Lincoln Electric MIG-180 Instruction Manual page 12

5.3 SITE
Locate the welding machine in an area where openings for cooling air are not
obstructed (forced circulation with fan), leave at least 250mm free space around the
welding machine; check that conductive dusts, corrosive vapours, humidity etc., will
not enter welding machine.
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WARNING: Position the welding machine on a flat surface with sufficient
carrying capacity for the weight of the welding machine, to prevent tipping or
hazardous movement.
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5.4 CONNECTIONTOTHE MAIN POWER SUPPLY
- Before making any electrical connection, make sure the rating data of the welding
machine correspond to the mains voltage and frequency available at the place of
installation..
- The welding machine should only be connected to a power supply system with the
neutral conductor connected to earth.
PLUG AND OUTLET: connect a normalised plug
having sufficient capacity- to the power cable and prepare a mains outlet fitted with
fuses or an automatic circuit-breaker; the special earth terminal should be connected
to the earth conductor (yellow-green) of the power supply line. Table 1
the recommended delayed fuse sizes in amps, chosen according to the max. nominal
current supplied by the welding machine, and the nominal voltage of the main power
supply.
VOLTAGE CHANGE
To carry out voltage change operations (only the 3-phase version), take off the panel
to gain access to the inside of the machine, and prepare the voltage change terminal
board so that the connection indicated on the special indicator plate corresponds to
the available power supply voltage.
Reassemble the panel carefully using the appropriate screws.
Warning!
In the factory the machine is set at the highest voltage of the available range, e.g.
⇐
U 400V Voltage setting at the factory.
1
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WARNING!
Failure to observe the above rules will make the (Class 1) safety system
installed by the manufacturer ineffective with consequent serious risks to
persons (e.g. electric shock) and objects (e.g. fire).
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5.5 CONNECTION OF THE WELDING CABLES
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WARNING! BEFORE MAKING THE FOLLOWING CONNECTIONS MAKE
SURETHEWELDING MACHINE IS SWITCHED OFF AND DISCONNECTED FROM
THE POWER SUPPLY OUTLET.
Table 1 (TAB. 1) gives the recommended values for the welding cables (in mm )
depending on the maximum current supplied by the welding machine.
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Connection to the wire feeder
(only for version with separate wire feeder)
- Carry out connections with the electrical generator (rear panel):
- cable for welding current to fast socket (+)
- control cable to appropriate connector.
- If the use of an extension cable is required, ensure that the connectors are firmly
tightened in order to prevent overheating and loss of efficiency.
- Connect the gas pipe from the pressure reducing valve on the cylinder and lock it with
the band supplied.
Connection to the gas bottle
- Gas bottle can be loaded on welding machine bottle support platform: max 20 Kg
- Screw the pressure reducing valve onto the gas bottle valve, inserting the
appropriate adapter supplied as an accessory, for when the gas used is Argon or
an Argon /CO mixture.
2
- Connect the gas inlet pipe to the pressure-reducing valve and tighten the band
supplied.
- Loosen the adjustment ring nut on the pressure-reducing valve before opening the
bottle valve.
Connecting the welding current return cable
Connect the welding current return cable to the piece to be welded or to the metal
bench on which it rests, as close as possible to the join being made.
Connecting the torch
Engage the torch (1) with its dedicated connector (2) by tightening the locking ring
manually as far down as it will go. Prepare the wire for loading the first time by
dismantling the nozzle and the contact tube to ease its exit.
Connecting the spool gun
Connect the spool gun (3) to the centralised torch connection
right down to fasten it.Then insert the control cable connector
(6) .The welding machine will recognise the spool gun automatically.
5.6 LOADINGTHEWIRE REEL
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WARNING! BEFORE STARTING THE OPERATIONS TO LOAD THE WIRE
MAKE SURETHEWELDING MACHINE IS SWITCHED OFF AND DISCONNECTED
FROMTHE MAIN POWER SUPPLY OUTLET.
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MAKE SURE THAT THE WIRE FEEDER ROLLERS, THE WIRE GUIDE HOSE AND
(2P + T for 1ph, 3P + T for 3ph)
(TAB.1)
Fig. F
Fig.G
Fig.H1
Fig.H1, H3
Fig.H2, H4
(4) screwing the ring nut
(5) in the special socket
Fig. I
THE CONTACT TIP OF THE TORCH MATCH THE DIAMETER AND TYPE OF WIRE
TO BE USED AND MAKE SURE THAT THESE ARE FITTED CORRECTLY. WHEN
INSERTING AND THREADING THE WIRE DO NOT WEAR PROTECTIVE GLOVES.
