Systematics PATRIOT PBE180 User manual

PBE180 M.I.G. COMBINATION UNIT
OWNER'S MANUAL
CONGRATULATIONS!
YOU HAVE JUST PURCHASED ONE OF THE FINEST
MIG WELDING SYSTEMS AVAILABLE TODAY. THE
PBE180 REPRESENTS FOURTH GENERATION TECH-
NOLOGICAL ADVANCEMENTS. THIS SYSTEM IS DE-
SIGNED AND ENGINEERED TO PROVIDE YOU WITH
YEARS OF PROFESSIONAL SERVICE.
FOR TECH. SERVICE, CALL 1-610-696-9040
FORM WC5368 Rev. 8/00, 5/01
INSTALLATION
OPERATION
MAINTENANCE

Systematics, Inc. West Chester, PA. 19380
MANUFACTURER’S LIMITED WARRANTY
This equipment is warranted against defects in materials
and workmanship for a period of two years from the date of
purchase.
EXCEPTION: THE MIG TORCH IS WARRANTED FOR A
PERIOD OF 30 DAYS FROM THE DATE OF PURCHASE.
Should the equipment become defective for such reason,
the Manufacturer will repair it without charge, if it is returned
to the Manufacturer’s factory, freight prepaid. This warranty
does not cover: (1) failure due to normal wear and tear; (2)
consumable parts, such as, but not limited to, torch contact
tips, gas cups and insulating bushings; (3) damage by
accident, force majeure, improper use, neglect, unauthor-
ized repair or alteration; (4) anyone other than the original
purchaser.
THIS LIMITED WARRANTY IS IN LIEU OF ALL OTHER
WARRANTIES, EXPRESS OR IMPLIED. THE MANUFAC-
TURER SHALL NOT BE LIABLE FOR ANY INJURY TO
PERSONS, INCLUDING DEATH; OR LOSS OR DAMAGE
TO ANY PROPERTY, DIRECT OR CONSEQUENTIAL,
INCLUDING, BUT NOT LIMITED TO, LOSS OF USE,
ARISING OUT OF THE USE, OR THE INABILITY TO USE,
THE PRODUCT. THE USER ASSUMES ALL RISK AND
LIABILITY WHATSOEVER IN CONNECTION WITH THE
USE OF THE PRODUCT, AND BEFORE DOING SO,
SHALL DETERMINE ITS SUITABILITY FOR HIS IN-
TENDED USE, AND SHALL ASCERTAIN THE PROPER
METHOD OF USING IT.
SOME STATES DO NOT ALLOW LIMITATIONS ON
HOW LONG AN IMPLIED WARRANTY LASTS, OR THE
EXCLUSIONS OR LIMITATIONS OF INCIDENTAL OR
CONSEQUENTIAL DAMAGES. SO THE ABOVE LIMITA-
TIONS OR EXCLUSIONS MAY NOT APPLY TO YOU. THIS
WARRANTY GIVES YOU SPECIFIC LEGAL RIGHTS, AND
YOU MAY HAVE OTHER RIGHTS WHICH MAY VARY
FROM STATE TO STATE.
ARC WELDING CAN BE INJURIOUS TO OPERA-
TOR AND PERSONS IN THE WORK AREA -——
CONSULT INSTRUCTION MANUAL BEFORE
OPERATING.
ELECTRIC SHOCK can kill.
•Do not touch electrodes or other electrically live parts.
•Insulate yourself from work and ground.
•Install and ground machine in accordance with the National
Electical Code and local code(s). Read Operating Manual
before installing or operating.
•Do not operate with protective covers, panels, or guard
removed.
•Disconnect input power before servicing.
•Only qualified personnel should install, use, or service this
equipment.
ARC RAYS can injure your eyes and burn
skin.
•Wear correct eye, ear, and body protection while welding.
FUMES AND GASES can be dangerous to your
health.
•Use enough ventilation and/or exhaust at the arc.
•Keep your head out of fumes.
•Do not breathe fumes.
READ AND UNDERSTAND THE
MANUFACTURER’S INSTRUCTIONS AND
YOUR EMPLOYER’S SAFETY PRACTICES.
See American National Standard Z49.1, “Safety in
Welding and Cutting”, published by the American
Welding Society, 2501 N.W. 7th St., Miami, Florida
33125; OSHA Safety and Health Standards, 29 CFR
1910 available from U.S. Dept. of Labor, Wash.,
D.C. 20210.
!WARNING
TABLE OF CONTENTS
INTRODUCTION ........................................................................... 1
DESCRIPTION, SPECIFICATIONS .............................................. 2
CHECK LIST (CONTENTS) .......................................................... 3
INSTALLATION & ELECTRICAL REQUIREMENTS .................... 3
OPERATION ................................................................................. 7
MAINTENANCE .......................................................................... 12
TROUBLE SHOOTING CHART .................................................. 14
CONNECTING TIG PACK OR SPOOL GUN ............................. 19
LINER INSTALLATION ............................................................... 20
PARTS BREAKDOWN - MIG TORCH ........................................ 21
OPTIONS - TIG PACK OR SPOOL GUN ................................... 23

