Lincoln Electric IM810 User's Manual
Contents
1. OPERATORS MANUAL O y Pro MIG 175 contact tip is sized for 023 025 0 6 mm wire LINCOLN ELECTRIC FIGURE A 1 A 3 INSTALLATION A 3 SELECT SUITABLE LOCATION Locate the welder in a dry location where there is free circulation of clean air into the louvers in the back and out the front of the unit A location that minimizes the amount of smoke and dirt drawn into the rear louvers reduces the chance of dirt accumulation that can block air passages and cause overheating STACKING Pro MIG 175 s 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 Refer to Figure A 2 1 Work Cable Access Hole 2 Gun Cable and Control Lead Access Hole 3 Connector Block 4 Gun Trigger Lead Connectors 5 Positive and negative output terminals 6 Wire Feed Gearbox 7 Cable Hanger 8 Thumbscrew Refer to the Accessories Section for available optional equipment Work Clamp Installation Aitach the work clamp per the following Refer to Figure A 3 FIGURE A 3 1 Insert the work cable terminal lug with the larger hole through the strain relief hole in the work clamp as shown above 2 Fasten securely with the bolt and nut provided FIGURE A 2 Can ARC VOLTS B DO NOT SWITC2. lists the obvious external possibilities that may contribute to the machine symptom Step 3 RECOMMENDED COURSE OF ACTION This column provides a course of action for the Possible Cause generally it states to contact your local Lincoln Authorized Field Service Facility If you do not understand or are unable to perform the Hecommended Course of Action safely contact your local Lincoln Authorized Field Service Facility A CAUTION 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 Pro MIG 175 LINCOLN TROUBLESHOOTING Observe all Safety Guidelines detailed throughout this manual 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 RECOMMENDED CAUSE COURSE OF ACTION OUTPUT PROBLEMS None Contact your local Authorized Field Service Facility Make sure correct voltage is applied to the machine See Installation section Electrical Connections Make certain that power switch is in the ON position Contact your local Lincoln Make sure circuit breaker is Authorized Field Service Facility reset The thermostat ma
3. feed compartment door for information on setting the Pro MIG 175 controls Refer to Table B 1 for aluminum and stainless wire Set the Voltage V and Wire Speed olo con trols to the settings suggested for the welding wire and base metal thickness being used refer to Applications chart on the inside of the wire drive compartment door Check that the polarity is correct for the welding wire being used and that the gas supply if required is turned on When using Innershield electrode remove the gas nozzle and install the gasless nozzle This will improve visibility of the arc and protect the gas dif fuser from weld spatter Refer to the MAINTE NANCE section for details on nozzle replacement Refer to Figure B 7 Connect work clamp to metal to be welded Work clamp must make good elec trical contact to the workpiece The workpiece must also be grounded as stated in Arc Welding Safety Precautions in the beginning of this manu al Position gun over joint End of wire may be lightly touching the work Lower welding helmet close gun trigger and begin welding Hold the gun so the contact tip to work distance is about 3 8 inch 10 mm To stop welding release the gun trigger and then pull the gun away from the work after the arc goes out OPERATION FIGURE B 7 GUN CABLE WORK CLAMP 10 When no more welding is to be done close valve on gas cylinder if used mom
4. Innershield NR 211 MP See Innershield FCAW Conversion in this sec tion for installation instructions and MAINTE NANCE section for proper feeding component con figuration and installation K549 2 045 1 2 mm Innershield Welding Kit Includes a contact tip a gasless nozzle and a 035 045 0 9 1 2 mm cable liner to permit the Magnum 100L gun and cable to use 045 1 2 mm diameter flux cored electrode The fitting on the end of the liner is stenciled with the maximum rated wire size 045 1 2 mm Also included is a 10 Ib 4 5 kg spool of 045 1 2 mm Innershield9 NR 211 MP and a knurled drive roll See Innershield FCAW Conversion in this sec tion for installation instructions and MAINTE NANCE section for proper feeding component con figuration and installation K664 2 Aluminum Feeding Kit This kit recom mended for welding with 035 Aluminum wire Included with this kit are a drive roll cable liner and 035 contact tip It is important when changing between welding with steel wire and aluminum to exchange feeding components due to the lubricant applied to steel wire Failure to do so may result in contaminated welds when welding aluminum See Maintenance section for instructions on installing drive roll cable liner contact tip and their proper configuration KP665 045C Drive Roll Optional Knurled drive roll for feeding 035 045 0 9 1 2 mm diameter flux cored e
5. KP2052 2B1 in Maintenance section for details Contact Tip Tapered 035 0 9 mm KP2052 3B1 4 Remove gas nozzle if installed and install gasless nozzle To remove simply unscrew Contact Tip Tapered 045 1 2mm KP2052 4B1 5 Load wire into machine and thread into gun and Liner 035 045 0 9 1 2 mm cable per Welding Wire Loading section KP1937 1 Note 1 The factory installed gun liner will feed Gas Diffuser 025 035 0 6 0 9mm wire KP2040 1 Gas Nozzle KP1938 1 Gas Nozzle Tip Recessed 3 8 9 5 mm Opening LD KP1942 1 Gas Nozzle Tip Recessed 1 2 12 7 mm Opening LD KP1942 2 Gas Nozzle Tip Recessed 5 8 15 9 mm Opening LD KP1942 3 Spot Welding Nozzle KP1956 1 Gasless Nozzle Innershield Only KP1939 1 Pro MIG 175 LINCOLN D 1 MAINTENANCE E MAINTENANCE SAFETY PRECAUTIONS ELECTRIC SHOCK can kill e 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 e Have qualified personnel do the mainte nance and trouble shooting work ROUTINE MAINTENANCE POWER SOURCE COMPARTMENT In extremely dusty locations dirt may clog the air passages causing the welder to run hot Blow dirt out of the welder with low pressure air at regular intervals to eliminate excessive dirt and dust build up on interval parts WIRE FEED COMPARTMENT 1 When necessary vacuum
6. e Quality wire drive with electronic overload protec tion e Quick Release idle roll pressure arm is easily adjusted e 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 diameter solid wire and 035 0 9 mm flux cored diameter wire Optional drive roll included in 045 1 2 mm Innershield welding kit must be installed to feed 045 1 2 mm flux cored wire Pro MIG 175 LINCOLN amp iin OPERATION B 2 Refer to Figure B 1b e No external shielding gas is required when used with Lincol 035 0 9 mm Innershield NR 211 MP electrode e Spindle accommodates both 8 in 200 mm diame ter and 4 in 100 mm diameter spools of wire WELDING CAPABILITY The Pro MIG 175 is rated at 130 amps 20 volts at 3096 duty cycle on a ten minute basis It is capable of higher output currents at lower duty cycles LIMITATIONS Arc Gouging cannot be performed with the Pro MIG 175 The Pro MIG 175 is not recommended for pipe thawing or TIG welding CONTROLS AND SETTINGS Refer to Figure B 1a 1 Power ON OFF Switch 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 OFF gun trigger is pressed 2 Voltage Control A 5 posi tion tap selector switch gives full range adjustment of
