Page 2 - SAFETY; WARNING
FOR ENGINEpowered equipment. 1.a. Turn the engine off before troubleshooting and maintenance work unless the maintenance work requires it to be running. ____________________________________________________ 1.b. Operate engines in open, well-ventilated areas or vent the engine exhaust fumes outdoors....
Page 3 - MINIMIZE EXPOSURE TO EMF
SAFETY 2.i.4 Connect the work cable to the work piece as close as possible to the area being welded. (This is also a goodpractice to eliminate a common problem on welding - apoor work connection. 2.i.5 Do not work next to the welding power source. ADDITIONAL PRECAUTIONS FORWELDERS WITH PACEMAKERS 2....
Page 4 - iii
iii SAFETY iii ARC RAYS can burn. 4.a. Use a shield with the proper filter and cover plates to protect your eyes from sparks andthe rays of the arc when welding or observingopen arc welding. Headshield and filter lensshould conform to ANSI Z87. I standards. 4.b. Use suitable clothing made from durab...
Page 5 - iv
FOR ELECTRICALLYpowered equipment. 8.a. Turn off input power using the disconnect switch at the fuse box before working onthe equipment. 8.b. I n s t a l l e q u i p m e n t i n a c c o r d a n c e w i t h t h e N a t i o n a l Electrical Code, all local codes and the manufacturer ’ s recommendation...
Page 6 - Conformance; Introduction; Assessment of Area; Methods of Reducing Emissions
SAFETY v v I N S T R U C T I O N S F O R E L E C T R O -MAGNETIC COMPATIBILITY Conformance Products displaying the C-Tick mark are in conformity withAustralian/New Zealand requirements for ElectromagneticCompatibility (EMC) according to standard (emission) AS/NZS3 6 5 2 " E l e c t r o m a g n e...
Page 7 - Thank You; Please Examine Carton and Equipment For Damage Immediately
Thank You for selecting a QUALITY product. We want you to take pride inoperating this LiquidArc product ••• as much pride as we have in bringing this product to you! Read this Operators Manual completely before attempting to use this equipment. Save this manual and keep ithandy for quick reference. ...
Page 8 - TABLE OF CONTENTS
vii vii TABLE OF CONTENTS Page Installation .......................................................................................................Section A Technical Specifications ........................................................................................A-1Identify and Locate Compone...
Page 10 - INSTALLATION; TECHNICAL SPECIFICATIONS
A-1 A-1 INSTALLATION Fuse or Output Mode Input Voltage Breaker Size Input Amps Power Cord RATED 240V/50Hz 25 Super Lag 12.7 15Amp, 240V, Three Pin Plug TECHNICAL SPECIFICATIONS – Handymig 170i INPUT – SINGLE PHASE ONLY RATED OUTPUT OUTPUT RECOMMENDED INPUT CABLE AND FUSE SIZES Height Width Depth Wei...
Page 11 - SAFETY PRECAUTIONS; Read entire installation section before starting; ELECTRIC SHOCK can kill.
A-2 INSTALLATION SAFETY PRECAUTIONS • Read entire installation section before starting installation. IDENTIFY AND LOCATE COMPONENTS I f y o u h a v e n o t a l r e a d y d o n e s o , u n p a c k t h eHandymig 170i from its carton and remove all packingmaterial around the Handymig 170i. Remove the f...
Page 12 - SELECT SUITABLE LOCATION; STACKING; OUTPUT CONNECTIONS; Work Clamp Installation
A-3 INSTALLATION SELECT SUITABLE LOCATION Locate the welder in a dry location where there is freecirculation of clean air into the louvers in the back andout the front of the unit. A location that minimizes theamount of smoke and dirt drawn into the rear louversreduces the chance of dirt accumulatio...
Page 13 - Work Cable Installation; GAS CONNECTION
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 Handymig 170i. 2. Pass the end of the work cable that has the termi- nal lug with the smaller hole through the WorkCable Access Hole (1) in the case front. 3. Route the cable...
Page 14 - INPUT CONNECTIONS
A-5 INSTALLATION BE SURE TO KEEP YOUR FACE AWAY FROM THEVALVE OUTLET WHEN “ CRACKING ” THE VALVE. Never stand directly in front of or behind the flowregulator when opening the cylinder valve. Alwaysstand to one side. 3. Attach the flow regulator to the cylinder valve and tighten the union nut secure...
Page 15 - Line Cord Connection
A-6 INSTALLATION ELECTRICAL INPUT CONNECTIONFOR RATED OUTPUT ELECTRIC SHOCK can kill. • Disconnect input power by removing plug from receptaclebefore working inside Handymig170i. • Use only grounded receptacle. • Do not touch electrically “ hot ” parts inside Handymig 170i. • Have qualified personne...
