AHP Tools Alpha Mig 140 User manual

AHPTools
MIG WELDER
Alpha Mig140
110v 140amp
INSTALLATIONAND OPERATING
INSTRUCTIONS

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Alpha Mig 140
ASSEMBLYANDOPERATING INSTRUCTIONS
Carefullyreadthe operationmanualpriorto using,
installingandmaintainingtheelectricweldingmachinefor
thepurposeofpreventingdamagessuchas fire,electric
shock andetc fromoccurring.Pleasekeepthemanualfor
the referenceinthe future
PRODUCT SPECIFICATIONS
ItemDescription
Rated Electrical Input 115 VAC/60Hz/20AMP
Max Voltage at no Load 28 V DC
Rated DutyCycle90A@20%
Wire Feed Rate 59to393in/min(1.5-10m/min
10.0m/min
Wire size /spool size .023 .030 Solid Steel Wire
.030-.035 Flux cored Wire
Welding Wire Spool 4”x5/8”(mounting hole diameter)
8”x 2”(mounting hole diameter)
Weight 54lbs
Overall Dimensions16”x9.5”x 14.5”

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SAVETHISMANUAL
Youwillneedthemanualforsafetywarningsandprecautions,assembly
instructions,operatingandmaintenance procedures,parts listand
diagram.Keepyourinvoice with thismanual.Writeinvoice numberand
dateof purchaseontheinsideof themanual.Keepthemanualandinvoice
ina safe and dry place forfuturereference.
WARNING !WELDING can be hazardous
WARNING:THIS WELDING MACHINEMUST BECONNECTEDTOPOWER
SOURCE INACCORDANCE WITHAPPLIANCE ELECTRICAL CODES
ADERTISSEMENT:LE RACCIROEMENTDE CETTE MACHINE DE SOUDAGE A
L'ALIMENTATION DOITETRE CONFORMEAUX CODES D'ELECTRICITE PERTINENTS
WARNING: DISCONNECTPOWER SOURCEBEFORE DISASSEMBLYOFTHE TORCH
ADVERTISSEMENT:COUPER L'ALIMINTATION AVANTLADEPOSEDE LA
WARNING: DISCONNECTPOWER SOURCEBEFORE DISASSEMBLYOFTHE TORCH
ADVERTISSEMENT:COUPER L'ALIMINTATION AVANTLADEPOSEDE LA
WARNING: THESHIELD CUPMUSTBE INSTALLED PRIOR TOOPERATION OFTHE
TORCH
ADVERTISSEMENT;ZVANTD'UTILBER LE CHALUMEAU S'ASSURER QUE L'ECRAN
DE PROTECTION ESTEN PLACE
WARNING: ALLINSTALLATION, MAINTENANCE, REPAIR OPERATION OFTHIS
EQUIPMENTSHOULDBE PREFORMED BYQUALIFIED PERSONS ONLYIN
ACCORDANCE V~THNATIONAL, STATEAND LOCALCODES
ELECTRICSHOCK can KILL
Improper useof electric arcweldercancauseelectricshock, injury
and death! Takeall precautionsdescribedin thismanual to reduce
thepossibilityof electric shock.
TheAlphaMig 140power switch isto bein theOFF ("0") position
when installing work cable and gun and when connecting power cord to inputpower.
Alwayswear dry,protectiveclothing and welding glovesand insulated footwear.
Alwaysoperate thewelderinaclean, dry,well ventilatedarea.Donotoperatethe
welder in humid, wet, rainyor poorlyventilated areas.
Besurethat thework piece isproperlysupportedand groundedprior tobeginning
and electric arcwelding operation.
Theelectrodeandwork (or ground) circuitsareelectrically"hot”whenthewelder

