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IM890-A
May, 2007
POWER MIG (140, 180 MODELS)
For use with machines having Code Numbers: 11254, 11255, 11256, 11257 and
11444
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, thin
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i i SAFETY WARNING CALIFORNIA PROPOSITION 65 WARNINGS 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 HAZARDOUS. PROTECT YOURSELF AND OTHERS FROM POSSIBLE SERIOUS INJURY
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ii ii SAFETY ELECTRIC SHOCK can ARC RAYS can burn. 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 “hot” when the welder is on. open arc welding. Headshield and filter lens Do not touch these “hot” 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. Us
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iii iii SAFETY WELDING and CUTTING CYLINDER may explode SPARKS can if damaged. cause fire or explosion. 7.a. Use only compressed gas cylinders 6.a. Remove fire hazards from the welding area. containing the correct shielding gas for the If this is not possible, cover them to prevent process used and properly operating the welding sparks from starting a fire. regulators designed for the gas and Remember that welding sparks and hot pressure used. All hoses, fittings, etc. should be suitable for mat
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iv iv SAFETY 5. Toujours porter des lunettes de sécurité dans la zone de PRÉCAUTIONS DE SÛRETÉ soudage. Utiliser des lunettes avec écrans lateraux dans les zones où lʼon pique le laitier. Pour votre propre protection lire et observer toutes les instructions et les précautions de sûreté specifiques qui parraissent dans ce 6. Eloigner les matériaux inflammables ou les recouvrir afin de manuel aussi bien que les précautions de sûreté générales suiv- prévenir tout risque dʼincendie dû aux étincelles
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v v INSTALLATION EN 60974-10 POWER MIG (140, 180 MODELS)
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vi vi INSTALLATION EN 60974-10: POWER MIG (140, 180 MODELS)
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vii vii for selecting a QUALITY product by Lincoln Electric. We want you to take pride in operating this Lincoln Electric Company product T Th ha an nk k Y Yo ou u ••• as much pride as we have in bringing this product to you! CUSTOMER ASSISTANCE POLICY The business of The Lincoln Electric Company is manufacturing and selling high quality welding equipment, consumables, and cutting equip- ment. Our challenge is to meet the needs of our customers and to exceed their expectations. On occasion, pur
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viii viii TABLE OF CONTENTS Page –––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––– Installation .......................................................................................................Section A Technical Specifications.................................................................................A-1, A-2 Safety Precautions.................................................................................................A-3 Location..................
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A-1 A-1 INSTALLATION TECHNICAL SPECIFICATIONS 180 Amp units (K2472-1 180T, K2473-1 180C) INPUT – SINGLE PHASE ONLY Standard Voltage/Frequency Input Current 230 V 60 Hz 20 Amps @ rated output 208 V 60 Hz 20 Amps @ rated output RATED OUTPUT Voltage/Duty Cycle Current Voltage at Rated Amperes 230 V 30% 130 Amps 20 208 V 30% 130 Amps 17 OUTPUT Welding Current Range Open Circuit Voltage Wire Speed Range 30-180 Amps 34 V 50 - 500 in/min. (1.3 -
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A-2 A-2 INSTALLATION TECHNICAL SPECIFICATIONS 180 Amp units (K2668-1 180C) INPUT – SINGLE PHASE ONLY Standard Voltage/Frequency Input Current I 20 Amps 240 V 50 Hz 1 max I 10.7 Amps 1 eff RATED OUTPUT Voltage/Duty Cycle Current Voltage at Rated Amperes 240 V 25% 130 Amps 20 OUTPUT Welding Current Range Open Circuit Voltage Wire Speed Range 30 - 180 Amps 34 V 50 - 500 in/min. 1.3 - 12.7 ( m/min.) RECOMMENDED INPUT CABLE AND FUSE SIZES 1 Input Voltage/Frequency
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A-3 A-3 INSTALLATION Read entire installation section before starting installation. SAFETY PRECAUTIONS WARNING ELECTRIC SHOCK can kill. • Only qualified personnel should perform this installation. • Only personnel that have read and under- stood the POWER MIG Operating Manual should install and operate this equipment. • Machine must be plugged into a receptacle which is grounded per any national, local or other applicable electrical codes. • The POWER MIG power switch is to be in the OFF (“O”
