RETURN TO MAIN MENU IM810 Pro-MIG 175 July, 2005 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 thoughtful 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.
i i SAFETY WARNING CALIFORNIA PROPOSITION 65 WARNINGS Diesel engine exhaust and some of its constituents are known to the State of California to cause cancer, birth defects, and other reproductive harm. The Above For Diesel Engines The engine exhaust from this product contains chemicals known to the State of California to cause cancer, birth defects, or other reproductive harm. The Above For Gasoline Engines ARC WELDING CAN BE HAZARDOUS.
ii ii SAFETY ARC RAYS can burn. 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.b. 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.
iii iii SAFETY WELDING SPARKS can 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. 6.b.
iv iv SAFETY PRÉCAUTIONS DE SÛRETÉ Pour votre propre protection lire et observer toutes les instructions et les précautions de sûreté specifiques qui parraissent dans ce manuel aussi bien que les précautions de sûreté générales suivantes: Sûreté Pour Soudage A L’Arc 1. Protegez-vous contre la secousse électrique: a. Les circuits à l’électrode et à la piéce sont sous tension quand la machine à souder est en marche.
v v Thank You for selecting a QUALITY product by Lincoln Electric. We want you to take pride in operating this Lincoln Electric Company product ••• as much pride as we have in bringing this product to you! Please Examine Carton and Equipment For Damage Immediately When this equipment is shipped, title passes to the purchaser upon receipt by the carrier.
vi vi TABLE OF CONTENTS Page Installation .......................................................................................................Section A Technical Specifications ........................................................................................A-1 Safety Precautions.................................................................................................A-2 Identify and Locate Components ...........................................................................
A-1 A-1 INSTALLATION TECHNICAL SPECIFICATIONS – Pro-MIG 175 INPUT – SINGLE PHASE ONLY Standard Voltage/Frequency 230V/60Hz 208V/60Hz Input Current 20 Amps – Rated Output 22 Amps – Rated Output RATED OUTPUT Duty Cycle 30% Duty Cycle @ 230V/60Hz 25% Duty Cycle @ 208V/60Hz Current 130 Amps 130 Amps Volts at Rated Amperes 20V 20V OUTPUT Welding Current Range Rated DC Output: 30 – 175 amps Maximum Open Circuit Voltage 33V Wire Speed Range 50-400IPM (1.3-10.
A-2 INSTALLATION A-2 FIGURE A.1 SAFETY PRECAUTIONS Read entire installation section before starting installation. WARNING 1 ELECTRIC SHOCK can kill. • Only qualified personnel should perform this installation. 2 • Only personnel that have read and understood the PRO-MIG 175 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.
A-3 A-3 INSTALLATION SELECT SUITABLE LOCATION 6. Wire Feed Gearbox. 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. 7. Cable Hanger. 8. Thumbscrew. Refer to the Accessories Section for available optional equipment.
A-4 A-4 INSTALLATION Work Cable Installation Refer to Figure A.2. 1. Open the wire feed section door on the right side of the Pro-MIG 175. NOTE: If .035" or .045" (0.9 mm or 1.2 mm) Innershield flux-cored wire is to be used, the appropriate Innershield kit is required. (see ACCESSORIES section) Connecting Gun Cable to the Pro-MIG 175 2. Pass the end of the work cable that has the terminal lug with the smaller hole through the Work Cable Access Hole (1) in the case front. 3.
A-5 A-5 INSTALLATION WARNING CYLINDER may explode if damaged. Keep cylinder upright and chained to support 2. With the cylinder securely installed, remove the cylinder cap. Stand to one side away from the outlet 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. • Keep cylinder away from areas where it may be damaged. • Never lift welder with cylinder attached. • Never allow welding electrode to touch cylinder.
A-6 INSTALLATION A-6 ELECTRICAL INPUT CONNECTION FOR RATED OUTPUT Line Cord Connection A 3 conductor line cord with a 50 amp, 250 volt, threeprong 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 applicable local codes. CONNECT TO A SYSTEM GROUNDING WIRE.