Systematics, Inc. West Chester, PA. 19380 1
POWER SOURCE
WIRE SPOOL
FEED
ROLLS
WORK
MIG
TORCH
+
REVERSE
POLARITY
(STD.)
_
SHIELDING GAS
ELEC-
TRODE
WORK
INTRODUCTION
The Systematics PBE180 is a com-
bination welding power source, wire
feed unit, MIG torch and accessory
package, and is designed to meet the
requirements of the metal fabrica-
tion industries. The PBE180 pro-
duces fusion welds by the Gas Metal
Arc Welding process (GMAW or MIG),
on steel and aluminum up to "5/16"
thick, using .023" through .045"
steel wire and .025" through 3/64"
aluminum wire with the optional
MHG7 spool gun. (optional liners
must be purchased to cover given
wire sizes). Heavier sections can
be easily welded using slightly
different techniques.
The number of controls on the unit
have been reduced to assist inexpe-
rienced operators to learn MIG
welding. This facilitates rapid
set up for welding various thick-
nesses of material requiring vari-
ous heat inputs. The VOLTAGE
control adjusts the welding voltage
and the WIRE SPEED control adjusts
the speed of the wire feed motor.
SHORT ARC OR DIP TRANSFER
Short arc transfer occurs at 12 to
22 arc volts (voltage while weld-
ing), depending on wire size. Weld-
ing commences as the arc is struck
and a weld pool is formed. The tip
of the electrode wire dips into the
pool and causes a short circuit.
The short circuit current flow
causes a rapid temperature rise in
the electrode wire and the end of
the wire is melted off. An arc is
immediately formed between the tip
of the wire and the weld pool,
maintaining the electrical circuit
and producing sufficient heat to
keep the weld pool fluid. The
electrode continues to feed and
again dips into the pool.
THE MIG PROCESS
AS APPLIED TO THE PBE180
The MIG process uses a bare,
consumable electrode in the form of
spooled wire, which is fed by a
controllable speed feed unit
through the cable and torch to the
weld. The emerging wire and the
weld are shielded by a stream of
CO2, Argon, or a mixture of the two,
which prevents oxidation of the
molten weld puddle. The gas shield
enables high quality welds to be
made without the use of flux,
eliminating the need for slag or
flux removal after the weld is
completed.
The consumable electrode wire is
melted and transferred to the weld
puddle by any of three arc modes;
short arc transfer, globular trans-
fer, or spray arc transfer. The
PBE180 is capable of performing all
modes.
This sequence of events is re-
peated up to 200 times per second.
Short arc transfer is suitable for
positional welding. The heat input
to the workpiece is kept to a
minimum which limits distortion and
makes possible the welding of thin
sheet material.
FIG. 1. SCHEMATIC OF M.I.G. PROCESS
FIG. 2. SHORT ARC TRANSFER

2 Systematics, Inc. West Chester, PA. 19380
ELECTRODE GAS NOZZLE
SHIELDING GAS
WORK
ELECTRODE GAS NOZZLE
SHIELDING GAS
WORK
Welder controls are simple and
clearly marked. The output voltage
is controlled by a twelve position
tap switch, providing 4 TIG and 8
MIG voltage selections. Wire feed
speed is controlled by the wire
speed potentiometer.
SPECIFICATIONS
PART NUMBER: PBE180
INPUT POWER REQUIREMENTS:
Voltage 208/230
Phase single phase
Frequency 50/60 hertz
Current 22/20
OUTPUT POWER @ 60% Duty Cycle:
180 Amps
DUTY CYCLE TIME PERIOD: 10 minutes
OPEN CIRCUIT VOLTAGE:
18 - 35 volts DC
ARC VOLTAGE: 14 - 26 volts DC
WELD CURRENT RANGE: 30 - 180 amps
WIRE TYPES: mild steel,
Recommended (for steel) ER70S-6
stainless steel, aluminum,
bronze, flux cored,
flux cored - gasless
WIRE SIZES: .023" - .045" steel,
3/64" aluminum,
(.023" - 3/64" alum. w/spool gun)
.030" - .035" bronze,
.030" - .045" flux cored
(gas shielded or gasless)
Recommended Size:Aluminum .035
Others .030
SHIELDING GASES:
For Steel CO2 or Argon/CO2 mix
Recommended (for steel) 75% Argon/
25% CO2
For Aluminum, Bronze Argon
For Stainless Steel
Argon/2% Oxygen
For Flux cored CO2 or
Argon/CO2 mix
GLOBULAR TRANSFER
Globular transfer occurs at the
intermediate range of 22 to 24 arc
volts, depending on wire size. As
the name implies, the transfer
takes place in the form of irregu-
larly shaped globules. Globular
transfer is useful in cases where a
lower heat input than that of true
spray is required.
SPRAY TRANSFER
Spray transfer occurs at 22 to 32
arc volts, depending on wire size.
The length of the arc is held
constant by the voltage available.
The higher voltage and current
causes the electrode wire to melt
off before touching the workpiece.
The molten metal crosses the gap to
the workpiece in a spray form.
Spray transfer is used in the down-
hand position and provides higher
deposition rates than short arc
transfer or globular transfer.
DESCRIPTION
The PBE180 consists of a combina-
tion MIG welding power source and
wire feed unit, a MIG torch with 10
foot cable, a ten foot work cable
with clamp, a twenty foot power
input cable, a gas regulator -
flowmeter, a torch accessory kit,
and a built-in cylinder rack and
industrial wheel kit.
FIG. 3. GLOBULAR TRANSFER
FIG. 4. SPRAY TRANSFER

