Air Liquide M 170 User manual

08/01

OWNER’S MANUAL

KEEP THIS MANUAL

The technical specifications and the wiring diagrams contained in this owner’s manual are valid only

for the model that has the part number indicated below.

M 130 - M 170

M 130:ALW-M120500381

M 170:ALW-M120500382

Air Liquide Welding is a trademark of L’Air Liquide S.A.

TABLE OF CONTENTS

1 SAFETY PRECAUTIONS - READ BEFORE USING

1.1 INSTALLATION OF EQUIPMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3

1.2 PERSONAL PROTECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3

1.3 FIRE AND EXPLOSION PREVENTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4

1.4 METAL FUME HAZARDS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4

1.5 TRANSPORTING THE POWER SOURCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4

1.6 MAGNETIC FIELDS CAN AFFECT PACEMAKERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4

1.7 H.F. RADIATION CAN CAUSE INJURY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5

1.8 ARC WELDING CAN CAUSE INTERFERENCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5

1.9 WELDING AND THE EFFECTS OF LOW FREQUENCY AND MAGNETIC FIELDS . . . . . . .5

1.10 PRINCIPAL SAFETY STANDARDS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5

2 SPECIFICATIONS AND DESCRIPTION

2.1 SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7

2.2 DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7

2.3 COMES COMPLETE WITH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7

2.4 DUTY CYCLE AND OVERHEATING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8

2.5 VOLT-AMPERE CURVES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9

3 INSTALLATION

3.1 CONNECTING THE EQUIPMENT TO THE MAIN SUPPLY . . . . . . . . . . . . . . . . . . . . . . . .10

3.2 SELECTING A LOCATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10

3.3 CHANGING POLARITY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10

3.4 INSTALLING WELDING GUN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10

3.5 INSTALLING WIRE SPOOL AND ADJUSTING HUB TENSION . . . . . . . . . . . . . . . . . . . . .12

3.6 INSTALLING THE WIRE INTO THE WELDING GUN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12

3.7 INSTALLING SG 185 SPOOL GUN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13

4 OPERATION

4.1 FRONT PANEL CONTROLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14

4.2 BACK PANEL CONTROLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14

5 MAINTENANCE AND TROUBLESHOOTING

5.1 TORCH MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14

5.2 REPLACING GUN LINER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15

5.3 TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15

6 M 130 ELECTRICAL DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16

7 M 170 ELECTRICAL DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17

8 M 130 SPARE PARTS LIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18

9 M 170 SPARE PARTS LIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20

10 M 130 – M 170 COMMON SPARE PARTS LIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22

11 MG 140 SPARE PARTS LIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .23

The use of welding equipment can cause

injury to the operator. The reading and understand-

ing of the safety standards mentioned below is com-

pulsory prior to connecting, preparing, using or

transporting welding equipment.

1.1 INSTALLATION OF EQUIPMENT

1. Installation and maintenance of equipment

must be performed in compliance with local

safety standards.

2. Frequently inspect the welder plug,

receptacle and wiring. If damaged, replace

immediately with approved electrical connec-

tions and adequately sized wiring.

3. Connect the welding ground as near as possi-

ble to the operating area.

4. Do not pass welding equipment cables through

or near lifting chains, crane cables or any elec-

trical lines.

5. If earth grounding of the workpiece is required,

ground it directly with a separate cable.

6. Do not touch the electrode if you are in contact

with the work, ground or another electrode from

a different welding machine.

7. Use only well-maintained equipment. Repair or

replace damaged parts immediately. Maintain

welding equipment according to owner’s manu-

al.

8. Never use welding equipment near water. Do not

spraywaterorotherliquids ontheweldingequipment.

9. Avoid direct contact between wet garments and

metal parts that are electrically charged.

10.Always wear gloves and rubber-soled shoes

when working in wet areas or standing on metal

surfaces.

11.Always turn off welding equipment that is not

being used. Do not leave welding equipment

unattended.

Significant DC voltage exists after removal of

input power or inverters.

• Always discharge input capacitors before touch-

ing any parts. Service work should be complet-

ed by qualified personnel only.

1.2 PERSONAL PROTECTION

1. Welding operations produce radiation, noise,

heat and noxious fumes. Suitable safety pre-

cautions must be taken to minimize the risk.

2. Wear fire resistant work gloves, long

sleeve shirts, pants, safety shoes, cap and

welding helmet to protect the skin from radia-

tion and metal sparks.

3. Always wear ear protection.

4. Always wear eye protection with side shields.

5. Position a fire resistant screen around the weld-

ing area to protect bystanders from radiation,

sparks and slag.

