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MP140 MIG COMBINATION UNIT

OWNER'S MANUAL

THE

MP140

REPRESENTS THE LATEST TECHNOLOGY
IN MIG COMBINATION UNITS. THE MP140 OPERATES
ON

115 VOLT AC

SINGLE PHASE CURRENT, AND FEATURES

"SMOOTH ARC" TRANSFORMER DESIGN CONCEPT.

FOR TECH. SERVICE, CALL 1-610-696-9040

INSTALLATION

OPERATION

MAINTENANCE

FORM WC5342

Rev. 8/00

Summary of Contents for MP140

Page 1: ...EPRESENTS THE LATEST TECHNOLOGY IN MIG COMBINATION UNITS THE MP140 OPERATES ON 115 VOLT AC SINGLE PHASE CURRENT AND FEATURES SMOOTH ARC TRANSFORMER DESIGN CONCEPT FOR TECH SERVICE CALL 1 610 696 9040 INSTALLATION OPERATION MAINTENANCE FORM WC5342 Rev 8 00 ...

Page 2: ...S 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 a...

Page 3: ...it or higher Never change fuses or circuit breakers to a higher value than the wires and outlet are designed for Breaker size Wire size 15 Amp 14 Gauge 20 Amp 12 Gauge 30 Amp 10 Gauge Do not rely on the circuit breaker built into the MP140 to protect your wiring This circuit breaker protects the MP140 internal wiring only Do not use undersized extension cords Follow the cord manufacturer s recomme...

Page 4: ...e 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 eliminat ing the need for slag or flux removal after the weld is com pleted The consumable electrode wire is melted and transferred to the weld puddle by t...

Page 5: ...OWER REQUIREMENTS Voltage 115 volts AC Phase single phase Frequency 50 60 hertz Current see OUTPUT POWER OUTPUT POWER 100 Duty Cycle 15 Amps Input Current 100 Amps 20 Amps Input Current 120 Amps OUTPUT POWER 60 Duty Cycle 30 Amps Input Current 140 Amps DUTY CYCLE TIME PERIOD 10 minutes OPEN CIRCUIT VOLTAGE 18 33 volts DC SPECIFICATIONS Cont ARC VOLTAGE 14 24 volts DC WELD CURRENT RANGE 30 140 amps...

Page 6: ... POSITIONING THE UNIT Locate the unit near the welding area and position it so there is adequate clearance all around for ventilation and maintenance ELECTRICAL SUPPLY Follow the Electrical Supply Requirements on page 1 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 provided 2 Rapidly open and close...

Page 7: ...inued on following page SHIELDING GAS CONNECTIONS Cont 4 Fit the gas hose from the welding machine to the regula tor outlet fitting and tighten it with a suitable wrench Open the cylinder valve 5 Check that the gas regulator is properly adjusted When weld ing steel the gas flow rate is 30 CFH When welding aluminum the gas flow rate is 40 CFH NOTE The MP140 must be turned ON and the MIG torch trigg...

Page 8: ...en 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 VOLTAGE control switch to 4 the function switch to CONTINUOUS WELD if the...

Page 9: ... 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 properly will result in erratic and porous welds 2 Install the unit as directed in ...

Page 10: ...orch 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 I NEGATIVE TERMINAL Negative output terminal The work cable is plugged into this terminal during standard weld ing operation The torch se lector cable can be plugged into this t...

Page 11: ...e and thickness as the material to be welded Refer to the Parameter Chart located on the access door to the wire feed compartment 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 CONTINUOUS WELDING ON STEEL 1 Trim the electrode wire to leave approximately 1 4 inch stickout be...

Page 12: ...ction 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 fore hand welding provides a gas shield for the cooling weld puddle and helps in obtaining an oxidation free weld de posit 4 Use a welding helmet with a shade 9 to 11 filter lens depending on operator prefer ence 5 Squeeze the t...

Page 13: ...r 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 figure 13 4 Follow steps 4 and 5 as in Continuous Welding on Steel FIGURE 12 NOZZLE ADJUSTMENT FOR WELDING ALUMINUM MIG SPOT WELDING ON STEEL OPTIONAL NOTE MIG Spot Welding is N...

Page 14: ...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 OPTIONAL NOTE Stitch Welding is used for very light material 1 Set Function Switch to STITCH 2 Adjust the TIM...

Page 15: ... gas diffuser Spatter buildup be tween the contact tip and the nozzle can cause a short circuit and consequently failure of the torch or welding machine The frequent use of anti spatter spray will help prevent the adherence of spatter to the torch components NOTE DO NOT use any anti spat ter spray when welding aluminum or stainless steel Restricted gas flow holding the torch too far from the work ...