B-1 OPERATION SAFTEY PRECAUTIONS B-1 GENERAL DESCRIPTION Read entire operation section before operating the Pro-MIG 175. WARNING ELECTRIC SHOCK can kill. • Do not touch electrically live parts or electrode with skin or wet clothing. Insulate yourself from work and ground. • Always wear dry insulating gloves. FUMES AND GASES can be dangerous. The Pro-MIG 175 is a complete semiautomatic constant voltage DC portable arc welder.
B-2 B-2 OPERATION Refer to Figure B.1b. ● No external shielding gas is required when used with Lincol .035” (0.9 mm) Innershield NR®-211MP electrode. ● Spindle accommodates both 8 in. (200 mm) diame- ter and 4 in. (100 mm) diameter spools of wire. 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 5. Gun Trigger - Activates welding output, wire feed, and gas solenoid operation.
B-3 OPERATION B-3 WELDING OPERATIONS Load an 8” (200 mm) diameter spool on the wire spool spindle shown in Figure B.2. 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].
B-4 B-4 OPERATION Wire Threading Refer to Figure B.4 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, maintain tension on the wire until after step 5. 3.
B-5 B-5 OPERATION FIGURE B.6 FIGURE B.7 Contact Tip GUN CABLE Wire Electrode 3/8"– 1/2"(10-13mm) Contact Tip to Work Distance(CTWD) WORKPIECE Making A Weld 1. See “Process Guidelines” in this section for selection of welding wire and shielding gas and for range of metal thicknesses that can be welded. 2. See the Application chart on the inside of the wire feed compartment door for information on setting the Pro-MIG 175 controls. Refer to Table B.1 for aluminum and stainless wire. 3.
B-6 OPERATION The Pro-MIG 175 is suitable for .035" aluminum wire and .023"– .035" stainless wire. Refer to Table B.1 for recommended procedure settings. (Requires K586-1 regulator kit and K664-2 Aluminum - Stainless Feeding Kit.) 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. CAUTION c) Turn off the Pro-MIG 175.
B-7 APPLICATION CHART Pro-MIG 175 B-7
C-1 ACCESSORIES OPTIONAL ACCESSORIES 1. K549-1 .035" (0.9 mm) Innershield® Welding Kit — Includes a contact tip, a gasless nozzle and a .030/.035 (.8/.9mm) cable liner to permit the Magnum™ 100L gun and cable to use .035" (0.9 mm) diameter flux-cored electrode. The fitting on the end of the liner is stenciled with the maximum rated wire size (.045"/1.2 mm). Also included is a 10 lb.(4.5 kg.) spool of .035" (0.9 mm) Innershield® NR-211-MP. C-1 5.
C-2 ACCESSORIES INNERSHIELD (FCAW) CONVERSION REPLACEMENT PARTS Several changes are needed to convert the unit for operation with the Innershield (FCAW) process. The K549-1 Innershield Kit includes all the necessary accessories for this conversion and is provided for this purpose. The following conversions should be made using the contents of this kit: 1. Change the output polarity to DC(–). See “Work Cable Installation” in Installation section for details. 2.
MAINTENANCE D-1 MAINTENANCE SAFETY PRECAUTIONS WARNING ELECTRIC SHOCK can kill. • Disconnect input power by removing plug from receptacle before working inside Pro-MIG 175. Use only grounded receptacle. Do not touch electrically “hot” parts inside Pro-MIG 175. • Have qualified personnel do the maintenance 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.
D-2 D-2 MAINTENANCE GUN AND CABLE MAINTENANCE FOR MAGNUM™ 100L GUN Gun Cable Cleaning Clean cable liner after using approximately 300 lbs (136 kg) of solid wire or 50 lbs (23 kg) of flux-cored wire. Remove the cable from the wire feeder and lay it out straight on the floor. Remove the contact tip from the gun. Using low pressure air, gently blow out the cable liner from the gas diffuser end. CAUTION Excessive pressure at the start may cause the dirt to form a plug.