Systematics, Inc. West Chester, PA. 19380 3
WIRE FEED SPEED RANGE:
50 - 800 inches per minute
DIMENSIONS:
Height 34 in.
Width 14-1/2 in.
Depth 34-1/2 in.
Weight 165 lbs.
TORCH SPECIFICATIONS
NECK ANGLE: 60 degrees
LEAD LENGTH: 10 feet
OVERALL LENGTH: 10 feet
COOLING METHOD: gas (air)
RATING - DUTY CYCLE:
With Argon/CO2 gas 150 amps @ 100%
With CO2 gas 200 amps @ 100%
CHECK LIST
THE SYSTEMATICS PBE180 INCLUDES THE
FOLLOWING:
1- Combination Power Source/Wire
Feeder
1- Cylinder Rack/Industrial Wheel
Kit-Factory installed
1- 15TG10 MIG Torch with adjustable
nozzle
1- 20 foot Power Input Cable
1- 10 foot Work Cable and Clamp
1- MP250PK-1 Parts Kit
1- GR-FM Gas Regulator/Flowmeter
1- Nozzle, 1/2 in. orifice (in-
stalled on MIG torch)
1- Contact Tip, for .030 in. wire
(installed on MIG torch)
1- ER70S-6-30-3, Sample Spool of
.030 Steel Wire
ITEMS REQUIRED FOR MIG WELDING
WHICH ARE NOT PROVIDED WITH THE
PBE180
1. Full cover welding helmet with
proper colored lens (shade 9 to
11 depending on operator’s pref-
erence).
2. Proper shielding gas and cylin-
der.
3. Leather welding gloves.
4. 208 or 230 volt 40 amp single
phase AC power.
5. Other personal protective
equipment which may vary to
match the welding being per-
formed.
INSTALLATION
POSITIONING THE UNIT
Locate the unit adjacent to the
welding area and position it so
there is adequate clearance all
around for ventilation and mainte-
nance.
ELECTRICAL SUPPLY
Ensure that there is a 208 or 230
volt, single phase, 40 amp electri-
cal supply within easy reach of the
unit. The input cable supplied is 20
feet long. A 50 foot cable is an
optional extra. Attach a suitable
plug making sure the green wire is
attached to the ground terminal of
the wall plug. All wiring should be
performed by a qualified electri-
cian.
230V INPUT SELECTION
1. Factory selected no change is
needed.
208V INPUT SELECTION
1. Remove the top cover.
SPECIFICATIONS (Cont.)
(continued on following page)

4 Systematics, Inc. West Chester, PA. 19380
CONTACTOR SWITCH
CONNECT
"230" WIRE FOR
OPERATION ON
230 VOLT INPUT.
CONNECT "208"
WIRE FOR
OPERATION ON
208 VOLT INPUT
FRONT OF
MACHINE
2. Rapidly open and close the cyl-
inder valve. This will purge
dust and foreign matter from the
valve.
CAUTION
Take care to point the
valve outlet away from
yourself or other people,
as escaping high pressure
gas may be dangerous.
3. Attach the gas regulator - flow-
meter supplied with this unit,
to the cylinder valve using a
suitable wrench.
NOTE
If this unit is to be used
with 100% CO2 shielding
gas, an optional gas regu-
lator coupler is required.
2. Locate the contactor switch,
which is mounted on top of the
main power transformer(See Fig-
ure 5).
CAUTION
MAKE SURE POWER SOURCE IS
UNPLUGGED BEFORE MAKING IN-
PUT SELECTION CHANGE-OVER.
3. Attached to the power source’s
contactor is one (2) two posi-
tion plug which allows easy
selection of input voltages of
either 208 or 230 volts.
4. Remove the one (1) plug labeled
230V and connect the one (1) plug
labeled 208V.
5. Reattach the top cover of the
machine. Voltage input selec-
tion is now complete.
SHIELDING GAS CONNECTIONS
1. Place a cylinder of the appro-
priate shielding gas in the rack
at the rear of the machine and
secure it with the chain pro-
vided. See recommended gases on
page 2.
4. Fit the gas hose from the welding
machine to the regulator outlet
fitting and tighten it with a
suitable wrench. Open the cyl-
inder valve.
FIG. 5. INPUT VOLTAGE SELECTIONS
FIG. 6. GAS FLOW ADJUSTMENT
GAUGE -
INDICATES
TANK
PRESSURE
OUTLET
FITTING
TO
WELDING
MACHINE
GAS FLOW
ADJUSTING
KNOB
INLET
FITTING
TO
TANK
FLOW TUBE
INDICATES
FLOW RATE
IN C.F.H.

Systematics, Inc. West Chester, PA. 19380 5
FITTING AND THREADING THE ELECTRODE
WIRE - ALWAYS USE ER70S-6 WELDING
WIRE WHEN WELDING STEEL.
1. Remove the wire spool clip from
the spool hub.
2. Unpack the spool of welding wire
from its protective packaging.
3. Place the spool of ER70S-6 weld-
ing wire onto the hub. The wire
is fed off the bottom of the
spool.
CAUTION
Look for wire protruding
from the center of the
spool. The protruding wire
is electrically HOT during
welding and must not touch
the machine. Cut this wire
flush with the spool.
4. Replace the spool clip on the
hub.
5. Unlatch the pressure roll arm
and swing it open.
6. Make sure the double v-groove
drive roll is installed to match
the wire size. To change the
wire size setting, remove the
drive roll, turn it over and
reinstall it on the shaft.
(continued on following page)
"B" SIDE FACING IN FOR
.023" - .035" STEEL WIRES
"C" SIDE FACING IN FOR
.040" - .045" STEEL WIRES
AND 3/64" ALUMINUM WIRES
5. Check that the gas regulator is
properly adjusted. When welding
steel, the gas flow rate is 30
CFH. When welding aluminum, the
gas flow rate is 40 CFH.
NOTE
The PBE180 must be turned
"ON" and the MIG torch
trigger depressed, before
the gas flow rate can be
adjusted.
TORCH CONNECTION
1. Open the access door of the
machine to its fullest extent.
2. Back out the thumb screw located
on the drive assembly mounting
bracket inside the machine. In-
sert the MIG torch into the torch
panel mount on the front panel
and TIGHTEN THE THUMB SCREW.
SHIELDING GAS CONNECTIONS (Cont.)
DRIVE
ASSEMBLY
MOUNTING
BRACKET
DRIVE
ROLL
TORCH
PANEL
MOUNT
THUMB
SCREW
PRESSURE
ROLLS
MIG
TORCH
INLET
GUIDE
FIG. 7. TORCH CONNECTION
FIG. 8. DOUBLE GROOVE DRIVE ROLL