Page 16: ...s contained combustibles IF IN DOUBT DON T DO IT BE SAFE DON T BE SORRY MAINTENANCE Cont 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 fitt...

Page 17: ...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 MP140S Install properly circuit board PC2 Defective spot timer MP140S Replace board circuit board CR2 PC2 Main power on Pressure roll arm unlatche...

Page 18: ...orch 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 MP140S Install properly circuit board PC2 Defective spot timer MP140S Replace board circuit board CR2 PC2 FAULTY WELDS Jer...

Page 19: ...ld torch closer to work Poor connections Check and tighten all connections Faulty diode Test diodes replace D1 D2 faulty diode s See page 18 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 le...

Page 20: ...t condition and must be replaced If there is continu ity in both directions the diode is in short circuit condition and must be replaced If there is continuity in one direction only the diode is functioning properly CAUTION 12 VOLT LIGHT BULB DIODE 12 VOLT BATTERY 12 VOLT LIGHT BULB DIODE 12 VOLT BATTERY 3 If all the diodes check out satisfactorily with the Volt Ohm Meter a load check must be made...

Page 21: ...IRED 1 Remove the top cover assembly from the unit 2 Locate the printed circuit board s 3 Referring to Figure 17 locate the trim resistor this is located 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 dr...

Page 22: ... OPERATION TO TIGIT2 OPERATION 1 Unplug the wire feed motor plug from the function receptacle 2 Unplug the torch selector cable and the work ground cable from the welder front panel 3 Plug the TIGIT2 torch power cable into the negative weld connector and plug the work ground cable into the positive weld connector This provides straight polar ity current as required for TIG welding 4 Plug the TIGIT...

Page 23: ...he torch assembly INSTALLING NEW LINER 1 Remove the new liner from the package 2 Uncoil liner and lay the liner parallel next to the MIG torch assembly 3 Adjust the liner stickout length to 3 4 as shown in fig 19 3 4 LINER STICKOUT GAS SEAL SET SCREW 3 4 CONNECTOR PLUG 1 1 4 PROTRUDING LINER NECK ASSEMBLY 4 Install the new liner into the MIG torch assembly until gas seal seats flush with the con n...

Page 24: ...pray Arc Welding ORIFICE 1 2 Longer 1 Longer WIRE SIZE PARTNUMBER CUP PARTNUMBER PARTNUMBER PARTNUMBER CUP 1 2 I D M3 C50L M3 C50XL INS BUSHING M3H B 020 025 inch M3 ST25 Flared CONTACT TIP NOZZLE NUT M3H NN 030 inch M3 ST30 Cup 020 025 inch M5 T25 M5 LT25 SPOT NOZZLE 035 inch M3 ST35 5 8 I D 030 inch M5 T30 M5 LT30 FlatSpot M3H NS1 040 047 inch M3 ST45 M3 C62 035 inch M5 T35 M5 LT35 InsideCorner ...

Page 25: ...STING SCREW M3 212 TRIGGER ADJUSTING SCREW ONLY M3 213 TRIGGER PIN M3 214 TRIGGER SPRING QUICK CONNECTOR GROUP M3 120 FERRULE M3 301A CONNECTOR HOUSING M3 305A CONNECTOR STEM M3 306 CONNECTOR PLUG WITH SETSCREW O RINGS M3 307 SETSCREW ONLY M3 308 O RING ONLY 2 REQUIRED M3 309 TERMINAL CONNECTOR CONTACT 2 REQUIRED M3 310A BOOT CABLE SUPPORT M1 401 HANDLE M3 402 HANDLE SCREW 2 REQUIRED M3 405 TERMIN...

Page 26: ...Locking Electric Switch with 14 foot cord installed on torch 1 each 12 1 2 foot Power Cable with Connector installed on torch 1 each 15 foot Gas Hose with fitting installed on torch 3 each 3C332 Collet for 3 32 tungsten 3 each 3C418 Collet for 1 8 tungsten 2 each 3CB332 Collet Body for 3 32 tungsten 2 each 3CB418 Collet Body for 1 8 tungsten 2 each 3A6 Gas Cup 3 8 orifice 6 each 3A7 Gas Cup 7 16 o...

Page 27: ...Systematics Inc 1025 Saunders Lane West Chester PA 19380 25 NOTES ...

Page 28: ...Systematics Inc 1025 Saunders Lane West Chester PA 19380 ...

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