D-3 D-3 MAINTENANCE 8. Push a length of straightened welding wire through the wire feeder guide tubes and adjust the position of the drive roll so that the groove is centered on the wire. Make certain the set screw is located on the flat portion of the shaft and tighten. Figure D.1 COMPONENT REPLACEMENT PROCEDURES CHANGING THE CONTACT TIP 1. Refer to Figure D.2. Remove the gas nozzle from the gun by unscrewing counter-clockwise. 2.
D-4 D-4 MAINTENANCE 1-1/4 (31.8 mm) Liner Trim Length Gas Diffuser Set Screw Brass Cable Connector Gas Nozzle or Gasless Nozzle 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 NOTICE: The variation in cable lengths prevents the interchangeability of liners.
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.
E-2 E-2 TROUBLESHOOTING Observe all Safety Guidelines detailed throughout this manual PROBLEMS (SYMPTOMS) POSSIBLE CAUSE RECOMMENDED COURSE OF ACTION OUTPUT PROBLEMS Major physical or electrical damage is evident. None Contact your local Authorized Field Service Facility. No wire feed, weld output or gas flow when gun trigger is pulled. Fan does NOT operate. 1. Make sure correct voltage is applied to the machine. See Installation section, “Electrical Connections”. 2.
E-3 TROUBLESHOOTING E-3 Observe all Safety Guidelines detailed throughout this manual PROBLEMS (SYMPTOMS) POSSIBLE CAUSE RECOMMENDED COURSE OF ACTION FEEDING PROBLEMS No wire feed when gun trigger is pulled. Fan runs, gas flows and machine has correct open circuit voltage (33 vcd maximum) – weld output. 1. If the wire drive motor is running make sure that the correct drive rolls are installed in the machine. 2. Check for clogged cable liner or contact tip.
E-4 E-4 TROUBLESHOOTING Observe all Safety Guidelines detailed throughout this manual PROBLEMS (SYMPTOMS) POSSIBLE CAUSE RECOMMENDED COURSE OF ACTION WELDING PROBLEMS Arc is unstable – Poor starting 1. Check for correct input voltage to machine. See Installation section, “Electrical Input Connections”. 2. Check for proper electrode polarity for process. 3. Check gun tip for wear or damage and proper size – Replace. 4. Check for proper gas and flow rate for process. (For MIG only.
Pro-MIG 175 A G N.D. BOLTED ALUMINUM CONNECTIONS REQUIRE T12837 JOINT COMPOUND (DOW CORNING 340) WHEN REATTACHING. HEATSINK, WHICH IS CLOSEST TO THE CENTER PANEL. N.C. COMPONENT VIEWED FROM REAR. N.B. DIODES D2,D4,D6 & D8 ARE MOUNTED ON THE INSIDE CIRCUIT BREAKER S1 ON-OFF SWITCH N.C. H2 H3 H1 T1 541 2 3 5 6 7 8 D3 202 X1 N.A. D1 D7 D5 D4 N.D. D2 203 D8 D6 203 203 209 213 N.C. 211 93,000 u f N.D.
NOTES
NOTES
● Do not touch electrically live parts or WARNING Spanish AVISO DE PRECAUCION French ATTENTION German WARNUNG Portuguese ATENÇÃO ● Keep flammable materials away. ● Wear eye, ear and body protection. ● Mantenga el material combustible ● Protéjase los ojos, los oídos y el 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 mojada. ● Aislese del trabajo y de la tierra.
● Keep your head out of fumes. ● Use ventilation or exhaust to ● Turn power off before servicing. ● Do not operate with panel open or guards off. remove fumes from breathing zone. ● Los humos fuera de la zona de res- piración. ● Mantenga la cabeza fuera de los humos. Utilice ventilación o aspiración para gases. ● Gardez la tête à l’écart des fumées. ● Utilisez un ventilateur ou un aspira- ● Desconectar el cable de ali- mentación de poder de la máquina antes de iniciar cualquier servicio.
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