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Systematics MP140 User Manual

Systematics MP140
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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
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Systematics MP140 Specifications

General IconGeneral
BrandSystematics
ModelMP140
CategoryWelding System
LanguageEnglish

Summary

MANUFACTURER'S LIMITED WARRANTY

WARNING

ELECTRICAL SUPPLY REQUIREMENTS

WARNING

Important safety precautions regarding electrical connections and circuit protection for the MP140 welder.

NOTE

Information on how circuit amperage affects the MP140's maximum output and voltage.

INTRODUCTION

THE MIG PROCESS

Explains the Gas Metal Arc Welding (GMAW/MIG) process and its application with the MP140 unit.

SHORT ARC OR DIP TRANSFER

Details the short arc transfer mode, including arc initiation, short circuit, and pool formation.

DESCRIPTION

SPECIFICATIONS

General Specifications

Covers input power, output power, duty cycle, voltage, current range, wire types, and sizes.

Torch and Cooling Specs

Details torch angle, lengths, cooling method, and duty cycle ratings.

CHECK LIST

INSTALLATION

POSITIONING THE UNIT

Guidance on placing the unit for optimal ventilation and maintenance access.

SHIELDING GAS CONNECTIONS

Step-by-step instructions for connecting the shielding gas cylinder and regulator.

FITTING AND THREADING THE ELECTRODE WIRE

TORCH CONNECTION

Procedure for connecting the MIG torch assembly to the welder's front panel.

WIRE FEED PRESSURE ROLL ADJUSTMENT

TORCH AND WORK CABLE CONNECTIONS

OPERATION

OPERATING SEQUENCE

Detailed steps for preparing and initiating the welding process.

PROCESS SELECTION

FRONT PANEL CONTROLS OVERVIEW

Description of controls like Voltage Control, Wire Speed, Circuit Breaker, Voltmeter, and terminals.

WIRE FEED COMPARTMENT CONTROLS

OPTIONAL SSTP-2 MODULE

Enables MIG Spot and Stitch welding capabilities when installed.

FUNCTION SWITCH

Controls welding modes: Continuous Weld, Spot, and Stitch.

CONTINUOUS WELDING ON STEEL

STEEL WELDING TECHNIQUES

Details nozzle adjustment, torch position, safety gear, and welding motion for steel.

CONTINUOUS WELDING ON ALUMINUM

ALUMINUM WELDING TECHNIQUES

Covers wire trimming, nozzle adjustment, torch position, and weld sequence for aluminum.

MIG SPOT WELDING ON STEEL

MIG SPOT WELDING ON STEEL

STITCH WELDING ON STEEL

OPERATING HINTS AND MAINTENANCE

BURN BACK AND SPATTER

Troubleshooting guide for wire burn back and managing weld spatter.

REGULAR MAINTENANCE

Routine checks and cleaning procedures to maintain equipment efficiency.

WEEKLY MAINTENANCE

SIX MONTH MAINTENANCE

RECOMMENDED SPARE PARTS

TROUBLESHOOTING EQUIPMENT MALFUNCTIONS

TROUBLESHOOTING FAULTY WELDS

TROUBLESHOOTING FAULTY WELDS

TESTING AND REPLACING DIODES

WIRE FEED CALIBRATION

CHECKING WIRE FEED CALIBRATION

Procedure to verify proper rotation of the drive roll without adjustment.

ADJUSTING WIRE FEED CALIBRATION

Steps to calibrate the wire feed speed using the trim resistor on the PC board.

CONNECTING OPTIONAL ACCESSORIES

CHANGING TO TIGIT2 OPERATION

Procedure to reconfigure the welder for TIG welding using the TIGIT2 torch.

CHANGING TO MHG7 SPOOL GUN OPERATION

Procedure to reconfigure the welder for aluminum welding with the MHG7 spool gun.

MIG TORCH LINER INSTALLATION

REMOVING OLD LINER

Step-by-step guide for removing the old torch liner from the welding machine.

INSTALLING NEW LINER

Procedure for installing a new MIG torch liner, including cutting and deburring.

PARTS BREAKDOWN

TG STYLE TORCH PARTS

Lists parts for the standard and special application TG style MIG torch front ends.

SG & XG STYLE TORCH PARTS

Details parts for optional SG and XG style MIG torch front ends, including gasless wires.

LINERS AND SEALS

Part numbers for steel and aluminum welding liners and seals.

15 SERIES MIG TORCH PARTS

TORCH NECK AND CONNECTOR PARTS

Lists components for the torch neck assembly and quick connector group.

TORCH REBUILD PROGRAM

Information on the factory torch rebuild program for the 15 Series torches.

OPTIONS

TIGIT2 WELDING OPTION

Enables TIG welding capabilities; includes specifications and components.

MHG7 SPOOL GUN OPTION

For aluminum MIG welding; includes specifications and system components.