Lincoln Electric Handy mig Bedienungsanleitung

IM3000

06/2003

Rev. 0

HANDY MIG / HANDY CORE

OPERATOR’S MANUAL

MANUALE OPERATIVO

BEDIENUNGSANLEITUNG

MANUAL DE INSTRUCCIONES

MANUEL D'UTILISATION

BRUKSANVISNING OG DELELISTE

GEBRUIKSAANWIJZING

BRUKSANVISNING

INSTRUKCJA OBS UGI

BESTER S.A.

ul. Jana III Sobieskiego 19A, 58-260 Bielawa, Poland

www.lincolnelectric.com

Declaration of conformity

Dichiarazione di conformità

Konformitätserklärung

Declaración de conformidad

Déclaration de conformité

Samsvars erklæring

Verklaring van overeenstemming

Försäkran om överensstämmelse

Deklaracja zgodności

BESTER S.A.

Declares that the welding machine:

Dichiara che Il generatore per saldatura tipo:

Erklärt, daß die Bauart der Maschine:

Declara que el equipo de soldadura:

Déclare que le poste de soudage:

Bekrefter at denne sveisemaskin:

Verklaart dat de volgende lasmachine:

Försäkrar att svetsomriktaren:

Deklaruje, że spawalnicze źródło energii:

HANDY MIG / HANDY CORE s/n

conforms to the following directives:

è conforme alle seguenti direttive:

den folgenden Bestimmungen entspricht:

es conforme con las siguientes directivas:

Est conforme aux directives suivantes:

er i samsvar med følgende direktiver:

Overeenkomt conform de volgende richtlijnen:

överensstämmer med följande direktiv:

spełnia następujące wytyczne:

73/23/CEE, 93/68/CEE, 89/336/CEE, 92/31/CEE

and has been designed in conformance with the following norms:

ed è stato progettato in conformità alle seguenti norme:

und in Übereinstimmung mit den nachstehenden Normen hergestellt wurde:

y ha sido diseñado de acuerdo con las siguientes normas:

et qu'il a été conçu en conformité avec les normes:

og er produsert og testet iht. følgende standarder:

en is ontworpen conform de volgende normen:

och att den konstruerats i överensstämmelse med följande standarder:

i że zostało zaprojektowane zgodnie z wymaganiami następujących norm:

EN 50199, EN 60974-1

BESTER S.A., ul. Jana III Sobieskiego 19A, 58-260 Bielawa, Poland

06/02

Safety 02/02

WARNING

Thisequipment mustbe used byqualifiedpersonnel. Besure that all installation,operation,maintenanceandrepair

proceduresareperformedonlyby qualified individuals.Read and understand this manual before operatingthis

equipment. Failuretofollow the instructionsin this manualcouldcauseserious personal injury, loss oflife, or damageto

thisequipment. Readandunderstandthefollowingexplanationsof thewarningsymbols. LincolnElectricis not

responsible for damages caused by improperinstallation, impropercare orabnormal operation.

WARNING: Thissymbol indicatesthat instructionsmust be followed to avoid seriouspersonal injury,

lossof life, ordamagetothisequipment. Protect yourself and othersfrom possible serious injuryor

death.

READ AND UNDERSTAND INSTRUCTIONS: Read andunderstandthismanualbeforeoperating

thisequipment. Arc welding canbehazardous. Failuretofollow theinstructionsinthismanual could

causeserious personal injury, loss of life, ordamagetothisequipment.

ELECTRIC SHOCK CAN KILL: Weldingequipment generateshighvoltages. Do not touch the

electrode, work clamp, orconnected workpieceswhen thisequipment ison. Insulateyourself from

theelectrode, workclamp, andconnected workpieces.

FUMES AND GASES CAN BE DANGEROUS: Welding mayproducefumesandgaseshazardousto

health. Avoid breathing these fumesandgases. To avoidthese dangersthe operatormust use

enoughventilation or exhaust tokeepfumesandgasesawayfromthebreathingzone.