7. DIE UNFALLVERHUTUNGSVORSCHRIFTEN DES ARBEITGEBERS SIND EBENFALLS ZU BEACHTEN Keep your head out of fumes Use ventilation or exhaust to remove fumes from breathing zone Los humos fuera de la zona de res piracion Mantenga la cabeza fuera de los humos Utilice ventilacion o aspiraci n para gases e Gardez la t te l cart des fum es e Utilisez un ventilateur ou un aspira teur pour ter les fum es des zones de travail e Vermeiden Sie das Einatmen von Schweibrauch e Sorgen Sie f r gute Be und Entl ftung des Arbeitsplatzes e Mantenha seu rosto da fumaca e Use ventilac o e exhaust o para remover fumo da zona respirat ria eti ADP5mtRES SELT F s ORAV HELCTIHELTFEL EEE E e 1 5f UR E s FB X8 aK BE SR ER Secr SHINS Belle Syor 23745 xs Bal 7HAXI717iu EDS AHgSHIAIg i s ye lua dll e CAS al bia jiga d A Jarl e Ag di A ge ll sag ue e Turn power off before servicing e Desconectar el cable de ali mentaci n de poder de la m quina antes de iniciar cualquier servicio e D branchez le courant avant l entre tien e Strom vor Wartungsarbeiten abschalten Netzstrom v llig ff nen Maschine anhalten e N o opere com as tampas removidas e Desligue a corrente antes de fazer servico e N o toque as partes el tricas nuas e xX 7TTL5ASUR UAUNMUT PARKE STEEL Fe 2 E TRS Us e EI Bi 9 RE se Ala Ada eui d ily jest Juill ail e e Do not op
8. Only qualified personnel should perform this installation e Only personnel that have read and under stood the PRO MIG 175 Operating Manual should install and operate this equipment e Machine must be plugged into a receptacle which is grounded per any national local or other applicable electrical codes e The PRO MIG 175 power switch is to be in the OFF O position when installing work cable and gun and when connecting power cord to input power IDENTIFY AND LOCATE 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 Gun and cable assembly 3 Literature and miscellaneous including a This operating manual b 2 extra 023 025 0 6 mm contact tips c 3 extra 035 0 9 mm contact tips d Hex key wrench for removal of drive roll 4 10 ft 3 0 m work cable 5 Work clamp 6 a 2 lb spool of 025 0 6 mm Super Arc L 56 MIG wire b Sample spool of Innershield 035 0 9 mm NR 211 MP 7 Hand shield with filter plate and lens 8 Adjustable mixed Gas Regulator amp Hose 9 Instructional video 10 Gasless Nozzle For available options and accessories refer to the Accessories Section of this manual 1 As shipped from the factory the Pro MIG 175 gun liner is ready to feed 023 0 6 mm 035 0 9 mm wire The
9. STATES NATIONAL ELECTRICAL CODE AND OR LOCAL CODES FOR OTHER DETAILS AND MEANS FOR PROPER GROUNDING CONNECT TO HOT WIRES OF A THREE WIRE SINGLE PHASE SYSTEM OR TO ONE PHASE OF A TWO OR THREE PHASE SYSTEM Grounding Type 75 C Wire Wire in Conduit Copper Input Copper Cond Cond Voltage AWG Size AWG Size __208 280 60 8 to 40 This welding machine must be connected to a power source in accordance with applicable elec trical codes The Electrical Code provides standards for amperage handling capability of supply conduc tors based on duty cycle of the welding source If there is any question about the installation meeting applicable electrical code requirements consult a qualified electrician ELECTRICAL INPUT CONNECTION FOR RATED OUTPUT ELECTRIC SHOCK can kill 0 e Disconnect input power by remov ing plug from receptacle before working inside Pro MIG 175 e Use only grounded receptacle e Do not touch electrically hot parts inside Pro MIG 175 e Have qualified personnel do the maintenance and troubleshooting work 230 Volt Input Connection The Pro MIG 175 is shipped from the factory connect ed for 230 volt input power If the welder has been reconnected for 208 volt input power and 230 volt input is desired perform the following reconnection instructions 1 Disconnect welder from input power and remove case side panel 2 Remove lead marked H3 from CR1
10. hot spatter or metal 2 FUMES AND GASES can be dangerous 5 a Welding may produce fumes and gases hazardous to health Avoid breathing these fumes and gases When welding keep your head out of the fume Use enough ventilation and or exhaust at the arc to keep fumes and gases away from the breathing zone When welding with electrodes which require special ventilation such as stainless or hard facing see instructions on container or MSDS or on lead or cadmium plated steel and other metals or coatings which produce highly toxic fumes keep exposure as low as possible and below Threshold Limit Values TLV using local exhaust or mechanical ventilation In confined spaces or in some circumstances outdoors a respirator may be required Additional precautions are also required when welding on galvanized steel Do not weld in locations near chlorinated hydrocarbon vapors coming from degreasing cleaning or spraying operations The heat and rays of the arc can react with solvent vapors to form phosgene a highly toxic gas and other irritating products Shielding gases used for arc welding can displace air and Cause injury or death Always use enough ventilation especially in confined areas to insure breathing air is safe Read and understand the manufacturer s instructions for this equipment and the consumables to be used including the material safety data sheet MSDS and follow your employer s safety practices MSDS fo
11. sur la charpente de la construction ou d autres endroits loign s de la zone de travail on augmente le risque de voir passer le courant de soudage par les chaines de lev age c bles de grue ou autres circuits Cela peut provoquer des risques d incendie ou d echauffement des chaines et des c bles jusqu ce qu ils se rompent Assurer une ventilation suffisante dans la zone de soudage Ceci est particuli rement important pour le soudage de t les galvanis es plomb es ou cadmi es ou tout autre m tal qui produit des fume s toxiques Ne pas souder en pr sence de vapeurs de chlore provenant d op rations de d graissage nettoyage ou pistolage La chaleur ou les rayons de l arc peuvent r agir avec les vapeurs du solvant pour produire du phosg ne gas fortement toxique ou autres produits irritants Pour obtenir de plus amples renseignements sur la s ret voir le code Code for safety in welding and cutting CSA Standard W 117 2 1974 2 Dans le cas de travail au dessus du niveau du sol se prot ger PRECAUTIONS DE SU RETE POUR contre les chutes dans le cas ou on recoit un choc Ne jamais enrouler le cable lectrode autour de n importe quelle partie LES MACHINES A SOU DER A alee TRANSFORMATEUR ETA Un coup d arc peut tre plus s vere qu un coup de soliel REDRESSEUR donc a Utiliser un bon masque avec un verre filtrant appropri ainsi qu un verre blanc afin de se prot ger les yeux du ray onneme
12. while feeding wire the pressure should be increased until the wire feeds properly Pro MIG 175 FIGURE B 4 The Wire Drive Feed Roll can accommodate two wire sizes by flipping the wire drive feed roll over 7 Refer to Figure B 5 Remove gas nozzle and con tact tip from end of gun 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 8 Turn the Pro MIG 175 ON I 9 Straighten the gun cable assembly 10 Depress the gun trigger switch and feed welding wire through the gun and cable Point gun away from yourself and others while feeding wire Helease gun trigger after wire appears at end of gun FIGURE B 5 Gun Handle Gas Diffuser Contact Tip Gas Nozzle 11 Turn the Pro MIG 175 OFF O 12 Replace contact tip and gas nozzle 13 Refer to Figure B 6 Cut the wire off 3 8 1 2 10 13 mm from the end of the tip The Pro MIG 175 is now ready to weld LINCOLN amp FIGURE B 6 Contact Tip Wire Electrode 3 8 1 2 10 13mm Contact Tip to Work Distance CTWD ooo 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 See the Application chart on the inside of the wire