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ison. Denottouch these"hot" partswith your bareor wetclothing.
Ground thework or metalto bewelded to agood electrical(earth) ground.
FUMES ANDGASES can be dangerous.
Do notbreathefumesthat areproduced bythearcwelding operation.
Thesefumesaredangerous.
Keep theheadandface outof thewelding fumes.
Shielding gasesused for arcwelding can displace air and causeinjury
or death. Alwaysuseenough ventilation.
WELDING SPARKScan cause fire orexplosion.
Do notoperate electric arcwelder inareaswhereflammable
or explosivevapors.
Alwayskeep afireextinguisher accessible while performing
arcwelding operations.
ARCRAYScan burn.
Useashield with theproper filter and cover platesto protect
your eyesfromsparksand theraysof thearcwhen welding or
observing open arcwelding.
Usesuitable clothing madefromdurable flame-resistantmaterial
to protectyour skin and that of your helpersfromtherays.
Protect other nearbypersonnel with suitablenon-flammable
screening or cautionthemnotto watchthearcnor exposethemselves
to thearcraysor to hotspatter or metal.
Heatmetal canburn
Electric arcwelding operationscausesparksand heat metalto
temperaturesthatcan causesevereburns! Useprotectiveglovesand
clothing when performing anymetal working operations.
Makesurethat all personsin thewelding area areprotected from
heat, sparksand ultraviolet rays. Useadditional faceshieldsand
flameresistantbarriersasneeded.
Never touch work piece until completelycooled.

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ELECTRICANDMANGETICFIELDSmaybe dangerous
Theelectricmagnetic field that isgenerated during arcwelding may
interferewith theoperation of variouselectricaland electronicdevices
such ascardiac pacemakers. Personsusing such devicesshould consult
with their physicianprior to performing anyelectric welding operations.
Exposureto electromagnetic fieldsduring welding mayhaveother
health effectswhicharenotknown.
I. UNPACKING
When unpacking, check tomakesureallthepartsshown asfollowing areincluded.
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O
P
E
R
A
T
O
R
' S
M
A
N
U
A
L
3
1
67
8
2
1Kgs Spool of 0.6mm MAGWire
Work clamp
Torch
2
Alpha-MIG140 welder
134
567
8
0.8mm ,0.9mm Contacttip
Operator'smanual
Hose
Gas Regulator

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II. COMPONENTS ANDCONTROLS
1. Mig gun connection
2. Ground Clamp connection
3. Power switch
4. OutputVoltagecontrol
5. Wirefeed speed adjustmentcontrol
6. Access cover Latch
7. Power Cord
8. Reset overload switch theoverload
Protection will trip thecircuitif thewelding
machineisin excess of themaximumload,
after which theswitch mustbemanuallyreset.
9. Shielding gasinletfitting.
10.Wirefeed drivemotor
11.Wirespoolspindle/shaft.
12.Wing screwto fasten thewelding torchcable
13.Positive(+) and negative(-) outputterminals
14.Controlcable connection of thewelding torch
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1
2
4
3
5
9
8
7
13
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4If Optional Spoolgun istobeusedthenpushswitchtoSpoolgun fromMiggun on
frontpanel and installspoolgun asabove.
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FigureC-2
III INSTALLATION
WeldingTorchInstallation (See FigureC-1)
Thereis one coilof0.6mmsolid core weldingwire attachedto the delivery of the
equipment bythe plant.With regardto the0.6 mmcurrent contactnozzle1 of the
defaultinstallationto thewelding torch,pleasechange itto be the one of 0.8mm
current contactnozzlewhere 0.8 mm weldingwire shallbeused. In the event that 0.9
mm welding wireshall beused,pleasechangeitanduse 0.9mm current contact
nozzle instead.
Connectthe weldingtorchtothewelding
machine. (See FigureC-2,Figure C-3)
1.Poweroffthe weldingmachine,namely
theswitch ispositioned at "O".
2.Plug thewelding torchinto the hole1
and plug itinto to theend ofit,thread the
controlwire of the weldingtorchpass
through the rectangularorificeofthe hole
1and insetthe controlwire into the
connector5 afteritis girded around the
wire feeder.
3.Screwtightthe butterflyscrew 3
attached to theconnectorof the wire
feederandfasten thewelding torchonto
the connector.
3
Figure C-1
Figure C-3
1
4
5
(See Figure C-2, Figure C-3)
NOTE:This methodofconnection is GMAW.
Whereothermethodsofwelding areapplied,
pleasereferto theReference TableT-2in
page 12