ARC RAYS CAN BURN: Use a shield with theproperfilter andcover platesto protect youreyesfrom

sparks andthe raysof thearcwhen weldingor observing. Use suitable clothing made from durable

flame-resistant material toprotect you skin and thatof your helpers. Protect other nearby personnel

withsuitable, non-flammablescreeningand warn them not towatch thearcnor exposethemselves to

thearc.

WELDING SPARKS CAN CAUSE FIRE OR EXPLOSION: Remove firehazardsfrom thewelding

areaandhavea fireextinguisherreadily available. Weldingsparks and hot materialsfrom thewelding

process can easily go throughsmall cracksand openingstoadjacent areas. Do not weld on any

tanks, drums, containers, ormaterial until theproper stepshavebeen taken to insure that no

flammableor toxicvaporswill bepresent. Never operate this equipment whenflammablegases,

vapors or liquid combustiblesarepresent.

ELECTRICALLY POWERED EQUIPMENT: Turnoff input power using thedisconnect switch at the

fuse boxbeforeworkingonthis equipment. Ground this equipment inaccordance with local electrical

regulations.

ELECTRICALLY POWERED EQUIPMENT: Regularly inspect the input, electrode, and work clamp

cables. If anyinsulationdamage existsreplace thecableimmediately. Do not place the electrode

holderdirectly on thewelding table oranyothersurface in contact with thework clamptoavoidthe

risk of accidental arcignition.

ELECTRIC AND MAGNETIC FIELDS MAY BE DANGEROUS: Electriccurrent flowing throughany

conductor creates electric andmagneticfields(EMF). EMF fieldsmayinterfere withsom e

pacemakers, and weldershavinga pacemaker should consult their physicianbeforeoperatingthis

equipment.

CYLINDER MAY EXPLODE IFDAMAGED: Use onlycompressed gascylinderscontainingthe

correct shieldinggasfor theprocess usedandproperly operating regulatorsdesigned for the gas and

pressure used. Alwayskeep cylinders in an upright positionsecurely chained to afixedsupport. Do

not move or transport gascylinderswith theprotectioncap removed. Donot allow the electrode,

electrode holder, workclamp or any other electrically live part totouch agascylinder. Gascylinders

must belocatedaway from areaswherethey maybe subjectedtophysical damageorthewelding

process includingsparks andheat sources.

WELDED MATERIALS CAN BURN: Weldinggeneratesalargeamount of heat. Hot surfacesand

materialsinwork areacan causeseriousburns. Usegloves andplierswhentouching ormoving

materialsinthe workarea.

CE COMPLIANCE: Thisequipment complies tothe EuropeanCommunities directives.

SAFETY MARK: This equipment is suitable for supplying power forweldingoperationscarried out in

anenvironment with increased hazardof electric shock.

Installation and Operator Instructions

Read thisentiresection before installationor operation

of themachine.

General Description

The machine isasemiautomaticconstant voltageDC

arc welder. Themachineuses a single phaseconstant

voltagetransformer,solidstaterectifier anda DC

permanent magnet motor forfeeding and weldingsolid

steel electrodeand flux-cored electrode (forHANDY

MIG) and only flux-coredelectrode (forHANDY CORE).

Thismachine is ideallysuitedforindividuals having

access to 230 volt AC input powerand wantingthe

ease ofuse, quality anddependabilityof bothmetal

inert gas (MIG)weldingand the Innershield electrode

process (self-shielded flux-coredwelding). The

machine will handlereels of wire up to 1 Kg.

Location and Environment

Thismachine will operate inharsh environments.

However, it isimportant that simple preventative

measuresarefollowedtoassure long life andreliable

operation.

•Do not place or operate this machineonasurface

with anincline greaterthan15° fromhorizontal.

•Thismachine must be locatedwherethere is free

circulationof clean air without restrictionsfor air

movement to and fromtheairvents. Donot cover

the machinewith paper, clothorragswhen

switchedon.

•Dirt and dust that can be drawninto themachine

should bekept to a minimum.

•Thismachinehas a protection ratingof IP21. Keep

it dry when possibleanddonot place it on wet

ground or in puddles.

