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058-9306-4

MIG 180 INVERTER WELDER

INSTRUCTION MANUAL

Summary of Contents for MIG 180

Page 1: ...058 9306 4 MIG 180 INVERTER WELDER INSTRUCTION MANUAL ...

Page 2: ...and this instruction manual thoroughly before using the product It contains important information for your safety as well as operating and maintenance advice Keep this instruction manual for future use Should this product be passed on to a third party this instruction manual must be included MIG 180 INVERTER WELDER 058 9306 4 ...

Page 3: ...uld be turned in MIG position when using spool gun this switch should be in Spool gun position Ce commutateur doit être placé à la position MIG si vous effectuez du soudage MIG normal et à la position SPOOL GUN si vous utilisez un pistolet à bobine DCEN DCEN FLUX CORE WIRE FIL AVEC ÂME EN FLUX Courant continu polarité normale Polarity switch setting Réglage du commutateur de polarité Direct curren...

Page 4: ...1 steps 4 5 page 32 refer to welding techniques if needed Stick welding STEP 1 Plug in the electrode holder cable 1 into the electrode cable connection and attach the electrode 2 in the electrode holder 3 page 19 steps 2 3 1 MC 589306 42 MC 589306 12 9 9 3 4 5 6 7 8 WIRE STICK A 10 3 4 5 6 7 8 10 POWER WARNIN G WORK V A STICK MIG GAS INERTE MIG V GAS INERTE ARC ARC FIL MARCHE 058 9306 4 AVERTISSEM...

Page 5: ... electrode 2 and raising it by 1 8 and maintain the gap throughout the weld page 35 steps 1 5 MC 589306 15 9 9 3 4 5 6 7 8 WIR E STICK A 10 3 4 5 6 7 8 10 POW ER WAR NING WOR K V A STICK MIG GAS INERTE MIG V GAS INER TE ARC ARC FIL MARC HE 058 9306 4 AVERT ISSEM ENT INTEN SITÉ MIG 180 INVERTER WELDER SOUDEUSE À ONDULEUR MIG 180 1 MC 589306 47 1 8 2 1 ...

Page 6: ...UIDE TECHNICAL SPECIFICATIONS 3 SAFETY GUIDELINES 4 8 KEY PARTS DIAGRAM 9 11 IMPORTANT INFORMATION 12 18 ASSEMBLY INSTRUCTIONS 19 29 OPERATING INSTRUCTIONS 30 41 MAINTENANCE 42 TROUBLESHOOTING 43 44 MAIN CIRCUIT CHART 45 EXPLODED VIEW 46 PARTS LIST 47 48 WARRANTY 49 50 ...

Page 7: ...USED 0 023 0 035 0 6 0 9 mm MIG wire 0 030 0 035 0 8 0 9 mm flux core wire WIRE DIAMETER 0 023 0 6 mm 0 030 0 8 mm 0 035 0 9 mm ELECTRODE DIAMETER 1 16 1 6 mm 5 64 2 0 mm 5 32 4 0 mm 3 32 2 5 mm 1 8 3 2 mm DIMENSIONS L x W x H 17 7 10 x 9 2 5 x 13 4 5 450 x 239 x 351 mm WEIGHT 48 lb 2 oz 21 8 kg CONNECTOR 4 pin quick connect power connection MOTOR VOLTAGE 24 V DC WIRE SPEED 590 min RATING 200 A w ...

Page 8: ...ate this information Note The word Note is used to inform the reader of something he she needs to know about the tool PERSONAL SAFETY These precautions are intended for the personal safety of the user and others working with the user Please take time to read and understand them DANGER Potential hazard that will result in serious injury or loss of life WARNING Potential hazard that could result in ...

Page 9: ...rounded power source as it might cause electrical shock to the user The welding process must conform to ANSI Z49 1 NFPA 51 OSHA 29 CFR part 1910 sub part Q CSA W117 2 American Welding Society standard A6 0 Do not expose the welder to rain Always disconnect the power supply when working on internal components Do not touch the PC board without being properly grounded with a wrist strap Place the PC ...

Page 10: ...ers sprays and degreasers can be highly toxic when heated Risk of burns Do not touch the welded materials with bare hands as the welded materials are hot and can cause severe burns Do not touch MIG gun nozzle or tip of the electrode holder after welding until it has been cooled Wear garments that are oil free with no pockets or cuffs that will collect sparks Risk of fire Do not weld on containers ...

Page 11: ...unskilled or untrained individuals to install and operate this welder Keep hands and fingers away from moving parts such as drive roll or fan while the welder is in use Before operating the welder check the insulation of the ground cable power cord and welding cable for damage Replace or repair the damaged components before using the welder Use only recommended parts for replacement Avoid contacti...

