Lincoln Electric Welder 170I User Manual

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IM711

January, 2001

Handymig 170i

For use with machine Code Numbers

10843

Safety Depends on You

LiquidArc machines are 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 READ-

ING THIS MANUAL AND THE

SAFETY PRECAUTIONS CON-

TAINED THROUGHOUT. And,

most importantly, think before you

act and be careful.

Date of Purchase:

Serial Number:

Code Number:

Model:

Where Purchased:

OPERATOR’S MANUAL

ISO 9001

ANSI RAB

QMS

Designed and Manufactured Under a

Quality Program Certified by

ABS Quality Evaluations, Inc.

to ISO 9001 Requirements.

CERTIFICATE NUMBER: 30273

Made exclusive for Australia

A Division of Lincoln Electric Company (Aust) Ply Ltd A.B.N. 36 000 040 308

35 Bryant Street, Padstow, NSW2211, Australia

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SAFETY

2.i.4 Connect the work cable to the work piece as close as

ELECTRIC AND

MAGNETIC FIELDS

may be dangerous

possible to the area being welded. (This is also a good

practice to eliminate a common problem on welding - a

poor work connection.

2.i.5 Do not work next to the welding power source.

2.a. Electric current flowing through any conductor causes

localized Electric and Magnetic Fields (EMF). Welding

current creates EMF fields around welding cables and

welding machines

ADDITIONAL PRECAUTIONS FOR

WELDERS WITH PACEMAKERS

2.j. There is no question that the fields in arc welding can interfere

with a pacemakers function. Generally the interference does

not permanently damage the pacemaker. Once the wearer

leaves the arc welding environment or stops welding, the pace-

maker returns to normal functioning. The welding arc has little

or no effect on the operation of some pacemakers, especially

designs that are bi-polar or designed to filter out such interfer-

ence.

2.b. EMF fields may interfere with some pacemakers, and

welders having a pacemaker should consult their physician

before welding.

2.c. Exposure to EMF fields in welding may have other health

effects which are now not known.

2.d. All welders should follow safe practices that minimize their

exposure to electric and magnetic fields (EMF).

2.k. For a welder or anyone working around electrical equipment

the selection of a pacemaker is very important. Get a doctor’s

advice about which pacemaker is the least sensitive to inter-

ference from welding while still being medically suitable.

2.e. For welders wearing implanted pacemakers, safe welding

practices are particularly important and additional procedures

should be followed by those who have decided to continue to

weld. (Hopefully in keeping with a doctor’s advice).

2.l. In addition to the normal safety precautions, the following addi-

tional procedures should be adopted by welders with pacemak-

ers.

2.f. The following procedures will not eliminate exposure to EMF or

the possibility of arc welding having an effect on a pacemaker,

however if followed, they will significantly reduce exposure to

electric and magnetic fields. Electric and magnetic fields are

created any time electric current flows through a conductor,

however it is not clear whether such exposure affects ones

health.

2.l.1 Use gas welding when the application is suitable.

2.l.2 Use the lowest current setting appropriate for the applica-

tion. Do not exceed 400 amps. Low current (75-200

amps) direct current (DC) welding should be used if arc

welding is necessary. Do not TIG weld with high frequen-

cy.

2.g. Some researchers have reported that exposure to EMF may

cause leukemia or other illnesses. These claims originally

arose in relation to high voltage electric power lines and are

very much in dispute in the medical and scientific arena, how-

ever the best advice is to minimize your exposure to EMF to

protect your health should doctors eventually decide there is a

risk.

2.l.3 Do not use repeated, short welds. Wait about ten sec-

onds between stopping one weld and starting the next.

When having difficulty starting an electrode, do not re-

strike the rod repeatedly.

2.l.4 If you feel light headed, dizzy or faint, immediately stop

welding. Lay the electrode holder down so that it does not

contact the work and move away from any welding being

performed. Arrange your work in advance so that, if you

become dizzy and drop the electrode holder it will not fall

on your body or strike the work.

2.h. There are four fundamental facts about EMF:

2.h.1 With direct current (DC), the field strength is relatively

constant and does not change.

2.h.2 With alternating current (AC), the field strength constant-

ly changes.

2.l.5 Do not work on a ladder or other elevated position or in a

cramped, confined place.

2.h.3 The greater the current flow, i.e. the higher the amps,

the stronger the field created by the current

2.l.6 Do not work alone. Work only in the presence of an indi-

vidual who understands these precautions and the possi-

ble effect welding may have on your pacemaker.

2.h.4 The closer the conductor or electrical device is to the

body the greater the exposure to the field.

2.l.7 Do not work near spot welding equipment.

MINIMIZE EXPOSURE TO EMF

2.l.8 If you have a pacemaker and wish to continue arc weld-

ing, discuss this and any other questions you may have

with your physician and follow his or her advice. The doc-

tor may wish to contact the pacemaker manufacturer for a

recommendation. As mentioned before, the design of the

pacemaker significantly affects the degree to which it is

subject to interference from a welding circuit. Do not rely

on the fact that you know another welder with a pacemak-

er who has welded for years without experiencing a prob-

lem.That welder and his or her pacemaker may be quite

different from you and your pacemaker.

2.i. All welders should use the following procedures to minimize

EMF exposure:

2.i.1 Route electrode or gun and work cables together. Secure

them with tape if possible.

2.i.2 Never coil the electrode lead around your body.

2.i.3 Do not place your body between the electrode and work

cables. If your electrode cable is on your right side the

work cable should also be on your right side.

Oct ‘00

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iii

SAFETY

ARC RAYS can burn.

ELECTRIC SHOCK can

4.a. Use a shield with the proper filter and cover

plates to protect your eyes from sparks and

the rays of the arc when welding or observing

open arc welding. Headshield and filter lens

should conform to ANSI Z87. I standards.

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.

4.b. Use suitable clothing made from durable flame-resistant

material to protect your skin and that of your helpers from

the arc rays.

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.

4.c. Protect other nearby personnel with suitable, non-flammable

screening and/or warn them not to watch the arc nor expose

themselves to the arc rays or to hot spatter or metal.

In addition to the normal safety precautions, if welding

must be performed under electrically hazardous

conditions (in damp locations or while wearing wet

clothing; on metal structures such as floors, gratings or

scaffolds; when in cramped positions such as sitting,

kneeling or lying, if there is a high risk of unavoidable or

accidental contact with the workpiece or ground) use

the following equipment:

FUMES AND GASES

can be dangerous.

5.a. Welding may produce fumes and gases

hazardous to health. Avoid breathing these

• Semiautomatic DC Constant Voltage (Wire) Welder.

• DC Manual (Stick) Welder.

fumes and gases.When welding, keep

your head out of the fume. Use enough

• AC Welder with Reduced Voltage Control.

ventilation and/or exhaust at the arc to keep

fumes and gases away from the breathing zone. When

welding with electrodes which require special

ventilation such as stainless or hard facing (see

instructions on container or MSDS) or on lead or

cadmium plated steel and other metals or coatings

which produce highly toxic fumes, keep exposure as

low as possible and below Threshold Limit Values (TLV)

using local exhaust or mechanical ventilation. In

confined spaces or in some circumstances, outdoors, a

respirator may be required. Additional precautions are

also required when welding on galvanized steel.

3.c. In semiautomatic or automatic wire welding, the electrode,

electrode reel, welding head, nozzle or semiautomatic

welding gun are also electrically “hot”.

3.d. Always be sure the work cable makes a good electrical

connection with the metal being welded. The connection

should be as close as possible to the area being welded.

3.e. Ground the work or metal to be welded to a good electrical

(earth) ground.

5.b. Do not weld in locations near chlorinated hydrocarbon vapors

coming from degreasing, cleaning or spraying operations.

The heat and rays of the arc can react with solvent vapors to

form phosgene, a highly toxic gas, and other irritating prod-

ucts.

3.f. Maintain the electrode holder, work clamp, welding cable and

welding machine in good, safe operating condition. Replace

damaged insulation.

3.g. Never dip the electrode in water for cooling.

5.c. Shielding gases used for arc welding can displace air and

cause injury or death. Always use enough ventilation,

especially in confined areas, to insure breathing air is safe.

3.h. Never simultaneously touch electrically “hot” parts of

electrode holders connected to two welders because voltage

between the two can be the total of the open circuit voltage

of both welders.

5.d. Read and understand the manufacturer’s instructions for this

equipment and the consumables to be used, including the

material safety data sheet (MSDS) and follow your

employer’s safety practices. MSDS forms are available from

your welding distributor or from the manufacturer.

3.i. When working above floor level, use a safety belt to protect

yourself from a fall should you get a shock.

3.j. Also see Items 6.c. and 8.

5.e. Also see item 1.b.

Mar ‘95

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SAFETY

WELDING SPARKS can

cause fire or explosion.

CYLINDER may explode

if damaged.

6.a. Remove fire hazards from the welding area.

If this is not possible, cover them to prevent

7.a. Use only compressed gas cylinders

containing the correct shielding gas for the

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.

process used and properly operating

regulators designed for the gas and

pressure used. All hoses, fittings, etc. should be suitable for

the application and maintained in good condition.

7.b. Always keep cylinders in an upright position securely

chained to an undercarriage or fixed support.

6.b. Where compressed gases are to be used at the job site,

special precautions should be used to prevent hazardous

situations. Refer to “Safety in Welding and Cutting” (ANSI

Standard Z49.1) and the operating information for the

equipment being used.

7.c. Cylinders should be located:

•Away from areas where they may be struck or subjected to

physical damage.

6.c. When not welding, make certain no part of the electrode

circuit is touching the work or ground. Accidental contact

can cause overheating and create a fire hazard.

•A safe distance from arc welding or cutting operations and

any other source of heat, sparks, or flame.

7.d. Never allow the electrode, electrode holder or any other

6.d. Do not heat, cut or weld tanks, drums or containers until the

proper steps have been taken to insure that such procedures

will not cause flammable or toxic vapors from substances

inside. They can cause an explosion even though they have

been “cleaned”. For information, purchase “Recommended

Safe Practices for the Preparation for Welding and Cutting of

Containers and Piping That Have Held Hazardous

Substances”, AWS F4.1 from the American Welding Society

(see address above).

electrically “hot” parts to touch a cylinder.

7.e. Keep your head and face away from the cylinder valve outlet

when opening the cylinder valve.

7.f. Valve protection caps should always be in place and hand

tight except when the cylinder is in use or connected for

use.

7.g. Read and follow the instructions on compressed gas

cylinders, associated equipment, and CGA publication P-l,

“Precautions for Safe Handling of Compressed Gases in

Cylinders,” available from the Compressed Gas Association

1235 Jefferson Davis Highway, Arlington, VA 22202.

6.e. Vent hollow castings or containers before heating, cutting or

welding. They may explode.

6.f. Sparks and spatter are thrown from the welding arc. Wear oil

free protective garments such as leather gloves, heavy shirt,

cuffless trousers, high shoes and a cap over your hair. Wear

ear plugs when welding out of position or in confined places.

Always wear safety glasses with side shields when in a

welding area.

FOR ELECTRICALLY

powered equipment.

6.g. Connect the work cable to the work as close to the welding

area as practical. Work cables connected to the building

framework or other locations away from the welding area

increase the possibility of the welding current passing

through lifting chains, crane cables or other alternate cir-

cuits. This can create fire hazards or overheat lifting chains

or cables until they fail.