- Open the reel compartment door
- Position the wire reel on the spindle, holding the end of the wire upwards; make sure
the tab for pulling the spindle is correctly seated in its hole
- Release the pressure counter-roller and move it away from the lower roller
- Free the end of the wire and remove the distorted end with a clean cut and no burr;
turn the reel anti-clockwise and thread the end of the wire into the wire-guide infeed,
pushing it 50-100mm into the wire guide of the torch fitting
- Re-position the counter-roller, adjusting the pressure to an intermediate value, and
make sure that the wire is correctly positioned in the groove of the lower roller
- Use the adjustment screw located at the centre of the spindle to apply a slight
braking pressure on the spindle itself.
- Remove the nozzle and contact tip.
- Insert the welding machine plug into the power outlet, switch on the welding
machine, press the torch button and wait for the end of the wire to run right through
the wire guide hose and protrude by 100-150mm from the front of the torch, release
the button.
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WARNING! During these operations the wire is live and subject to
mechanical stress; therefore if adequate precautions are not taken the wire
shows
could cause hazardous electric shock, injury and striking of electric arcs:
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- Do not direct the mouthpiece of the torch towards parts of the body.
- Keep the torch away from the gas bottle.
- Re-fit the contact tip and the nozzle onto the torch.
- Check that wire feed is regular; set the roller and spindle braking pressure to the
minimum possible values making sure that the wire does not slide in the groove and
when feed is halted the loops of wire are not loosened by excessive reel inertia
- Cut the end of the wire so that 10-15 mm protrude from the nozzle.
- Close the reel compartment door
5.7 LOADINGTHEWIRE REEL ONTOTHE SPOOL GUN
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WARNING! BEFORE STARTING THE OPERATIONS TO LOAD THE WIRE
MAKE SURETHEWELDING MACHINE IS SWITCHED OFF AND DISCONNECTED
FROM THE MAIN POWER SUPPLY OR THAT THE SPOOL GUN IS
DISCONNECTED FROMTHEWELDING MACHINE.
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MAKE SURE THE WIRE PULLER ROLLERS, THE WIRE GUIDE HOSE AND THE
SPOOL GUN CONTACT TUBE HAVE SUITABLE DIAMETERS CORRESPONDING
TO THAT OF THE WIRE TO BE USED AND MAKE SURE THEY ARE ASSEMBLED
CORRECTLY. DO NOT WEAR PROTECTIVE GLOVES WHEN THREADING IN THE
WIRE.
- Remove the cover by undoing the appropriate screw
- Position the wire reel on the reel holder.
- Free the pressure counter-roller and move it away from the lower roller
2
- Free the end of the wire, cut off the distorted end with a clean cut leaving no burrs;
turn the reel anti-clockwise and thread the end of the wire into the wire-guide
infeed, pushing it 50-100mm inside the lance
- Reposition the counter-roller, adjusting the pressure to an intermediate value and
make sure the wire is correctly positioned in the lower roller recess
- Brake the reel holder slightly by adjusting the appropriate screw.
- Switch on the welding machine, putting the switch to ( I ), press the spool gun button
and wait until the end of the wire runs through the complete wire guide hose and 10-
15 cm comes out of the front of the torch then release the torch button.
- With the Spool gun connected, switch on the machine, press the spool gun button
and wait for the end of the wire to pass completely through the wire guide hose and
for 10-15 cm to come out of the front of the torch, release the torch button.
6.WELDING: DESCRIPTION OFTHE PROCEDURE
Only for the 3-phase version:
Insert the earth outlet in the desired quick (-) connector, depending on the material to
be welded
- quick connector (-) with max.
alloys (Al), copper alloys (CuAl/CuSi).
- quick connector (-) with min. reactance
and low alloys (Fe).
- Connect the return cable to the piece being welded.
- Turn on and adjust the protective gas using the pressure reducing valve (5-7 l/min)
NOTE: At the end of the job, remember to turn off the protective gas.
6.1WELDINGWITHTHE MIGTORCH
- Switch on the welding machine,
- Select the type of material, the type of gas and the wire diameter by pressing buttons
, ,
respectively.
- Set the welding current by means of the switch and rotary switch (if present)
- The display will show the welding current corresponding to the setting that has just
been made. Pressing button
wire feed rate (LED
NOTE: ensure good welding results can be ensured by varying the wire feed rate
within a preset interval. This interval is indicated by LED
outside the DEFAULT interval the LED will go off.
- Select the welding mode by pressing button
- Press the torch button to start welding.
NOTE: during welding the display will show the actual value of the current.
- Wire feed rate can be modified by turning knob (7), and the display will instantly show
the corresponding value; the current reading will re-appear as soon as the
adjustment has been completed.
Important: for each position of the switch, the welding machine will store all the
parameters for the last welding job to be carried out (material, gas, wire diameter, wire
feed rate).
- 12 -
Fig. L
(1) .
(2) .
Fig. H1-M
reactance for aluminium material and derivative
for stainless steel (SS), carbon steel
Fig.B, C
will show the corresponding factory setting for the
DEFAULT on).
.
(1) .
(2) .
(2) .
(3) .
(2) .
(3) .
(Fig.N) .
DEFAULT lighting up;