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Wire Drive Roll Installation (See Figure C-4)
Thereversibledual groovewiredriverollthat is
Supplied with theAlphaMig 140 hastwo wiregrooves;
Onefor .025”(0.6mm) solid welding
wireand theother for .030-.035”(0.8-0.9mm)
solid or flux-cored welding wire.The
factorydefault installation is.025”(0.6mm).
In theeventthat .030”(0.8mm) - .035”
(0.9mm) welding wiresareused, thewirefeed
roll groovemustbechanged.
1. Ensurethat theAlphaMig 140 welding machineis
powered off.
2. Unlatch thespringloaded pressurearmand FigureC-4
open theidle roll arm. (1) and liftup theidle
roll arm. (2)
3. Loosen thehex bolt (3) thatattachesthewiredriveroll.
4. Removethewiredriveroll (4) and flipthewiredriverolloversothat the.030
(0.8mm)mark facestheuser.
5. Reinstallbyputting back thewiredriveroll and tightenthehex bolt.
Welding Wire Installation
Your AlphaMig140welding machinecanusebotha8”and 4”diameterspoolof
wire(themaximumwidthof thespoolcanbeno morethan2.2”). Thereisaplastic
tube(2”diameter) attachedtothewiredrive.Thespringscrewcanadjustthe
resistance of thewelding wirespoolto preventthewirefromloosening off .
For installation (SeeFigureD-1) of wirespoolof 8"(200 mm)diameter,install the
spoolovertheplastic barrel ②with50mm indiameterattachedtothewelding
machine.Thepositioning tabon theplastic barrel shouldbelinedup withthe
positioning holeon thewirespoolpole of theplasticbarreland thiswill lockthe
spoolonto thespoolwireholder once thespring tension nutistightened.
(Note: thewirespoolwill rotate clockwisewhen wireispulled off.)
Removethe2”diameter plastic spoolwhen using a4”Spool
Unscrewthewing nutand removeSecuring spacer (6) and the2”plastictube
Install the4”diameterspoolontothemetal shaftandslipspacerbackon and tighten
with wing nut.
4
3
1
2
FigureC-4

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Feed the Welding Wirethoughthe WireFeederbyfollowing the
instructionsasshown below (FigureD-3)
1. Releasethespring tensionedpressurearm①of thewirefeederand liftup theidle
roll arm②,verifythat thegroovesize matchesthatof thewirediameterbeing
used.( see previouschapter describing installation of feed rollers)
2. Pull outthewelding wire③fromthewelding wirespooltaking caretokeepthe
wireundertensionuntilafterstep5intheproceduresoastopreventthespooled
wirefromunwinding.
3. Inspect wireend tomakesureit isstraightfor easyinstallation intothetubefeed
guide.Haveatleast3”of straightwiretoallowfor easyinstallation intowire
feeder..
4. Feedtheweldingwirethrough thewirefeedtube(4) andoverthegroovedroller
intothemainfeedtube(6) feedapproximately3”to6”of wireintothemiggun
line.
5. Place theidlearminto theoperating position andsecurewith ②and secureit with
thespring loadedtension bar①
6. Set wing nuton tension barsoastoallowsmoothfeeding ofthewelding wirewith
no slipping or binding being present.
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64
3
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Figure D-3

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Protective GasInstallation
Compressedgascylindercontaining amixedgasof 75% Argon and 25% CO2isthe
mostcommon gasused in MIG( GMAWGasMetal ArcWelding) Theflowregulator,
and supplylineisincludedwithyourAlphaMig140 Welder.You cansource
Compressed gascylindersfromyour localwelding supplier.
1.Secureyour gascylinderwithachain, strapor otherdevisetopreventthecylinder
fromfalling .Bottle mustbesecured intheuprightposition .
2. Aftersecuring thecylinder,removethesafetycapandhavethesupplyvalve
opening facing awayfromyou.
Crackopenthevalvemomentarilytocleanoutanydustor dirtinthesupplyvalve
opening.
3. Install flowregulator (CGA-580) to thesupplyvalveconnection on thegascylinder
and tighten using awrench
4. Install thesupplied hosefromtheflowmeterto therear of theAlphaMig 140 and
tighten using awrench (connectionsused arecommon 5/8”-18threaded fittings)
5. Open thegascylinder valveslowly
6. Depress themiggun triggerand setflowtobetween20to30cfh (7 to17. Close
valvewhenyou arenotusing welder.Whenwelding iscompletedclosemainvalve
on cylinder and releasegasfrommig gun linebydepressing trigger
Connector aperture of
protective gas input
Valve of air
bottle Flow regulator
Air pipe