8.a. Turn off input power using the disconnect

switch at the fuse box before working on

the equipment.

8.b. Install equipment in accordance with the National

Electrical Code, all local codes and the manufacturer’s

recommendations.

6.h. Also see item 1.c.

8.c. Ground the equipment in accordance with the National

Electrical Code and the manufacturer’s recommendations.

Mar ‘95

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SAFETY

The size of the surrounding area to be considered will depend on

the structure of the building and other activities that are taking

place. The surrounding area may extend beyond the boundaries of

the premises.

INSTRUCTIONS FOR ELECTRO-

MAGNETIC COMPATIBILITY

Conformance

Methods of Reducing Emissions

Products displaying the C-Tick mark are in conformity with

Australian/New Zealand requirements for Electromagnetic

Compatibility (EMC) according to standard (emission) AS/NZS

3652 "Electromagnetic Compatibility – Arc Welding

Equipment".

Mains Supply

Welding equipment should be connected to the mains supply

according to the manufacturer’s recommendations.If interference

occurs, it may be necessary to take additional precautions such as

filtering the mains supply. Consideration should be given to shield-

ing the supply cable of permanently installed welding equipment in

metallic conduit or equivalent. Shielding should be electrically con-

tinuous throughout its length. The shielding should be connected to

the welding power source so that good electrical contact is main-

tained between the conduit and the welding power source enclo-

sure.

Products displaying the CE mark are in conformity with

European Community Council Directive 89/336/EEC require-

ments for EMC by implementing EN50199 "Electromagnetic

Compatibility (EMC) – Product standard for arc welding equip-

ment".

Products are:

• For use with other Lincoln Electric/LiquidArc equipment.

• Designed for industrial and professional use.

Maintenance of the Welding Equipment

Introduction

The welding equipment should be routinely maintained according

to the manufacturer’s recommendations. All access and service

doors and covers should be closed and properly fastened when the

welding equipment is in operation. The welding equipment should

not be modified in any way except for those changes and adjust-

ment covered in the manufacturer’s instructions. In particular, the

spark gaps of arc initiation and stabilizing devices should be adjust-

ed and maintained according to the manufacturer’s recommenda-

tions.

All electrical equipment generates small amounts of electromagnet-

ic emission. Electrical emission may be transmitted through power

lines or radiated through space, similar to a radio transmitter. When

emissions are received by other equipment, electrical interference

may result. Electrical emissions may effect many kinds of electrical

equipment: other nearby welding equipment, radio and TV trans-

mitters and receivers, numerical controlled machines, telephone

systems, computers, etc. Be aware that interference may result

and extra precautions may be required when a welding power

source is used in a domestic establishment.

Welding Cables

The welding cables should be kept as short as possible and should

be positioned close together, running at or close to the floor level.

Installation and Use

The purchaser/user is responsible for installing and using the weld-

ing equipment according to the manufacturer’s instructions. If elec-

tromagnetic disturbances are detected then it shall be the responsi-

bility of the purchaser/user of the welding equipment to resolve the

situation with the technical assistance of the manufacturer. In some

cases this remedial action may be as simple as earthing (ground-

ing) the welding circuit (see note below). In other cases it could

involve constructing an electromagnetic screen enclosing the

power source and the work complete with associated input filters.

In all cases electromagnetic disturbances must be reduced to the

point where they are no longer troublesome.

Equipotential Bonding

Bonding of all metallic components in the welding installation and

adjacent to it should be considered. However, metallic components

bonded to the work piece will increase the risk that the operator

could receive a shock by touching these metallic components and

the electrode at the same time. The operator should be insulated

from all such bonded metallic components.

Earthing of the workpiece

Where the workpiece is not bonded to earth for electrical safety,

nor connected to earth because of its size and position, eg. ship’s

hull or building steelwork, a connection bonding the workpiece to

earth may reduce emissions in some, but not all instances. Care

should be taken to prevent the earthing of work pieces increasing

the risk of injury to users, or damage to other electrical equipment.

Where necessary, the connection of the workpiece to earth should

be made by direct connection to the workpiece, but in some coun-

tries where direct connection is not permitted, the bonding should

be achieved by suitable capacitance, selected according to national

regulations.

Note: The welding circuit may or may not be earthed for safety rea-

sons according to national codes. Changing the earthing arrange-

ments should only be authorized by a person who is competent to

assess whether the changes increase the risk of injury, eg. by

allowing parallel welding current return paths which may damage

the earth circuits of other equipment.

Assessment of Area

Before installing welding equipment the purchaser/user shall make

an assessment of potential problems in the surrounding area.

Screening and Shielding

The following shall be taken into account:

Selective screening and shielding of other cables and equipment in

the surrounding area may alleviate problems of interference.

Screening of the entire welding installation may be considered for

special applications.

• Other supply cables, control cables, signalling and telephone

cables above, below and adjacent to the welding equipment;

• Radio and television transmitters and receivers;

Portions of the preceding text are extracted from:

• Computer and other control equipment;

• Australian/New Zealand standard AS/NZS 3652. Permission to

reproduce has been granted by Standards Australia and

Standards New Zealand. For further explanation, readers should

be referred to the standard itself.

• Safety critical safety equipment, eg. guarding of industrial

equipment;

• The health of people around, eg. the use of pacemakers and

• British Standards Institution standard BS EN 50199:1995.

Reproduced with permission of BSI under license number

2000SK0631. Complete standards can be obtained from BSI

Customer Services, 389 Chiswick High Road, London W4 4AL.

United Kingdom. (Tel +44 (0) 20 8996 9001).

Standards New Zealand and British Standards Institution.

Permission to reproduce the text must be obtained.

hearing aids;

• Equipment used for calibration or measurement;

• The immunity of other equipment in the environment. The

purchaser/user shall ensure that other equipment being used

in the environment is compatible. This may require additional

protection measures;

• The time of the day that welding or other activities are to be

carried out.

JAN ‘01

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for selecting a QUALITY product. We want you to take pride in

operating this LiquidArc product ••• as much pride as we have in

bringing this product to you!

Thank You

Please Examine Carton and Equipment For Damage Immediately

When this equipment is shipped, title passes to the purchaser upon receipt by the carrier. Consequently, Claims

for material damaged in shipment must be made by the purchaser against the transportation company at the

time the shipment is received.

Please record your equipment identification information below for future reference. This information can be

found on your machine nameplate.

Model Name & Number _____________________________________

Code & Serial Number _____________________________________

Date of Purchase _____________________________________

Whenever you request replacement parts for or information on this equipment always supply the information

you have recorded above.

Read this Operators Manual completely before attempting to use this equipment. Save this manual and keep it

handy for quick reference. Pay particular attention to the safety instructions we have provided for your protection.

The level of seriousness to be applied to each is explained below:

WARNING

This statement appears where the information must be followed exactly to avoid serious personal injury or

loss of life.

CAUTION

This statement appears where the information must be followed to avoid minor personal injury or damage to

this equipment.

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vii

TABLE OF CONTENTS

Page

Installation .......................................................................................................Section A

Technical Specifications ........................................................................................A-1

Identify and Locate Components...........................................................................A-2

Select Suitable Location ........................................................................................A-3

Stacking ..........................................................................................................A-3

Tilting...............................................................................................................A-3

Output Connections...............................................................................................A-3

Work Clamp Installation ..................................................................................A-3

Work Cable Installation ...................................................................................A-4

Gun Installation......................................................................................................A-4

Connecting Gun Cable to the Handymig 170i.................................................A-4

Gas Connection.....................................................................................................A-4

Input Connections..................................................................................................A-5

Electrical Input Connection for Rated Output ........................................................A-6

Line Cord Connection .....................................................................................A-6

Operation .........................................................................................................Section B

Safety Precautions ................................................................................................B-1

General Description...............................................................................................B-1

Recommended Processess ............................................................................B-1

Optional Features and Controls ......................................................................B-1

Design Features and Advantages .........................................................................B-1

Welding Capability.................................................................................................B-2

Limitations..............................................................................................................B-2

Controls and Settings ............................................................................................B-2

Welding Operations ...............................................................................................B-3

Sequence of Operations .................................................................................B-3

Wire Loading..............................................................................................B-3

Friction Brake Adjustments ........................................................................B-3

Wire Threading...........................................................................................B-4

Making a Weld ...........................................................................................B-5

Cleaning Tip and Nozzle............................................................................B-5

Process Guidelines................................................................................................B-5

Changing Over to Feed Other Wire Sizes .............................................................B-6

Welding with GMAW..............................................................................................B-6

Welding with FCAW...............................................................................................B-6

Learning to Weld .......................................................................................................B-7

Overload Protection...............................................................................................B-7

Output Overload..............................................................................................B-7

Thermal Protection..........................................................................................B-7

Electronic Wire Drive Motor Protection ...........................................................B-7

Learning to Weld....................................................................................................B-7

The Arc-Welding Circuit ..................................................................................B-7

The Self-Shielded FCAW Welding Arc............................................................B-8

The GMAW (MIG) Welding Arc.......................................................................B-8

Process Selection ...........................................................................................B-9

For GMAW (MIG) Process.........................................................................B-9

For FCAW (Innershield) Process ...............................................................B-9

Common Metals..............................................................................................B-9

Joints Types and Positions .............................................................................B-9

Butt Welds..................................................................................................B-9

Penetration...............................................................................................B-10

Fillet Welds...............................................................................................B-10

Handymig 170i

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viii

TABLE OF CONTENTS

Page

Learning to Weld (Continues)......................................................................................------

Welding in a Vertical Position........................................................................B-10

Vertical-up and Overhead Welding .........................................................B-10

Vertical-down Welding ............................................................................B-11

Machine Set Up for the Self-Shielded FCAW Process .................................B-11

Welding Techniques for the Self-Shielded FCAW Process ..........................B-11

The Correct Welding Position .................................................................B-11

The Correct Way to Strick an Arc............................................................B-12

The Correct Electrical Stick Out..............................................................B-12

The Correct Welding Speed....................................................................B-12

Helpful Hints..................................................................................................B-13

Practice .........................................................................................................B-13

Machine Set Up for the GMAW (MIG) Process.............................................B-14

Welding Techniques for the GMAW (MIG) Process......................................B-14

The Correct Welding Position .................................................................B-14

The Correct Way to Strick an Arc............................................................B-14

The Correct Electrical Stick Out..............................................................B-15

The Correct Welding Speed....................................................................B-15

Helpful Hints..................................................................................................B-15

Practice .........................................................................................................B-15

Troblreshooting Welds ..................................................................................B-16

To Eliminate Porosity .............................................................................B-16

To Eliminate a Ropy Convex Bead ........................................................B-16

To Reduce Spatter.................................................................................B-16

To Correct Poor Penetration ..................................................................B-16

If Arc Blow Occurs..................................................................................B-16

To Eliminate Stubbing............................................................................B-16

Proper Gun Handling .............................................................................B-17

Application Chart .....................................................................................................B-18

Maintenance ....................................................................................................Section D

Safety Precautions ................................................................................................D-1

Routine Maintenance.............................................................................................D-1

Wire Feed Compartment.................................................................................D-1

Fan Motor........................................................................................................D-1

Wire Reel Spindle ...........................................................................................D-1

Gun and Cable................................................................................................D-1

Gun Cable Cleaning................................................................................D-1

Contact Tips, Nozzles, and Gun Tubes ..................................................D-1

Component Replacement Procedures ..................................................................D-2

Changing the Contact Tip ...............................................................................D-2

Changing Drive Roll........................................................................................D-2

Changing Liner................................................................................................D-3

Gun Handle Parts ...........................................................................................D-3

Ground Test Procedure.........................................................................................D-4

Troubleshooting..............................................................................................Section E

Safety Precautions.................................................................................................E-1

How to Use Troubleshooting Guide.......................................................................E-1

Troubleshooting Guide.............................................................................E-2 thru E-4

Wiring Diagrams..............................................................................................Section F

Handymig 170i Wiring Diagram .............................................................................F-1

Handymig 170i Parts ............................................................................P390,P202,P189

Handymig 170i

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A-1

INSTALLATION

TECHNICAL SPECIFICATIONS – Handymig 170i

INPUT – SINGLE PHASE ONLY

Standard Voltage/Frequency

AS1966.1

240V/50Hz

Rated Input Current

12.7 Amps

RATED OUTPUT

Duty Cycle

Amps

Volts at Rated Amperes

20%

130

OUTPUT

Welding Current Range

Maximum Open Circuit Voltage

Auxiliary Power

Rated DC Output: 30 – 170 amps

N/A

RECOMMENDED INPUT CABLE AND FUSE SIZES

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

PHYSICAL DIMENSIONS

Height

305 mm

Width

248 mm

Depth

419 mm

Weight

25.9 kg

Handymig 170i

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A-2

INSTALLATION

FIGURE A.1

SAFETY PRECAUTIONS

• Read entire installation section before starting

installation.