•Locatethe machineaway from radiocontrolled

machinery. Normal operation may adverselyaffect

the operationof nearby radiocontrolledmachinery,

whichmay result ininjuryor equipment damage.

Read the section on electromagneticcompatibility

inthismanual.

•Do not operate inareaswithanambient

temperaturegreaterthan 40°C.

Input SupplyConnection

Check theinputvoltage, phase, and frequency supplied

to this machinebeforeturningit on. The allowable input

voltage is indicatedinthe technical specification section

of this manualand onthe ratingplateof the machine.

Verify theconnectionof groundingwires from the

machinetothe input source.

Makesuretheamount of power availablefrom theinput

connection isadequatefornormal operation of the

machine. Thenecessary fuseand cable sizesare

indicatedin thetechnical specificationsection of this

manual.

Shielding GasConnection (onlyfor

HandyMIG)

When using theMIG process, acylinderof shielding

gas(appropriate for the metalbeingwelded) must be

obtained.

1. Chain thecylinder toa wall or otherstationary

support toprevent the cylinderfrom thework circuit

and earthground.

2. Withthe cylinder securely installed, remove the

cylindercup. Stand to oneside away fromthe

outlet and openthe cylinder valvevery slightly for

aninstant. Thisblowsawayany dust ordirty which

may have accumulatedinthe valveoutlet. Install

theregulator on thegascylinder.

3. Attach one endof the inlet hosetothe output of the

regulatorsecure with hose clamp. Connect the

other endtothe Gas Inlet Fittingon themachine

and securewith hose clamp. Make certainthe gas

inlet hoseisnot kinked ortwisted.

Changing Polarity(onlyfor Handy

MIG)

1. ForNegative Polarity welding(DC-): Refer to

below Figure. Asdelivered, the machineiswired

for Negative polarity with theguncableconnected

to theNegative(-)output terminal. This isthe

typical configuration for FluxCoredWelding

(FCAW). Tocomplete the installation, connect the

workcable’sterminal lug tothe Positive (+) output

terminal. Make sure that boththumbscrews are

tigh.

2. ForPositive Polarity (DC+): Referto below Figure.

Towire for Positivepolarity, connect the guncable

to thePositive (+) output terminal and thework

cable to theNegative(-)terminal. Thisisthe

typical configuration for the Metal Inert Gas(MIG)

process. Makesurethat boththumbscrewsare

tight.

Controls and Operational Features

Refer toabove Figures.

1. Thermal Protection Indicator: Themachinehas

a ratedoutput duty cycleof 20%. If theduty cycle

isexceeded, thermal protectorwill shut off the

output until the machine coolsto anormal

operating temperature. Thisisanautomatic

function of themachine anddoesnot requireuser

intervention.

2. Wire Speed Control

3. Power ON/OFFSwitch: Whenthe power is ON

thewelding output andwire feederare ON (“hot”)

when theguntrigger ispressed.

4. Low / HighHeatRange Switch: A rocker switch

control thatgives low or highcoarse range

adjustment of thepower source output voltage.

5. 1 - 2Fine Heat AdjustmentSwitch: Allowsfine

adjustment of thevoltagewithinthe selected Low

or High output range.

MIG Welding

Tablebelow shows the recommended material/gas

combinations forMIGweldingwithsolid electrodes.

Material Gas

CarbonSteel CO2or Argon / CO2

Low Alloy Steel CO2or Argon / CO2

Flux-cored (Innershield)Welding

The recommended electrodefortheflux-cored,

selfshield processis 0.9 mm diameter Lincoln

Innershield NR-211-MP on 0.45kgspools.

Sequence of Operations for Wire Loading

Turnmachinepowerswitch to the OFF (“0”) position

before workinginsidethe wirefeedenclosure. Make

sure that the wirefeeddriveroll andcontact tipof the

gunmatch thediameter and typeof wireused.

1. Push the spool onto thespindle so that the wire

feedsoff the bottom of the spool, towardthedrive

roll.