6 Systematics, Inc. West Chester, PA. 19380
7. Release the wire from the spool
and trim off the kinked end with
wire cutters. The wire must be
straight when it enters the
inlet guide.
8. Thread the electrode wire
through the inlet guide, over
the feed roll and into the outlet
guide. Ensure that the wire
locates in the feed roll groove.
Do not allow the wire on the
spool to loosen.
9. Close and relatch the pressure
roll arm.
10.Stretch the torch cable straight
out in front of the machine
making sure there are no kinks.
Remove the nozzle and contact
tip from the torch.
11.Turn "ON" the circuit breaker on
the front of the machine. The
cooling fan will start and the
"ON" indicator light will illu-
minate. Set the TIG/MIG VOLTAGE
control switch to "MIG 3" and the
WIRE SPEED control to "5". Pull
the trigger on the MIG torch.
The wire feed system will start
and wire will be fed through the
cable liner and torch. If the
wire does not feed, or appears to
slip, tighten the pressure roll
arm adjusting nut. Feed the wire
until it protrudes from the
front of the torch approximately
six inches.
CAUTION
Keep hands and face away
from the front of the torch
and do not allow the wire to
contact the Work. The wire
is electrically HOT when
the torch trigger is actu-
ated.
12.Install the contact tip over the
protruding wire and tighten it
firmly using a proper size
wrench. Make sure the tip is the
correct size for the wire being
used.
13.Install the nozzle on the torch.
For steel, the contact tip
should be flush or stick out up
to 1/16 inch beyond the end of
the nozzle. For aluminum, the
contact tip should be recessed
1/8 to 1/4 inch inside the
nozzle. Using wire cutters,
trim off the wire so the stickout
is approximately 1/4 inch for
steel or 1 inch for aluminum.
For aluminum, the end of the wire
should be bent over so it does
not JAM into the work. This is
called a "scratch start".
14.For steel welding only, spray
anti-spatter compound inside
the nozzle and on the outside of
the contact tip. For aluminum or
stainless steel welding, NO
anti-spatter compound can be
used as it will contaminate the
weld.
FITTING AND THREADING THE ELECTRODE
WIRE (Cont.)
FOR ALUMINUM:
CONTACT TIP
RECESSED 1/8" - 1/4"
FOR STEEL:
CONTACT TIP
FLUSH WITH NOZZLE
1/4"
STICK-OUT
1"
STICK-OUT
FIG. 9. WIRE STICKOUT - STEEL, ALUMINUM

Systematics, Inc. West Chester, PA. 19380 7
WIRE FEED PRESSURE ROLL ADJUSTMENT
The wire feed pressure roll is
adjusted to the proper setting at
the factory, prior to delivery. It
may be necessary to readjust the
setting as components "seat in" or
when changing to a different diame-
ter wire. To check for proper roll
pressure, hold the torch in one hand
and the wire between two fingers of
the other hand. Pull the torch
trigger. If the wire continues to
feed when firm pressure is applied
to the wire, the pressure roll
adjusting nut should be backed off
until the feed rolls start to slip.
If the wire will not feed with very
little pressure applied, the pres-
sure roll adjusting nut should be
tightened.
OPERATION
The following operating instruc-
tions and detailed setup procedures
enable an operator without previous
experience to produce quality fu-
sion welds. It is recommended that
an operator without prior experi-
ence with this equipment, first
practice on scrap metal of the same
type and thickness as the material
to be welded.
OPERATING SEQUENCE
1. Make sure that the pieces of
metal to be welded are free of
grease, dirt, paint and scale.
Use a wire brush to remove paint
and scale. Paint must be com-
pletely removed to bare metal.
Grease and oil could burn and
cause a fire or safety hazard.
Failure to clean the metal prop-
erly will result in erratic and
porous welds.
2. Install the unit as directed in
the installation instructions
and make sure the work clamp is
firmly attached to a cleaned
area on the workpiece to be
welded.
3. Open the shielding gas cylinder
valve. Press the torch trigger
and listen for gas flow.
CAUTION
The welding wire will feed
when the trigger is actu-
ated. Take care that the
wire is not directed to hit
yourself or anything that
is common to the work cable
on the welder.
PRESSURE
ROLL ARM
PRESSURE
ROLL
DRIVE
ROLL
TORCH SELECTOR CABLE
Plug the torch selector cable
into the Positive (+) terminal on
the machine (see PROCESS SELECTION
on page 8 for further details).
WORK (GROUND) CABLE
Uncoil the work (ground) cable
and plug it into the negative (-)
terminal on the machine.
FIG. 10. PRESSURE ROLL ADJUSTMENT
PRESSURE ROLL
ADJUSTING NUT