WARNING

ELECTRIC SHOCK can kill.

• Only qualified personnel should perform

this installation.

• Only personnel that have read and under-

stood the Handymig 170i 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 Handymig 170i power switch is to be

in the OFF (“O”) position when installing

work cable and gun and when connecting

power cord to input power.

IDENTIFY AND LOCATE

COMPONENTS

If you have not already done so, unpack the

Handymig 170i from its carton and remove all packing

material around the Handymig 170i. Remove the fol-

lowing loose items from the carton (see Figure A.1):

1. Handymig 170i

2. Gun and cable assembly⁽¹⁾

3. Literature and miscellaneous includes:

a) This operating manual

b) A separate .030" (0.8 mm) contact tip

c) Hex key wrench for removal of drive roll.

4. 10 ft (3,0 m) work cable.

5. Work clamp.

6. Adjustable mixed-Gas Regulator & Hose.

⁽¹⁾The gun is ready to feed .023" – .025" (0.6 mm)

diameter wire.

Handymig 170i

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A-3

INSTALLATION

6. Wire Feed Gearbox.

SELECT SUITABLE LOCATION

7. Cable Hanger.

8. Thumbscrew.

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.

Work Clamp Installation

STACKING

Attach the work clamp per the following: Refer to

Figure A-3.

Handymig 170i’s cannot be stacked.

TILTING

Each machine must be placed on a secure, level sur-

face, either directly or on the recommended cart. The

machine may topple over if this procedure is not fol-

lowed.

OUTPUT CONNECTIONS

Refer to Figure A.2.

FIGURE A.3

1. Insert the work cable terminal lug with the larger

hole through the strain relief hole in the work clamp

as shown above.

1. Work Cable Access Hole.

2. Gun Cable and Control Lead Access Hole.

3. Connector Block.

2. Fasten securely with the bolt and nut provided.

4. Gun Trigger Lead Connectors.

5. Positive (+) and negative (–) output terminals.

FIGURE A.2

WELDING AMP RANGE

30-70

Handymig 170i

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A-4

INSTALLATION

Work Cable Installation

NOTE: If .035" or .045" (0.9 mm or 1.2 mm)

Innershield flux-cored wire is to be used, the appropri-

ate Innershield kit is required.

Refer to Figure A.2.

1. Open the wire feed section door on the right side of

the Handymig 170i.

Connecting Gun Cable to the Handymig

170i.

2. Pass the end of the work cable that has the termi-

nal lug with the smaller hole through the Work

Cable Access Hole (1) in the case front.

1. Refer to Figure A.2. Unplug the machine or turn

power switch to the OFF “O” position.

3. Route the cable under and around the back of the

Wire Feed Gearbox (6).

2. Pass the insulated terminals of the gun trigger con-

trol leads, one at a time, through the Gun Cable

and Control Lead Access Slot (2) in the case front.

The leads are to be routed up the inside of the

case front, behind the gas line.

4. For GMAW Only: Refer to Figure A.2. As deliv-

ered, the machine is connected for positive elec-

trode polarity. This is the appropriate configuration

for the GMAW (MIG) process. To complete installa-

tion, use the provided wing nut to connect the work

cable’s terminal lug to the negative (–) output ter-

minal (5) located above the Wire Feed Gearbox

(6). Make sure that both wing nuts are tight.

3. Insert the connector on the gun conductor cable

through the Gun Cable Access Hole (2) in the

Handymig 170i case front. Make sure the connec-

tor is all the way in the brass connector block to

obtain proper gas flow. If the gun connector will not

fully insert, unscrew the thumbscrew on the con-

nector block a few turns. Rotate the connector so

control leads are on the underside and tighten the

Thumbscrew on the connector block.

5. For Innershield Only: Refer to Figure A.4. To wire

for negative polarity (required for the Innershield

process), connect the short cable attached to the

connector block (1) to the negative (–) output termi-

nal (2) and the work cable (3) to the positive (+) ter-

minal (4).

4. Connect the gun trigger control lead terminals to

the two insulated 1/4" (6,4 mm) tab terminal con-

nector bushings located above the “Gun Trigger

Connection” decal in the wire feed section (4).

Either lead can go to either connector.

FIGURE A.4

CAUTION

If the gun trigger switch being used is other than

that supplied, the switch must be a normally open,

momentary switch. The terminals of the switch

must be insulated from the welding circuit.

Malfunction of the Handymig 170i may result if

this switch shorts to the Handymig 170i welding

output circuit or is common to any electrical cir-

cuit other than the Handymig 170i trigger circuit.

GAS CONNECTION

The Handymig 170i is supplied with a mixed gas

Regulator and a 3m gas hose. A cylinder of an appro-

priate shielding gas must be obtained from your gas

distributor.

GUN INSTALLATION

As shipped from the factory, the Handymig 170i gun is

ready to feed .023" – .025"(.6mm) solid wire. If .030"

(0.8 mm) solid wire is to be used, change the contact

tip to the appropriate size.

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A-5

INSTALLATION

WARNING

BE SURE TO KEEP YOUR FACE AWAY FROM THE

VALVE OUTLET WHEN “CRACKING” THE VALVE.

Never stand directly in front of or behind the flow

regulator when opening the cylinder valve. Always

stand to one side.

CYLINDER may explode if dam-

aged. Keep cylinder upright and

chained to support

• Keep cylinder away from areas

where it may be damaged.

3. Attach the flow regulator to the cylinder valve and

tighten the union nut securely with a wrench..

• Never lift welder with cylinder

attached.

• Never allow welding electrode to

touch cylinder.

• Keep cylinder away from welding

4. Refer to Figure A.6. Attach one end of inlet gas

hose to the outlet fitting of the flow regulator and

tighten the union nut securely with a wrench.

Connect the other end to the Handymig 170i Gas

Solenoid Inlet Fitting (5/8-18 female threads — for

CGA — 032 fitting). Make certain the gas hose is

not kinked or twisted.

or other live electrical circuits.

WARNING

BUILDUP OF SHIELDING GAS may

harm health or kill.

5. Reinstall case side before connecting input power.

• Shut off shielding gas supply

when not in use.

INPUT CONNECTIONS

FIGURE A.6

1. Chain the cylinder to a wall or other stationary sup-

port to prevent the cylinder from falling over.

Insulate the cylinder from the work circuit and earth

ground. Refer to Figure A.5.

FIGURE A.5

Cylinder Valve

Flow Regulator

Gas Hose

GAS SOLENOID

INLET FITTING

POWER INPUT

CABLE

Refer to Figure A.6.

2. With the cylinder securely installed, remove the

cylinder cap. Stand to one side away from the out-

let 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.

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A-6

INSTALLATION

ELECTRICAL INPUT CONNECTION

FOR RATED OUTPUT

WARNING

ELECTRIC SHOCK can kill.

• Disconnect input power by

removing plug from receptacle

before working inside Handymig

170i.

• Use only grounded receptacle.

• Do not touch electrically “hot”

parts inside Handymig 170i.

• Have qualified personnel do the

maintenance and troubleshooting

work.

Line Cord Connection

A three conductor line cord with a 15 amp, 240 volt,

three pin plug is factory installed. Connect this plug to

a mating grounded receptacle which is connected to

an appropriate power supply per the Wiring Rules and

any applicable local codes.

WARNING

• This welding machine must be connected to a

power source in accordance with applicable

electrical codes.

• If there is any question about the installation

meeting applicable electrical code requirements,

consult a qualified electrician.

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B-1

OPERATION

SAFETY PRECAUTIONS

GENERAL DESCRIPTION

The Handymig 170i is a complete semiautomatic con-

stant voltage DC portable arc welder. Included is a

tap-switch controlled, single phase constant voltage

transformer/rectifier power source and a wire feeder

with welding gun for feeding .023" (0.6 mm) through

.030" (0.8 mm) solid steel electrode. Optional kits are

available for .035" (0.9 mm) and .045" (1.2 mm)

Innershield^®NR-211-MP.

WARNING

ELECTRIC SHOCK can kill.

• Do not touch electrically live

parts or electrode with skin or

wet clothing. Insulate yourself

from work and ground.

It is ideally suited for individuals having access to 240

volts 50 Hz AC input power and want the ease of use,

quality and dependability of both gas metal arc weld-

ing or GMAW (also known as MIG welding) and the

Innershield^®process (self-shielded flux-cored or

FCAW). A convenient chart is mounted inside the wire

feed section door for setting welding procedures for 24

gauge (.60 mm) through 5/16" (8.0 mm) mild steel.

The machine is rugged and reliable and has designed

for dependable service and long life.

• Always wear dry insulating

gloves.

FUMES AND GASES can be

dangerous.

• Keep your head out of fumes.

• Use ventilation or exhaust to

remove fumes from breathing

zone.

RECOMMENDED PROCESSES

The Handymig 170i can be used for welding mild steel

using the GMAW, single pass, process which requires

a supply of shielding gas or it can be used with the

self-shielded, Innershield^®process (FCAW).

WELDING SPARKS can

cause fire or explosion.

• Keep flammable material away.

• Do not weld on closed contain-

ers.

OPERATIONAL FEATURES AND

CONTROLS

The Handymig 170i has the following controls as stan-

dard: Power ON/OFF Switch, Voltage Control, Wire

Speed Control, Trigger Switch, and a Circuit Breaker.

ARC RAYS can burn eyes

and skin.

DESIGN FEATURES AND

ADVANTAGES

• Wear eye, ear and body protec-

tion.

• “Cold electrode” until gun trigger is pressed for an

added measure of safety.

* Overload protection — incorporates both a thermo-

stat and a circuit breaker.

• Quality wire drive with electronic overload protection.

• “Quick Release” idle roll pressure arm is easily

adjusted.

