liquidarc Handymig 170i User manual

Handymig 170i
OPERATOR’S MANUAL
IM796
April, 2006
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.
For use with machine Code Numbers 10984
A Division of Lincoln Electric Company (Aust) Ply Ltd A.B.N. 36 000 040 308
Copyright © 2000 Lincoln Global Inc.
35 Bryant Street, Padstow, NSW2211, Australia
Made exclusive for Australia
This manual covers equipment which is no
longer in production by The Lincoln Electric Co.
Specications and availability of optional
features may have changed.

FOR ENGINE
powered equipment.
1.a. Turn the engine off before troubleshooting and maintenance
work unless the maintenance work requires it to be running.
------------------------------------------------------------------------
1.b. Operate engines in open, well-ventilated
areas or vent the engine exhaust fumes
outdoors.
____________________________________________________
1.c. Do not add the fuel near an open flame
welding arc or when the engine is running.
Stop the engine and allow it to cool before
refueling to prevent spilled fuel from vapor-
izing on contact with hot engine parts and
igniting. Do not spill fuel when filling tank. If
fuel is spilled, wipe it up and do not start
engine until fumes have been eliminated.
____________________________________________________
1.d. Keep all equipment safety guards, covers
and devices in position and in good
repair.Keep hands, hair, clothing and tools
away from V-belts, gears, fans and all
other moving parts when starting, operating
or repairing equipment.
____________________________________________________
i
SAFETY
i
ARC WELDING CAN BE HAZARDOUS. PROTECT YOURSELF AND OTHERS FROM POSSIBLE SERIOUS INJURY OR DEATH.
KEEP CHILDREN AWAY. PACEMAKER WEARERS SHOULD CONSULT WITH THEIR DOCTOR BEFORE OPERATING.
For more detailed information it is strongly recommended that you purchase a copy of "Safety in Welding and Cutting - ANSI
Standard Z49.1" and WTIA Technical Note 7. All WTIA publications and ANSI/AWS Standards are available from the
Welding Technology Institute of Australia, PO Box 6165 Silverwater NSW 2128. For copies of various Australian Standards
contact your local S.A.A. office.
BE SURE THAT ALL INSTALLATION, OPERATION, MAINTENANCE AND REPAIR PROCEDURES ARE
PERFORMED ONLY BY QUALIFIED INDIVIDUALS.
WARNING
1.h. To avoid scalding, do not remove the
radiator pressure cap when the engine is
hot.
1.e. In some cases it may be necessary to remove safety
guards to perform required maintenance. Remove
guards only when necessary and replace them when the
maintenance requiring their removal is complete.
Always use the greatest care when working near moving
parts.
___________________________________________________
1.f. Do not put your hands near the engine fan. Do not attempt to
override the governor or idler by pushing on the throttle control
rods while the engine is running.
___________________________________________________
1.g. To prevent accidentally starting gasoline engines while
turning the engine or welding generator during maintenance
work, disconnect the spark plug wires, distributor cap or
magneto wire as appropriate.
Oct ‘00

SAFETY
2.i.4 Connect the work cable to the work piece as close as
possible to the area being welded. (This is also a 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.
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.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.l. In addition to the normal safety precautions, the following addi-
tional procedures should be adopted by welders with pacemak-
ers.
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.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.l.5 Do not work on a ladder or other elevated position or in a
cramped, confined place.
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.l.7 Do not work near spot welding equipment.
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.
ELECTRIC AND
MAGNETIC FIELDS
may be dangerous
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
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.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.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.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.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.h.3 The greater the current flow, i.e. the higher the amps,
the stronger the field created by the current
2.h.4 The closer the conductor or electrical device is to the
body the greater the exposure to the field.
MINIMIZE EXPOSURE TO EMF
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.
ii ii
Oct ‘00

iii
SAFETY
iii
ARC RAYS can burn.
4.a. Use a shield with the proper filter and cover
plates to protect your eyes from sparks and
the rays of the arc when welding or observing
open arc welding. Headshield and filter lens
should conform to ANSI Z87. I standards.
4.b. Use suitable clothing made from durable flame-resistant
material to protect your skin and that of your helpers from
the arc rays.
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.
ELECTRIC SHOCK can
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.
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.
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:
• Semiautomatic DC Constant Voltage (Wire) Welder.
• DC Manual (Stick) Welder.
• AC Welder with Reduced Voltage Control.
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.
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.
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.
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.
FUMES AND GASES
can be dangerous.
5.a. Welding may produce fumes and gases
hazardous to health. Avoid breathing these
fumes and gases.When welding, keep
your head out of the fume. Use enough
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.
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.
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.
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.
5.e. Also see item 1.b.
Mar ‘95

FOR ELECTRICALLY
powered equipment.
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.
8.c. Ground the equipment in accordance with the National
Electrical Code and the manufacturer’s recommendations.
CYLINDER may explode
if damaged.
7.a. Use only compressed gas cylinders
containing the correct shielding gas for the
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.
7.c. Cylinders should be located:
• Away from areas where they may be struck or subjected to
physical damage.
• 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
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.
iv
SAFETY
iv
Mar ‘95
WELDING SPARKS can
cause fire or explosion.
6.a. Remove fire hazards from the welding area.
If this is not possible, cover them to prevent
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.
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.
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.
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).
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.
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.
6.h. Also see item 1.c.