13. 2 Smooth grooves 0 6 09mm Small 023 025 0 6mm Large 030 0 8mm Components shipped with Pro MIG 175 K549 1 035 0 9mm Innershield Welding Kit KP2039 3B1 035 0 9mm KP 1937 3 035 0 9mm Use Large groove of KP665 035 K549 2 045 1 2mm Innershield Welding Kit KP2039 4B1 045 1 2mm KP 1937 1 045 1 2mm KP665 045C Use Large groove K664 2 035 0 9mm Aluminum Welding Kit KP2078 1B1 035A 0 9mm KP1959 1 035 0 9mm M19631 e f 030 0 8mm Solid wire feeding is desired use the KP2039 2B1 Contact Tip shipped loose with your Pro MIG 175 It is important when changing between welding with steel wire and aluminum to exchange feeding components due to the lubricant applied to steel wire Failure to do so may result in contaminated welds when welding aluminum Pro MIG 175 LINCOLN Ds MAINTENANCE D 3 COMPONENT 8 Push a length of straightened welding wire through REPLACEMENT the wire feeder guide tubes and adjust the position f the drive roll so that the groove is centered on PROCEDURES gt the wire Make certain the set screw is located on the flat portion of the shaft and tighten Figure D 1 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 4 Rep
14. 303 430 13M LO3NNOO OL NMOHS SV AOE HOS GALOANNOO AHOLOVA WO Q3ddlHS 3HV SANIHOVI ANIHOVW 39V L1OA Vna 401 NOLLO3NNOO3M AOVLIOA YINOLSNO SUIYOBU SIU See JO esn jejsur p noys suosiad palenb uc sped en Ajeoujeje yono jou oq A ONINHVM V Doug SJ9A09 UJIM ajeJado jou oq e INVHOVIG ONIHIM SZL SIIN O4d 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 Pro MIG 175 LINCOLN NOTES NOTES Spanish AVISO DE PRECAUCION French ATTENTION German WARNUNG ATENCAO Japanese Se FIR Do not touch electrically live parts or electrode with skin or wet clothing Insulate yourself from work and ground No toque las partes o los electrodos bajo carga con la piel o ropa moja da e Aislese del trabajo y de la tierra e Ne laissez ni la peau ni des v te ments mouill s entrer en contact avec des pi ces sous tension e Isolez vous du travail et de la terre e Ber hren Sie keine stromf hrenden Teile oder Elektroden mit Ihrem K rper oder feuchter Kleidung e isolieren Sie sich von den Elektroden und dem Erdboden e N o toque partes el tricas e elec trodos com a pele ou roupa molha da e Isole se da peca e terra e HE POETA AA SH F PMN Fe Ft CHMNEWUTE MLMPT APSSAMMEBS NTWSRILTFAUY e X BA
15. H WHEN WELDING A Pro MIG 175 PES 4 Pro MIG 175 LINCOLN AUT INSTALLATION A 4 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 Gearbox 6 4 For GMAW Only Refer to Figure A 2 As deliv ered the machine is connected for positive elec trode polarity This is the appropriate configuration for the GMAW MIG process To complete installa tion use the provided wing nut to connect the work cable s terminal lug to the negative output ter minal 5 located above the Wire Feed Gearbox 6 Make sure that both wing nuts are tight 5 For Innershield Only Refer to Figure A 4 To wire for negative polarity required for the Innershield process connect the short cable attached to the connector block 1 to the negative output termi nal 2 and the work cable 3 to the positive ter minal 4 FIGURE A 4 GUN INSTALLATION As shipped from the factory the Pro MIG 175 gun is ready to feed 023 025 solid wire If 030 035 0 8 09mm solid wire is to be used change the con tact tip to the appropriate size If 035 Flux cored wire is to be used change the contact tip and nozzle to the appropiate type a
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17. N 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 Pro MIG 175 LINCOLN amp EDT TROUBLESHOOTING E Observe all Safety Guidelines detailed throughout this manual PROBLEMS POSSIBLE RECOMMENDED SYMPTOMS CAUSE COURSE OF ACTION WELDING PROBLEMS Arc is unstable Poor starting Check for correct input voltage to machine See Installation sec tion Electrical Input Connections Check for proper electrode polarity for process Check gun tip for wear or dam age and proper size Replace Contact your local Lincoln Check for proper gas and flow Authorized Field Service Facility rate for process For MIG only Check work cable for loose or faulty connections Check gun for damage or breaks Check for proper drive roll orien tation and alignment 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 LINCOLN ELECTRIC FIELD SERVICE FACILITY for assistance before you proceed Pro MIG 175 LINCOLN F 1 WIRING DIAGRAMS F 1 v LOZIN gd ALIHM M yov 19 4 3009 40109 QV31 ZESLA Yad S IOSINAS III ONIHOV LLV3H N3HM 07 9NINHOO MOG GNNOdWOD LNIOF ZE8ZLL 3HIQY1O3H SNOILLO3NNOO IARNI
18. RETURN TO MAIN MENU E IM810 Pro MIG 1 75 nm For use with machine Code Numbers 11009 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 AND THE SAFETY PRECAUTIONS CONTAINED THROUGHOUT And most importantly think before you act and be careful OPERATOR S MANUAL ISO 9001 n Evan Pec mM M Ae S tg EE z S d KN r Syston E Accredited by the RvA igned a to ISO 9001 Requiremen ts CERTIFICATE NUMBER 30273 Copyright O 2005 Lincoln Global Inc LINCOLN ELECTRIC e World s Leader in Welding and Cutting Products e e Sales and Service through Subsidiaries and Distributors Worldwide Cleveland Ohio 44117 1199 U S A TEL 216 481 8100 FAX 216 486 1751 WEB SITE www lincolnelectric com SAFETY A WARNING CALIFORNIA PROPOSITION 65 WARNINGS A Diesel engine exhaust and some of its constituents The engine exhaust from this product contains are known to the State of California to cause can chemicals known to the State of California to cause cer birth defects and other reproductive harm cancer birth defects or other reproductive harm The Above For Diesel Engines The Above For Gasoline Engines ARC WELDING CAN BE HA
19. SCR UL DEBARRAR SE tiri CHa He Jui ab e ll ol ja Quali YO Aral clay ag el d pth ee ell Ald guapa aal DIS dua ule Y jo pue Keep flammable materials away Mantenga el material combustible fuera del area de trabajo e Gardez l cart de tout mat riel inflammable e Entfernen Sie brennbarres Material e Mantenha inflam veis bem guarda dos e 920v 6008 CORTIETEX LSC IR EVA e i z VUE IS BET TER BI Ha AIX ale day la Qiii AL AA aa e e Wear eye ear and body protection e Prot jase los ojos los o dos y el cuerpo e Prot gez vos yeux vos oreilles et votre corps e Tragen Sie Augen Ohren und K r perschutz e Use prote o para a vista ouvido e corpo e H ERU B SICIRRER amp LC SU ORR HRAERSRREAR er H Sal 15478 SCHER Stal due de Lully ud Cl gal kg dau 9 READ AND UNDERSTAND 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 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
20. ZARDOUS PROTECT YOURSELF AND OTHERS FROM POSSIBLE SERIOUS INJURY OR DEATH KEEP CHILDREN AWAY PACEMAKER WEARERS SHOULD CONSULT WITH THEIR DOCTOR BEFORE OPERATING Read and understand the following safety highlights For additional safety information it is strongly recommended that you purchase a copy of Safety in Welding Cutting ANSI Standard 249 1 from the American Welding Society P O Box 351040 Miami Florida 33135 or CSA Standard W117 2 1974 A Free copy of Arc Welding Safety booklet E205 is available from the Lincoln Electric Company 22801 St Clair Avenue Cleveland Ohio 44117 1199 BE SURE THAT ALL INSTALLATION OPERATION MAINTENANCE AND REPAIR PROCEDURES ARE PERFORMED ONLY BY QUALIFIED INDIVIDUALS FOR ENGINE d 1 h To avoid scalding do not remove the A radiator pressure cap when the engine is powered equipment hot 1 a Turn the engine off before troubleshooting and maintenance work unless the maintenance work requires it to be running 3 T OX ELECTRIC AND MAGNETIC FIELDS may be dangerous 1 6 Operate engines in open well ventilatedareas or vent the engine exhaust fumes outdoors 2 a Electric current flowing through any conductor causes Hf localized Electric and Magnetic Fields EMF Welding current creates EMF fields around welding cables and d welding machines EMF fields may interfere with some pacemakers and welders having a pacemaker should consult their physician Do not ad