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L-56 MIG WIRE A-4 A-4 INSTALLATION IDENTIFY AND LOCATE COMPONENTS • .030” -.045” (0.8 - 1.1mm) Knurled Drive Roll (Installed on Machine) INCLUDED COMPONENTS • Wire Feeder Welder. • .025” -.035” (0.6 - 0.9mm) Inner Wire guide • .035” -.045” (0.9 - 1.1mm) Inner Wire Guide (Installed on Machine) • Outer Wire Guide (Installed on Machine) INNER WIRE GUIDE INNER WIRE GUIDE OUTER WIRE GUIDE .025-.035 (.6-.9mm) .035-.045 (.9-1.1mm) • Work Cable & Clamp. • Black Flux-cored Gasless Gun Nozzle (Inst
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B-1 B-1 OPERATION PRODUCT DESCRIPTION (PRODUCT Read entire operation section before CAPABILITIES) operating the POWER MIG. These small portable wire feed welders are capable of MIG welding on steel, stainless steel, and aluminum. WARNING They are also capable of flux-cored welding on mild steel. ELECTRIC SHOCK can kill. • Do not touch electrically live MIG welding stands for Metal Inert Gas welding and parts or electrode with skin or requires a separate bottle of shielding gas to protect wet c
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B-2 B-2 OPERATION CONTROLS AND SETTINGS This machine has the following controls: FIGURE B.1 See Figure B.1 1. POWER SWITCH – Turns power on and off to the 2 machine. 2. ARC VOLTAGE CONTROL – This knob sets the output voltage of the machine. Along with wire feed speed (WFS) this control sets a weld procedure. Refer to the procedure decal on the inside wire drive compartment door to set a correct welding 3 procedure based on type of material and thickness being welded. 3. WIRE FEED SPEED CONTROL
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B-3 B-3 OPERATION See Figure B.3 FIGURE B.3 8. WELDING GUN CONNECTOR BUSHING & THUMBSCREW – Provides electrical power to the welding gun. The thumbscrew holds the welding gun into the connector block. (Front of Machine, Side Door and Wire Drive Cover have been removed for clarity of Items 8 and 9). 9. OUTPUT TERMINALS –These connections allow 8 to change the welding polarity of the machine depending on whether you are MIG welding or flux- cored welding. 9 FIGURE B.4 See Figure B.4 2"(51mm) SPIND
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B-4 B-4 OPERATION TABLE B.1 DRIVE ROLL AND WIRE GUIDES Wire Diameter & Drive Roll Drive Roll Part Inner Wire Guide Inner Wire Guide Type Number Part Number .025”(0.6mm) MIG wire .025”/.030” (0.6mm/0.8mm) Smooth Drive Roll KP2529-1 .030”(0.8mm) MIG wire .025”-.035” .035”(0.9mm) MIG wire .035”(0.9mm) Smooth Drive Roll KP2529-2 (0.6mm-0.9mm) KP2531-1 Steel Wire Guide .030”(0.8mm) flux-cored .030”/.045” (0.8mm/1.1mm) Knurled Drive Roll KP2529-3 .035”(0.9mm) flux-cored .045”(1.1mm) Steel .045”(1.1m
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F L U X - B-5 B-5 OPERATION SETTING UP AND MAKING A FLUX-CORED WELD A. ITEMS NEEDED FOR FLUX CORED WELDING 7. Work Cable & Clamp 1. 035”(0.9mm) Contact Tip 2. .025”-.035”(0.6mm-0.9mm) wire guide INNER WIRE GUIDE .025-.035 (.6-.9mm) 3. Knurled Drive Roll 4. .035”(0.9mm) NR-211MP Flux-Cored Wire 5. Black Flux Cored gun nozzle 6. Welding Gun POWER MIG (140, 180 MODELS) C O .035 NR-211 MP R E W I R E .030 .045 .035
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OPEN LATCH DOOR CASE SIDE DOOR SLIDE CONNECTOR END HERE TERMINAL END (FITS ON STUD INSIDE SEE FIGURE BELOW) (4 PIN) LEAD CONNECTOR CONNECTOR END ATTACH (4 PIN) TRIGGER RECEPTACLE PLUGGED IN B-6 B-6 OPERATION LOCATE COMPONENTS B. CONNECT LEADS AND CABLES ON FIGURE B.7 TO CONNECT TO THE FRONT OF MACHINE THE MACHINE (See Figure B.7) 1. Open the case side door 2. Slide the connector end of the gun and cable through the hole in the machine front and into the gun connector bushing on the wire drive.
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B-7 B-7 OPERATION FIGURE B.9 (See Figure B.9) TOP DRIVE ROLL PRESSED AGAINST 9. Feed the wire through the wire drive inlet along the LOWER DRIVE ROLL TENSION ADJUSTOR LOCKED IN POSITION inner wire guide groove and into the wire drive outlet on the gun side. DIRECTION OF WIRE 10. Close the top drive roll pressure arm and secure by WIRE SPOOL SLIDE WIRE .035" (0.9mm) INTO GUN pivoting the tension adjustor back to the up position. CONNECTOR SIDE NR-211-MP 11. Re-install the outer wire guide. (S