Page 16 - OPERATION; RECOMMENDED PROCESSES
B-1 OPERATION SAFETY PRECAUTIONS ELECTRIC SHOCK can kill. • Do not touch electrically live parts or electrode with skin orwet clothing. Insulate yourselffrom work and ground. • Always wear dry insulating gloves. FUMES AND GASES can bedangerous. • Keep your head out of fumes. • Use ventilation or exh...
Page 17 - WELDING CAPABILITY; OFF
B-2 B-2 OPERATION WELDING CAPABILITY The Handymig 170i is rated at 130 amps, 20 volts, at20% duty cycle on a ten minute basis. It is capable ofhigher output currents at lower duty cycles. . LIMITATIONS Arc Gouging cannot be performed with the Handymig170i. The Handymig 170i is not recommended for pi...
Page 18 - WELDING OPERATIONS; SEQUENCE OF OPERATION; Note: The brake should be adjusted with a spool of; CAUTION
B-3 OPERATION WELDING OPERATIONS SEQUENCE OF OPERATION Wire LoadingRefer to Figure B.2 and B.3.The machine power switch should be turned to theOFF ( “ O ” ) position before working inside the wire feed enclosure. The machine is shipped from the factory ready to feed8 ” (200 mm) diameter spools [2.2 ...
Page 20 - Making A Weld; PROCESS GUIDELINES
B-5 B-5 OPERATION Making A Weld 1. See “ Process Guidelines ” in this section for selec- tion of welding wire and shielding gas and forrange of metal thicknesses that can be welded. 2. See the Application chart on the inside of the wire feed compartment door for information on settingthe Handymig 17...
Page 21 - Welding Kit
B-6 B-6 OPERATION The Handymig 170i is suitable for .035"(0.9mm) alu-minum wire and .023" – .035"(0.6-0.9mm) stainless wire. Refer to Table B.1 for recommended procedures e t t i n g s . ( R e q u i r e s K 6 6 4 - 2 A l u m i n u m - S t a i n l e s sFeeding Kit.) It is important when c...
Page 22 - THE ARC-WELDING CIRCUIT; OVERLOAD PROTECTION; OUTPUT OVERLOAD; LEARNING TO WELD
Fumes and slag generated fromInnershield type electrodes recom-mended for use with this weldingmachine can be toxic. • Avoid contact with eyes and skin. • Do not take internally. • Keep out of reach of children. • Follow all safety precautions found in this operating manual. B-7 B-7 LEARNING TO WELD...
Page 24 - PROCESS SELECTION
B-9 B-9 LEARNING TO WELD PROCESS SELECTION By gaining knowledge of the differences between thetwo processes, you will be able to select the bestprocess for the job you have at hand. In selecting aprocess, you should consider: For GMAW (MIG) Process1. Is most of my welding performed on 16 gauge and l...
Page 25 - Welding In The Vertical Position
B-10 B-10 LEARNING TO WELD FIGURE B.12 PenetrationUnless a weld penetrates close to 100% of the metalthickness, a butt weld will be weaker than the materialwelded together. In the example shown in FigureB.13, the total weld is only half the thickness of thematerial thus the weld is only approximatel...
Page 27 - ARC RAYS can burn eyes and skin.
B-12 B-12 LEARNING TO WELD ARC RAYS can burn eyes and skin. When using an open arc process, itIs necessary to use correct eye,head and body protection. Protect yourself and others, read “ ARC RAYS can burn ” at the front of this manual. • The Correct Way To Strike An Arc • Be sure the work clamp mak...
Page 28 - Mild Steel; Helpful Hints
B-13 B-13 LEARNING TO WELD Mild Steel 16 gauge or 1/16 inch (1.6 mm) Electrode 0.035" (0.9 mm) Steelcore 71T-GS Innershield Wire Voltage Setting “ V ” A Wire Feed Speed “ o|o ” 1.5 For the Handymig 170i, use the following: Helpful Hints • For general welding, it is not necessary to weavethe arc,...
Page 29 - The Correct Way To Strike An Arc
B-14 B-14 LEARNING TO WELD MACHINE SET UP FOR THE GMAW (MIG)PROCESS • See PROCESS GUIDELINES in the OPERATIONsection for selection of welding wire and shieldinggas, and for range of metal thicknesses that can bewelded. • See the Application Guide on the inside of wirefeed section door for informatio...
Page 30 - For the Handymig 170i, use the following:
Helpful Hints • For general welding, it is not necessary to weavethe arc, neither forward or backward nor sideways.Weld along at a steady pace. You will find it easier. • When welding on thin plate, you will find that youwill have to increase the welding speed, whereaswhen welding on heavy plate, it...