See additional warning information at

front of this opeerator’s manual.

• Reversible, dual groove drive roll, shipped ready to

feed .023"/.025" (0.6 mm) diameter wire. The drive

roll is easily reversed to feed .030" (0.8 mm) diame-

ter solid wire and .035" (0.9 mm) flux-cored diameter

wire. Optional drive roll included in .045" (1.2 mm)

Innershield^®welding kit must be installed to feed

.045" (1.2 mm) flux-cored wire.

• No external shielding gas is required when used with

Liquid Arc steelcore 71T-GS electrode.

• Spindle accommodates both 8 in. (200 mm) diameter

and 4 in. (100 mm) diameter spools of wire.

Handymig 170i

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B-2

OPERATION

WELDING CAPABILITY

The Handymig 170i is rated at 130 amps, 20 volts, at

20% duty cycle on a ten minute basis. It is capable of

higher output currents at lower duty cycles. .

FIGURE B.1a

LIMITATIONS

Arc Gouging cannot be performed with the Handymig

170i. The Handymig 170i is not recommended for pipe

thawing or TIG welding.

CONTROLS AND SETTINGS

Refer to Figure B.1a.

1. Power ON/OFF Switch —

When the power is on the

fan motor will run and air will

be exhausted out the louvers

in the front of the machine.

The welding output and wire

feeder remain off until the

gun trigger is pressed.

2. Wire Speed Control —

OFF

Controls the wire feed speed

from 50 – 400 in/min (1.2 –

10.2 m/min). The control can

be preset on the dial to the

setting specified on the

FIGURE B.1b

Handymig 170i Application

Chart located on the inside

of the wire feed section door.

WIRE SPEED

3. Voltage Control — A 5-posi-

tion tap selector switch gives

full range adjustment of

ARC VOLTS

power source output voltage.

Do not switch while welding.

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.

Handymig 170i

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B-3

OPERATION

WELDING OPERATIONS

FIGURE B.3

SEQUENCE OF OPERATION

Wire Loading

Refer to Figure B.2 and B.3.

Wire Spindle Shaft

4" Wire Spool

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]. These spools fit on a 2” (50 mm) diameter

spindle that has a built-in adjustable friction brake to

prevent overrun of the spool and excess slack in the

wire.

Wing Nut

and Spacer

To wire drive

Note:When loading and removing the 8” Spools make

sure that the wing nut (inside the wire spool spindle

hub) is turned 90° from the wire spool spindle locking

tab. If the wing nut is positioned in line with the locking

tab, the tab cannot be depressed to load or unload

the wire spool.

Note: The brake should be adjusted with a spool of

wire installed. When properly adjusted it should

move freely but not coast.

CAUTION

FIGURE B.2

Some spools can have the start wire protruding

from the side of the spool. This must be insulated

from internal metal components otherwise electri-

cal grounding faults will result and the machine

will be seriously damaged.

8” Wire Spool

Wire Spool Spindle

Friction Brake Adjustments

1. With wire spool installed, check free movement

and coast of the spool.

Be sure that this stud engages

the hole in the wire spool.

2. To tighten the brake turn the wing nut clockwise in

1/4 turn increments until coasting stops.

To Wire Drive

3. To loosen the brake turn the wing nut counter-

clockwise in 1/4 turn increments until the wire spool

moves freely without coasting.

Wire Spool must be pushed all the way on the spindle so that the

spindle’s tab will hold it in place. The Wire Spool will rotate clock-

wise when wire is dereeled.

Load an 8” (200 mm) diameter spool on the wire spool

spindle shown in Figure B.2.

To use 4” (100 mm) diameter spools, the 2” (50 mm)

diameter spindle must be removed (See Figure B.3).

Remove the wing nut and spacer at the end of the

shaft and remove the outside plastic wire spool spin-

dle. The spindle can be stored in the wire feed com-

partment. A 4” (100 mm) diameter spool is mounted

directly on the 5/8” (16 mm) diameter shaft and held in

place with the previously removed hardware. Also

make certain the start end of the wire, which may pro-

trude through the side of the spool does not contact

any metallic case parts.

Handymig 170i

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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, main-

tain tension on the wire until after step 5.

The Wire Drive Feed Roll can

accommodate two wire sizes by

flipping the wire drive feed roll

over.

3. Cut the bent portion of wire off and straighten the

frist 4” (100 mm).

4. Thread the wire through the ingoing guide tube

(4), over the drive roll (3), and into the outgoing

guide tube (5).

8. Turn the Handymig 170i ON (“I”).

5. Close the idle roll arm and latch the spring loaded

pressure arm (2) in place. Rotate the spool coun-

terclockwise if required to take up extra slack in

the wire.

9. Straighten the gun cable assembly.

6. The idle roll pressure adjustment wing nut is nor-

mally set for mid-position on the pressure arm

threads. If feeding problems occur because the

wire is flattened excessively, turn the pressure

adjustment counter-clockwise to reduce distortion

of the wire. Slightly less pressure may be required

when using 0.023 – 0.025” (0,6 mm) wire. If the

6. drive roll slips while feeding wire, the pressure

should be increased until the wire feeds properly.

10. Depress the gun trigger switch and feed welding

wire through the gun and cable. (Point gun away

from yourself and others while feeding wire.)

Release gun trigger after wire appears at end of

gun.

11. Turn the Handymig 170i OFF (“O”).

WARNING

When inching the welding wire, the drive rolls, the

gun connector block and the gun contact tip are

electrically energized relative to work and ground

and remain energized for several seconds after

the gun trigger is released.

FIGURE B.5

Gun Handle

7. Refer to Figure B.5. Remove gas nozzle and con-

tact tip from end of gun.

Gas Diffuser/

Contact Tip

Gas Nozzle

12. Replace contact tip and gas nozzle.

13. Refer to Figure B-6. Cut the wire off 1/4” – 3/8” (6

– 10 mm) from the end of the tip. The Handymig

170i is now ready to weld.

Handymig 170i

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B-5

OPERATION

FIGURE B.7

FIGURE B.6

Contact Tip

GUN CABLE

Wire Electrode

3/8" – 1/2" Electrical Stickout

(10-12 mm)

WORKPIECE

ARC

WORK CLAMP

Making A Weld

1. See “Process Guidelines” in this section for selec-

tion of welding wire and shielding gas and for

range of metal thicknesses that can be welded.

10. When no more welding is to be done, close valve

on gas cylinder (if used), momentarily operate gun

trigger to release gas pressure, and turn off the

Handymig 170i.

2. See the Application chart on the inside of the wire

feed compartment door for information on setting

the Handymig 170i controls. Refer to Table B.1 for

aluminum and stainless wire.

Cleaning Tip And Nozzle

Clean the contact tip and nozzle to avoid arc bridging

between the nozzle and contact tip which can result in

a shorted nozzle, poor welds and an overheated gun.

Hint: Anti-stick spray or gel, available from a welding

supply distributor, may reduce buildup and aid in spat-

ter removal.

3. Set the Voltage (“V”) and Wire Speed (“olo’”) con-

trols to the settings suggested for the welding wire

and base metal thickness being used, refer to

3. Applications chart on the inside of the wire drive

compartment door.

4. Check that the polarity is correct for the welding

wire being used and that the gas supply, if

required, is turned on.

PROCESS GUIDELINES

The Handymig 170i can be used for welding mild steel

using the GMAW, single pass, process which requires

a supply of shielding gas or it can be used for the self-

shielded, Innershield^®process (FCAW).

5. When using Innershield electrode, remove the gas

nozzle and install the gasless nozzle. This will

improve visibility of the arc and protect the gas dif-

fuser from weld spatter. Refer to the MAINTE-

NANCE section for details on nozzle replacement.

The recommended gases and electrodes for GMAW

are welding grade CO₂gas or an argon-CO₂blended

gas (75 to 80% argon and 25 to 20% CO₂) and .025"

(0.6 mm) diameter Liquid Arc S6 mild-steel welding

wire, supplied on 12-1/2 lb (5 kg) spools. The blended

gas is recommended for welding on heavier steel, 14

gauge (2.0 mm), for example.

6. Refer to Figure B.7. Connect work clamp to metal

to be welded. Work clamp must make good elec-

trical contact to the workpiece. The workpiece

must also be grounded as stated in “Arc Welding

Safety Precautions” in the beginning of this manu-

al.

The recommended electrode for the self-shielded

process is Liquid Arc steelcore 71T-GS on 10 lb (4.5

kg) spools. This electrode is available as .035" (0.9

mm) and .045" (1.2 mm) NR-211-MP for all position

welding of 18 gauge (1.2 mm) through 5/16" (8.0 mm)

steel. Thickness of 1/4" (6.4 mm) and 5/16" (7.9 mm)

require multiple passes. both wire sizes can also be

used for the welding of galvanized coated sheet

metal.

7. Position gun over joint. End of wire may be lightly

touching the work.

8. Lower welding helmet, close gun trigger, and

begin welding. Hold the gun so the contact tip to

work distance is about 3/8 inch (10 mm).

9. To stop welding, release the gun trigger and then

pull the gun away from the work after the arc goes

out.

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B-6

OPERATION

• Keep the cylinder valve closed, except when using

the Handymig 170i. When finished welding:

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 procedure

settings. (Requires K664-2 Aluminum - Stainless

Feeding Kit.)

• Close the cylinder valve to stop gas flow.

• Depress the gun trigger briefly to release the

pressure in the gas hose.

• Turn off the Handymig 170i.

CAUTION

WELDING WITH FCAW (Innershield)

It is important when changing between welding

with steel wire and aluminum to exchange feeding

components due to the lubricant applied to steel

wire. Failure to do so may result in contaminated

welds when welding aluminum.

------------------------------------------------------------------------

TABLE B.1 — Handymig 170i

When using the FCAW process, the correct drive roll

and electrode polarity must be used. See Work Cable

Installation in INSTALLATION section for changing the

polarity.

Use optional Innershield welding kit K549-1 (for 0.9

mm) or K549-2 (for 1.2 mm), as appropriate.

Voltage/Wire Speed

Shielding

Gas

• K549-1 0.9mm (.035”) Innershield® Welding Kit—

Includes a contact tip, a gasless nozzle and a 0.9-

1.2mm cable liner to permit the Magnum™ 100L gun

and cable to use 0.9mm diameter flux-cored elec-

trode. The fitting on the end of the liner is stencilled

with the maximum rated wiresize (.045”/1.2mm). Also

included is a spool of 0.9mm Innershield® NR-211-MP.

Process

Welding Wire

16 ga 14 ga 12 ga 10 ga 3/16

D-8.5 E-10

MIG DC+ .035 Dia

4043/5356

Aluminum Wire

MIG DC+ .023 Dia

308L Stainless

100% Argon A-5 B6.5 C-8

98% Argon/ A-4 B-6

2% Oxygen

C-8

—

Steel Wire

MIG DC+ .030 Dia

98% Argon/ B-3.5 C-6.5 D-7

2% Oxygen

E-8 E-9

E-8 E-8

308L Stainless

Steel Wire

• K549-2 1.2mm (.045”) Innershield® Welding Kit—

Includes a contact tip, a gasless nozzle and a 0.9-

1.2mm cable liner to permit Magnum™ 100L gun

and cable to use 1.2mm diameter flux-cored elec-

trode. The fitting on the endof the liner is stencilled

with the maximum rated wire size (.045”/1.2mm).