2. Push the spool spacer ontothe spindle,against the

spool. If it isnecessary, for gettingproper breaking

torque you should rotatethe spool spacer.

3. Slide thespring onto thespool, then press onthe

spool lock, turningit clockwisetolockthe spool

assembly onto thespindle.

4. Releasethe springloadedthumbscrew androtate

the idleroll arm away from the wire feeddrive roll.

Ensurethat thevisible, stenciledsize on thedrive

roll sidefacingyou matchesthe wiresize being

used.

5. Carefully detachthe end of the wire fromthespool

maintain tensionon thewire. To prevent the spool

fromunwindinganddonot release thewire until

afterstep 8.

6. Cut the bent portion of wireoffandstraightenthe

first 100mm.

7. Threadthe wirethrough theingoingguidetube,

overthedriveroll, and intothegunliner.

8. Close theidleroll arm andturndownthe

thumbscrew until theidle rollerpressesdown firmly

onthe wire. (Now you may release thewelding

wire.) Make sure thewire is positioned in the

groove of lowerdrive roll.

9. The springloadedthumbscrew on theidle roll arm

canbe used asa“brake”to adjust the pressureon

thewire. Adjust pressure by turning the

thumbscrew toprevent wireoverrun, but still allow

smooth and easy wire feeding. Start with the

pressure set to anintermediatevalue. Readjust, if

necessary. Slightly less pressure may be required

when using 0.6mm wire. If the driveroll slipswhile

feeding wire, the pressure shouldbe increased

until the wirefeedsproperly.

10. Remove thenozzle andcontact tipfrom the gun.

11. Turnthe machineON (“I”).

12. Straighten thegun cable assembly.

13. Depress theguntrigger switch and feed welding

wirethrough thegunand cable. (Point the gun

away fromyourself andotherswhile feeding wire.)

Release thegun triggerafter wire appears at the

end of thegun.

14. Turnthe machineOFF (“0”).

15. Replace thecontact tip. Cut thewire off so that10

to 15mmprotrudes from the endof thetip.

16. Turnon themachine. The machineisnow ready to

weld.

Shielding Gas (only for HandyMIG)

When using theMIG process, you will need acylinder

of carbon dioxide(CO2) or argon-carbondioxide mixed

shielding gas. The regulatorshouldbe installedon the

gascylinder. Anadapterandplasticwasher are needed

for using100% CO2gas. Thisadapter isavailable from

yourlocal gassupplier.

1. Openthe cylinder valveslowlyafractionof aturn.

When thecylinder pressure gauge pointerstops

moving, open thevalvefully.

2. Keep thecylindervalve closed, except when

welding. When finished welding:

•Close thecylindervalve to stopgasflow.

•Depress theguntrigger briefly toreleasethe

pressure inthe gashose.

•Turnoff themachine.

Welding

1. Select the right weldingprocessbased onthe type

andconditionof thepiecestobe welded; the

environment inwhichwelding is tobedone; and

the desiredfinished appearance of theweld.

2. Select and install thewelding wiretomatch the

process. UseGenuine Lincoln Electric Brandwire.

Wirequality isessential for successful welding.

3. Install the driveroll, contact tip, andnozzle

appropriate for the weldprocess.

4. Check that the polarity is correct forthewelding

wirebeingusedand that thegassupply, if

required, is turnedon.

5. Refer toabove Figure. Connect the workclamp to

themetal to be welded. The workclamp must

makegoodelectrical contact tothe workpiece.

The workpiece must alsobegroundedasstatedin

WeldingSafety Precautionsin thebeginningof this

manual.

6. Based onthe weldingprocess type and material

thickness of thework piece, set thecorrect wire

speedandheat range setting.

7. Based onthe weldjoint typeandorientationof the

weldjoint, position theguninto thejointat the

correct angel.

8. Tobegin welding, raiseyour hand shield to protect

youreyesandpull thetrigger.

9. Whilewelding, travel ataconstant speed and

maintainanelectrodestickout of 9mm. Follow the

correct directionof travel fortheprocessandjoint

type andorientation.

