MasterCraft MIG 180 Instruction Manual

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INSTRUCTION MANUAL

MIG 180 INVERTER WELDER

058-9306-4

If any parts are missing or damaged, or if you have any questions, please call

1-800-689-9928.

Read and understand 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.

Quick Start Guide

MIG 180 INVERTER WELDER 058-9306-4

MIG welding

STEP 1

Installing the wire

Remove the nozzle (1) and contact tip (2) from the end of the torch assembly. Identify the leading end of the wire secured on the edge of the wire spool. Place the spool onto the hub with the wire passing from the bottom of the spool into the drive mechanism.

pages 26

27, steps 1

STEP 2

Setting the wire tension

Press the trigger on the gun. Turn the drive tension adjustment knob (1) clockwise to increase the drive tension until the wire feeds smoothly without slipping. page 29, steps 1

MC-589306-34

MIG

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.

SPOOL GUN/PISTOLET À BOBINE

WARNING / AVERTISSEMENT

ELECTRIC SHOCK can kill

• Welding wire and drive parts may be at welding voltage.

trigger is depressed.

UN CHOC ÉLECTRIQUE peut tuer.

• Le fil de soudure et les pièces motrices sont peut-être a la

• Ne touchez pas le fil oules parties motrices à mains nues ou

avec des outils lorsque la detente est sous, pression.

• Keep all doors, covers and panels closed and securely in place.

LES PIÉCES MOBILES peuvent causer des blessur es.

• Maintenez tous les couvercles, panneaus et portes fermés et

solidement en place.

Direct current, electrode nagative

Courant continu polarité normale

FIL AVEC ÂME EN FLUX

Polarity switch setting:

Réglage du commutateur de polarité:

DCEP

Direct current, electrode positive

Courant continu, electrode positive

MIG

Polarity switch setting:

Réglage du commutateur de polarité:

STICK

BAGUETTE

Réglage du commutateur de polarité:

NO GAS/PAS DE GAZ

GAS/GAZ

AVERTISSEMENT

SHOCK can kill e and drive parts may be at welding voltage.

ch wire or drive parts with bare hands or tools when

trigger is depressed.

C ÉLECTRIQUE peut tuer.

udure et les pièces motrices sont peut-être a la

tension de soudage.

pas le fil oules parties motrices à mains nues ou

avec des outils lorsque la detente est sous, pr ession.

PARTS can cause injury.

from moving parts.

rs, covers and panels closed and securely in place.

MOBILES peuvent causer des blessures.

les couvercles, panneaus et portes fermés et

solidement en place.

DCEN

Direct current, electrode nagative

Courant continu polarité normale

FLUX CORE WIRE

FIL AVEC ÂME EN FLUX

Polarity switch setting:

Réglage du commutateur de polarité:

DCEP

Direct current, electrode

Courant continu, electrode

MIG

Polarity switch setting:

Réglage du commutateur de polar

NO GAS/PAS DE GAZ

GAS/

MC-589306-39

MIG 180 INVERTER WELDER 058-9306-4

STEP 3

Operation

Hold the torch in one hand and turn the wire speed dial with the other hand to its maximum position. Pull the trigger (1) on the torch to start an arc. Drag the torch on the work piece while simultaneously turning the wire speed dial counterclockwise. page 31, steps 4

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

MC-589306-42

STICK

ARC

058-9306-4

POWER

MAR

CHE

AVERTISSEMENT

WIRE

FIL

WORK

INTENSITÉ

GAS INER MIG TE

MIG

GAS INER

TER WELDER

MC-589306-12

STEP 2

Turn the mode selector switch (1) to the stick welding mode. page 20, step 6

058-9306-4

STICK

ARC

POWER

MARCHE

RNIN

8 WIRE

FIL

WORK

INTENSITÉ

MIG

GAS INER

MIG

GAS INER

9 A

STICK

ARC

MIG 180 INVER

SOUDEUSE À ONDULEUR MIG 180

TER WELDER

STEP 3

Operation

Strike an arc by scratching the work piece (1) with the electrode (2) and raising it by 1/8" and maintain the gap throughout the weld.

page 35, steps 1 5

MC-589306-15

1/8"