Also included is a spool of 1.2mm Innershield® NR-

211-MP and a knurled drive roll.

MIG DC+ .035 Dia

98% Argon/ B-2.5 C-4

2% Oxygen

D-6

308L Stainless

Steel Wire

CHANGING MACHINE OVER TO

FEED OTHER WIRE SIZES

Several changes are needed to convert the unit for

operation with the Innershield (FCAW) process. The

K549-1 or K549-2 Innershield Kits include all the nec-

essary accessories for this conversion and are provid-

ed for this purpose. The following conversions should

be made using the contents of this kit:

The Handymig 170i is shipped from the factory ready

to feed 0.023” – .025" (0.6 mm) diameter wire. To

operate the Handymig 170i with other sizes of wire, it

is necessary to change the contact tip and change the

drive roll over to other sizes. Refer to Changing the

Contact Tip and Changing the Drive Roll, in the MAIN-

TENANCE section, for specific information on these

procedures.

• Change the output polarity to DC(-). See “Work

Cable Installation” in Installation Section for details.

WELDING WITH GMAW (MIG)

• Install proper drive roll for wire size selected. See

“Changing Drive Roll” in Maintenance Section for

details.

Shielding Gas

When using the GMAW process, install a gas regula-

tor and hose kit.

• Install the proper gun liner and tip for the wire size

selected. See “Component Replacement” in the

Maintenance Section for details.

• For CO₂, open the cylinder very slowly. For argon-

mixed gas, open cylinder valve slowly a fraction of

a turn. When the cylinder pressure gauge pointer

stops moving, open the valve fully.

• If using a regulator with an adjustable flow meter,

close the gun trigger and adjust the flow to give 15

– 20 cubic ft per hour (CFH) (7 – 10 I/min) [use 20

– 25 CFH (10 – 12 I/min) when welding out of posi-

tion or in a drafty location.

• Remove gas nozzle (if installed) and install gasless-

nozzle. To remove, simply unscrew.

• Load wire into machine and thread into gun and

cable per “Welding Wire Loading” section.

Handymig 170i

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B-7

LEARNING TO WELD

THE ARC-WELDING CIRCUIT

OVERLOAD PROTECTION

The operator’s knowledge of arc welding must go

beyond the arc itself. The operator must know how to

control the arc, and this requires a knowledge of the

welding circuit and the equipment that provides the

electric current used in the arc. Figure B.7 illustrates

the welding circuit for a typical welding machine. The

circuit begins where the gun cable is attached to the

welding machine. Current flows through the gun

cable, gun, and contact tip, to the wire and across the

arc. On the work side of the arc, current flows through

the base metal to the work cable and back to the

welding machine. This circuit must be complete for

the current to flow.

OUTPUT OVERLOAD

The Handymig 170i is equipped with a circuit breaker

which protects the machine from damage if a severe

overload occurs. The circuit breaker button will extend

out when tripped. The circuit breaker must be manual-

ly reset.

THERMAL PROTECTION

The Handymig 170i has a rated output duty cycle of

30%. If the duty cycle is exceeded, a thermal protec-

tor will shut off the output until the machine cools to a

reasonable operating temperature. This is an auto-

matic function of the Handymig 170i and does not

require user intervention. The fan continues to run

during cooling.

This machine’s welding circuit has a voltage output of

33 volts DC maximum. This voltage is quite low and is

only present when the gun triggers depressed.

To weld, the work clamp must be tightly connected to

clean base metal. Remove paint, rust, dirt or oil as

necessary and connect the work clamp as close as

possible to the area you wish to weld. This helps pre-

vent current from going through an unwanted path.

Avoid allowing the welding circuit to pass through

hinges, bearings, electronic components, or similar

devices that can be damaged. See Figure B.8. Always

disconnect electrical devices before welding upon

them.

ELECTRONIC WIRE DRIVE MOTOR

PROTECTION

The Handymig 170i has built-in protection for wire

drive motor overload.

LEARNING TO WELD

No one can learn to weld simply by reading about it.

Skill comes only with practice. The following pages

will help the inexperienced operator to understand

welding and develop this skill. For more detailed infor-

mation, order a copy of “New Lessons in Arc Welding”

listed at the end of this manual.

FIGURE B.8

Electronic Components

WARNING

Fumes and slag generated from

Innershield type electrodes recom-

mended for use with this welding

machine can be toxic.

• Avoid contact with eyes and skin.

• Do not take internally.

Hinges

Bearings

The gun and cable assembly is held by the operator

who guides the automatically fed wire along the joint,

maintaining a contact tip to work distance of about 3/8

to 1/2 inch (10 – 12 mm). This is called electrical

stickout. This electrical stickout (ESO) must be prop-

erly maintained by the operator. The electric arc is

made in the gap between the work and the tip end of

a small diameter wire. When the power source is

properly set, the arc gap is maintained automatically.

• Keep out of reach of children.

• Follow all safety precautions

found in this operating manual.

Arc welding is a manual skill requiring a steady hand,

good physical condition, and good eyesight. The

operator controls the welding arc, and, therefore, the

quality of the weld made.

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B-8

LEARNING TO WELD

After running a weld bead, the slag may be removed

with a chipping hammer and wire brush. This

improves appearance and allows for inspection of the

finished weld.

THE SELF-SHIELDED FCAW WELDING

ARC

Figure B.9 illustrates the action taking place in the self

shielded FCAW (Innershield) welding arc. It closely

resembles what is actually seen while welding.

Since machine size and output characteristics limit the

size and type of wire electrode which can be used,

Steelcore 71T-GS Innershield electrode is recom-

mended for Self-Shielded Flux Cored Arc Welding

with this machine.

FIGURE B.9

THE GMAW (MIG) WELDING ARC

Burning of core materials

Cored Wire

Protective Slag

inside wire electrode

results in shield of gas.

Figure B.10 illustrates the GMAW (MIG) welding arc.

Solid wire does not contain fluxes or ingredients to

form its own shielding and no slag forms to protect the

molten weld metal. For this reason, a continuous even

flow of shielding gas is needed to protect the molten

weld metal from atmospheric contaminants such as

oxygen and nitrogen. Shielding gas is supplied

through the gun and cable assembly, through the gas

nozzle and into the welding zone.

Arc Stream

Weld Metal

The “arc stream” is seen in the middle of the picture.

This is the electric arc created by the electric current

flowing through the space between the end of the wire

electrode and the base metal. The temperature of this

arc is about 6000°F, which is more than enough to

melt metal. The arc is very bright, as well as hot, and

cannot be looked at with the naked eye without risking

painful injury. The very dark lens, specifically

designed for arc welding must be used with the hand

or face shield whenever viewing the arc.

Gas nozzle

Solid wire

electrode

Shielding gas

The arc melts the base metal and actually digs into it

much as water through a nozzle on a garden hose

digs into the earth. The molten metal forms a molten

pool or crater and tends to flow away from the arc. As

it moves away from the arc, it cools and solidifies.

The function of the Innershield cored wire electrode is

much more than simply to carry current to the arc. The

wire core is composed of fluxes and/or alloying ingre-

dients around which a steel sheath has been formed.

It is simply a stick electrode turned inside out in a con-

tinuous wire form.

Weld metal

Base metal

FIGURE B.10

When comparing the GMAW and FCAW processes,

you can see that the principal difference between the

two lies in the type of shielding used. GMAW uses gas

for shielding, thus we have Gas Metal Arc Welding.

FCAW uses the melting or burning of the core ingredi-

ents for shielding, and is thus termed Self-Shielded

Flux Cored Arc Welding.

The cored wire melts in the arc and tiny droplets of

molten metal shoot across the arc into the molten

pool. The wire sheath provides additional filler metal

for the joint to fill the groove or gap between the two

pieces of base metal.

The recommended wire for Gas Metal Arc Welding

(MIG) is Steelmig S6. Steelmig S6 is capable of weld-

ing a wide range of mild steels in all positions, howev-

er, more skill is required for out-of-position welding

with the GMAW process.

The core materials also melt or burn in the arc and

perform several functions. They make the arc stead-

ier, provide a shield of smoke-like gas around the arc

to keep oxygen and nitrogen in the air away from the

molten metal, and provide a flux for the molten pool.

The flux picks up impurities and forms the protective

slag on top of the weld during cooling.

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B-9

LEARNING TO WELD

PROCESS SELECTION

JOINT TYPES AND POSITIONS

By gaining knowledge of the differences between the

two processes, you will be able to select the best

process for the job you have at hand. In selecting a

process, you should consider:

Five types of welding joints are: Butt Welds, Fillet

Welds, Lap Welds, Edge Welds and Corner Welds.

See Figure B.11.

Of these, the Butt Weld and Fillet Weld are the two

most common welds.

For GMAW (MIG) Process

1. Is most of my welding performed on 16 gauge and

lighter materials?

2. Can I afford the extra expense, space, and lack of

portability required for gas cylinders and gas sup-

ply?

Butt weld

Lap weld

3. Do I require clean, finished-looking welds?

If you have answered yes to all the above questions

GMAW may be the process for you. If you have

answered no to any of the above questions, then you

should consider using the FCAW process.

Edge weld

Fillet weld

Corner weld

For FCAW (Innershield) Process

1. Do I want simplicity and portability?

FIGURE B.11

2. Will welding be performed outdoors or under windy

conditions?

Butt Welds

Place two plates side by side, leaving a space approx-

imately one half the thickness of the metal between

them in order to get deeper penetration.

3. Do I require good all position welding capability?

4. Will most welding be performed on 16 gauge and

heavier, somewhat rusty or dirty materials?

Securely clamp or tack weld the plates at both ends,

otherwise the heat will cause the plates to move apart.

See Figure B.12.

5. Weld must be cleaned prior to painting.

COMMON METALS

Now weld the two plates together. Weld from left to

right (if right handed). Point the wire electrode down in

the crack between the two plates, keeping the gun

slightly tilted in the direction of travel. Watch the

molten metal to be sure it distributes itself evenly on

both edges and in between the plates. This is refered

to as the “pull technique”. On thin gauge sheet metal,

use the “push technique”. See “Welding Techniques

for GMAW (MIG) Process”.

Most metals found around the farm, small shop or

home are low carbon steel, sometimes referred to as

mild steel. Typical items made with this type of steel

include most sheet metal, plate, pipe and rolled

shapes such as channels and angle irons. This type of

steel can usually be easily welded without special pre-

cautions. Some steels, however, contain higher car-

bon levels or other alloys and are more difficult to

weld. Basically, if a magnet sticks to the metal and

you can easily cut the metal with a file, chances are

good that the metal is mild steel and that you will be

able to weld the material. In addition, aluminum and

stainless steel can be welded using the K664-1

Aluminum Welding Kit. For further information on

identifying various types of steels and other metals,

and for proper procedures for welding them, we again

suggest you purchase a copy of “New Lessons in Arc

Welding”.

Regardless of the type of metal being welded, in order

to get a quality weld, it is important that the metal is

free of oil, paint, rust or other contaminants.

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B-10

LEARNING TO WELD

45°

FIGURE B.12

FIGURE B.15

Penetration

Welding In The Vertical Position

Unless a weld penetrates close to 100% of the metal

thickness, a butt weld will be weaker than the material

welded together. In the example shown in Figure

B.13, the total weld is only half the thickness of the

material thus the weld is only approximately half as

strong as the metal.