21. accumulated dirt from gearbox and wire feed section 2 Occasionally inspect the incoming guide tube and clean inside diameter if necessary 3 Motor and gearbox have lifetime lubrication and require no maintenance FAN MOTOR Has lifetime lubrication requires no maintenance WIRE REEL SPINDLE Hequires no maintenance Do not lubricate shaft Pro MIG 175 LINCOLN idi MAINTENANCE D 2 GUN AND CABLE MAINTENANCE FOR MAGNUM 100L GUN Gun Cable Cleaning Clean cable liner after using approximately 300 Ibs 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 liner from the gas diffuser end CAUTION Excessive pressure at the start may cause the dirt to form a plug Flex the cable over its entire length and again blow out the cable Repeat this procedure until no further dirt comes out Contact Tips Nozzles and Gun Tubes 1 Dirt can accumulate in the contact tip hole and 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 Use the wire as a reamer to remove dirt that may be adhering to the wall of the hole through the tip 2 Replace worn contact tips as required A variable or hunting arc is a typical symptom of a worn con tac
22. c wire welding the electrode electrode reel welding head nozzle or semiautomatic welding gun are also electrically hot Always be sure the work cable makes a good electrical connection with the metal being welded The connection should be as close as possible to the area being welded Ground the work or metal to be welded to a good electrical earth ground Maintain the electrode holder work clamp welding cable and welding machine in good safe operating condition Replace damaged insulation Never dip the electrode in water for cooling Never simultaneously touch electrically hot parts of electrode holders connected to two welders because voltage between the two can be the total of the open circuit voltage of both welders When working above floor level use a safety belt to protect yourself from a fall should you get a shock Also see Items 6 c and 8 LINCOLN ARC RAYS can burn 4 a Use a shield with the proper filter and cover plates to protect your eyes from sparks and the rays of the arc when welding or observing open arc welding Headshield and filter lens should conform to ANSI Z87 standards 4 b Use suitable clothing made from durable flame resistant material to protect your skin and that of your helpers from the arc rays Protect other nearby personnel with suitable non flammable screening and or warn them not to watch the arc nor expose themselves to the arc rays or to
23. constant voltage transformer rectifier power source and a wire feeder with welding gun for feeding 023 0 6 mm through 030 0 8 mm solid steel electrode Optional kits are available for 035 0 9 mm and 045 1 2 mm Innershield NR 211 MP It is ideally suited for individuals having access to 230 or 208 volt 60 Hz AC input power and want the ease of use quality and dependability of both gas metal arc welding or GMAW also known as MIG welding and the Innershield process self shielded flux cored or FCAW A convenient chart is mounted inside the wire feed section door for setting welding procedures for 24 gauge 60 mm through 5 16 8 0 mm mild steel The machine is rugged and reliable and has designed for dependable service and long life RECOMMENDED PROCESSES The Pro MIG 175 can be used for welding mild steel using the GMAW single pass process which requires a supply of shielding gas or it can be used for the self shielded Innershield process FCAW OPERATIONAL FEATURES AND CONTROLS The Pro MIG 175 has the following controls as stan dard Power ON OFF Switch Voltage Control Wire Speed Control Trigger Switch and a Circuit Breaker DESIGN FEATURES AND ADVANTAGES e Reconnectable for 230 volt or 208 volt single phase 60 Hz input power e Cold electrode until gun trigger is pressed for an added measure of safety O Overload protection incorporates both a thermo stat and a circuit breaker
24. d the fuel near an open flame welding arc or when before welding the engine is running Stop the engine and allow P it to cool before refueling to prevent spilled fuel c Exposure to EMF fields in welding may have other health from vaporizing on contact with hot engine parts effects which are now not known and igniting Do not spill fuel when filling tank If N fuel is spilled wipe it up and do not start engine d All welders should use the following procedures in order to until tumes have been eliminated minimize exposure to EMF fields from the welding circuit 2 d 1 Route the electrode and work cables together Secure Keep all equipment safety guards covers and devices in them with tape when possible position and in good repair Keep hands hair clothing and tools away from V belts gears fans and all other moving 2d o Never coil the electrode lead around your body parts when starting operating or repairing equipment 2 4 3 Do not place your body between the electrode and work cables If the electrode cable is on your right In some cases it may be necessary to remove safety side the work cable should also be on your right side guards to perform required maintenance Remove guards only when necessary and replace them when the maintenance requiring their removal is complete d 4 Connect the work cable to the workpiece as close as Always use the greatest care when working near moving possible to the area b
25. dW LLZ edN T3IHSUSNNI VIC unu 60 Gen 90 03409 X014 SS31Sv5 1NO 3NI9V3 3ZIS d3112N31S 03810038 IHL HUM 1104 JAYA 71WLSNI NOIIVIN3IHO 1104 JAA SE ope G v a C p3pU3UILIOD3I SI IOUE uoims 1eds Jeuondo esuewiopied 1580 104 y panda sassed ajd ij npy GL g F FY FEY seo seasea ev eo oro sro 5 ES SSSNNIIHL Dis MYLIST 3a N1I03NII wuz ul app uu ut Seo uug o ur oen unum o ur Gp dZS JJM 104 709 02 02 uny 5608 62 Gel 40 W lt 02 2 S2 ug y 08 02 Sed 40 02 TVANVIA 33 SONILLAS INANINATY ANY 713318 SSTINIVIS 404 9NIGQT3M H03 SONILLAS Q318399flS SUE a geiunsuo 9 q89 pue unb 1001 NANI d3i409 XM13 SSI 1SV9 di LZ el OTS IHSHANNI Wid mw e U ur ep diN L a T3IHSH3NNI Vid ww 6 0 U Geo 997 9 014M N109N17 JHIM 13318 01 108 VIE ww g o u peo 95 1 913M NT02NT AIM 1331s dios Vig ww 90 u 820 3d 03802 Xf113 S S31SV9 S SUN giis313 3a NIOONIT Pro MIG 175 LINCOLN amp C 1 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 rated wire size 045 1 2 mm Also included is a 10 Ib 4 5 kg spool of 035 0 9 mm
26. e GUN HANDLE PARTS 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 place a screwdriver against the tab on the collar and give the screwdriver a sharp blow to turn the collar past an internal locking rib See Figure D 3 Figure D 3 Been Pro MIG 175 LINCOLN E 1 TROUBLESHOOTING E 1 HOW TO USE TROUBLESHOOTING GUIDE WARNING Service and Repair should only be performed by Lincoln Electric 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 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 SYMP TOMS This column describes possible symptoms that the machine may exhibit Find the listing that best describes the symptom that the machine is exhibiting Step 2 POSSIBLE CAUSE The second column labeled POSSIBLE CAUSE