MC-589306-47

QUICK START GUIDE

TECHNICAL SPECIFICATIONS

SAFETY GUIDELINES

KEY PARTS DIAGRAM

IMPORTANT INFORMATION

ASSEMBLY INSTRUCTIONS

OPERATING INSTRUCTIONS

MAINTENANCE

TROUBLESHOOTING

MAIN CIRCUIT CHART

EXPLODED VIEW

PARTS LIST

WARRANTY

3 4–8

9–11

12–18

19–29

30–41

42 43–44

45

46 47–48

49–50

MIG 180 INVERTER WELDER 058-9306-4

WELDER SPECIFICATION

POWER SUPPLY

NO-LOAD VOLTAGE

OUTPUT CURRENT

DUTY CYCLE

Single-phase, 230 V, 60 Hz

78 V

30–200 A DC

WIRE USED

WIRE DIAMETER

ELECTRODE DIAMETER

30%

0.023–0.035" (0.6

– 0.9 mm) MIG wire

0.030–0.035" (0.8

– 0.9 mm) flux-core wire

0.023" (0.6 mm) , 0.030" (0.8 mm) ,

0.035" (0.9 mm)

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)

SPOOL GUN (OPTIONAL) SPECIFICATION

CONNECTOR

MOTOR VOLTAGE

WIRE SPEED

RATING

4-pin quick connect power connection

24 V DC

590"/min

200 A w/CO

2 gas

140 A A/Ar gas

MIG 180 INVERTER WELDER 058-9306-4

This manual contains information that relates to PROTECTING PERSONAL SAFETY and PREVENTING

EQUIPMENT PROBLEMS. It is very important to read this manual carefully and understand it thoroughly before using the product. The symbols listed below are used to indicate this information.

DANGER!

Potential hazard that will result in serious injury or loss of life.

WARNING!

Potential hazard that could result in serious injury or loss of life.

CAUTION!

Potential hazard that may result in moderate injury or damage to equipment.

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.

MIG 180 INVERTER WELDER 058-9306-4

DANGER!

Potential hazard that will result in serious injury or loss of life.

• Keep children or other personnel away from the work area while welding. Do not allow children or persons with mental or physical disabilities to handle the welder.

• Do not use the welder in the presence of flammable liquids or gases. Sparks that are created during use may ignite gases.

• Always ensure that a fire extinguisher is available in an adequate distance within the welding environment.

• Have the welder repaired by a qualified technician in accordance with local, provincial and national codes.

• Do not repair or maintain the welder while the power is on.

• Do not use an ungrounded 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 board in a static proof bag while shipping.

• Make sure harmful arc rays are shielded from view of other personnel.

•

Do not operate the welder in humid, wet or poorly ventilated areas.

•

Risk of electric shock: Do not touch electrical live parts or metal components connected to the welding wire, as doing so may cause fatal shock and severe burns. Secure the ground lead before welding. Poor ground connection creates hazardous situation. Wear a dry protective apparel like a coat, shirt, gloves, and insulated footwear.

MIG 180 INVERTER WELDER 058-9306-4

• Risk of explosion: Keep high pressure shielding gas cylinder away from welding or electrical circuits. Never expose cylinders to high heat, sparks, open flames, mechanical shocks or arcs. Do not touch the cylinder with MIG gun and do not weld on the cylinder. Use proper regulators, gas hoses and fittings for the specific application. Use protective cylinder cap whenever possible.

• Risk for breathing: Never directly inhale the emission of harmful fumes during welding. Make sure the work area is clean, dry and ventilated. Use a ventilation device to remove welding fumes from the work environment.

• Do not weld on coated materials like galvanized, cadmium plated or contacting zinc, mercury or barium, as they emit harmful fumes that are dangerous to breathe. If required, use a respirator with air supply or remove coating from the material in the weld area.

• Do not weld near materials that will emit toxic fumes when heated. Vapours from cleaners, 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 or pipes that contain flammable, gaseous or liquid combustibles.

Welding creates sparks and heat that ignite flammable and explosive materials. Remove all flammable materials within

35 feet of the welding arc or tightly cover the flammable materials with fireproof covers. Ensure that flying sparks do not cause fires or explosions in hidden areas, cracks or areas that are out of vision. Use a fire extinguisher in the work area.