Page 31 - TROUBLESHOOTING WELDS
B-16 B-16 LEARNING TO WELD • After you strike the arc, practice the correct electri-cal stickout. Learn to distinguish it by its sound. • When you are sure that you can hold the correctelectrical stickout, with a smooth “ crackling ” arc, start moving. Look at the molten puddle constantly, • Run bea...
Page 32 - Proper Gun Handling
B-17 B-17 LEARNING TO WELD Proper Gun Handling Most feeding problems are caused by improper han-dling of the gun cable or electrodes. • Do not kink or pull the gun around sharp corners • Keep the gun cable as straight as practical whenwelding. • Do not allow dolly wheels or trucks to run over thecab...
Page 33 - APPLICATION CHART
Page 34 - FOR MAGNUM; MAINTENANCE; ROUTINE MAINTENANCE; POWER SOURCE COMPARTMENT
D-1 GUN AND CABLE MAINTENANCE FOR MAGNUM ™ 100L GUN Gun Cable CleaningClean cable liner after using approximately 300 lbs(136 kg) of solid wire or 50 lbs (23 kg) of flux-coredwire. Remove the cable from the wire feeder and lay itout straight on the floor. Remove the contact tip fromthe gun. Using lo...
Page 35 - CHANGING THE CONTACT TIP
D-2 D-2 MAINTENANCE COMPONENTREPLACEMENT PROCEDURES 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....
Page 36 - GUN HANDLE PARTS; CHANGING LINER; Liner trim length
GUN HANDLE PARTS The gun handle consists of two halves that are heldtogether with a collar on each end. To open up thehandle, turn the collars approximately 60 degreescounter-clockwise until the collar reaches a stop. Thenpull the collar off the gun handle. If the collars are diffi-cult to turn, pos...
Page 37 - GROUND TEST PROCEDURE; WARNING ELECTRIC SHOCK can kill
D-4 D-4 GROUND TEST PROCEDURE WARNING ELECTRIC SHOCK can kill WARNING: This procedure is only suitable for applica-tions using DC mega testers up to 500V. Note: This procedure is for ‘ machines as built ’ many modifications could have taken place over the life of aparticular machine, so details of t...
Page 38 - TROUBLESHOOTING; HOW TO USE TROUBLESHOOTING GUIDE
E-1 E-1 TROUBLESHOOTING This Troubleshooting Guide is provided tohelp you locate and repair possible machinemalfunctions. Simply follow the three-stepprocedure listed below. Step 1. LOCATE PROBLEM (SYMPTOM). Look under the column labeled “ PROBLEM (SYMPTOMS) ” . This column describes pos- s i b l e ...
Page 39 - TROUBLESHOOTING GUIDE; OUTPUT PROBLEMS; LIQUID ARC
E-2 E-2 TROUBLESHOOTING Observe Safety Guidelines detailed in the beginning of this manual. TROUBLESHOOTING GUIDE PROBLEMS(SYMPTOMS) Major physical or electrical damageis evident. No wire feed, weld output or gasflow when gun trigger is pulled. Fandoes NOT operate. No wire feed, weld output or gasfl...
Page 40 - FEEDING PROBLEMS; GAS FLOW PROBLEMS
E-3 E-3 TROUBLESHOOTING TROUBLESHOOTING GUIDE Observe Safety Guidelinesdetailed in the beginning of this manual. PROBLEMS(SYMPTOMS) No wire feed when gun trigger ispulled. Fan runs, gas flows andmachine has correct open circuitvoltage (33 vcd maximum) – weld output. POSSIBLE AREAS OFMISADJUSTMENT(S)...
Page 41 - WELDING PROBLEMS
E-4 E-4 TROUBLESHOOTING Observe Safety Guidelines detailed in the beginning of this manual. TROUBLESHOOTING GUIDE If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact yourLOCAL AUTHORIZED LIQUID ARC FIELD SERVICE FACILITY for assistan...
Page 42 - WIRING DIAGRAMS; Hand
F-1 F-1 WIRING DIAGRAMS Handymig 170i WIRING DIAGRAM: Code 10842 Hand ymig 170i WIRING DIA GRAM 10/00 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 enclos...
Page 43 - ÇÃ
WARNING AVISO DE PRECAUCION ATTENTION WARNUNG ATEN ÇÃ O Spanish French German Portuguese Japanese Chinese Korean Arabic READ AND UNDERSTAND THE MANUFACTURER’S INSTRUCTION FOR THIS EQUIPMENT AND THE CONSUMABLES TO BEUSED AND FOLLOW YOUR EMPLOYER’S SAFETY PRACTICES. SE RECOMIENDA LEER Y ENTENDER LAS I...