27. e Refer to Table B 1 for recommended procedure settings Requires K586 1 regulator kit and K664 2 Aluminum Stainless Feeding Kit 44 CAUTION It is important when changing between welding with steel wire and aluminum to exchange feeding components due to the lubricant applied to steel wire Failure to do so may result in contaminated welds when welding aluminum TABLE B 1 PRO MIG 175 WELDING PROCEDURES ge ET Shielding Process wetang wre aos ees Ss DAS 035 Dia 0 9mm 100 Argon A 4 5 B 6 5 D 8 5 D 10 E 10 E 10 4043 Aluminum Wire 16 ga 14 ga 030 Dia 98 Argon A 3 C 6 D 7 5D 7 5 308L Stainless 2 Oxygen Steel Wire Test assembly preheated to 250 F CHANGING MACHINE OVER TO FEED OTHER WIRE SIZES The Pro MIG 175 is shipped from the factory ready to feed 0 023 025 0 9 mm diameter wire To oper ate the Pro MIG 175 with other sizes of wire it maybe necessary to change the contact tip drive roll and gun liner configuration For component configuration and placement Refer to the MAINTENANCE section on these procedures WELDING WITH GMAW MIG Shielding Gas When using the GMAW process install the gas regu lator and hose 1 For CO an optional adjustment is required Open the cylinder very slowly For argon mixed gas open cylinder valve slowly a fraction of a turn When the cylinder pressure gauge pointer stops moving open the valve fully 2 If using a regulator with a
28. eing welded parts Do not work next to welding power source Do not put your hands near the engine fan Do not attempt to override the governor or idler by pushing on the throttle control rods while the engine is running To prevent accidentally starting gasoline engines while Mar 95 turning the engine or welding generator during maintenance work disconnect the spark plug wires distributor cap or magneto wire as appropriate LINCOLN ELECTRIC SAFETY ELECTRIC SHOCK can kill 3 a The electrode and work or ground circuits are electrically hot when the welder is on Do not touch these hot parts with your bare skin or wet clothing Wear dry hole free gloves to insulate hands 3 6 Insulate yourself from work and ground using dry insulation Make certain the insulation is large enough to cover your full area of physical contact with work and ground In addition to the normal safety precautions if welding must be performed under electrically hazardous conditions in damp locations or while wearing wet clothing on metal structures such as floors gratings or scaffolds when in cramped positions such as sitting kneeling or lying if there is a high risk of unavoidable or accidental contact with the workpiece or ground use the following equipment e Semiautomatic DC Constant Voltage Wire Welder e DC Manual Stick Welder e AC Welder with Reduced Voltage Control In semiautomatic or automati
29. ent 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 vi TABLE OF CONTENTS Page o em rc Section A Technical Specifications EE E ED A 1 SAIS AAA aa se a te ea ea na A 2 Identify and Locate Components ss A 2 ano a ISOC A TO A 3 OU AE dioe QNT NES A 3 Work Clamp EE E A 3 Work Cable Installation chere A 3 SU RS o E AT E E E A 4 GaS CONNECCION aa A 5 ANU CONE CHON E A 6 Line geleet ee TERME A 6 230 Volt input CORRECTE EE A 6 208 Volt Input Connection EEN A 6 KREE Section B Sale UE CC LE B 1 General Description RE m Um TUNIS B 2 Design Features and Advantages Re B 2 Welding Capabillly T Eai B 2 A o B 2 Controls and KEE ale EE B 2 MV GOING OD GRAN AAA SU PA B 3 Wire e A mA AP ea B 3 Wire TEE AO UA EE B 4 Making a Weld ES CE EE B 5 Process Gels otto traas B 5 Chaning Over to Feed Other Wire Sizes n0annnnnennnnnennnnnnnnnnennrrrennrrnresrrrensnnnee B 6 Welding WT IAW Y EE B 6 Welding wiih PC AW B 6 Overdaad FOV HOM M B 6 Applicaton As eee ee ene ner eee neem ener eee B 18 ACCES SONICS en ee ea Section C FANS Os cic e ee O eee ee eee C 1 mise ters Ra I
30. entarily operate gun trigger to release gas pressure and turn off the Pro MIG 175 Cleaning Tip And Nozzle Clean the contact tip and nozzle to avoid arc bridging between the nozzle and contact tip which can result in a shorted nozzle poor welds and an overheated gun Hint Anti stick spray or gel available from a welding supply distributor may reduce buildup and aid in spat ter removal PROCESS GUIDELINES The Pro MIG 175 can be used for welding mild steel using the GMAW single pass process which requires a supply of shielding gas or it can be used for the self shielded Innershield9 process FCAW The recommended gases and electrodes for GMAW are welding grade CO gas or an argon CO blended gas 75 to 80 argon and 25 to 20 CO and 025 0 6 mm diameter Lincoln Super Arc L 56 mild steel welding wire The blended gas is recommended for welding on heavier steel 14 gauge 2 0 mm for example The recommended electrode for the self shielded process is Lincoln Innershield NR 21 1 MP This elec trode is available as 035 0 9 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 steel Thickness of 1 4 6 4 mm and 5 16 7 9 mm require multiple passes both wire sizes can also be used for the weld ing of galvanized coated sheet metal Pro MIG 175 LINCOLN B 6 OPERATION B 6 The Pro MIG 175 is suitable for 035 aluminum wire and 023 035 stainless wir
31. erate with panel open or guards off e No operar con panel abierto o guardas quitadas e N op rez pas avec les panneaux ouverts ou avec les dispositifs de protection enlev s e Anlage nie ohne Schutzgeh use oder Innenschutzverkleidung in Betrieb setzen e Mantenha se afastado das partes moventes e N o opere com os paineis abertos ou guardas removidas O0ONAIPAN ERMVALIZE TRBHRPFELEVCE FL AE E ES NS Ko e gaol Y D l AIS Ah Yi cils UI yal la Jedd y e dle Gil Ail dl Gaga Spanish AVISO DE PRECAUCION French ATTENTION German WARNUNG ATEN O FR Chinese Korean LEIA E COMPREENDA AS INSTRUGOES DO FABRICANTE PARA ESTE EQUIPAMENTO E AS PARTES DE USO E SIGA AS PRATICAS DE SEGURANCA DO EMPREGADOR fESRMM CRUD A A OIRBEE HA EFBRLTF EW CL CRHORSRMELTE TRE CIS TUE E21 VERRE ORI RMA REM MEAR AJA RRR BIE o gea AMES SAAD HALO AIA RAS ES SD spart S El all cala Ai sl class aul y Lila Sub al gll y all oig SS Sall late v i y ay L LINCOLN e World s Leader in Welding and Cutting Products e e Sales and Service through Subsidiaries and Distributors Worldwide Cleveland Ohio 44117 1199 U S A TEL 216 481 8100 FAX 216 486 1751 WEB SITE www lincolnelectric com
32. event overrun of the spool and excess slack in the wire Too much drag may result in wire feeding problems and may cause pre mature wear of wire drive system components Pro MIG 175 LINCOLN 4 OPERATION 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 wire size being used See Maintenance section for further information 2 Carefully detach the end of the wire from the spool To prevent the spool from unwinding main tain tension on the wire until after step 5 3 Cut the bent portion of wire off and straighten the first 4 100mm 4 Thread the wire through the ingoing guide tube 4 over the drive roll 3 and into the outgoing guide tube 5 5 Close the idle roll arm 2 and latch the spring loaded pressure arm 1 in place Rotate the spool counterclockwise if required to take up extra slack in the wire 6 The idle roll pressure adjustment wing nut is facto ry set to approximately five full turns from where the wing nut first engages the threads of the pres sure arm 1 If feeding problems occur because the wire is flattened excessively turn the pressure adjustment counter clockwise to reduce distortion of the wire Slightly less pressure may be required when using 0 023 0 025 0 6 mm wire If the drive roll slips
33. g 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 NOTE If connecting to 100 CO gt cylinder insert regulator adapter provided with MIG Conversion Kit between regulator and cylinder valve If adapter is equipped with a plastic washer be sure it is seat ed for connection to the CO cylinder 4 Refer to Figure A 6 Attach one end of inlet gas hose to the outlet fitting of the flow regulator and tighten the union nut securely with a wrench Connect the other end to the machine Gas Solenoid Inlet Fitting 5 8 18 female threads for CGA 032 fitting Make certain the gas hose is not kinked or twisted 5 Reinstall case side before connecting input power INPUT CONNECTIONS Hefer to Figure A 6 The machine has two input connections the power input cable and the Gas Solenoid Inlet Fitting Both are located on the rear of the machine FIGURE A 6 GAS SOLENOID INLET FITTING POWER INPUT CABLE O O i O Pro MIG 175 LINCOLN A 6 INSTALLATION A 6 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 WIRE SEE THE UNITED