8 Systematics, Inc. West Chester, PA. 19380
PROCESS SELECTION
The following controls are lo-
cated on the front of the PBE180.
F. (-)NEGATIVE TERMINAL
Negative output terminal. The
work cable is plugged into this
terminal during standard weld-
ing operation. The torch selec-
tor cable can be plugged into
this terminal for straight po-
larity welding on very light
sheet metal, or for using flux
cored gasless wire.
G. MODE SWITCH (PBE180S ONLY)
Controls mode of operation of
welding machine. "CONT." posi-
tion is for normal, continuous
welding operation. "SPOT" posi-
tion puts the spot timer in the
circuit for automatic MIG Con-
sumable Spot Welding. "STITCH"
position is used for stitch
welding on very light materials.
H. SPOT/STITCH TIME (PBE180S ONLY)
After the torch trigger is actu-
ated, the timer allows the wire
to feed and the gas and power to
flow for the time selected. The
Mode Switch must be set in "SPOT
or STITCH" position for timing
operation.
I. TORCH PANEL MOUNT
Combination power output, con-
tactor switch connection, gas
supply connection, and wire feed
output in a single unit.
J. TORCH SELECTOR CABLE
Plugs into (+) positive terminal
for standard welding operation
or (-) negative terminal for
straight polarity welding on
very light sheet metal, or for
using flux cored gasless wire.
K. (+)POSITIVE TERMINAL
Positive output terminal from
the welder DC power source. The
torch selector cable is plugged
into this terminal for standard
welding operation. The work
cable can be plugged into this
terminal for straight polarity
welding on very light sheet
metal, or for using flux cored
gasless wire.
A.
WIRE
SPEED
B.
MIG/TIG
VOLTAGE
SWITCH
C.
VOLT-
METER
D.
CIRCUIT
BREAKER
E.
"ON"
INDICATOR
LIGHT
F.
(-)NEGATIVE
TERMINAL
G.
MODE
SWITCH
(PBE180S
ONLY)
H.
SPOT/
STITCH
TIME
(PBE180S
ONLY)
I.
TORCH
PANEL
MOUNT
J.
TORCH
SELECTOR
CABLE
K.
(+)POSITIVE
TERMINAL
A. WIRE SPEED
Potentiometer controls speed of
wire drive motor to give wire
speed of 50 to 800 inches per
minute.
B. MIG/TIG VOLTAGE SWITCH
Twelve position switch provides
"4" TIG (requires optional TIG
PACK) and "8" MIG voltage set-
tings.
C. VOLTMETER
Indicates open circuit voltage
when torch trigger switch is
activated and arc (welding)
voltage during welding.
D. CIRCUIT BREAKER
Primary power switch and over-
load protection device.
E. "ON" INDICATOR LIGHT
Illuminates when the circuit
breaker on the machine is "ON".
FIGURE 11. FRONT PANEL

Systematics, Inc. West Chester, PA. 19380 9
WELDING
Optimum control settings will
vary according to the thickness of
the metal, the type of joint,
operator preference, etc. Best
results can be obtained through
experience with the welding machine
or by making trial welds. Select
some sample material of the same
type and thickness as the material
to be welded. Set the welding
controls for optimum results using
the sample material thickness and
wire size being used as a starting
point, weld until experience is
gained using the unit.Refer to the
chart inside the access door for the
approximate welder settings.
CONTINUOUS WELDING ON
STEEL
1. Trim the electrode wire to leave
approximately 1/4 inch stickout
beyond the end of the contact tip
and install the welding nozzle.
The contact tip should be flush
or stick out up to 1/16 inch
beyond the end of the nozzle.
NOZZLE
CONTACT TIP
(FLUSH TO
1/16" STICKOUT)
ELECTRODE WIRE
(1/4" STICKOUT)
NOTE
When welding steel, the ideal
position for holding the torch
is inclined approximately 30
degrees towards the direction
of travel. This allows the arc
to be seen easily, resulting
in greater control of the weld
pool. Most right-handed wel-
dors move from left to right.
This method, known as forehand
welding, provides a gas shield
for the cooling weld puddle
and helps in obtaining an
oxidation free weld deposit.
2. Spray the inside of the nozzle
and the outside of the contact
tip with anti-spatter compound.
3. Locate the torch over the joint
to be welded with the contact tip
approximately 3/4 inch from the
work surface.
FIG. 12. NOZZLE ADJUSTMENT
FOR WELDING STEEL
FIG. 13. TORCH POSITION
FOR WELDING STEEL
- RIGHTHANDED WELDOR
WORK
SHIELDING
GAS
30 DEGREES
DIRECTION
OF TRAVEL
4. Use a welding helmet with a shade
9 to 11 filter lens, depending on
operator preference.
5. Squeeze the torch trigger. The
wire will feed and an arc will be
established. As the weld is
deposited, move the torch slowly
along the weld seam at a constant
speed, while maintaining a con-
stant arc length and a constant
tip-to-work distance.

