Lincoln Electric handy mig User manual

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

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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

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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.

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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.

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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.

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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.

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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.

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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.