34. lace gas nozzle CHANGING DRIVE ROLL Refer to Figure D 1 The drive roll has two grooves one for 023 025 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 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 1 and lift the idle roll arm away 2 from the drive roll 3 3 Turn the power switch to ON marked TL 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 O 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 Pro MIG 175 LINCOLN amp D 4 MAINTENANCE D 4 1 1 4 31 8 mm Set Screw Brass Cable Y Y Connector Liner Assembly Liner bushing to be sealed tight against bras
35. lectrode Pro MIG 175 ACCESSORIES i 5 K520 Utility Cart Designed to transport the Lincoln family of small welders Has provisions for mounting a single gas cylinder Has front casters and large rear wheels Handle height is easily adjustable Bottom tray provided for tools and accessories Easy assembly required takes less than 15 minutes K586 1 Deluxe Adjustable Gas Regulator amp Hose Kit Accommodates CO or mixed Gas Cylinders LINCOLN oe ACCESSORIES C 2 INNERSHIELD FCAW CONVERSION Several changes are needed to convert the unit for operation with the Innershield FCAW process The REPLACEMENT PARTS Complete Gun and Cable Assembly L8311 6 K530 4 Contact Tip 025 0 6 mm K549 1 Innershield Kit includes all the necessary KP2039 1B1 accessories for this conversion and is provided for this purpose The following conversions should be made Contact Tip 030 0 8 mm using the contents of this kit KP2039 2B1 Contact Tip 035 0 9 mm 1 Change the output polarity to DC See Work KP2039 3B1 Cable Installation in Installation section for details Contact Tip 045 1 2 mm 2 Install proper drive roll for the wire size selected KP2039 4B1 see Changing Drive Roll in Maintenance section Contact Tip Tapered 025 0 6 mm for details KP2052 1B1 3 Install the proper gun liner Note 1 and tip for the Contact Tip Tapered 030 0 8 mm wire size selected See Component Replacement
36. mine 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 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 e 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 e For On Line Registration Go to our WEB SITE at www lincolnelectric com Choose Quick Links and then Product Registration 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 A WARNING This statem
37. motor overload Pro MIG 175 LINCOLN B 7 APPLICATION CHART COLLET AZLBLS ON Med JaSnig se SIHIN ON 1184 9 ZZON a Se9 Qui ul g g UM ZU UI 8 ul urg E v899LIN 01 Duiuadp DN Id passaJag dig Sa ZZON seg CRRDRLW VBSS IN uw zu ui z L Y Guada ysnj4 dip 3 zzoN 529 uuz HU ul epp ung ol ur Sen ug ol ur OED 3 ung ur Gp 1 84202S 3Z S JM 103 ON Med palade gt 2e U07 LDH LTC 3HV KIDH11713 ANY 1234 WIM 57704 0314 5534430 YOM MNI FHL ONY NO SI 3THfYOS SM Od ONIOTIM FHL NIHM MI Zu NOISNAL SAOS SHA LNOS 4004117141 D 4100130 31 NINIMULNSO XITY3 1008 ST1 339 N03NG 153 LOLS NA 3 103 130 V1 300 D 3H3NVHB 18 33vun S 30 3150d 17 1ND 4071 JNHIN355 LH3AV y A n Ip nq 314440 Aj iisundsaa ayy sj Ajquuasse 10 janpoad e JO Iqe3911138 agp Uone Jo Sd SIL Bu Adde uir pau 18300 enga eu 934 sajene Bupe pue Aq Wasser uane ude UBIS3p esne ag JENLEN Bungiodg sip Ul SNOILOVO3d AL34JVS 9NIOCT3AN OHV UO uonas ay pue aunj2giu Buip aA siy uio SBUIUJEM au purejsjepun pue peal o ains ag HM RISIUSIUU unu SU Gpo a4 ur papnjou Jam DCD In IESU 84M Gyp pue geg 101 jor an p paynuy unn 99M 111101130 Gan 104 Pale sul eg inu di pue 19u Sho 20045 43H 11 310UH TWAS dlA 11Z 38N 13IHSH3NNI va uu SU Gg 3HIM 13318 l109 3HIM 13318 anos wid ww g g peo Wid um 9 5 Cu o ow O
38. n adjustable flow meter close the gun trigger and adjust the flow to give 15 20 cubic ft per hour CFH 7 10 l min use 20 25 CFH 10 12 l min when welding out of position or in a drafty location 3 Keep the cylinder valve closed except when using the Pro MIG 175 When finished welding a Close the cylinder valve to stop gas flow b Depress the gun trigger briefly to release the pressure in the gas hose C Turn off the Pro MIG 175 WELDING WITH FCAW Innershield When using the FCAW process the correct drive roll and electrode polarity must be used See Work Cable Installation in INSTALLATION section for changing the polarity Innershield welding kits K549 1 for 035 and K549 2 for 045 are also available OVERLOAD PROTECTION Output Overload The Pro MIG 175 is equipped with a circuit breaker which protects the machine from damage if a severe overload occurs The circuit breaker button will extend out when tripped The circuit breaker must be manual ly reset Thermal Protection The Pro MIG 175 has a rated output duty cycle of 30 If the duty cycle is exceeded a thermal protector will shut off the output until the machine cools to a rea sonable operating temperature This is an automatic function of the Pro MIG 175 and does not require user intervention The fan continues to run during cooling Electronic Wire Drive Motor Protection The Pro MIG 175 has built in protection for wire drive
39. nd orient the drive roll to the appro priate groove size NOTE If 035 or 045 0 9 mm or 1 2 mm Innershield flux cored wire is to be used the appropri ate Innershield kit is required see ACCESSORIES section Connecting Gun Cable to the Pro MIG 175 1 Refer to Figure A 2 Unplug the machine or turn power switch to the OFF O position 2 Pass the insulated terminals of the gun trigger con trol leads one at a time through the Gun Cable and Control Lead Access Slot 2 in the case front The leads are to be routed up the inside of the case front behind the gas line 3 Insert the connector on the gun conductor cable through the Gun Cable Access Hole 2 in the Pro MIG 175 case front Make sure the connector is all the way in the brass connector block to obtain proper gas flow If the gun connector will not fully insert unscrew the thumbscrew on the connector block a few turns Rotate the connector so control leads are on the underside and tighten the Thumbscrew on the connector block 4 Connect the gun trigger control lead terminals to the two insulated 1 4 6 4 mm tab terminal con nector bushings located above the Gun Trigger Connection decal in the wire feed section 4 Either lead can go to either connector CAUTION 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 must be insulated from the welding circ
40. ndle locking tab If the wing nut is positioned in line with the locking tab the tab cannot be depressed to load or unload the wire spool FIGURE B 2 Wire Spool Spindle 8 Wire Spool Be sure that this stud engages the hole in the wire spool To Wire Drive Wire Spool must be pushed all the way on the spindle so that the spindle s tab will hold it in place The Wire Spool will rotate clock wise when wire is dereeled Load an 8 200 mm diameter spool on the wire spool spindle shown in Figure B 2 To use 4 100 mm diameter spools the 2 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 4 100 mm diameter spool is mounted directly on the 5 8 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 FIGURE B 3 Wire Spindle Shaft Wing Nut and Spacer To wire drive Friction Brake Adjustment With wire spool installed on the spindle shaft and the wing nut loose turn the spool by hand while slowly tightening the wing nut until a light drag is felt Tighten the wing nut an additional 1 4 turn Note When properly adjusted the brake should pro vide only enough drag to pr