10 Systematics, Inc. West Chester, PA. 19380
CONTINUOUS WELDING
ON ALUMINUM
(Optional Nylon liner and 100%
Argon shielding gas are required)
1. Trim the electrode wire, leaving
approximately 1 inch stickout
beyond the end of the nozzle.
Bend the wire over as shown, to
allow for a scratch start. The
contact tip should be recessed
inside the nozzle approximately
3/8 inch. This helps prevent the
welding wire from burning back
to the contact tip.
2. DO NOT spray any anti-spatter
material on the torch or base
metal and DO NOT attempt to
lubricate the aluminum wire in
any way. Weld contamination
will occur unless the wire, base
metal, torch and work area are
kept clean.
3. Bring the torch nozzle to 1/2 to
5/8 inch from the workpiece.
The recommended position of the
torch and direction of travel
for welding aluminum are shown
in the following illustration.
4. Follow steps 4 and 5 as in
"Continuous Welding on Steel".
FIG. 15. TORCH POSITION
FOR WELDING ALUMINUM
FIG. 14. NOZZLE ADJUSTMENT
FOR WELDING ALUMINUM
ELECTRODE
WIRE
(1" STICKOUT)
NOZZLE
CONTACT TIP
(RECESSED 3/8")
SHIELDING GAS
10 DEGREES
WORK
DIRECTION
OF TRAVEL

Systematics, Inc. West Chester, PA. 19380 11
FIG. 17. STITCH WELDING
DIRECTION
OF TRAVEL
30 DEGREES
WORK SHIELDING GAS
MIG SPOT WELDING ON STEEL
(PBE180S ONLY)
NOTE
MIG Spot Welding is NOT
recommended for aluminum.
1. Trim the electrode wire so the
stickout from the contact tip
will be flush with the nozzle
face, and fit the spot nozzle in
place.
2. Set the VOLTAGE on the welder
around 20 volts, the WIRE FEED
control "8", the MODE Switch to
"SPOT", and the TIME control to
"3", then adjust the controls to
obtain a perfect weld.
3. Locate the torch on the area to
be welded and press the nozzle
firmly against the work to hold
the metals in place.
4. Guard the eyes against stray arc
flash. A weldor’s helmet is not
necessary when spot welding,
however, care must be taken to
avoid looking at the arc.
5. Activate the torch trigger to
start the weld sequence. When
the timer switches off the weld
current, release the trigger but
maintain firm contact between
the torch and work. Wait one
second for the weld puddle to
solidify, then move to the next
spot position. If the wire
"freezes" in the puddle, a quick
squeeze of the torch trigger
will melt it off.
6. To ascertain a good spot weld,
look at the back side of the
welded material. A small melt-
through of approximately 1/16
inch diameter is ideal.
STITCH WELDING ON STEEL
(PBE180S ONLY)
NOTE
Stitch Welding is used for
very light material.
1. Set MODE Switch to "STITCH".
2. Adjust the TIME control to set
the time the welder is "on" and
feeding wire. The lower the
setting, the shorter the "on"
time and the faster the unit
cycles on and off.
3. Weld using "Continuous Welding"
torch position and direction of
travel.
FIG. 16. MIG SPOT WELDING
PRESS NOZZLE
FIRMLY
AGAINST WORK
SPOTWELD
NOZZLE
CONTACT
TIP
SPOTWELD WORK

12 Systematics, Inc. West Chester, PA. 19380
The frequent use of anti-spatter
spray will help prevent the adher-
ence of spatter to the torch compo-
nents.
NOTE
DO NOT use any anti-spatter
spray when welding aluminum or
stainless steel.
Restricted gas flow, holding the
torch too far from the work piece,
and the use of CO2 gas rather than
75% Argon - 25% CO2 will increase
the spatter levels.
MAINTENANCE
To ensure that this equipment
maintains its operating effi-
ciency, the following maintenance
schedule and procedures are recom-
mended. These routines should be
performed regularly by the opera-
tor.
REGULARLY - Usage and shop condi-
tions determine frequency.
1. Remove and clean the torch
nozzle and contact tip. The use
of anti-spatter compound will
reduce the adherence of spatter
and makes its removal easier.
2. Blow out the torch liner prior to
the installation of each new
spool of wire. The contact tip
and gas diffuser must be re-
moved, but it is not necessary to
remove the liner.
3. If the torch cable assembly is
bent severely, a kink may devel-
ope in the steel liner. This can
cause wire feeding problems so a
new liner should be installed.
OPERATING HINTS
BURN BACK
In the event the welding wire
burns back into the contact tip:
1. Remove the nozzle from the
torch.
2. Unscrew the contact tip from the
gas diffuser using a pair of
pliers as the tip will be very
hot.
3. Free the wire from the contact
tip and clean the end of the tip
so the new wire will slide
smoothly through the hole. DO
NOT use a drill or reamer to
clean the hole as they will
enlarge it and cause an erratic
arc. Replace the contact tip if
it is badly damaged.
4. Install the contact tip in the
torch and tighten it firmly with
an appropriate wrench.
5. Reinstall the torch nozzle.
6. If the wire continues to burn
back, check for erratic wire
feed, or speed up the wire by
increasing the WIRE SPEED con-
trol setting or reducing the
VOLTAGE control setting.
SPATTER
Before beginning to weld and
periodically during welding, the
torch nozzle must be removed and the
spatter (small globules of melted
metal) cleared from the inside of
the nozzle and the outside of the
contact tip and the gas diffuser.
Spatter buildup between the contact
tip and the nozzle can cause a short
circuit and consequently, failure
of the torch or welding machine. (continued on following page)