Welding in the vertical position can be done either ver-

tical-up or vertical-down. Vertical-up is used whenever

a larger, stronger weld is desired. Vertical-down is

used primarily on sheet metal 5/32” (3.9 mm) and

under for fast, low penetrating welds.

WARNING

Use of this unit on thicker materials than recom-

mended may result in poor welds. The welds may

“look” good, but may just be “sitting” on top, of

the plate. This is called “Cold Casting” and will

result in weld failure.

FIGURE B.13

Vertical-up And Overhead Welding

The problem, when welding vertical-up, is to put the

molten metal where it is wanted and make it stay

there. If too much molten metal is deposited, gravity

will pull it downwards and make it “drip”. Therefore, a

certain technique has to be followed.

When welding out-of-position, run stringer beads.

Don’t whip, break the arc, move out of the puddle, or

move too fast in any direction. Use Wire Feed Speed

(WFS) in the low portion of the range. The general

technique and proper gun angle is illustrated in Figure

B.16.

FIGURE B.14

In the example shown in Figure B.14, the joint has

been welded so that 100% penetration could be

achieved. The weld, if properly made, is as strong as

or stronger than the original metal.

Generally, keep the electrode nearly perpendicular to

the joint as illustrated. The maximum angle above per-

pendicular may be required if porosity becomes a

problem.

Fillet Welds

When welding fillet welds, it is very important to hold

the wire electrode at a 45° angle between the two

sides or the metal will not distribute itself evenly. The

gun nozzle is generally formed at an angle to facilitate

this. See Figure B.15.

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B-11

LEARNING TO WELD

MACHINE SET UP FOR THE

SELF-SHIELDED FCAW PROCESS

• See PROCESS GUIDELINES in the OPERATION

section for selection of welding wire and shielding

gas, and for range of metal thicknesses that can be

welded.

• See the Application Guide on the inside of wire

feed section door for information on setting the

controls.

PROPER GUN ANGLE

FOR GMAW PROCESS

FOR FCAW PROCESS

WELDING IN THE VERTICAL UP POSITION

• Set the “Voltage” and “Wire Speed” controls to the

settings suggested on the Application Guide for the

welding wire and base metal thickness being used.

The voltage control is marked “V” and the wire feed

speed is marked ‘’olo.’’

FIGURE B.16

Vertical-down Welding

Refer to Figure B.17 Vertical-down welds are applied

at a fast pace. These welds are therefore shallow and

narrow and, as such, are excellent for sheet metal.

Vertical-down welds may be applied to 5/32” (3.9 mm)

and lighter material.

• Check that the polarity is correct for the welding

wire being used. Set the polarity for DC(–) when

welding with Steelcore 71T-GS Innershield elec-

trode. See Work Cable Installation in the INSTALLA-

TION section for instructions on changing polarity.

Use stringer beads and tip the gun in the direction of

travel so the arc force helps hold the molten metal in

the joint. Move as fast as possible consistent with

desired bead shape.

• When using Innershield electrode, the gasless noz-

zle may be used instead of a gas nozzle to improve

visibility of the arc.

The important thing is to continue lowering the entire

arm as the weld is made so the angle of the gun does

not change. Move the electrode wire fast enough that

the slag does not catch up with the arc. Vertical-down

welding gives thin, shallow welds. It should not be

used on heavy material where large welds are

required.

• Connect work clamp to metal to be welded. Work

clamp must make good electrical contact to the

work piece. The work piece must also be grounded

as stated in the “Arc Welding Safety Precautions”

at the beginning of this manual.

WELDING TECHNIQUES FOR THE SELF-

SHIELDED FCAW PROCESS

Four simple manipulations are of prime importance

when welding. With complete mastery of the four,

welding will be easy. They are as follows:

• The Correct Welding Position

Figure B.11 illustrates the correct welding position

for right handed people. (For left handed people, it

is the opposite.)

Hold the gun (of the gun and cable assembly) in

your right hand and hold the shield with your left

hand. (Left handers simply do the opposite.)

FIGURE B.17

When using the FCAW Process, weld from left to

right (if you are right handed). This enables you to

clearly see what you are doing. (Left handers do

the opposite.) Tilt the gun toward the direction of

travel holding the electrode at an angle as shown

in Figure B.18.

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B-12

LEARNING TO WELD

Contact Tip

Wire Electrode

FIGURE B.18

3/8 – 1/2” (10 – 12 mm)

Electrical Stickout (ESO)

WARNING

FIGURE B.19

ARC RAYS can burn eyes and skin.

The easiest way to tell whether the ESO is the cor-

rect length is by listening to its sound. The correct

ESO has a distinctive “crackling” sound, very much

like eggs frying in a pan. A long ESO has a hollow,

blowing or hissing sound. If the ESO is too short,

you may stick the contact tip or nozzle to the weld

puddle and/or fuse the wire to the contact tip.

When using an open arc process, it

Is 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 Welding Speed

• The Correct Way To Strike An Arc

The important thing to watch while welding is the

puddle of molten metal right behind the arc. See

Figure B.20. Do not watch the arc itself. It is the

appearance of the puddle and the ridge where the

molten puddle solidifies that indicates correct weld-

ing speed. The ridge should be approximately 3/8”

(10 mm) behind the wire electrode.

•

Be sure the work clamp makes good electrical

contact to the work.

Position gun over joint. End of wire may be

lightly touching the work.

Position face shield to protect face and eyes,

close gun trigger, and begin welding. Hold the

gun so that the contact tip to work distance is

about 3/8 to 1/2 inch (10 – 12 mm).

Most beginners tend to weld too fast, resulting in a

thin uneven, “wormy” looking bead. They are not

watching the molten metal.

•

To stop welding, release the gun trigger and

the pull the gun away from the work after the

arc goes out.

A ball may form at the tip end of the wire after

welding. For easier restrikes (with Innershield

wire) the ball may be removed by feeding out a

few inches of wire and simply bending the wire

back and forth until it breaks off.

Solidifying ridge

Molten puddle

•

When no more welding is to be done, turn off

the machine.

• The Correct Electrical Stickout (ESO)

The electrical stickout (ESO) is the distance from

the end of the contact tip to the end of the wire.

FIGURE B.20

See Figure B.19.

Once the arc has been established, maintaining

the correct ESO becomes extremely important.

The ESO should be approximately 3/8 to 1/2 inch

(10 to 12 mm) long.

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B-13

LEARNING TO WELD

Helpful Hints

For the Handymig 170i, use the following:

Mild Steel

Electrode

16 gauge or 1/16 inch

• For general welding, it is not necessary to weave

the arc, neither forward or backward nor sideways.

Weld along at a steady pace. You will find it easier.

(1.6 mm)

0.035" (0.9 mm)

Steelcore 71T-GS

Innershield Wire

• When welding on thin plate, you will find that you

will have to increase the welding speed, whereas

when welding on heavy plate, it is necessary to go

more slowly in order to get good penetration.

Voltage Setting “V”

Wire Feed Speed “o|o”

1.5

• When welding sheet metal 16 gauge (1.5 mm) and

lighter, heat buildup may cause part warpage and

burn through. One way to eliminate these problems

is to use the back-stepping method illustrated in

Figure B.21.

Refer to Figure B.22.

• Learn to strike an arc by positioning the gun over

the joint and touching the wire to the work.

• Position face shield to protect face and eyes.

First weld from A to B; then from C to A; then

from D to C; then from E to D, and so on.

• Depress gun trigger, hold gun so contact tip to

work distance is about 3/8 to 1/2 inch (10 to 12

mm) and the gun is at proper angle.

• After you strike the arc, practice the correct electri-

cal stickout. Learn to distinguish it by its sound.

Back-Stepping

FIGURE B.21

• When you are sure that you can hold the correct

electrical stickout, with a smooth “crackling” arc

start moving. Look at the molten puddle constantly,

and look at the “ridge” where the metal solidifies.

Practice

The best way of getting practice in the four skills that

enable you to maintain:

• Run beads on a flat plate. Run them parallel to the

top edge (the edge farthest away from you). This

gives you practice in running straight welds, and

also gives you an easy way to check your

progress. The 10th weld will look considerably bet-

ter than the first weld. By constantly checking on

your mistakes and your progress, welding will soon

be a matter of routine.

• Correct welding position

• Correct way to strike an arc

• Correct electrical stickout

• Correct welding speed

is to perform the following exercise.

WELD BEAD

(REPRESENTATION)

Contact

Tip

ESO

Gun Angle

FIGURE B.22

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B-14

LEARNING TO WELD

MACHINE SET UP FOR THE GMAW (MIG)

PROCESS

• See PROCESS GUIDELINES in the OPERATION

section for selection of welding wire and shielding

gas, and for range of metal thicknesses that can be

welded.

• See the Application Guide on the inside of wire

feed section door for information on setting the

controls.

FIGURE B.23

When using the GMAW process on light gauge mater-

ial, weld from right to left (if you are right handed).

This results in a colder weld and has less tendency for

burn through.

• Set the “Voltage” and “Wire Speed” controls to the

settings suggested on the Application Guide for the

welding wire and base metal thickness being used.

The voltage control is marked “V” and the wire feed

speed is marked ‘’olo.’’

• The Correct Way To Strike An Arc

WARNING

• Check that the polarity is correct for the welding

wire being used. Set the polarity for DC(+) when

welding with the GMAW (MIG) process. See Work

Cable Installation in the INSTALLATION section for

instructions for changing polarity.

ARC RAYS can burn eyes and skin.

When using an open arc process, it

Is necessary to use correct eye,

head and body protection.

• Check that the gas nozzle and proper size liner

and contact tip are being used and that the gas

supply is turned on. If adjustable, set for 15 to 20

cubic feet per hour (7 to 10 l/min.) under normal

conditions, increase to as high as 35 CFH (17

I/min.) under drafty (slightly windy) conditions.

Protect yourself and others, read

“ARC RAYS can burn” at the front

of this manual.

• Be sure the work clamp makes good electrical con-

• Connect work clamp to metal to be welded. Work

clamp must make good electrical contact to the

work piece. The work piece must also be grounded

as stated in the “Arc Welding Safety Precautions”

at the beginning of this manual.

tact to the work.

• Position gun over joint. End of wire may be lightly

touching the work.

• Position face shield to protect face and eyes, close

gun trigger, and begin welding. Hold the gun so

that the contact tip to work distance is about 3/8 to

1/2 inch (10 – 12 mm).

WELDING TECHNIQUES FOR THE GMAW

(MIG) PROCESS

Four simple manipulations are of prime importance

when welding. With complete mastery of the four,

welding will be easy. They are as follows:

• To stop welding, release the gun trigger and pull

the gun away from the work after the arc goes out.

• A ball may form at the tip end of the wire after

welding. For easier restrikes, the ball may be

removed by feeding out a few inches of wire and

cutting off the end of the wire with wire cutters.

• The Correct Welding Position

Figure B.23 illustrates the correct welding position

for right handed people. (For left handed people, it

is the opposite.)

• When no more welding is to be done, close the

valve on the gas cylinder, momentarily operate the

gun trigger to release gas pressure, then turn off

the machine.

When GMAW (MIG) welding on sheet metal, it is

important to use the “forehand” push technique.

Hold the gun (of the gun and cable assembly) in

your right hand and hold the shield with your left

hand. (Left handers simply do the opposite.)