10. Tostopwelding, release theguntrigger.

11. When nomore weldingisto be done, closethe

valve on thegascylinder(if used), momentarily

operatethe gun triggerto release gas pressure,

and turnoff themachine.

Cleaning Tip and Gas Nozzle

Clean thecontact tipand gasnuzzle to avoid arc

bridgingbetweenthem. Bridging canresult inashorted

nozzle, poorweldsandanoverheatinggun. Anti-stick

sprayor gel, available from a weldingdistributor, may

reduce buildup andaid inspatter removal.

Electromagnetic Compatibility(EMC) 02/02

Thismachinehas beendesigned in accordancewithall relative directives and norms. However, it may still generate

electromagneticdisturbancesthat can affect other systems liketelecommunications (telephone, radio, andtelevision)or

other safety systems. Thesedisturbances can cause safetyproblemsin theaffectedsystems. Read andunderstand

thissectiontoeliminate orreduce theamountof electromagneticdisturbancegenerated by this machine.

Thismachinehasbeen designedtooperate in an industrial area. To operatein a domesticarea it is

necessary to observeparticular precautionstoeliminate possible electromagneticdisturbances. The

operator must install andoperatethisequipment asdescribed inthismanual. If anyelectromagnetic

disturbancesare detectedthe operatormust put in place corrective actions toeliminate these disturbances

with, if necessary, assistancefrom Lincoln Electric.

Before installing themachine, theoperator must checkthe workarea for any devicesthat may malfunctionbecauseof

electromagneticdisturbances. Consider the following.

•Input and output cables, control cables, and telephone cables that are inoradjacent to thework areaandthe

machine.

•Radio and/ortelevision transmitters andreceivers. Computersorcomputercontrolledequipment.

•Safety andcontrol equipment forindustrial processes. Equipment forcalibrationandmeasurement.

•Personal medical deviceslike pacemakersandhearing aids.

•Check theelectromagnetic immunity forequipment operatingin or near the workarea. Theoperator must be sure

that all equipment in thearea is compatible. Thismay require additional protectionmeasures.

•Thedimensionsof thework areatoconsider will dependonthe constructionof the areaand other activitiesthat are

taking place.

Considerthefollowingguidelinesto reduce electromagneticemissionsfrom the machine.

•Connect the machinetothe input supplyaccording to this manual. If disturbances occur if may be necessary to take

additional precautionssuchasfilteringthe input supply.

•Theoutput cablesshouldbekept as short aspossibleand shouldbe positionedtogether. If possibleconnect the

workpiecetoground inorder toreducethe electromagneticemissions. Theoperator must checkthat connecting

the workpiece to ground doesnot cause problemsorunsafeoperating conditions forpersonnel andequipment.

•Shieldingof cablesinthe work area canreduceelectromagneticemissions. This may be necessary for special

applications.

Technical Specifications

INPUT

Input Voltage

230 V ±10%

SinglePhase

Input Powerat RatedOutput

2.5 kW@20% DutyCycle Frequency

50/60Hertz (Hz)

RATED OUTPUT AT40°C

Duty Cycle

(Based ona 10 min.period)

20%

Output Current

70 A

Output Voltage

17.5 Vdc

OUTPUTRANGE

Welding Current Range

45-80Amps MaximumOpenCircuit Voltage

29Vdc

RECOMMENDED INPUTCABLE AND FUSE SIZES

Fuse or Circuit Breaker Size

16 A Superlag Type of Plug

16A/250V

(Included with Machine)

Input Power Cable

3Conductor, 1.5mm2

PHYSICAL DIMENSIONS

Height

345mm Width

220mm Length

455 mm Weight

20.9 Kg

OperatingTemperature

–20°C to +40°C Storage Temperature

-25°C to +55°C

Forany maintenanceor repair operationsit isrecommended tocontact thenearest technical service center or Lincoln

Electric.Maintenanceor repairsperformedbyunauthorizedservice centers or personnel will null and voidthe

manufacturerswarranty.

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