41. nt de l arc et des projections quand on soude ou quand on regarde l arc Porter des v tements convenables afin de prot ger la peau de soudeur et des aides contre le rayonnement de l arc Prot ger l autre personnel travaillant proximit au soudage l aide d crans appropri s et non inflammables Des gouttes de laitier en fusion sont mises de l arc de soudage Se prot ger avec des v tements de protection libres de l huile tels que les gants en cuir chemise paisse pan talons sans revers et chaussures montantes Toujours porter des lunettes de s curit dans la zone de soudage Utiliser des lunettes avec crans lateraux dans les zones ou l on pique le laitier LINCOLN Relier la terre le chassis du poste conformement au code de l lectricit et aux recommendations du fabricant Le dispositif de montage ou la piece souder doit tre branch une bonne mise la terre Autant que possible l installation et l entretien du poste seront effectu s par un lectricien qualifi Avant de faires des travaux l interieur de poste la debranch er l interrupteur la boite de fusibles Garder tous les couvercles et dispositifs de s ret leur place V V for selecting a QUALITY product by Lincoln Electric We want you Thank You 0 take pride in operating this Lincoln Electric Company product eee as much pride as we have in bringing this product to you Please Exa
42. on the control P C Board 3 Remove tape securing H1 to lead sleeving and connect H1 to CH1 4 Insulate unused H3 lead for 300 volts with electri cal tape and secure to lead sleeving 5 Reinstall case side before connecting input power 208 Volt Input Connection 1 Disconnect welder from input power and remove case side 2 Remove lead marked H1 from CR1 on the control P C Board 3 Remove tape securing H3 to lead sleeving and connect H3 to CH1 4 Insulate unused H1 lead for 300V with electrical tape and secure to lead sleeving Pro MIG 175 LINCOLN 5 p OPERATION B 1 SAFTEY PRECAUTIONS Read entire operation section before operating the Pro MIG 175 ELECTRIC SHOCK can kill e Do not touch electrically live parts or electrode with skin or wet clothing Insulate yourself from work and ground e Always wear dry insulating gloves FUMES AND GASES can be dangerous e Keep your head out of fumes 3 Use ventilation or exhaust to remove fumes from breathing zone ee d WELDING SPARKS can cause fire or explosion e Keep flammable material away e Do not weld on closed containers ARC RAYS can burn eyes and skin e Wear eye ear and body protec tion VE Observe all safety information throughout this manual GENERAL DESCRIPTION The Pro MIG 175 is a complete semiautomatic con stant voltage DC portable arc welder Included is a tap switch controlled single phase
43. power source output voltage ARC VOLTS Do not switch while welding 3 Wire Speed Control Controls the wire feed speed from 50 400 in min 1 2 WIDE SPEED 10 2 m min The control can be preset on the dial to the setting specified on the Pro MIG 175 Application Chart located on the inside of the wire feed section door Pro MIG 175 LINCOLN amp 4 Circuit Breaker Protects machine from damage if maximum output is exceeded Button will extend out when tripped Manual reset Refer to Figure B 1b Gun Trigger Activates welding output wire feed and gas solenoid operation Releasing the trigger deactivates welding and simultaneously activates the burnback function so that the welding wire does not stick in the weld puddle Pro MIG 175 FIGURE B 1a FIGURE B 1b B 3 OPERATION B 3 WELDING OPERATIONS SEQUENCE OF OPERATION 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 fit on a 2 50 mm diameter 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 Spools make sure that the wing nut inside the wire spool spindle hub is turned 90 from the wire spool spi
44. rms are available from your welding distributor or from the manufacturer 5 e Also see item 1 b Mar 95 SAFETY 3 72 WELDING SPARKS can 5 cause fire or explosion 6 a Remove fire hazards from the welding area If this is not possible cover them to prevent the welding sparks from starting a fire Remember that welding sparks and hot materials from welding can easily go through small cracks and openings to adjacent areas Avoid welding near hydraulic lines Have a fire extinguisher readily available Where compressed gases are to be used at the job site special precautions should be used to prevent hazardous situations Refer to Safety in Welding and Cutting ANSI Standard Z49 1 and the operating information for the equipment being used When not welding make certain no part of the electrode circuit is touching the work or ground Accidental contact can cause overheating and create a fire hazard Do not heat cut or weld tanks drums or containers until the proper steps have been taken to insure that such procedures will not cause flammable or toxic vapors from substances inside They can cause an explosion even though they have been cleaned For information purchase Hecommended Safe Practices for the Preparation for Welding and Cutting of Containers and Piping That Have Held Hazardous Substances AWS F4 1 from the American Welding Society see address above Vent hollow castings or con
45. s cable connector FIGURE D 2 Liner trim length CHANGING LINER 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 requirement Refer to Figure D 2 1 Remove the gas nozzle from the gun by unscrew ing counter clockwise 2 Remove the existing contact tip from the gun by unscrewing counter clockwise 3 Remove the gas diffuser from the gun tube by unscrewing counter clockwise 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 6 Fully seat the liner bushing into the connector Tighten the set screw on the brass cable connector 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 Liner Trim Length Gas Nozzle or Gasless Nozzle 8 Screw the gas diffuser onto the end of the gun tube and securely tighten 9 Replace the contact tip and nozzl
46. si Fe UNG E C 2 A ASS E TOT Section D Safety Be le D 1 POMC WVU nn UT m D 1 Gun and Cable Maintenance D 2 Configuration of Components in Wire Feeding System D 2 Component Replacement Procedures nonnnannnnnnoennnnnnnennnnnnnnnnnnnrnnrrnnrnnrrenrennnne D 3 Pandino NAGE ET Anse etes oies D 4 Gun Handle PS a RSE sia D 4 lee CMTS SC CN aaron Section E How to Use Troubleshooting E le sereine E 1 Troubleshooting GUIAS css ici ire E 2 THRU E 4 WENO DOTAS aa a atea Section F PRO MIG 175 Winng Diada Miente coord F 1 PRO MIG 175 ln P471 Series amp P202 E vi n INSTALLATION m TECHNICAL SPECIFICATIONS Pro MIG 175 INPUT SINGLE PHASE ONLY Standard Voltage Frequency Input Current 230V 60Hz 20 Amps Rated Output 208V 60Hz 22 Amps Rated Output RATED OUTPUT Duty Cycle Current Volts at Rated Amperes 30 Duty Cycle 230V 60Hz 130 Amps 20V 25 Duty Cycle 208V 60Hz 130 Amps 20V OUTPUT Welding Current Range Maximum Open Circuit Voltage Wire Speed Range Rated DC Output 30 175 amps 33V 50 400IPM 1 3 10 2m min RECOMMENDED INPUT CABLE AND FUSE SIZES Fuse or Output Mode Input Voltage Breaker Size Power Cord 230V 60Hz 40 Super Lag 20 22 50 Amp 250V 208V 60Hz Three Prong Plug NEMA Type 6 50P PHYSICAL DIMENSIONS Pro MIG 175 LINCOLN A 2 INSTALLATION SAFETY PRECAUTIONS Read entire installation section before starting installation A WARNING 0 ELECTRIC SHOCK can kill e