Do not have any items that are combustible, such as lighters or matches

•

Connect the work lead to the weld area as close as possible to prevent any unknown, unintended paths of electrical current from causing electrical shock and fire hazards. To prevent any unintended arcs after welding, cut off the excess wire that extends past the end of the nozzle more than ¼" .

MIG 180 INVERTER WELDER 058-9306-4

• Risk of UV and IR arc rays: Do not look at the welding arc without proper eye protection, as the welding arc produces ultraviolet (UV) and infrared (IR) rays.

Use shields that adheres to ANSI Z87.1. For welders under 160 A output, use a shade 10 lens; for above 160 A, use a shade 12 lens. Wear flame retardant clothes, leather shirts, pants or shoes to cover the bare skin from the arc.

• Use appropriate shield to prevent other personnel from being affected by harmful rays.

• Risk of electromagnetic fields: Electromagnetic field can damage electrical and electronic devices like pacemakers and hearing aids. Make sure people using pacemakers are away from your welding area when welding. Always wrap the MIG gun and ground cable together.

WARNING!

Potential hazard that could result in serious injury or loss of life.

•

Do not allow 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 contacting or touching welding wire, work piece, ground connection or electrode from another welder.

• Do not drape cables over or around the body.

• Do not point the MIG gun toward yourself or other personnel.

• Consult a doctor before using the electric arc welder.

• Always have a secure stance while welding to prevent accident.

• Do not use this welder when you are tired or under influence of alcohol or drugs.

• Connect the ground lead close to the work area to ensure proper ground connection.

• Always secure the high pressure cylinder upright to a cart or stationary object.

• Do not use a welder to thaw frozen pipes.

• Do not look into the valve of the high pressure cylinder when opening it.

MIG 180 INVERTER WELDER 058-9306-4

CAUTION!

Potential hazard that may result in moderate injury or damage to equipment.

• Do not operate the welder if the welding cables, electrode, MIG gun, wire or wire feed system is wet. Do not immerse them in water. The welder and its components must be completely dry before attempting to use the welder.

• Keep the welder in the OFF position when not in use.

• Do not wear watches, rings, bracelets, or loose clothing when using the welder.

• Maintain a correct position while using the welder. Mount the welder on a secure bench or cart to prevent it from tipping over or falling.

• Wear a full covered helmet with appropriate shade that conforms to

ANSI Z87.1 safety standard, 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 components are clean and in good working condition before use.

• Do not use an extension cord, as it causes the voltage to drop and affects the performance of the welder. If needed, use an extension cord having a minimum size of 12 gauge and maximum length of 25 feet.

•

Use safety goggles and ear protection:

Wear safety glasses with side shields when operating the welder and verify that others in the work area are also wearing safety glasses. Safety glasses must conform to

American National Standards Institute (ANSI Z87.1) requirements and must provide protection from flying particles from the front and the sides.

Always wear ear protection to help prevent hearing damage.

Failure to comply may result in loss of hearing.

Note: Recycle unwanted materials rather than disposing of as waste. Sort the tools, hoses, and packaging in specific categories. Take them to the local recycling centre or dispose of in an environmentally safe way.

MC-OM-01

MIG 180 INVERTER WELDER 058-9306-4

058-9306-4

STICK

ARC

POWER

MARCHE

AVER

RNIN

WIRE

FIL

MIG

GAS INER

MIG

GAS INER

STICK

ARC

MIG 180 INVER

SOUDEUSE À ONDULEUR MIG 180

TER WELDER

No.

Description

Voltage control (MIG mode) / Amperage control (stick mode)

Wire feed speed control

Power cord

Wire drive compartment door

MIG gun connection

Electrode cable connection

No.

Description

MIG gun trigger connection

MIG gun cable

Ground cable with clamp

MIG gun trigger cable

Ground cable connection

MC-589306-01

MIG 180 INVERTER WELDER 058-9306-4

Welder

pper front panel

058-9306-4

POWER

MARCHE

STICK

ARC

WARNING

AVERTISSEMENT

WORK

INTENSITÉ

MIG

GAS INERTE

WIRE

FIL

MIG

GAS INERTE

STICK

ARC

No.