SAFETY v
v
INSTRUCTIONS FOR ELECTRO-
MAGNETIC COMPATIBILITY
Conformance
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".
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.
Introduction
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.
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.
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.
The following shall be taken into account:
• Other supply cables, control cables, signalling and telephone
cables above, below and adjacent to the welding equipment;
• Radio and television transmitters and receivers;
• Computer and other control equipment;
• Safety critical safety equipment, eg. guarding of industrial
equipment;
• The health of people around, eg. the use of pacemakers and
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.
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.
Methods of Reducing Emissions
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.
Maintenance of the Welding Equipment
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.
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.
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.
Screening and Shielding
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.
Portions of the preceding text are extracted from:
• 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.
• 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 [phone]).
Copyright of above text is property of Standards Australia,
Standards New Zealand and British Standards Institution.
Permission to reproduce the text must be obtained.
JAN ‘01

vivi
Thank You for selecting a QUALITY product by Lincoln Electric. We want you
to take pride in operating this Lincoln Electric Company product
••• as much pride as we have in bringing this product to you!
Read this Operators Manual completely before attempting to use this equipment. Save this manual and keep 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.
This statement appears where the information must be followed to avoid minor personal injury or damage to
this equipment.
CAUTION
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.
Product _________________________________________________________________________________
Model Number ___________________________________________________________________________
Code Number or Date Code_________________________________________________________________
Serial Number____________________________________________________________________________
Date Purchased___________________________________________________________________________
Where Purchased_________________________________________________________________________
Whenever you request replacement parts or information on this equipment, always supply the information you
have recorded above. The code number is especially important when identifying the correct replacement parts.
On-Line Product Registration
- Register your machine with Lincoln Electric either via fax or over the Internet.
• For faxing: Complete the form on the back of the warranty statement included in the literature packet
accompanying this machine and fax the form per the instructions printed on it.
• For On-Line Registration: Go to our
WEB SITE at www.lincolnelectric.com. Choose “Quick Links” and then
“Product Registration”. Please complete the form and submit your registration.

vii
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 Processes ..............................................................................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
Application Chart.................................................................................................B-7
Handymig 170i

viii
viii
TABLE OF CONTENTS
Page
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 ............................................................................P463,P202,P189
Handymig 170i

A-1
A-1 INSTALLATION
Fuse or
Output Mode Input Voltage Breaker Size Input Amps Power Cord
RATED 240V/50Hz 25 Super Lag 12.7 15Amp, 240V,
Three Pin Plug
TECHNICAL SPECIFICATIONS – Handymig 170i
INPUT – SINGLE PHASE ONLY
RATED OUTPUT
OUTPUT
RECOMMENDED INPUT CABLE AND FUSE SIZES
Height Width Depth Weight
305 mm 248 mm 419 mm 25.9 kg
PHYSICAL DIMENSIONS
Standard Voltage/Frequency AS1966.1
240V/50Hz Rated Input Current
12.7 Amps
Duty Cycle Amps Volts at Rated Amperes
20% 130 20
Welding Current Range Maximum Open Circuit Voltage Auxiliary Power
Rated DC Output: 30 – 170 amps 33 N/A
Handymig 170i

A-2 INSTALLATION
SAFETY PRECAUTIONS
• Read entire installation section before starting
installation.
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.
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.
WARNING
FIGURE A.1
12
3
4
5
Handymig 170i
WELDING AMP RANGEWELDING AMP RANGE
25-12525-125
6
A-2
Handymig 170i

A-3
INSTALLATION
SELECT SUITABLE LOCATION
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.
STACKING
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.
1. Work Cable Access Hole.
2. Gun Cable and Control Lead Access Hole.
3. Connector Block.
4. Gun Trigger Lead Connectors.
5. Positive (+) and negative (–) output terminals.
6. Wire Feed Gearbox.
7. Cable Hanger.
8. Thumbscrew.
Work Clamp Installation
Attach the work clamp per the following: Refer to
Figure A-3.
Handymig 170i
12
E
WELDING AMP RANGE
30-70
4
5
8
367
+
-
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.
2. Fasten securely with the bolt and nut provided.
FIGURE A.2
A-3
Handymig 170i

A-4
A-4 INSTALLATION
Work Cable Installation
Refer to Figure A.2.
1. Open the wire feed section door on the right side of
the Handymig 170i.
2. Pass the end of the work cable that has the termi-
nal lug with the smaller hole through the Work
Cable Access Hole (1) in the case front.
3. Route the cable under and around the back of the
Wire Feed Gearbox (6).
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.
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).
FIGURE A.4
NOTE: If .045" or 1.2 mm) Innershield flux-cored wire
is to be used, the appropriate Innershield kit is
required.
Connecting Gun Cable to the Handymig
170i.
1. Refer to Figure A.2. Unplug the machine or turn
power switch to the OFF “O”position.
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.
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.
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.
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.
CAUTION
GUN INSTALLATION
As shipped from the factory, the Handymig 170i gun is
ready to feed .023" –.025"(.6mm) solid wire. If .030"-
.035”(0.8-.09 mm) solid wire is to be used, change the
contact tip to the appropriate size. If .035”Flux-cored
wire is to be used, change the contact tip and nozzle
to the appropriate types and orient the drive roll to the
appropriate groove size
2
43
1
Handymig 170i