1. SAFETY PRECAUTIONS - READ BEFORE USING

WARNING

Read and understand this entire Owner’s Manual before installing,operating or servicing this equipment. While

the information contained in this Owner’s manual represents our best judgment, Air Liquide assumes no lia-

bility for its use.

Reproduction of this work, in whole or part, without written permission of the publisher is prohibited.

The publisher does not assume and hereby disclaims any liability to any party for any loss or damage caused

by any error or omission in the Air Liquide M 130 – M 170 Owner’s Manual, whether such error results from neg-

ligence, accident or any other causes.

6. Compressed gas cylinders

are potentially dangerous. Consult the supplier

for correct handling procedures. Always protect

compressed gas cylinders from the sun’s rays,

flames and sudden temperature changes.

1.3 FIRE AND EXPLOSION PREVENTION

Hot slag and sparks can

cause fire. The risk of fire and explosion can

be minimized by removing all flammable mate-

rial from the welding area.

1. Always perform welding operation with caution.

Containers and tubes that have been emptied

and thoroughly cleaned still represent a poten-

tial hazard.

2. Never perform welding operations or cut a

closed container or pipe.

3. Never perform welding operations on open con-

tainers or pipes that may have been contami-

nated with substances that could explode or

react when exposed to heat or humidity.

4. As a preventative measure, keep fire extin-

guishers near the welding operation.

1.4 METAL FUME HAZARDS

Welding fumes and gases may be

hazardous if inhaled.

1. Install a ventilation system in the welding area.

2. Use a forced air system when welding lead,

beryllium, cadmium, zinc, zinc-coated or paint-

ed material. Always wear a protective mask.

3. If the ventilation system is inadequate, use an

air respirator.

4. Beware of gas leaks. Shielding gases such as

argon are heavier than air and when used in

small spaces, will replace the air.

5. In the event that a welding operation occurs in

a confined place, the operator should be

accompanied by another person.

6. Always keep gas cylinders in a well-ventilated

area. Close the main gas valve when cylinder

is not in use.

7. Do not perform welding operations near chlori-

nated hydrocarbon vapors produced by

degreasing or painting. The heat generated by

arc rays can react to form phosgene, a highly

toxic gas.

8. Irritation of the eyes, nose and throat are symp-

toms of inadequate ventilation. Take immediate

steps to improve ventilation. Do not continue

welding if symptoms persist.

1.5 TRANSPORTING THE POWER

SOURCE

The welding machine may be carried by the

handle.

1. Always disconnect the power source and

accessories from the main supply before lifting

or handling the welding equipment.

2. Do not drag, pull or lift welding equipment by

the weld cables.

1.6 MAGNETIC FIELDS CAN AFFECT

PACEMAKERS

1. Keep pacemaker wearers away from

welding operations.

2. Pacemaker wearers should consult with a

physician prior to being exposed to any welding

or cutting operation.

1.7 H.F. RADIATION CAN CAUSE INJURY

1. High frequency (HF) emissions can

interfere with radio navigation, safety devices,

computers and communication equipment.

2. Installation of welding equipment should be

performed by a qualified electrician.

3. The operator is responsible for having a quali-

fied electrician correct any interference problem

resulting from the welding equipment installa-

tion.

4. If notified by the FCC about interference, stop

using the welding equipment immediately.

5. Have the welding equipment installation

checked and maintained on a regular basis.

6. Keep high-frequency source doors and panels

tightly shut. Keep spark gaps at the correct set-

ting and use grounding to minimize the possi-

bility of interference.

1.8 ARC WELDING CAN CAUSE INTER-

FERENCE

1. Electromagnetic energy can interfere

with sensitive electronic equipment such as

computers and computer-driven equipment like

robots.

2. Be sure that all equipment in the welding area

is electro-magnetically compatible.

3. To reduce possible interference, keep weld

cables as short as possible, close together and

down low.

4. Locate welding operations at least 100 meters

(350 feet) away from any sensitive electronic

equipment.

5. Be sure welding equipment is installed and

grounded according to this manual.

6. If interference still occurs, the operator must

take extra measures such as moving the weld-

ing machine, using shielded cables, using line

filters or shielding the work area.

1.9 WELDING ANDTHE EFFECTS OF LOW

FREQUENCY AND MAGNETIC FIELDS

As welding current flows through welding cables, it

can cause electromagnetic fields.To reduce mag-

netic fields, use the following procedures:

1Keep cables close together by twisting or taping

them.

2. Arrange cables to one side and away from the

operator.