Description

Power ON indicator

Thermal overload indicator

No.

Description

Output current indicator

Mode selector switch

MC-589306-02

MIG 180 INVERTER WELDER 058-9306-4

Welder back panel

／ 0589306

MIG

GAZ INERTE

160 A

22 V

STICK

ARC

140 A

25.6 V

230 V AC, 30 A max

ELECTRICAL WARNING

AVERTISSEMENT RELATIE À L’ÉLECTRICITÉ

• Disconnect from power supply before servicing.

• Do not operate with any panels or covers removed.

• Service on this machine should only be performed by

a Qualified technician.

• 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.

POWER

PUISSANCE

MARCHE

OFF

ARRÊT

GAS INPUT

ENTRÊE DE GAZ

NORMAL

OVER CURRENT

SURINTENSITEE

1PH

220V ~ 240V

3 2

No.

Description

Primary power switch

Current overload circuit breaker

No.

Description

Inert gas connection

MC-589306-03

MIG 180 INVERTER WELDER 058-9306-4

General use

The Mastercraft Maximum ® portable and gasless MIG 180 Inverter Welder uses AC single phase

230V, 60 Hz with a 30 A time delayed fuse or circuit breaker. The welder is capable of MIG welding, flux

core welding and DC stick welding. The MIG mode has an infinite voltage control and can weld

24 gauge mild steel to 1/4". The welder can also MIG weld stainless steel and aluminium with an optional spool gun. The stick mode can weld up to

180

A DC and can weld 3/16" on mild steel in a single pass. The welder provides wire feed speed control, overload and thermal protection. The welder can be used as a portable multi purpose machine.

Guidelines for proper usage and description

Removing from carton

1. Remove the welder and other accessories from the packaging.

2. Check the contents with the packaging list. Refer to Packaging 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 connection is located on the lower front panel and connects the cable of the electrode holder with the welding unit during the stick welding mode.

Ground cable connection

This connection is located in the lower front panel and connects the ground cable and the clamp to the welding unit.

Inert gas connection

This connection is located on the back panel and connects the inert gas hose from the gas cylinder to the welding unit providing the unit with shielding gas in the MIG welding mode.

MIG gun connection

This connection is located in the lower front panel and serves as a connection for both the wire feed and shielding gas for the MIG gun or spool gun during the MIG welding mode.

MIG 180 INVERTER WELDER 058-9306-4

MIG gun trigger connection

This MIG gun trigger connection (1) is located in the lower front panel and connects the 4 pin quick connect plug of the MIG gun or the spool gun (not included) with the welding unit.

Connections 1 and 2 are provided for the MIG gun/spool gun and connections 3 and 4 are provided for the wire feed motor.

MIG 180 INVER

SOUDEUSE À ONDULEUR MIG 180

TER WELDER

MC-589306-35

Mode selector switch

This switch is located on the upper front panel of the welder and is used to select either MIG welding mode or stick welding mode.

Power ON indicator

This indicator is located on the upper front panel of the welder and glows when the primary power plug is connected to the power supply and the switch is turned ON.

Primary power switch

This switch is located on the back panel of the welder and enables to turn the welding unit ON or OFF.

Spool gun selector

The spool gun selector (1) is located inside the wire compartment. This selector is switched to spool gun mode when an optional spool gun

(not included) is being used, otherwise it stays in the MIG mode. Refer to spool gun’s manual for its connection instructions.

MIG 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 » et à la position « SPOOL GUN » si vous utilisez un pistolet à bobine.

SPOOL GUN/PISTOLET À BOBINE

WARNING / AVERTISSEMENT

• Welding wire and drive parts may be at welding voltage.

ELECTRIC SHOCK can kill

trigger is depressed.

• Do not touch wire or drive parts with bare hands or tools when

• Le fil de soudure et les pièces motrices sont peut-être a la UN CHOC ÉLECTRIQUE peut tuer.

• Ne touchez pas le fil oules parties motrices à mains nues ou tension de soudage.

avec des outils lorsque la detente est sous, pression.

MOUING PARTS can cause injury.

• Keep away from moving parts.

• Keep all doors, covers and panels closed and securely in place.