A-5
INSTALLATION
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.
3. Attach the flow regulator to the cylinder valve and
tighten the union nut securely with a wrench..
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.
5. Reinstall case side before connecting input power.
INPUT CONNECTIONS
FIGURE A.6
Refer to Figure A.6.
CYLINDER may explode if dam-
aged. Keep cylinder upright and
chained to support
• Keep cylinder away from areas
where it may be damaged.
• Never lift welder with cylinder
attached.
• Never allow welding electrode to
touch cylinder.
• Keep cylinder away from welding
or other live electrical circuits.
BUILDUP OF SHIELDING GAS may
harm health or kill.
• Shut off shielding gas supply
when not in use.
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
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.
WARNING
Cylinder Valve
Gas Hose
Flow Regulator
WARNING
WARNING
POWER INPUT
CABLE
GAS SOLENOID
INLET FITTING
A-5
Handymig 170i

A-6 INSTALLATION
ELECTRICAL INPUT CONNECTION
FOR RATED OUTPUT
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.
• 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.
WARNING
WARNING
A-6
Handymig 170i

B-1
OPERATION
SAFETY PRECAUTIONS
ELECTRIC SHOCK can kill.
• Do not touch electrically live
parts or electrode with skin or
wet clothing. Insulate yourself
from work and ground.
• 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.
WELDING SPARKS can
cause fire or explosion.
• Keep flammable material away.
• Do not weld on closed contain-
ers.
ARC RAYS can burn eyes
and skin.
• Wear eye, ear and body protec-
tion.
See additional warning information at
front of this operator’s manual.
WARNING
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.
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.
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).
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.
DESIGN FEATURES AND
ADVANTAGES
•“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.
•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.
B-1
Handymig 170i

B-2
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. .
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 —
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
Handymig 170i Application
Chart located on the inside
of the wire feed section door.
3. Voltage Control —A 5-posi-
tion tap selector switch gives
full range adjustment of
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.
OFF
ON
ARC VOLTS
WIRE SPEED
FIGURE B.1a
FIGURE B.1b
4
+
-
Handymig 170i

B-3
OPERATION
WELDING OPERATIONS
SEQUENCE OF OPERATION
Wire Loading
Refer to Figure B.2 and B.3.
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.
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.
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.
Note: The brake should be adjusted with a spool of
wire installed. When properly adjusted it should
move freely but not coast.
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.
Friction Brake Adjustments
1. With wire spool installed, check free movement
and coast of the spool.
2. To tighten the brake turn the wing nut clockwise in
1/4 turn increments until coasting stops.
3. To loosen the brake turn the wing nut counter-
clockwise in 1/4 turn increments until the wire spool
moves freely without coasting.
FIGURE B.2
FIGURE B.3
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.
8”Wire Spool
To Wire Drive
Wire Spool Spindle
Be sure that this stud engages
the hole in the wire spool.
Wire Spindle Shaft 4" Wire Spool
Wing Nut
and Spacer
To wire drive
CAUTION
B-3
Handymig 170i

B-4 B-4
OPERATION
Wire Threading
Refer to 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.
3. Cut the bent portion of wire off and straighten the
first 4”(100 mm).
4. Thread the wire through the incoming guide tube
(4), over the drive roll (3), and into the outgoing
guide tube (5).
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.
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.
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.
------------------------------------------------------------------------
7. Refer to Figure B.5. Remove gas nozzle and con-
tact tip from end of gun.
8. Turn the Handymig 170i ON (“I”).
9. Straighten the gun cable assembly.
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”).
12. Replace contact tip and gas nozzle.
13. Refer to Figure B-6. Cut the wire off 3/8”–1/2”(10
–12 mm) from the end of the tip. The Handymig
170i is now ready to weld.
WARNING
FIGURE B.4
The Wire Drive Feed Roll can
accommodate two wire sizes by
flipping the wire drive feed roll
over.
FIGURE B.5
Gun Handle
Gas Diffuser/
Contact Tip
Gas Nozzle
1
2
3
4
5
Handymig 170i

B-5
B-5 OPERATION
Making A Weld
1. See “Process Guidelines”in this section for selec-
tion of welding wire and shielding gas and for
range of metal thicknesses that can be welded.
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.
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.
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.
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.
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.
FIGURE B.6
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.
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.
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).
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.
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.
3/8" –1/2" Contact Tip To Work Distance
(10-12 mm) (CTWD)
Contact Tip
Wire Electrode
FIGURE B.7
WORKPIECE
GUN CABLE
ARC
WORK CLAMP
Handymig 170i