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Systematics PATRIOT PBE180 Owner's Manual

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PBE180 M.I.G. COMBINATION UNIT
CONGRATULATIONS!
YOU HAVE JUST PURCHASED ONE OF THE FINEST
MIG WELDING SYSTEMS AVAILABLE TODAY. THE
PBE180 REPRESENTS FOURTH GENERATION TECH-
NOLOGICAL ADVANCEMENTS. THIS SYSTEM IS DE-
SIGNED AND ENGINEERED TO PROVIDE YOU WITH
YEARS OF PROFESSIONAL SERVICE.
FORM WC5368
OWNER'S MANUAL
FOR TECH. SERVICE, CALL 1-610-696-9040
INSTALLATION
OPERATION
MAINTENANCE
Rev. 8/00, 5/01

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Summary of Contents for Systematics PATRIOT PBE180

  • Page 1 OWNER'S MANUAL PBE180 M.I.G. COMBINATION UNIT CONGRATULATIONS! YOU HAVE JUST PURCHASED ONE OF THE FINEST MIG WELDING SYSTEMS AVAILABLE TODAY. THE PBE180 REPRESENTS FOURTH GENERATION TECH- NOLOGICAL ADVANCEMENTS. THIS SYSTEM IS DE- SIGNED AND ENGINEERED TO PROVIDE YOU WITH YEARS OF PROFESSIONAL SERVICE. FOR TECH.

  • Page 2: Table Of Contents

    MAINTENANCE ................12 TROUBLE SHOOTING CHART ..........14 CONNECTING TIG PACK OR SPOOL GUN ......19 LINER INSTALLATION ............... 20 PARTS BREAKDOWN - MIG TORCH ........21 OPTIONS - TIG PACK OR SPOOL GUN ........23 Systematics, Inc. West Chester, PA. 19380...

  • Page 3: Introduction

    INTRODUCTION WIRE SPOOL The Systematics PBE180 is a com- FEED ROLLS bination welding power source, wire feed unit, MIG torch and accessory package, and is designed to meet the POWER SOURCE requirements of the metal fabrica- TORCH tion industries. The PBE180 pro-...

  • Page 4: Description, Specifications

    For Stainless Steel Argon/2% Oxygen input cable, a gas regulator - flowmeter, a torch accessory kit, For Flux cored CO2 or and a built-in cylinder rack and Argon/CO2 mix industrial wheel kit. Systematics, Inc. West Chester, PA. 19380...

  • Page 5: Check List (Contents)

    1. Factory selected no change is 1- Contact Tip, for .030 in. wire needed. (installed on MIG torch) 208V INPUT SELECTION 1- ER70S-6-30-3, Sample Spool of .030 Steel Wire 1. Remove the top cover. (continued on following page) Systematics, Inc. West Chester, PA. 19380...
  • Page 6 See recommended gases on suitable wrench. Open the cyl- page 2. inder valve. Systematics, Inc. West Chester, PA. 19380...
  • Page 7 DRIVE DRIVE ASSEMBLY ROLL "C" SIDE FACING IN FOR MOUNTING .040" - .045" STEEL WIRES BRACKET AND 3/64" ALUMINUM WIRES FIG. 8. DOUBLE GROOVE DRIVE ROLL FIG. 7. TORCH CONNECTION (continued on following page) Systematics, Inc. West Chester, PA. 19380...
  • Page 8 Work. The wire is electrically HOT when the torch trigger is actu- ated. FIG. 9. WIRE STICKOUT - STEEL, ALUMINUM Systematics, Inc. West Chester, PA. 19380...

  • Page 9: Operation

    8 for further details). yourself or anything that is common to the work cable WORK (GROUND) CABLE on the welder. Uncoil the work (ground) cable and plug it into the negative (-) terminal on the machine. Systematics, Inc. West Chester, PA. 19380...
  • Page 10 E. "ON" INDICATOR LIGHT metal, or for using flux cored Illuminates when the circuit gasless wire. breaker on the machine is "ON". Systematics, Inc. West Chester, PA. 19380...
  • Page 11 3/4 inch from the stant arc length and a constant work surface. tip-to-work distance. Systematics, Inc. West Chester, PA. 19380...
  • Page 12 "Continuous Welding on Steel". 10 DEGREES NOZZLE DIRECTION OF TRAVEL CONTACT TIP (RECESSED 3/8") SHIELDING GAS ELECTRODE WIRE (1" STICKOUT) WORK FIG. 14. NOZZLE ADJUSTMENT FIG. 15. TORCH POSITION FOR WELDING ALUMINUM FOR WELDING ALUMINUM Systematics, Inc. West Chester, PA. 19380...
  • Page 13 6. To ascertain a good spot weld, WORK SHIELDING GAS look at the back side of the welded material. A small melt- through of approximately 1/16 FIG. 17. STITCH WELDING inch diameter is ideal. Systematics, Inc. West Chester, PA. 19380...

