Systematics PATRIOT PBE180, Owner'S Manual

Page 1: ...E FINEST MIG WELDING SYSTEMS AVAILABLE TODAY THE PBE180REPRESENTSFOURTHGENERATIONTECH NOLOGICALADVANCEMENTS 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 ...

Page 2: ...NTIAL 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 ...

Page 3: ...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 di...

Page 4: ...on 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 r...

Page 5: ...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...

Page 6: ...ON 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 CO...

Page 7: ...ing 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 to...

Page 8: ... 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 t...

Page 9: ... 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...

Page 10: ... 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...

Page 11: ...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 oxidat...

Page 12: ...y 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 Foll...

Page 13: ...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 loo...

Page 14: ...er 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 t...

Page 15: ... 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 com...

Page 16: ...ctions 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 ...

Page 17: ... 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 WELD...

Page 18: ...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 ...

Page 19: ... 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...

Page 20: ...S 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 bo...

Page 21: ... with bulkhead gas fittings for quick and easy chan gover from standard MIG operation to spool gun operation 1 Remove the thread cap from the SPOOL GUN fitting 2 Unscrew the selector hose from the MIG TORCH fitting 3 Move the selector hose to the SPOOL GUN fitting and tighten 4 Install the thread cap removed in step 1 on the MIG TORCH fitting to prevent dirt and other contaminants from enter ing t...

Page 22: ... firmly then pull The liner should easily slide from 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 21 M I G TORCH LINER INSTALLATION steel only 4 Install the new liner into the MIG torch assembly until gas seal seats flush with the con nec...

Page 23: ...ray Arc Welding ORIFICE 1 2 Longer 1 Longer WIRE SIZE PART NUMBER CUP PART NUMBER PART NUMBER PART NUMBER 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 InsideCorn...

Page 24: ...EW 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 TERMINAL TORCH ...

Page 25: ...nt cable is 25 feet in length 35 foot and 50 foot cables are optional The wire speed control knob is built into the gun handle With the following options the MHG7 can also be used to weld steel or stainless steel 030 035 diameter wire size HG 160K Knurled Drive Roll for steel wire M5 T30 Contact tip for 030 steel wire or M5 T35 Contact tip for 035 steel wire SPECIFICATIONS Part Number MHG7 Gun Rat...

Page 26: ...24 Systematics Inc West Chester PA 19380 NOTES ...

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

Page 28: ...26 Systematics Inc West Chester PA 19380 ...