Page 12: ...d proper gloves and protective clothing such as leather shirt coat pants and insulated footwear to prevent the skin from being exposed to hot metals UV and IR rays while welding Do not overheat or overuse the welder to prevent it from being heated Allow proper cooling time between duty cycles Always use this welder in the rated duty cycle to prevent excessive heat and failure Ensure that all the c...

Page 13: ...r cord 9 Ground cable with clamp 4 Wire drive compartment door 10 MIG gun trigger cable 5 MIG gun connection 11 Ground cable connection 6 Electrode cable connection MC 589306 01 GAS INER 9 9 3 4 5 6 7 8 WIRE MIG V STIC K A 10 3 4 5 6 7 8 10 POWER WARNING WO RK V A STICK MIG 2 5 4 3 6 7 8 9 10 11 FIL AVE RTISSE MENT 1 GAS INERTE ARC ARC MARCHE 058 9306 4 INTENS ITÉ MIG 180 INVERTER WELDER SOUDEUSE ...

Page 14: ...escription 1 Power ON indicator 3 Output current indicator 2 Thermal overload indicator 4 Mode selector switch WIRE STICK MIG GAS INERTE GAS INERTE V A POWER WARNING WORK V A STICK MIG 1 2 3 4 5 6 7 8 9 10 1 2 3 4 5 6 7 8 9 10 1 2 3 4 MC 589306 02 FIL ARC ARC AVERTISSEMENT 058 9306 4 INTENSITÉ MARCHE ...

Page 15: ...G AVERTISSEMENT RELATIE À L ÉLECTRICITÉ Disconnect from power supply before servicing Do not operate with any panels or covers removed Débranchez le cordon de la source d alimentation avant l entretien Ne faites pas fonctionner cet appareil avec les panneaux ou les couvercles retirés L entretien de cet appareil doit toujours être effectué par un technicien Qualifie Service on this machine should o...

Page 16: ... content list page 18 After unpacking the welder unit inspect for any damage that may have occurred during transit Check for loose missing or damaged parts A shipping damage claim must be filled with carrier Welder kit components Current overload circuit breaker This component is located on the back panel of the welder and it protects the unit from current overload Electrode cable connection This ...

Page 17: ...WARNING AVERTISSEMENT ELECTRIC SHOCK can kill UN CHOC ÉLECTRIQUE peut tuer MOUING PARTS can cause injury LES PIÉCES MOBILES peuvent causer des blessures Welding wire and drive parts may be at welding voltage Keep away from moving parts Ne vous approchez pas des pièces mobiles Maintenez tous les couvercles panneaus et portes fermés et solidement en place Keep all doors covers and panels closed and ...

Page 18: ...r and glows when the welding unit is providing enough power to weld Wire feed speed control This control is located on the upper front panel of the welder and used to adjust the speed of the wire being fed when in the MIG welding mode Polarity changing For flux core welding no shielding gas is required the MIG gun lead is connected to the negative terminal and the ground cable is connected to the ...

Page 19: ...ement en place Keep all doors covers and panels closed and securely in place Le fil de soudure et les pièces motrices sont peut être a la tension de soudage Ne touchez pas le fil oules parties motrices à mains nues ou avec des outils lorsque la detente est sous pression Do not touch wire or drive parts with bare hands or tools when trigger is depressed MIG SPOOL GUN PISTOLET À BOBINE When normal M...

Page 20: ... coated with a layer of flux During the process of welding electrical current flows between the electrode rod and the grounded metal work piece The intense heat of the arc between the rod and the grounded metal melts the electrode and the flux The most popular electrodes are mentioned below Torch travel Refers to the movement of the welding torch along the weld joint Travel direction Refers to the...

Page 21: ... spool adaptor 1 5 MIG gun 1 6 Electrode holder with welding cable 1 7 MIG consumable kit nozzle contact tips L shaped hexagonal wrench 1 8 Gas hose 1 9 9 3 4 5 6 7 8 WIRE STICK A 10 3 4 5 6 7 8 10 POWER WARNING WORK V A STICK MIG GAS INERTE MIG V GAS INERTE ARC ARC FIL MARCHE 058 9306 4 AVERTISSEMENT INTENSITÉ MIG 180 INVERTER WELDER SOUDEUSE À ONDULEUR MIG 180 250 300 350 400 0 10 50 100 150 200...

Page 22: ...IMPORTANT INFORMATION 18 MIG 180 INVERTER WELDER 058 9306 4 9 Wire spool 2 10 Electrode 10 11 Owner s manual 1 No Material name Quantity Illustration ...

