLERS. DIE UNFALLVERH脺TUNGSVORSCHRIFTEN DES ARBEITGEBERS SIND EBENFALLS ZU BEACHTEN.
G Keep your head out of fumes. G Turn power off before servicing. G Do not operate with panel open or
G Use ventilation or exhaust to
WARNING
guards off.
remove fumes from breathing zone.
Spanish
G Los humos fuera de la zona de res- G Desconectar el cable de ali- G No operar con panel abierto o
AVISO DE
piraci贸n. mentaci贸n de poder de la m谩quina guardas quitadas.
G Mantenga la cabeza fuera de los antes de iniciar cualquier servicio.
PRECAUCION
humos. Utilice ventilaci贸n o
aspiraci贸n para gases.
French
G D茅branchez le courant avant l鈥檈ntre- G N鈥檕p茅rez pas avec les panneaux
G Gardez la t锚te 脿 l鈥櫭ヽart des fum茅es.
G Utilisez un ventilateur ou un aspira- tien. ouverts ou avec les dispositifs de
ATTENTION
protection enlev茅s.
teur pour 么ter les fum茅es des zones
de travail.
German
G Strom vor Wartungsarbeiten G Anlage nie ohne Schutzgeh盲use
G Vermeiden Sie das Einatmen von
abschalten! (Netzstrom v枚llig 枚ff- oder Innenschutzverkleidung in
Schweibrauch!
WARNUNG
G Sorgen Sie f眉r gute Be- und nen; Maschine anhalten!) Betrieb setzen!
Entl眉ftung des Arbeitsplatzes!
Portuguese
G N茫o opere com as tampas removidas. G Mantenha-se afastado das partes
G Mantenha seu rosto da fuma莽a.
G Desligue a corrente antes de fazer
G Use ventila莽茫o e exhaust茫o para moventes.
ATEN脟脙O
servi莽o. G N茫o opere com os paineis abertos
remover fumo da zona respirat贸ria.
G N茫o toque as partes el茅tricas nuas. ou guardas removidas.
Japanese
Chinese
Korean
Arabic
LEIA E COMPREENDA AS INSTRU脟脮ES DO FABRICANTE PARA ESTE EQUIPAMENTO E AS PARTES DE USO, E SIGA AS
PR脕TICAS DE SEGURAN脟A DO EMPREGADOR.
A Division of Lincoln Electric Company (Aust) Ply Ltd A.B.N. 36 000 040 308
35 Bryant Street, Padstow, NSW2211, Australia
Copyright 漏 2000 Lincoln Global Inc.
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