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B-15

LEARNING TO WELD

Helpful Hints

• For general welding, it is not necessary to weave

the arc, neither forward or backward nor sideways.

Weld along at a steady pace. You will find it easier.

Contact Tip

• When welding on thin plate, you will find that you

will have to increase the welding speed, whereas

when welding on heavy plate, it is necessary to go

more slowly in order to get good penetration.

Wire Electrode

ESO

• When welding sheet metal 16 gauge (1.5 mm) and

lighter, heat buildup may cause part warpage and

burn through. One way to eliminate these problems

is to use the back-stepping method illustrated in

Figure B.21.

FIGURE B.24

• The Correct Electrical Stickout (ESO)

The electrical stickout (ESO) is the distance from

the end of the contact tip to the end of the wire.

See Figure B.24.

Practice

Once the arc has been established, maintaining

the correct ESO becomes extremely important.

The ESO should be approximately 3/8 to 1/2 inch

(10 to 12 mm) long.

The best way of getting practice in the four skills that

enable you to maintain:

• Correct welding position

• Correct way to strike an arc

• Correct electrical stickout

• Correct welding speed

The easiest way to tell whether the ESO is the cor-

rect length is by listening to its sound. The correct

ESO has a distinctive “crackling” sound, very much

like eggs frying in a pan. A long ESO has a hollow,

blowing or hissing sound. If the ESO is too short,

you may stick the contact tip or nozzle to the weld

puddle and/or fuse the wire to the contact tip.

is to perform the following exercise.

• The Correct Welding Speed

For the Handymig 170i, use the following:

The important thing to watch while welding is the

puddle of molten metal right behind the arc. See

Figure B.25. Do not watch the arc itself. It is the

appearance of the puddle and the ridge where the

molten Puddle solidifies that indicates correct weld-

ing speed. The ridge should be approximately 3/8”

(10 mm) behind the wire electrode.

Mild Steel

16 gauge or 1/16 inch

(1.6 mm)

Electrode

Steelmig S6 electrode CO₂

Voltage Setting “V”

Wire Feed Speed “o|o”

Most beginners tend to weld too fast, resulting in a

thin, uneven, “wormy” looking bead. They are not

watching the molten metal.

Refer to Figure B.22.

• Learn to strike an arc by positioning the gun over

the joint and touching the wire to the work.

Molten puddle

• Position face shield to protect face and eyes.

Weld metal ridge

• Depress gun trigger, hold gun so contact tip to

work distance Is about 3/8 to 1/2 inch (10 to 12

mm) and the gun is at proper angle.

Base metal

FIGURE B.25

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B-16

LEARNING TO WELD

• Increase voltage

• After you strike the arc, practice the correct electri-

• Decrease stickout.

cal stickout. Learn to distinguish it by its sound.

• Decrease WFS (wire feed speed.

• Decrease travel speed.

• Decrease drag angle.

• When you are sure that you can hold the correct

electrical stickout, with a smooth “crackling” arc,

start moving. Look at the molten puddle constantly,

• Check for correct gas, if used.

• Run beads on a flat plate. Run them parallel to the

top edge (the edge farthest away from you). This

gives you practice in running straight welds, and

also gives you an easy way to check your

progress. The 10th weld will look considerably bet-

ter than the first weld. By constantly checking on

your mistakes and your progress, welding will soon

be a matter of routine.

To Reduce Spatter (in order of importance):

TROUBLESHOOTING WELDS

Good welds have excellent appearance.

• Increase voltage.

• Increase drag angle.

• Decrease stickout.

• Increase WFS (wire feed speed).

• Decrease travel speed.

• Check for correct gas, if used.

To Correct Poor Penetration (in order of impor-

tance):

To Eliminate Porosity (in order of importance):

• Decrease stickout.

• Increase WFS (wire feed speed).

• Increase voltage.

• Decrease speed.

• Decrease drag angle.

• Check for correct gas, if used.

• Turn on gas supply, if used

• Decrease voltage.

If Arc Blow Occurs (in order of importance):

NOTE: Try different ground connection locations

before adjusting procedures.

• Increase stickout.

• Increase WFS (wire feed speed).

• Decrease drag angle.

• Decrease travel speed.

• Decrease drag angle.

• Increase stickout.

• Decrease voltage.

NOTE: Always be sure the joint is free from moisture,

• Decrease WFS (wire feed speed.

• Decrease travel speed.

oil, rust, paint or other contaminants.

To Eliminate a Ropy Convex Bead

(in order of importance):

To Eliminate Stubbing* (in order of importance):

• Increase voltage

• Decrease WFS (wire feed speed)

• Decrease stickout

• Increase drag angle

* Stubbing occurs when the electrode drives through

the molten puddle and hits the bottom plate tending

to push the gun up.

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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 when

welding.

• Do not allow dolly wheels or trucks to run over the

cables.

• Keep the cable clean.

• Innershield electrode has proper surface lubrica-

tion. Use only clean, rust-free electrode.

• Replace contact tip when it becomes worn or the

end is fused or deformed.

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B-18

APPLICATION CHART

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D-1

MAINTENANCE

GUN AND CABLE

SAFETY PRECAUTIONS

WARNING

MAINTENANCE

FOR MAGNUM™ 100L GUN

ELECTRIC SHOCK can kill.

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.

• Disconnect input power by

removing plug from receptacle

before working inside Handymig

170i. Use only grounded recepta-

cle. Do not touch electrically

“hot” parts inside Handymig 170i.

CAUTION

• Have qualified personnel do the

maintenance and trouble shoot-

ing work.

Excessive pressure at the start may cause the dirt

to form a plug.

ROUTINE MAINTENANCE

Flex the cable over its entire length and again blow

out the cable. Repeat this procedure until no further

dirt comes out.

POWER SOURCE COMPARTMENT

In extremely dusty locations, dirt may clog the air pas-

sages causing the welder to run hot. Blow dirt out of

the welder with low pressure air at regular intervals to

eliminate excessive dirt and dust build-up on internal

parts.

Contact Tips, Nozzles, and Gun Tubes

• Dirt can accumulate in the contact tip hole and

restrict wire feeding. After each spool of wire is

used, remove the contact tip and clean it by push-

ing a short piece of wire through the tip repeatedly.

Use the wire as a reamer to remove dirt that may

be adhering to the wall of the hole through the tip.

WIRE FEED COMPARTMENT

• When necessary, vacuum accumulated dirt from

gearbox and wire feed section.

• Replace worn contact tips as required. A variable

or “hunting” arc is a typical symptom of a worn con-

tact tip. To install a new tip, choose the correct size

contact tip for the electrode being used (wire size is

stenciled on the side of the contact tip) and screw it

snugly into the gas diffuser.

• Occasionally inspect the incoming guide tube and

clean inside diameter if necessary.

• Motor and gearbox have lifetime lubrication and

require no maintenance.

• Remove spatter from inside of gas nozzle and from

tip after each 10 minutes of arc time or as required.

FAN MOTOR

• Be sure the gas nozzle is fully screwed onto the

diffuser for gas shielded processes. For the

Innershield^®process, the gasless nozzle should be

screwed onto the diffuser.

Has lifetime lubrication — requires no maintenance.

WIRE REEL SPINDLE

Requires no maintenance. Do not lubricate shaft.

Handymig 170i

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D-2

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.

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. Remove the existing contact tip from the gun by

unscrewing counter-clockwise.

3. Insert and hand tighten desired contact tip.

4. Replace gas nozzle.

CHANGING DRIVE ROLL

The drive roll has two grooves; one for .023" – .025"

(0.6 mm) solid steel electrode and a larger groove for

.030" (0.8 mm) solid and .035" (0.9 mm) flux-cored

steel electrode. As shipped, the drive roll is installed in

the .023"-.025" (0.6 mm) position.

If .030"/.035" (0.8/0.9 mm) wire is to be used, the

drive roll must be reversed as follows:

1. Connect the machine to its rated input power per

instructions in Installation section.

2. Release the spring-loaded pressure arm and lift the

idle roll arm away from the drive roll.

3. Turn the power switch to ON (marked “I”).

4. Set the wire speed to minimum and jog the drive

unit with the trigger switch until the drive roll set

screw is facing up.

CAUTION

When inching the welding wire, the drive rolls,

gun connector block, and gun contact tip are

energized relative to work and ground and remain

energized for several seconds after the gun trig-

ger is released.

5. Turn the power switch to OFF (marked “O”).

6. Loosen the drive roll set screw with the 5/64" (2.0

mm) hex wrench supplied.

7. Remove the drive roll, flip over and reinstall with the

.030/.035" (0.8/0.9 mm) groove (the larger groove)

closest to the gearbox.

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D-3

MAINTENANCE

1-1/4 (31.8 mm)

Liner Trim Length

Gas Diffuser

Gas Nozzle or

Gasless Nozzle

Set Screw

Brass Cable

Connector

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

9. Replace the contact tip and nozzle.

NOTICE: The variation in cable lengths prevents the

interchangeability of liners. Once a liner has been cut

for a particular gun, it should not be installed in anoth-

er gun unless it can meet the liner cutoff length

requirement. Refer to Figure D.2.

GUN HANDLE PARTS

The gun handle consists of two halves that are held

together with a collar on each end. To open up the

handle, turn the collars approximately 60 degrees

counter-clockwise until the collar reaches a stop. Then

pull the collar off the gun handle. If the collars are diffi-

cult to turn, position the gun handle against a corner,

place a screwdriver against the tab on the collar and

give the screwdriver a sharp blow to turn the collar

past an internal locking rib. See Figure D-3.

1. Remove the gas nozzle from the gun by unscrew-

ing counter-clockwise.

2. Remove the existing contact tip from the gun by

unscrewing counter-clockwise.

3. Remove the gas diffuser from the gun tube by

unscrewing counter-clockwise.

4. Lay the gun and cable out straight on a flat surface.

Loosen the set screw located in the brass connec-

tor at the wire feeder end of the cable. Pull the liner

out of the cable.

5. Insert a new untrimmed liner into the connector end

of the cable. Be sure the liner bushing is stenciled

appropriately for the wire size being used.

6. Fully seat the liner bushing into the connector.

Tighten the set screw on the brass cable connec-

tor. At this time, the gas diffuser should not be

installed onto the end of the gun tube.

Counter-clockwise

7. With the gas nozzle and diffuser removed from the

gun tube, be sure the cable is straight, and then

trim the liner to the length shown in the Figure D.2.

Remove any burrs from the end of the liner.

Handymig 170i

FIGURE D.3

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D-4

GROUND TEST PROCEDURE

• Welding circuit to auxiliary circuit test: Connect one-

WARNING

lead of the mega tester to the positive output stud

and the other to the jumper on pins 4 & 5 in the

shorting socket. Apply the test. (Minimum resistance

1M•)

• Wire drive test: Connect one lead of the mega tester-

to the positive output stud and the other to the drive

roll shaft. Apply the test. (Minimum resistance 1M•)

• Remove all harness shorting plugs and connect all

plug and leads to PCB. Remove all shorting jumpers.

If any problems are encountered, refer to your near-

est authorised Liquid Arc Field Service Shop.

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 a

particular machine, so details of this procedure may

need to be ‘adjusted’ to suit these modifications.

For prompt service contact your local authorised Liquid

Arc Field Service shop.

The insulation resistance values listed below are from

Australian Standard AS1966.1.