Page 23: ... 5 6 7 8 WIRE MIG V STICK A 10 3 4 5 6 7 8 10 POWER WARNIN G 058 930 6 4 WORK V A STICK fig 1A 1 FIL AVERTISS EMENT MARCHE GAS INERTE GAS INE MIG ARC ARC INTENSIT É MIG 180 INVERTER WELDER SOUDEUSE À ONDULEUR MIG 180 MC 589306 11 9 9 3 4 5 6 7 8 WIRE MIG V STICK A 10 3 4 5 6 7 8 10 POWER WARNING WORK V A STICK fig 1B 1 FIL AVERTISSEME NT MARCHE GAS INERTE MIG GAS INE ARC ARC INTENSITÉ 058 9306 4 M...

Page 24: ...L AVERTISS EMENT MARCHE GAS INERTE GAS IN MIG ARC ARC INTENSIT É 058 9306 4 MIG 180 INVERTER WELDER SOUDEUSE À ONDULEUR MIG 180 MC 589306 15 fig 1F 9 9 3 4 5 6 7 8 WIRE STICK A 10 3 4 5 6 7 8 10 POWE R WARN ING WORK V A STICK MIG GAS INERTE MIG V GAS INERT E ARC ARC FIL MARCH E 058 9306 4 AVERTIS SEMENT INTENS ITÉ MIG 180 INVERTER WELDER SOUDEUSE À ONDULEUR MIG 180 1 MC 589306 16 ELECTRICAL WARNIN...

Page 25: ... 1I 250 300 350 400 0 10 50 100 150 200 20 30 40 50 1 2 MC 589306 19 fig 1J 250 300 350 400 0 10 50 100 150 200 20 30 40 50 1 2 MC 589306 20 fig 1K 250 300 350 400 0 10 50 100 150 200 20 30 40 50 GAS INPUT ENTRÊE DE GAZ NORMAL NORMAL OFF ON MARCHE ARRÊT POWER PUISSANCE OVER CURRENT SURINTENSITEE ELECTRICAL WARNING AVERTISSEMENT RELATIE À L ÉLECTRICITÉ Disconnect from power supply before servicing ...

Page 26: ...re et les pièces motrices sont peut être a la tension de soudage Ne touchez pas le fil oules parties motrices à mains nues ou avec des outils lorsque la detente est sous pression Do not touch wire or drive parts with bare hands or tools when trigger is depressed MIG SPOOL GUN PISTOLET À BOBINE When normal MIG welding this switch should be turned in MIG position when using spool gun this switch sho...

Page 27: ... be turned in MIG position when using spool gun this switch should be in Spool gun position Ce commutateur doit être placé à la position MIG si vous effectuez du soudage MIG normal et à la position SPOOL GUN si vous utilisez un pistolet à bobine DCEN DCEN FLUX CORE WIRE FIL AVEC ÂME EN FLUX Courant continu polarité normale Polarity switch setting Réglage du commutateur de polarité Direct current e...

Page 28: ...n the welder roll the wire back onto the wire spool by manually rotating the wire spool clockwise Do not allow the wire to come out of rear end of the inlet guide tube MC 589306 29 fig 1T GAS INPUT ENTRÊE DE GAZ NORMAL NORMAL OFF ON MARCHE ARRÊT POWER PUISSANCE OVER CURRENT SURINTENSITEE 1 ELECTRICAL WARNING AVERTISSEMENT RELATIE À L ÉLECTRICITÉ Disconnect from power supply before servicing Do not...

Page 29: ... the below chart to select the roll groove based on the wire diameter 6 Attach the drive roll onto the drive roll shaft and tighten the drive roll on to the shaft using the wrench Note When installing the drive roll the number stamped on the drive roll should face the user 7 Close the wire drive compartment MC 589306 32 fig 1W 2 1 MC 589306 33 fig 1X 1 2 Wire diameter Roll groove 0 023 0 6 0 030 0...

Page 30: ...tep 4 and then follow step 7 If an 8 spool is used skip to step 5 WARNING Potential hazard that could result in serious injury or loss of life Always switch the power OFF and unplug the power cord from the AC power source before installing the wire Remove rusty wire or rusty wire spool Do not weld work pieces that are thinner than 24 gauge The welding unit is not designed to do so Doing so may bur...