47. t contact entre les parties sous tension et la peau nue ou les v tements mouill s Porter des gants secs et sans trous pour isoler les mains Faire tr s attention de bien s isoler de la masse quand on soude dans des endroits humides ou sur un plancher metallique ou des grilles metalliques principalement dans les positions assis ou couch pour lesquelles une grande partie du corps peut tre en contact avec la masse Maintenir le porte lectrode la pince de masse le c ble de soudage et la machine souder en bon et s r tat defonctionnement d Ne jamais plonger le porte lectrode dans l eau pour le refroidir Ne jamais toucher simultan ment les parties sous tension des porte lectrodes connect s deux machines souder parce que la tension entre les deux pinces peut tre le total de la tension vide des deux machines Si on utilise la machine souder comme une source de courant pour soudage semi automatique ces precautions pour le porte lectrode s applicuent aussi au pistolet de soudage 6 Eloigner les mat riaux inflammables ou les recouvrir afin de pr venir tout risque d incendie d aux tincelles Quand on ne soude pas poser la pince une endroit isol de la masse Un court circuit accidental peut provoquer un chauffement et un risque d incendie S assurer que la masse est connect e le plus pr s possible de la zone de travail qu il est pratique de le faire Si on place la masse
48. t tip To install a new tip choose the correct size contact tip for the electrode being used wire size is stenciled on the side of the contact tip and screw it snugly into the gas diffuser 3 Remove spatter from inside of gas nozzle and from tip after each 10 minutes of arc time or as required 4 Be sure the gas nozzle is fully screwed onto the diffuser for gas shielded processes For the Innershield process the gasless nozzle should be screwed onto the diffuser 5 To remove gun tube from gun remove gas nozzle or gasless nozzle and remove diffuser from gun tube Remove both collars from each end of the gun handle and separate the handle halves Loosen the locking nut holding the gun tube in place against the gun end cable connector Unscrew gun tube from cable connector To install gun tube screw the locking nut on the gun tube as far as possible Then screw the gun tube into the cable connector until it bottoms Then unscrew no more than one turn the gun tube until its axis is perpendicular to the flat sides of the cable connec tor and pointed in the direction of the trigger Tighten the locking nut so as to maintain the proper relationship between the gun tube and the cable connector Replace the gun handle trigger and dif fuser Replace the gas nozzle or gasless nozzle CONFIGURATION OF COMPONENTS IN WIRE FEEDING SYSTEM as Contact Tip Cable Liner Drive Roll KP2039 1B1 KP1937 3 KP665 035 025 0 6mm 025 035
49. tainers before heating cutting or welding They may explode Sparks and spatter are thrown from the welding arc Wear oil free protective garments such as leather gloves heavy shirt cuffless trousers high shoes and a cap over your hair Wear ear plugs when welding out of position or in confined places Always wear safety glasses with side shields when in a welding area Connect the work cable to the work as close to the welding area as practical Work cables connected to the building framework or other locations away from the welding area increase the possibility of the welding current passing through lifting chains crane cables or other alternate cir cuits This can create fire hazards or overheat lifting chains or cables until they fail 6 h Also see item 1 c LINCOLN CYLINDER may explode Es if damaged Ra boy gt 7 a Use only compressed gas cylinders containing the correct shielding gas for the process used and properly operating regulators designed for the gas and pressure used All hoses fittings etc should be suitable for the application and maintained in good condition Always keep cylinders in an upright position securely chained to an undercarriage or fixed support Oylinders should be located e Away from areas where they may be struck or subjected to physical damage A safe distance from arc welding or cutting operations and any other source of heat sparks or flame Ne
50. uit Malfunction of the Pro MIG 175 may result if this switch shorts to the Pro MIG 175 welding output circuit or is common to any electrical circuit other than the Pro MIG 175 trigger circuit Pro MIG 175 LINCOLN A 5 INSTALLATION ge CYLINDER may explode if dam aged Keep cylinder upright and chained to support e Keep cylinder away from areas where it may be damaged e Never lift welder with cylinder attached e Never allow welding electrode to touch cylinder e Keep cylinder away from welding or other live electrical circuits BUILDUP OF SHIELDING GAS may harm health or kill e Shut off shielding gas supply when not in use e SEE AMERICAN NATIONAL STANDARD Z 49 1 SAFETY IN WELDING AND CUTTING PUB LISHED BY THE AMERICAN WELDING SOCIETY 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 Flow Regulator Cylinder Valve Gas Hose 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 CRACKING THE VALVE Never stand directly in front of or behind the flow regulator when openin
51. ver allow the electrode electrode holder or any other electrically hot parts to touch a cylinder Keep your head and face away from the cylinder valve outlet when opening the cylinder valve Valve protection caps should always be in place and hand tight except when the cylinder is in use or connected for use Read and follow the instructions on compressed gas cylinders associated equipment and CGA publication PL Precautions for Safe Handling of Compressed Gases in Cylinders available from the Compressed Gas Association 1235 Jefferson Davis Highway Arlington VA 22202 FOR ELECTRICALLY powered equipment 8 a Turn off input power using the disconnect switch at the fuse box before working on the equipment Install equipment in accordance with the U S National Electrical Code all local codes and the manufacturer s recommendations Ground the equipment in accordance with the U S National Electrical Code and the manufacturer s recommendations M SAFETY PR CAUTIONS DE S RET Pour votre propre protection lire et observer toutes les instructions et les pr cautions de s ret specifiques qui parraissent dans ce manuel aussi bien que les pr cautions de s ret g n rales suiv antes S ret Pour Soudage A L Arc 1 Protegez vous contre la secousse lectrique a Les circuits l lectrode et la pi ce sont sous tension quand la machine souder est en marche Eviter toujours tou
52. y be tripped due to overheating Let machine cool Weld at lower duty cycle Check for obstructions in air flow Check Gun Trigger connections See Installation section 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 LINCOLN ELECTRIC FIELD SERVICE FACILITY for assistance before you proceed Pro MIG 175 LINCOLN amp E 3 TROUBLESHOOTING E 3 Observe all Safety Guidelines detailed throughout this manual PROBLEMS POSSIBLE RECOMMENDED SYMPTOMS CAUSE COURSE OF ACTION FEEDING PROBLEMS No wire feed when gun trigger is If the wire drive motor is running pulled Fan runs gas flows and make sure that the correct drive machine has correct open circuit rolls are installed in the machine voltage 33 vcd maximum weld Contact your local Lincoln output Check for clogged cable liner or Authorized Field Service Facility contact tip Check for proper size cable liner and contact tip PROBLEMS POSSIBLE AREAS OF RECOMMENDED SYMPTOMS MISADJUSTMENT S COURSE OF ACTION 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 Contact your local Lincoln output and fan operate normally Authorized Field Service Facility 2 Check gun connection to machine for obstruction or leaky seals CAUTIO
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