Systematics, Inc. West Chester, PA. 19380 13
WEEKLY
1. Remove dirt and dust from the
wire feed compartment. Use low
pressure dry compressed air.
2. Remove dirt and metal deposits
from the grooves in the feed
roll. If the grooves are badly
worn, the feed roll should be
replaced. If the pressure roll
does not turn freely, it should
be replaced.
3. Check all gas fittings for
leaks. Tighten or repair as
required.
EVERY SIX MONTHS
1. Disconnect the welder from its
main power supply.
2. Remove the machine’s side pan-
els.
3. Using low pressure dry com-
pressed air, remove dust and
dirt from all components.
4. Check for loose or frayed wir-
ing. Particularly check welding
current wire connections.
5. Replace torch liner if neces-
sary.
RECOMMENDED
CUSTOMER SPARE PARTS
The Systematics PBE180 is a ma-
chine of proven design and relia-
bility. Following is a list of
consumable items recommended as
spare parts for this unit.
contact tips ....... M3-T30, etc.
gas nozzles ............. M3T-N50
nozzle insulators ......... M3T-B
gas diffusers ............. M3T-D
steel liner(.020-.030) .. M103L-B
steel liner(.035-.045) .. M104L-N
In the event of the failure of any
part of this equipment, contact
your Systematics representative
for replacement parts and service.
WARNING
DO NOT lift the unit when a gas
cylinder is installed or at-
tached.
DO NOT weld on any item that
has a common electrical
ground.
DO NOT operate the unit with
the side panels removed.
Overheating will occur.
DO NOT weld upon the case of
the welding machine.
ONLY a qualified electrician
should perform work inside the
welding machine.
ALWAYS wear protective cloth-
ing, leather gloves and a full
cover welding hood while weld-
ing.
DO NOT weld in a closed in
area. Proper ventilation is a
necessity, or a fresh air
supplied hood should be worn.
WHEN welding near com-
bustibles, a helper or
"watcher" should stand by with
a fire extinguisher or other
fire protective device.
NEVER weld on a closed vessel
or one that has contained
combustibles.
IF IN DOUBT - DON’T DO IT!
BE SAFE - DON’T BE SORRY!
MAINTENANCE (Cont.)

14 Systematics, Inc. West Chester, PA. 19380
TROUBLE SHOOTING (SYMBOL*)
FOR TECH. SERVICE, CALL 1-610-696-9040
The Trouble Shooting Chart is a guide in identifying and correcting
possible troubles which may occur when operating this equipment.
FAULT POSSIBLE CAUSE REMEDY
EQUIPMENT MALFUNCTION
No main power, PBE180 switch is "OFF". (CB1) Turn switch "on".
fan does not Wall breaker is "tripped". Reset wall breaker.
operate, "Open" circuit breaker Reset or replace
"on" indicator on PBE180. (CB1) breaker.
light is off. Loose or broken connection Tighten or repair
in power input circuit. connection.
Main power on, MIG torch unplugged. Plug in MIG torch.
torch Faulty trigger switch. (S1) Replace micro switch.
trigger Fault in torch cable. Check torch cable
activated, for continuity.
no response. Loose or broken connection Check or repair
on wiring harness. connections.
Wire feed motor unplugged. Plug in motor.
(RC1)
Faulty control transformer. Check for 28VAC output.
(T2)
Loose spot timer circuit Install properly.
board. (PBE180S ONLY) (PC2)
Defective spot timer Replace board.
circuit board.
(PBE180S ONLY) (CR2)(PC2)
Main power on, Pressure roll arm unlatched. Latch arm & add tension.
torch "Slippage" at drive rolls. Increase drive roll
trigger tension. See page 7.
activated, Wire path restricted. Clean path or replace
no wire feed torch liner.
but contactor 5 amp mini breaker is Reset or replace
operates & tripped. (CB2) breaker.
gas flows. Wire feed circuit board Calibrate wire feed
needs calibrated. circuit board. See
page 18.
Defective wire feed Replace circuit board.
circuit board. (PC1)
Faulty wire feed motor Repair or replace
or connection. (M) faulty item.
Check motor on a
12VDC battery.
Faulty motor relay. (CR1) Sand points or replace
relay.
Loose or broken connection. Tighten or repair
connection.
(SYMBOL*) - USE THIS IDENTIFIER, ALONG WITH THE SCHEMATIC DIAGRAM FOUND IN THE SERVICE
MANUAL, FOR TROUBLE-SHOOTING PURPOSES.

Systematics, Inc. West Chester, PA. 19380 15
FAULT POSSIBLE CAUSE REMEDY
TROUBLE SHOOTING (Cont.) (SYMBOL*)
FOR TECH. SERVICE, CALL 1-610-696-9040
(continued on following page)
EQUIPMENT MALFUNCTION (Cont.)
Main power on, Loose torch thumb screw. Tighten thumb screw.
torch Broken or loose connection. Check cables for
trigger continuity.
activated, Repair or tighten
no welding connections.
current, but Unplugged or faulty power Plug in or replace
gas flows & contactor switch. (W) switch.
wire feeds. 208/230 Selector wire off. (W) Reattach wire.
"Opened" thermal switch. Allow unit to cool, then
(TP1) retry.
Faulty diodes. Check diodes. See page
(D1-D4) 17.
Torch No shielding gas Replace tank.
trigger - tank empty.
activated, Loose or broken Tighten or repair
no gas flow, connections. connections.
but contactor Faulty Gas solenoid Repair or replace
operates & valve. (GS) valve.
wire feeds. Clogged gas flow path. Locate & clean clog.
Loose spot timer circuit Install properly.
board. (PBE180S ONLY) (PC2)
Defective spot timer Replace board.
circuit board.
(PBE180S ONLY) (CR2)(PC2)
FAULTY WELDS
"Jerky" or Worn , kinked or dirty torch Clean or replace
"slipping" liner. liner.
wire feed. Wire spool turns too Lubricate spool shaft.
hard.
Worn double v-groove drive Replace drive roll.
roll.
Weak pressure roll spring. Replace spring.
Worn or dirty contact tip. Replace contact tip.
Worn inlet guide(s). Clean or replace guides.
Sticking pressure roll. Replace pressure roll.
Feed roll tension incorrect. Adjust feed roll ten
sion. See page 7.