Page 31: ...sily 8 spool installation optional 5 Slide an 8 spool adaptor 1 on the hub and secure the washer 2 bushing 3 and wing nut 4 fig 2A Note Ensure the spool adaptor is not firmly tightened It should be able to move easily 6 Slide the 8 spool over the adaptor fig 2B 7 Place the spool on the hub with the wire passing from the bottom of the spool into the drive mechanism fig 2C fig 1Z MC 589306 35 1 2 3 ...

Page 32: ... Align the wire with the correct groove in the drive roll 14 Fix the drive tension arm in place over the drive roll 15 Tighten the drive tension adjusting knob until the tension roller applies enough force on the wire to prevent it from slipping in the drive roll 16 Plug in and turn the welder ON Set the voltage switch to the voltage setting recommended for the gauge of the work piece Refer to the...

Page 33: ...th bare hands or tools when trigger is depressed MIG SPOOL GUN PISTOLET À BOBINE When normal MIG welding this switch should be turned in MIG position when using spool gun this switch should be in Spool gun position Ce commutateur doit être placé à la position MIG si vous effectuez du soudage MIG normal et à la position SPOOL GUN si vous utilisez un pistolet à bobine DCEN DCEN FLUX CORE WIRE FIL AV...

Page 34: ...amp to a scrap piece of the same type as the work piece Note The thickness of the scrap piece should be equal to or greater than the thickness of the actual work piece and free of oil paint and rust 2 Set the wire speed using the wire feed speed control 3 Hold the torch in one hand and allow the nozzle to rest on the edge of the work piece farther from the user and at angle A or angle B depending ...

Page 35: ...e the wire feed control to slightly increase or decrease the heat and penetration by selecting higher or lower wire feed settings Repeat the above steps 1 5 if a new wire speed a different diameter wire or a different type of welding wire is selected Angle A 60 degrees Angle B 30 45 degrees Angle A is the angle between the nozzle and the work piece and can be varied but in most cases the optimum a...

Page 36: ... for greater weld puddle visibility Note For a fixed wire feed speed setting when the speed is increased a decrease in penetration and a narrowing of the finished weld bead will result WARNING Potential hazard that could result in serious injury or loss of life Prolonged exposure to the welding arc can cause blindness and burns Do not perform any welding while standing kneeling or lying on the gro...

Page 37: ...for thick and heavy metals 4 Try the intended weld on scrap metal to ensure the proper determination of the type of electrode and the amperage On selection of a proper electrode The bead will lay smoothly over the work piece without ragged edges fig 2I The base metal puddle will be as deep as the bead that rises above it The welding operation will make a crackling sound On selection of a small ele...

Page 38: ...l 1 Use lower output settings for 1 16 electrodes 2 Use higher output settings for 5 64 electrodes 3 Set higher amperage for thick and heavy metals 4 Set lower amperage for light and thin metals 5 Try the intended weld on scrap metal to ensure the proper amperage determination Welding techniques Holding the electrode 1 Hold the electrode in a way that is most comfortable to work 2 Hold the electro...

Page 39: ...rock the welding rod back and forth when the rod sticks to the work piece to separate them Note A stuck electrode will cause a short circuit and the thermal overload protector will shut the welder OFF 4 Make sure the arc is accompanied by a crisp cracking sound as it indicates a proper arc 5 Move the electrode 1 downwards along desired direction to lay a weld bead fig 2M DANGER Potential hazard th...

Page 40: ...d edges fig 2N The base metal puddle will be as deep as the bead that rises above it The welding operation will make a crackling sound Faster weld speed The bead will be high and irregular fig 2O The arc will be difficult to maintain Slower weld speed The arc will burn through light metals The bead will undercut the work The bead will be flat and porous fig 2P MC 589306 49 fig 2N MC 589306 50 fig ...

Page 41: ...ent proper fusion or create an uneven bead Finishing the bead 1 During welding the outer layer of the electrode burns off to form a cover of protective gases over the molten metal to prevent contamination of the weld and the burning coating forms a slag 2 Remove the slag using a chipping hammer or scratch brush as it appears as an accumulation of dirty metal scale on the finished weld Note The chi...

Page 42: ...prevents the weld puddle from running downward while allowing slow enough travel speed For this position angle B should be about 30 degrees fig 2U Stringer bead Weave bead The stringer bead is formed by the torch travelling in a straight line while keeping the wire and nozzle centered over the weld joint fig 2R The weave bead is made by weaving the wire from side to side while moving with the torc...

Page 43: ...ling of molten metal into the nozzle fig 2W Angle B should be zero so that the wire is aiming directly into the weld joint If excessive dripping of the weld puddle occurs select a lower heat setting Multiple pass welding 1 Butt weld joint When butt welding thicker materials prepare the edges of the material to be joined by grinding a bevel on the edges of the metal pieces being joined When this pr...