  • Page 14: Maintenance

    Spatter buildup between the contact cause wire feeding problems so a tip and the nozzle can cause a short new liner should be installed. circuit and consequently, failure of the torch or welding machine. (continued on following page) Systematics, Inc. West Chester, PA. 19380...
  • Page 15 CUSTOMER SPARE PARTS bustibles, helper "watcher" should stand by with The Systematics PBE180 is a ma- a fire extinguisher or other chine of proven design and relia- fire protective device. bility. Following is a list of consumable...

  • Page 16: Trouble Shooting Chart

    Faulty motor relay. Sand points or replace (CR1) relay. Loose or broken connection. Tighten or repair connection. - USE THIS IDENTIFIER, ALONG WITH THE SCHEMATIC DIAGRAM FOUND IN THE SERVICE (SYMBOL*) MANUAL, FOR TROUBLE-SHOOTING PURPOSES. Systematics, Inc. West Chester, PA. 19380...
  • Page 17 Worn or dirty contact tip. Replace contact tip. Worn inlet guide(s). Clean or replace guides. Sticking pressure roll. Replace pressure roll. Feed roll tension incorrect. Adjust feed roll ten sion. See page 7. (continued on following page) Systematics, Inc. West Chester, PA. 19380...
  • Page 18 Replace solenoid. (GS) Incorrect electrode wire. Use correct wire. Contaminated base material. Clean or etch base material. - USE THIS IDENTIFIER, ALONG WITH THE SCHEMATIC DIAGRAM FOUND IN THE SERVICE (SYMBOL*) MANUAL, FOR TROUBLE-SHOOTING PURPOSES. Systematics, Inc. West Chester, PA. 19380...
  • Page 19 4. When replacing diodes, it is very important that a heat con- ductive compound (Radio Shack #276-1372) be used where the diode makes contact with the aluminum heat sink. Do not grease the threads on the diode. Systematics, Inc. West Chester, PA. 19380...
  • Page 20 (on the front of the machine) should affect the speed 5. Remove any tension on the drive of the drive roll from "0" thru roll. "10". 6. Activate the torch trigger. 10.Adjustment is now complete! Systematics, Inc. West Chester, PA. 19380...

  • Page 21: Connecting Tig Pack Or Spool Gun

    RECEPTACLE) SELECTOR gover from standard MIG operation LABEL HOSE to spool gun operation. THREAD 1. Remove the thread cap from the FIG. 20. BULKHEAD CONNECTIONS "SPOOL GUN" fitting. Systematics, Inc. West Chester, PA. 19380...

  • Page 22: Liner Installation

    MIG torch 10.Install the TWIST-ON adjustable assembly. nozzle twist nozzle during the installation. Turn to 3. Adjust the liner stickout length Page 9 for correct nozzle ad- to 3/4" as shown in FIG. 21. justment. Systematics, Inc. West Chester, PA. 19380...

  • Page 23: Parts Breakdown - Mig Torch

    ONLY ONLY ONLY .020-.030 inch 10 feet M103L-B M3LS-B (Blue) .035 inch 10 feet M103AL M3-6ALS M3-THS 10 feet M104L-N .035-.045 inch M4LS-N (Natural) 3/64 inch 10 feet M104AL M3-6ALS M3-THS 12 feet M124L-N Systematics, Inc. West Chester, PA. 19380...
  • Page 24 ITEMS WITH THE ASTERICK M3-308 M3-306 M3-120* ARE AVAILABLE FACTORY (2 REQD.) INSTALLED ONLY. TORCH REBUILD PROGRAM 15 SERIES TORCHES CAN BE REBUILT BY THE M3-310A FACTORY FOR A NOMINAL LABOR + PARTS CHARGE. Systematics, Inc. West Chester, PA. 19380...

  • Page 25: Options - Tig Pack Or Spool Gun

    THE TIG PACK WILL NOT WELD ALUMINUM. The TIG Welding Process is used to produce the highest quality, porosity-free welds. The TIG PACK adds TIG Welding capabilities to your Systematics Patriot MIG Welder. The TIG PACK is designed for Tungsten-Inert Gas (TIG) welding with Direct Current, Straight Polarity (DCSP) on steel, stainless steel, chrome-moly, copper or cast iron (18 Ga.
  • Page 26 NOTES Systematics, Inc. West Chester, PA. 19380...
  • Page 27 NOTES Systematics, Inc. West Chester, PA. 19380...
  • Page 28 Systematics, Inc. West Chester, PA. 19380...

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