• Disconnect input power by removing plug from mains

supply.

• Remove welding leads (gun and work lead) from the

machine before any tests are carried out.

• Remove plug from PCB, install a shorting socket into

the harness plug. (The shorting socket is to have pins

4 & 5 jumpered together and all other pins jumpered

together separately and insulated.)

• Connect a shorting jumper across the connections to

the capacitor and from the capacitor to each rectifier

heat sink plate.

• Set power switch to ‘on’ position.

• Input circuit test: Connect one lead of the mega tester

to the frame of the machine and the other lead to

both the ‘active’ & ‘neutral’ terminals of the 240V

input plug. Apply the test. (Minimum resistance 1M•)

• Welding circuit test: Connect one lead of the mega

tester to the frame of the machine and the other lead

to the positive output stud. Apply the test. (Minimum

resistance 1M•)

• Auxiliary circuit test: Connect one lead of the mega

tester to the frame of the machine and the other lead

to jumper on pins 4 & 5 in the shorting socket. Apply

the test. (Minimum resistance 1M•)

• Input circuit to welding circuit test: Connect one lead-

of the mega tester to both the ‘active’ & ‘neutral’ ter-

minals of the 240V input plug and the other to the

positive output stud. Apply the test(s). (Minimum

resistance 10M•)

• Input circuit to auxiliary circuit test: Connect one lead-

of the mega tester to both the ‘active’ & ‘neutral’ ter-

minals of the 240V input plug and the other to the

jumper on pins 4 & 5 in the shorting socket. Apply the

test. (Minimum resistance 1M•)

Handymig 170i

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E-1

TROUBLESHOOTING

HOW TO USE TROUBLESHOOTING GUIDE

WARNING

Service and Repair should only be performed by Liquid Arc 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.

__________________________________________________________________________

Step 2. PERFORM EXTERNAL TESTS.

The second column labeled “POSSIBLE

AREAS OF MISADJUSTMENT(S)” lists the

obvious external possibilities that may con-

tribute to the machine symptom. Perform

these tests/checks in the order listed. In

general, these tests can be conducted with-

out removing the case wrap-around cover.

This Troubleshooting Guide is provided to

help you locate and repair possible machine

malfunctions. Simply follow the three-step

procedure listed below.

Step 1. LOCATE PROBLEM (SYMPTOM).

Look under the column labeled “PROBLEM

(SYMPTOMS)”. This column describes pos-

sible symptoms that the machine may

exhibit. Find the listing that best describes

the symptom that the machine is exhibiting.

Step 3. PERFORM COMPONENT TESTS.

If you have exhausted all of the recom-

mended tests in Step 2, Consult your Local

Authorized Field Service Facility.

Symptoms are grouped into three main cat-

egories: output problems, function prob-

lems, welding problems.

CAUTION

If for any reason you do not understand the test procedures or are unable to perform

the tests safely, contact your LOCAL AUTHORIZED LIQUID ARC FIELD SERVICE

FACILITY for assistance before you proceed.

_____________________________________________________________________

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E-2

TROUBLESHOOTING

Observe Safety Guidelines

detailed in the beginning of this manual.

TROUBLESHOOTING GUIDE

PROBLEMS

POSSIBLE AREAS OF

RECOMMENDED

(SYMPTOMS)

MISADJUSTMENT(S)

COURSE OF ACTION

OUTPUT PROBLEMS

Major physical or electrical damage None

is evident.

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. Make certain that power switch

is in the ON position.

If all recommended possible areas

of misadjustments have been

checked and the problem persists,

contact your local Liquid Arc

Authorized Field Service Facility.

3. Make sure circuit breaker inside

wire drive compartment is reset.

No wire feed, weld output or gas

flow when gun trigger is pulled Fan

operates normally.

1. The thermostat may be tripped

due to overheating. Let machine

cool. Weld at lower duty cycle.

2. Check for obstructions in air

flow.

3. Check Gun Trigger connections.

See Installation section.

4. Gun trigger may be faulty.

CAUTION

If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your

LOCAL AUTHORIZED LIQUID ARC FIELD SERVICE FACILITY for assistance before you proceed.

Handymig 170i

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E-3

TROUBLESHOOTING

Observe Safety Guidelines

detailed in the beginning of this manual.

TROUBLESHOOTING GUIDE

PROBLEMS

(SYMPTOMS)

POSSIBLE AREAS OF

MISADJUSTMENT(S)

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.

If all recommended possible areas

of misadjustments have been

checked and the problem persists,

contact your local Liquid Arc

Authorized Field Service Facility.

2. Check for clogged cable liner or

contact tip.

3. Check for proper size cable liner

and contact tip.

PROBLEMS

(SYMPTOMS)

POSSIBLE AREAS OF

MISADJUSTMENT(S)

RECOMMENDED

COURSE OF ACTION

GAS FLOW PROBLEMS

Low or no gas flow when gun

trigger is pulled. Wire feed, weld

output and fan operate normally.

1. Check gas supply, flow regulator

and gas hoses.

If all recommended possible areas

of misadjustments have been

checked and the problem persists,

contact your local Liquid Arc

Authorized Field Service Facility.

2. Check gun connection to

machine for obstruction or leaky

seals.

CAUTION

If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your

LOCAL AUTHORIZED LIQUID ARC FIELD SERVICE FACILITY for assistance before you proceed.

Handymig 170i

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E-4

TROUBLESHOOTING

Observe Safety Guidelines

detailed in the beginning of this manual.

TROUBLESHOOTING GUIDE

PROBLEMS

POSSIBLE AREAS OF

RECOMMENDED

(SYMPTOMS)

MISADJUSTMENT(S)

COURSE OF ACTION

WELDING PROBLEMS

Arc is unstable – Poor starting

1. Check for correct input voltage

to machine. See Installation sec-

tion, “Electrical Input

Connections”.

2. Check for proper electrode

polarity for process.

3. Check gun tip for wear or dam-

age and proper size – Replace.

If all recommended possible areas

of misadjustments have been

checked and the problem persists,

contact your local Liquid Arc

Authorized Field Service Facility.

4. Check for proper gas and flow

rate for process. (For MIG only.)

5. Check work cable for loose or

faulty connections.

6. Check gun for damage or

breaks.

7. Check for proper drive roll orien-

tation and alignment.

8. Check liner for proper size.

CAUTION

If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your

LOCAL AUTHORIZED LIQUID ARC FIELD SERVICE FACILITY for assistance before you proceed.

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F-1

WIRING DIAGRAMS

Handymig 170i WIRING DIAGRAM: Code 10842

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 enclosure panels.

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● Do not touch electrically live parts or

electrode with skin or wet clothing.

● Insulate yourself from work and

ground.

● Keep flammable materials away.

● Wear eye, ear and body protection.

WARNING

Spanish

● No toque las partes o los electrodos ● Mantenga el material combustible

● Protéjase los ojos, los oídos y el

bajo carga con la piel o ropa moja-

da.

● Aislese del trabajo y de la tierra.

fuera del área de trabajo.

cuerpo.

AVISO DE

PRECAUCION

French

● Ne laissez ni la peau ni des vête-

ments mouillés entrer en contact

avec des pièces sous tension.

● Gardez à l’écart de tout matériel

inflammable.

● Protégez vos yeux, vos oreilles et

votre corps.

ATTENTION

● Isolez-vous du travail et de la terre.

German

● Berühren Sie keine stromführenden

Teile oder Elektroden mit Ihrem

Körper oder feuchter Kleidung!

● Isolieren Sie sich von den

● Entfernen Sie brennbarres Material! ● Tragen Sie Augen-, Ohren- und Kör-

perschutz!

WARNUNG

Elektroden und dem Erdboden!

Portuguese

● Não toque partes elétricas e elec-

trodos com a pele ou roupa molha-

da.

● Mantenha inflamáveis bem guarda- ● Use proteção para a vista, ouvido e

dos.

corpo.

ATENÇÃO

● Isole-se da peça e terra.

Japanese

Chinese

Korean

Arabic

READ AND UNDERSTAND THE MANUFACTURER’S INSTRUCTION FOR THIS EQUIPMENT AND THE CONSUMABLES TO BE

USED AND FOLLOW YOUR EMPLOYER’S SAFETY PRACTICES.

SE RECOMIENDA LEER Y ENTENDER LAS INSTRUCCIONES DEL FABRICANTE PARA EL USO DE ESTE EQUIPO Y LOS

CONSUMIBLES QUE VA A UTILIZAR, SIGA LAS MEDIDAS DE SEGURIDAD DE SU SUPERVISOR.

LISEZ ET COMPRENEZ LES INSTRUCTIONS DU FABRICANT EN CE QUI REGARDE CET EQUIPMENT ET LES PRODUITS A

ETRE EMPLOYES ET SUIVEZ LES PROCEDURES DE SECURITE DE VOTRE EMPLOYEUR.

LESEN SIE UND BEFOLGEN SIE DIE BETRIEBSANLEITUNG DER ANLAGE UND DEN ELEKTRODENEINSATZ DES HER-

STELLERS. DIE UNFALLVERHÜTUNGSVORSCHRIFTEN DES ARBEITGEBERS SIND EBENFALLS ZU BEACHTEN.

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● Keep your head out of fumes.

● Use ventilation or exhaust to

remove fumes from breathing zone.

● Turn power off before servicing.

● Do not operate with panel open or

guards off.

WARNING

Spanish

● Los humos fuera de la zona de res-

piración.

● Mantenga la cabeza fuera de los

humos. Utilice ventilación o

aspiración para gases.

● Desconectar el cable de ali-

mentación de poder de la máquina

antes de iniciar cualquier servicio.

● No operar con panel abierto o

guardas quitadas.

AVISO DE

PRECAUCION

French

● Débranchez le courant avant l’entre- ● N’opérez pas avec les panneaux

tien.

● Gardez la tête à l’écart des fumées.

● Utilisez un ventilateur ou un aspira-

teur pour ôter les fumées des zones

de travail.

ouverts ou avec les dispositifs de

protection enlevés.

ATTENTION

German

● Strom vor Wartungsarbeiten

abschalten! (Netzstrom völlig öff-

nen; Maschine anhalten!)

● Anlage nie ohne Schutzgehäuse

oder Innenschutzverkleidung in

Betrieb setzen!

● Vermeiden Sie das Einatmen von

Schweibrauch!

● Sorgen Sie für gute Be- und

Entlüftung des Arbeitsplatzes!

WARNUNG

Portuguese

● Não opere com as tampas removidas.

● Desligue a corrente antes de fazer

serviço.

● Mantenha-se afastado das partes

moventes.

● Não opere com os paineis abertos

ou guardas removidas.

● Mantenha seu rosto da fumaça.

● Use ventilação e exhaustão para

remover fumo da zona respiratória.

ATENÇÃO

● Não toque as partes elétricas nuas.

Japanese

Chinese

Korean

Arabic

LEIA E COMPREENDA AS INSTRUÇÕES DO FABRICANTE PARA ESTE EQUIPAMENTO E AS PARTES DE USO, E SIGA AS

PRÁTICAS DE SEGURANÇA DO EMPREGADOR.

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A Division of Lincoln Electric Company (Aust) Ply Ltd A.B.N. 36 000 040 308

35 Bryant Street, Padstow, NSW2211, Australia

2000 Lincoln Global Inc.

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