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Welding Operations
1. Power on theAlphaMig 140 Welding Machine
3. Straighten Mig gun line
4. Removecontact tipfromgun nozzle(allows wiretofeedeasierat end)Depress
miggun triggersoastofeedwelding wireintoline.Stop whenwireisexposedat
nozzle end. pressing
5. Reinstallthecontact tipand nozzle.
6. Cutexposed wireback to approximately ¼” to 3/8”fromtip.
7. Place protectivesafetyequipmenton (jackets,gloves,Masks)and youareready
for welding.
Welding Process
1. Pleaserefertothewelding Manualand select thecorrect welding wireand
protectivegasbasedon themetal thickness.
2. Areferencechartisattachedtotheinsidedoor panel.Thischartgivesthecorrect
voltageand wirespeedsfor thecorresponding metal thickness from24 gaugeto
5/16”thick.
3. Checktheoutputpolarityfor your welding process .ifusing solidwiregas
shielding thenyourGround (work )clampshouldbeattachedtothenegative
outputterminal(-)insidetheAlphaMig140 access panelifFlux CoredWireis
usedthenthepolaritymustbechangedfor theGround (Work)clamptobeon the
Positive( +) outputterminal and Mig gun connectedto thenegativeterminal.
4Connect theground clamptothework piecethatismaking surethereisagood
ground connection made.Thematerial mayneedtobecleanedinordertoget the
bestground ,thiscanbedonebygrinding thework piece to apolished finish .
5. Themiggun shouldhaveenough slack linesoastobeeasilymaneuveredalong the
area to bewelded.
6. Flipdownthewelding helmet,and press thetriggerof theMiggun and beginto
weld. Keepthecontact nozzle of thewelding gun at around 3/8”awayfromthe
weld surface joint.
7. Releasetrigger tostop theweld process.
8. Afterwelding, closethevalveof gascylinder(If solidwireisused)and depress
Mig gun trigger to releasestored gas.Finally, power off thewelding machine

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VI. Overload Protection Device
Overload protection forpowersupplyto welding
Therearetwoprotection devicesthat aretemperaturecontrolledand overload
breakerequippedontheAlphaMig140 Migwelder.Bothprotection deviceswill be
activatedtoprotectthewelding machinewhenevertheoutputof themachineis
operatedinexcess of itsmaximumoutput.If eitheroneisactivateditwillcutofthe
outputvoltageandwirefeeddriverollermotor.Thecooling fanwill remainon in
order to coolthewelder and to bring itback to within operating parameters.
If theOverloadrelayistriggeredthenyou will needtoreset thebreakerbutton. This
needstobedoneaftergiving theunit time tocooldowntotheoperating parameters
(normallyseveral minutesfor cooling).
If thereisno voltageoutputand thebreakerhasnottrippedthanit isthethermal
overloadson theheat sink that havebeenactivatedand haveshutdownoutputvoltage.
Theunit needstobeleftrunning for several minutestoallowthefanstocooldown
thewelder beforeit will reset and beginoperating onceagain.
Overload Protection to Wire feeder
TheAlphaMig140 model hastwoautomaticcircuitstoprotect themotor of the
wirefeeder,ifthereisfaultdetectedtothemotor,thecircuitwill poweroffthewire
feeder and cutoff theoutput..
Whenthetriggerofthemiggun ispressedagainand isreleasedthecircuit
cutting off thewirefeeder will beautomaticallyreset.

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