16 Systematics, Inc. West Chester, PA. 19380
TROUBLE SHOOTING (Cont.) (SYMBOL*)
FOR TECH. SERVICE, CALL 1-610-696-9040
FAULT POSSIBLE CAUSE REMEDY
FAULTY WELDS (Cont.)
"Birdnesting" Excessive feed roll tension. Reduce tension. See page
(Wire wrapping 7.
around drive Poor alignment. Make sure wire is
rolls) properly aligned
across roller.
Oversize contact tip. Replace contact tip with
correct size.
"Cold" weld Incorrect machine settings. Increase heat & wire
puddle. speed.
Incorrect shielding gas. Replace with proper gas.
Excessive wire stick-out. Hold torch closer to
work.
Poor connections. Check and tighten all
connections.
Faulty diode. Test diodes, replace
(D1-D4) faulty diode(s). See
page 17.
Heavy spatter. Incorrect machine settings. Increase heat, decrease
wire feed speed.
Incorrect shielding gas. Replace with proper gas.
Excessive wire stick-out. Hold torch closer to
work.
Porous welds. No shielding gas. Turn on gas.
Not enough gas flow. Check hoses for leaks,
make sure cylinder is
not empty. Increase
flow rate.
Contaminated wire. Change wire.
Faulty gas solenoid. Replace solenoid.
(GS)
Incorrect electrode wire. Use correct wire.
Contaminated base material. Clean or etch base
material.
(SYMBOL*) - USE THIS IDENTIFIER, ALONG WITH THE SCHEMATIC DIAGRAM FOUND IN THE SERVICE
MANUAL, FOR TROUBLE-SHOOTING PURPOSES.

Systematics, Inc. West Chester, PA. 19380 17
12 VOLT
BAT-
TERY
DIODE
12 VOLT
LIGHT BULB
12 VOLT
BAT-
TERY
12 VOLT
LIGHT BULB
DIODE
+-
+-
TESTING AND REPLACING DIODES
Silicon diodes have proven to be
highly reliable. However, weld
spatter build-up in the torch can
short out and cause diode overload
and consequent failure. The follow-
ing information is provided as a
guide should a failure be sus-
pected.
Silicon diodes exhibit two main
fault conditions:
1. "Open Circuit" - causes a reduc-
tion in welder output.
2. "Short Circuit" - causes the
circuit breaker to trip.
If a fault is suspected, the diode
may be tested as follows:
1. Remove the top connection of
each diode to be tested.
2. Using a Volt-Ohm Meter set on
RX1K, check for continuity
through the diode in both direc-
tions. If there is no continuity
in either direction, the diode
is in "open circuit" condition
and must be replaced. If there
is continuity in both direc-
tions, the diode is in "short
circuit" condition and must be
replaced. If there is continu-
ity in one direction only, the
diode is functioning properly.
3. If all the diodes check out
satisfactorily with the Volt-
Ohm Meter, a load check must be
made. This is easily accom-
plished using a twelve volt
battery and a twelve volt light
bulb connected as shown. Again
test for electrical current flow
in both directions. The bulb
should light in one (1) direc-
tion only - not both.
CAUTION
NEVER use a "megger" or a
high voltage device to test
a diode.
4. When replacing diodes, it is
very important that a heat con-
ductive compound (Radio Shack
#276-1372) be used where the
diode makes contact with the
aluminum heat sink. Do not
grease the threads on the diode.
FIG. 18. DIODE LOAD CHECK CONNECTION
DIAGRAM - TEST FOR FLOW IN BOTH
DIRECTIONS

18 Systematics, Inc. West Chester, PA. 19380
TRIM
RESISTOR
WIRE FEED CALIBRATION
Due to INPUT LINE VOLTAGE varia-
tions supplied to the welding ma-
chine. The WIRE FEED SPEED should be
checked for proper operation.
TO CHECK
1. Remove any tension on the drive
roll.
2. Turn the wire speed dial (on the
front of the machine) to "0".
3. Activate the torch trigger.
4. The bottom drive roll should
rotate very slowly(non-jerky).
5. If this proves to be true, no
adjustment is required.
IF ADJUSTMENT IS REQUIRED
1. Remove the top cover assembly
from the unit.
2. Locate the printed circuit
board(s).
3. Referring to Figure 19, locate
the trim resistor, this is lo-
cated in the upper right hand
corner of the wire feed PC board.
4. Turn the wire speed dial (on the
front of the machine) to "0".
5. Remove any tension on the drive
roll.
6. Activate the torch trigger.
7. Rotate the trim resistor, back
and forth, until the bottom
drive roll moves.
8. Calibrate so the bottom drive
roll rotates very slowly (non-
jerky).
9. If calibrated correctly the wire
speed dial (on the front of the
machine) should affect the speed
of the drive roll from "0" thru
"10".
10.Adjustment is now complete!
FIG. 19. WIRE FEED PC BOARD