Page 44: ...5 is suitable for this method Always select the high heat setting for this method and tune in the wire speed prior to making a spot weld fig 2Z Note Do not use 0 030 self shielding flux core wires when using this method unless the metal is very thin or excessive filler metal and minimal penetration is acceptable 2 Punch and fill method In this method a hole is punched or drilled into the top piece...

Page 45: ... 1 Select the wire diameter and heat setting recommended above for the intended method of spot welding 2 Tune in the wire speed as if a continuous weld is to be performed 3 Hold the nozzle piece completely perpendicular to and about 1 4 off the work piece 4 Pull the trigger on the torch and release it when the desired penetration is achieved 5 Make practice spot welds on scrap metal and vary the d...

Page 46: ... at a temperature of 12 C 48 C 10 F 120 F and relative humidity of less than 90 It is recommended to repack the welder when transporting or storing the welder after use Cleaning is required before storage WARNING Potential hazard that could result in serious injury or loss of life Unplug the welder before performing any maintenance or service Only use the welder after replacing or repairing any da...

Page 47: ... switch is broken 4 Transformer is broken 1 Check the circuit or fuse of the power supply 2 Replace the power cord 3 Replace the main switch 4 Replace the transformer The welder does not weld 1 Incorrect power input 2 Inadequate current at the output 3 Poor connection of output cable 4 Welder components and work piece surface are dirty 5 Wrong welding wire 6 Wrong mode selector switch setting 1 Ch...

Page 48: ...ot enough drive roll pressure 2 Spool hub tension too tight or loose 3 Contact tip worn or wrong size 4 Rusty or corroded wire 5 Electrode or damaged flux is too big 1 Tighten the drive tension adjustor on wire feeder 2 Adjust the wing nut on the spool holder 3 Replace the contact tip 4 Replace the wire 5 Use correct or undamaged electrode PROBLEM POSSIBLE CAUSES SOLUTIONS ...

Page 49: ...ZD6 T3 C9 L2 C10 D4 D5 C11 C12 C13 R7 R8 R9 D6 D7 YR1 YR2 CN207 CN207 CN201 CN202 XXXXXXX XXXXXXX XXXXXXX XXXX LED201 LED203 LED202 GREEN YELLOW RED XXXXXXXXXXXX XXXXXXX XXXXXXX XXXXXXX Spool Gun 4 Pin Socket 1 2 3 4 xxxxx Wire Speed xxx xxx XXXX ZD7 RG7 RG8 XXXX XXXX ZD8 Q1 ZD2 ZD3 ZD4 TH1 CN1 XXXXX Handy MIG S CONTROL ZD1 RLY101 T101 CN101 L N PE MAIN CIRCUIT MINI MMA 001 F T T MC 589306 65 ...

Page 50: ...W 46 MIG 180 INVERTER WELDER 058 9306 4 MC 589306 64 1 2 3 4 5 6 7 16 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 44 45 46 47 48 52 49 51 43 17 18 53 54 19 20 21 55 56 8 51 50 10 11 12 13 14 15 9 ...

Page 51: ...2 Wire feeder assembly 1 10 Board 1 33 Welding mode MIG Stick selector 1 11 Holder 1 34 Quick connector female 2 12 Spool adaptor 1 35 Trigger lead receptacle 1 13 Spool fixed cover 1 36 Feet 4 14 Washer 1 37 Sheet metal case base 1 15 Butterfly nut 1 38 Loaded PCB 1 16 Vertical centre sheet metal 1 39 Capacitance PCB 1 17 Connection terminal red 2 40 Heat sink 1 18 Connection terminal black 2 41 ...

Page 52: ...4 47 Circuit breaker 1 52 Handle 1 48 Main switch 1 53 Dual gas regulator 1 49 Copper nut 1 54 Gas hose 1 50 Gas valve connector 1 55 Fuse board 1 51 Gas solenoid valve 1 56 Spool gun function selector switch 1 No Description Qty No Description Qty ...

Page 53: ...is caused by repairs made or attempted by others i e persons not authorized by the manufacturer f this warranty will not apply to any product that was sold to the original purchaser as a reconditioned or refurbished product unless otherwise specified in writing g this warranty will not apply to any product or part thereof if any part from another manufacturer is installed therein or any repairs or...

Page 54: ...manufacturer shall be liable for any other expense loss or damage including without limitation any indirect incidental consequential or exemplary damages arising in connection with the sale use or inability to use this product Notice to consumer This warranty gives you specific legal rights and you may have other rights which may vary from province to province The provisions contained in this warr...

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