3. Do not coil or drape coils around operators

body.

4. Keep welding power source and cables as far

away from the operator as practically possible.

5. Connect work clamp to workpiece as close to

the weld as possible.

1.10 PRINCIPAL SAFETY STANDARDS

Safety in Welding and Cutting, ANSI Standard

Z49.1 from the American Welding Society, 550

N.W. Lejeune Rd., Miami, FL 33126.

Safety and Health Standards, OSHA 29 CFR

1910, from the Superintendent of Documents,

U.S. Government Printing Office, Washington,

D.C. 20402.

Recommended Safe Practices for the Preparation

for Welding and Cutting of Containers That Have

Held Hazardous Substances, American Welding

Society Standard AWS F4.1, from the American

Welding Society, 550 N.W.Lejeune Rd., Miami, FL

33126.

National Electrical Code, NFPA Standard 70, from

the National Fire Protection Association,

Batterymarch Park, Quincy, MA 02269.

Safe Handling of Compressed Gases in Cylinders,

CGA Pamphlet P-1, from the Compressed Gas

Association, 1235 Jefferson Davis Highway, Suite

501, Arlington, VA 22202.

Code for Safety in Welding and Cutting, CSA

Standard W117.2, from the Canadian Standards

Association, Standard Sales, 178 Rexdale

Boulevard, Rexdale, Ontario M9W 1R3.

Safe Practices For Occupation And Educational

Eye And Face Protection, ANSI Standards Z87.1

from the American National Standards Institute,

1430 Broadway, NewYork, NY 10018.

Cutting And Welding Processes, NFPA Standards

51B, from the National Fire Protection Association,

Batterymarch Park, Quincy, MA 02269.

EQUIPMENT INSTALLATION AND MAINTENANCE MUST BE PERFORMED IN

COMPLIANCE WITH LOCAL SAFETY STANDARDS.

• INSTALLATION AND MAINTENANCE OPERATIONS MUST BE PERFORMED BY QUALIFIED PERSONS

ONLY.

• BEFORE INSTALLING the power source, check that the power socket satisfies ampere and voltage

requirements (see data table plate). ENSURE that the socket is protected by appropriate fuses and auto-

matic switches.

• CONNECT an approved standard plug corresponding to the system socket to the power supply cable.

Electric shock could be fatal

1. Never touch exposed electrical

parts.

2. Switch off and disconnect the

power source before installing

or opening.

3. Installation may be performed

by qualified persons only.

4. Installation procedure must

comply with national electricity

standards and all other relevant

regulations.

Fumes and gases may repre-

sent a safety hazard.

Fumes and gases generated

during welding may be danger-

ous if inhaled over a long period

of time.

1. Keep clear of fumes.

2. Ventilate welding area or wear

a breathing mask.

3. Install a natural or forced air

ventilation system in the work

area.

Use a protective mask with suit-

able glass filter (at least NR10)

to safeguard eyes.

1. Wear appropriate eye, ear and

body protection equipment.

2. Protect face, ears and neck

during welding operations.

Advise other persons in the

vicinity to look away and stand

clear of arc rays and hot metal.

The positioning of welding

equipment on inflammable sur-

faces could lead to fire outbreak

or explosion.

1. Never position equipment on

combustible or inflammable

surfaces.

2. Do not install equipment in the

vicinity of inflammable liquids.

A falling power source or other

equipment may cause serious

injury to persons or damage to

objects.

1. Always make use of the handle

to lift power source (applies to

portable models).

2. Use eye bolts and adequate lift-

ing equipment to raise the

power source.

WELDING MAY CAUSE FIRES OR

EXPLOSIONS. Never weld near

inflammable materials.

1. Beware of weld flame. Always

keep a fire extinguisher close at

hand.

2. Never place welding equipment

on inflammable surfaces.

3. Do not weld in closed containers.

4. Let welding equipment and

material cool before handling

them.

Moving parts may cause injury.

1. Keep clear of hazardous areas,

such as moving rollers.

2. Keep all doors, panels and

covers closed and in place.

Hot areas may cause injury.

Let the power source or other

parts cool before performing

any maintenance or servicing.

Welding wire may cause injury.

Do not point the torch toward

any part of the body, other per-

sons or any type of metal when

unwinding welding wire.

2. SPECIFICATIONS AND DESCRIPTION

2.1 SPECIFICATIONS

2.2 DESCRIPTION

M 130 is a complete semi-automatic, constant

voltage, DC arc welding machine. This compact,

reliable unit, capable of welding material thick-

nesses from 0.5 mm (24 gauge) to 4.8 mm (3/16

in), is ideal for the home hobbyist, the workshop

or auto body repairs. The easy-to-use M 130

plugs into any 110-volt receptacle and delivers a

superior, consistent arc. The portable M 130

weighs 23 kg (50 lb) and offers excellent perform-

ance throughout the entire welding range. Throw

on an optional spool gun and you have a conven-

ient, immediate solution for all your

aluminum welding needs.

M 170 is a complete semi-automatic, constant voltage,

DC arc welding machine. This compact, reliable unit,

capable of welding material thicknesses from 0.5 mm

(24 gauge) to 6.35 mm (1⁄4in) is ideal for light fabrica-

tion, the garage or auto body repairs.The easy-to-use

M 170 offers versatility and delivers a superior, consis-

tent arc. The portable M 170 weighs 28 kg (62 lb) and

offers excellent performance throughout the entire

welding range.Throw on an optional spool gun and you

have a convenient, immediate solution for all your alu-

minum welding needs.

2.3 COMES COMPLETE WITH:

1. 2.4 m (8 ft) input power cord with

5p-15 plug (M 130) or 6p-50 plug (M 170)

2. 3 m (10 ft) MIG gun

3. Extra contact tips

4. 3 m (10 ft) ground cable with clamp

5. 1 lb spool adaptor

M 130 M 170

M 170

2.4 DUTY CYCLE AND OVERHEATING:

Duty cycle is the percentage of 10 minutes that the unit can weld at its rated output without overheating. If the

unit overheats, the weld output will stop.To correct this situation, wait fifteen minutes for the unit to cool. Reduce

amperage or duty cycle before starting to weld again.

• Exceeding duty cycle can damage unit and void warranty.

DUTY CHART M 130

100

120

10 20 30 40 50 60 70 80 90 100

% DUTY CYCLE

DUTY CHART M 170

100

120

140

10 20 25 30 40 50 60 70 80 90 100

% DUTY CYCLE

OUTPUT, AMPERESOUTPUT, AMPERES

M 130 Duty Cycle

M 170 Duty Cycle

0 20 40 60 80 100 120 140 160 180 200 220 240

2.5 VOLT-AMPERE CURVES

Volt-ampere curves show the maximum voltage and amperage output capabilities of the welding power source.

Curves of other settings fall under curves shown.

Volts Volts

Amps

M 130 Volt-Ampere Curve

M 170 Volt-Ampere Curve

3. INSTALLATION

3.1 CONNECTING THE EQUIPMENT TO

THE MAIN SUPPLY

The equipment works within an input range of

±10%.

Check to ensure that the power outlet is equipped

with a fuse that is capable of carrying the amps

indicated on the data plate of this unit.

3.2 SELECTING A LOCATION

Special installation may be required

where gasoline or volatile liquids are present

(See NEC Article 511 or CEC Section 20). Do

not move or operate this equipment where it

could tip over. When selecting a location for

this equipment, ensure that the following

guidelines are followed:

1. Use data plate to determine input power

requirements.

2. The operator must have unobstructed access to

all controls and equipment connections.

3. Do not position equipment in small, closed

places. Ventilation of the power source is

extremely important. Make sure that the louvers

on the side panels are not obstructed and that

there is no risk of obstruction during operation.

4. Avoid areas where dust or other objects could

be sucked into the system.

5. Equipment must not obstruct corridors or work

activities of other personnel.

6. Position the power source securely to avoid

falling or overturning.

7. Understand the risk of falling equipment situat-

ed in overhead positions.

3.3 CHANGING POLARITY

TURN OFF WELDER BEFORE MAKING

CONNECTIONS.

(Consult wire data to verify polarity require-

ments.)

DCEN (Straight Polarity)

1. Connect the ground cable to the positive recep-

tacle inside the unit.

2. Connect the power cable to the negative recep-

tacle inside the unit.

DCEP (Reverse Polarity)

1.Connect the ground cable to the negative recep-

tacle inside the unit.

2. Connect the power cable to the positive recep-

tacle inside the unit.

INSTALLING GAS HOSE AND REGULATOR

1. Install the gas hose on the inlet connection

located on the rear of the machine.

2. Install the regulator on the cylinder outlet con-

nection located on the top of the compressed

gas cylinder.

3. Connect the male gas hose connection to the

female regulator connection.

3.4 INSTALLING WELDING GUN

TURN OFF WELDER BEFORE MAKING

CONNECTIONS.

Before connecting the torch, ensure that the drive

rolls, gun liner and contact tip match the diameter

of the wire being used.

When installing the welding gun, follow the

sequence described below.

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