• Ne vous approchez pas des pièces mobiles.

LES PIÉCES MOBILES peuvent causer des blessures.

solidement en place.

• Maintenez tous les couvercles, panneaus et portes fermés et

DCEN

Direct current, electrode nagative DCEN

Courant continu polarité normale FLUX CORE WIRE

Polarity switch setting:

DCEP

DCEP Direct current, electrode positive

Courant continu, electrode positive MIG

Polarity switch setting: MIG

STICK

Polarity switch setting: BAGUETTE

Réglage du commutateur de polarité: + Réglage du commutateur de polarité: Réglage du commutateur de polarité:

+ +

NO GAS/PAS DE GAZ GAS/GAZ

MIG

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.

SPOOL GUN/PISTOLET À BOBINE

Thermal overload indicator

This indicator is located on the upper front panel of the welder and glows when the thermal overload circuit is activated. The welding unit stops working during this period protecting the unit from any damage. The cooling fan of the welding unit continues to work even if the welding unit is shut down by the thermal overload circuit.

MIG 180 INVERTER WELDER 058-9306-4

Voltage control (MIG mode)/Amperage control (stick mode)

This control is located on the upper front panel of the welder. It is used to adjust the welding voltage when the MIG mode is engaged and to adjust the welding amperage when the stick mode is engaged.

Output current indicator

This indicator is located on the upper front panel of the welder 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 positive (“+”) terminal.

For MIG welding (solid wire) using shielding gas, the MIG gun lead is connected to the positive (“+”) terminal and the ground cable is connected to the negative (“-”) terminal.

GAS

MC-589306-06

MIG 180 INVERTER WELDER 058-9306-4

Wire drive compartment

The wire drive compartment has wire feed components such as drive tension adjustment knob (1), drive tension arm (2), drive roll (3), MIG gun securement screw (4), set

up chart (5), polarity terminals (6), and spool hub (7).

MIG

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.

SPOOL GUN/PISTOLET À BOBINE

WARNING / AVERTISSEMENT

ELECTRIC SHOCK can kill

• Welding wire and drive parts may be at welding voltage.

• Do not touch wire or drive parts with bare hands or tools when

trigger is depressed.

UN CHOC ÉLECTRIQUE peut tuer.

• Le fil de soudure et les pièces motrices sont peut-êtr e 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, pr ession.

MOUING PARTS can cause injury.

• Keep all doors, covers and panels closed and secur ely in place.

LES PIÉCES MOBILES peuvent causer des blessur es.

• Ne vous approchez pas des pièces mobiles.

• Maintenez tous les couvercles, panneaus et portes fermés et

solidement en place.

DCEN

Direct current, electrode nagative

Courant continu polarité normale

FLUX CORE WIRE

FIL AVEC ÂME EN FLUX

Polarity switch setting:

Réglage du commutateur de polarité:

DCEP

Direct current, electrode positive

Courant continu, electrode positive

MIG

Polarity switch setting:

Réglage du commutateur de polarité:

STICK

BAGUETTE

Polarity switch setting:

Réglage du commutateur de polarité:

NO GAS/PAS DE GAZ

GAS/GAZ

2 3

MIG 180 INVERTER WELDER 058-9306-4

Gas selection

Different materials require different shielding gas when MIG welding. Refer to the set up chart inside the wire drive compartment.

Mild steel: Use 75% Argon and 25% for reduced spatter and reduced penetration for thinner materials. Use CO

for deeper penetration and increased spatter.

Note: Do not use argon gas concentrations higher than 75% on steel. The result will be extremely poor penetration, porosity, and brittleness of weld.

Stainless steel: Use a mixed gas consisting of Helium, Argon, and CO

Aluminum or bronze: Use 100% Argon.

Electrode

The welding electrode is a rod 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:

Type of electrode

E6011

E6013

E7014

E7018AC

Tensile strength

60,000 PSI

70,000 PSI

Application

Deep penetration process

Poor fitup application

High deposition and fast travel speed with light penetration process

Tack welding and out of position application

Torch travel:

Refers to the movement of the welding torch along the weld joint.

Travel direction:

Refers to the direction of the torch moving along the weld joint in relation to the weld puddle.

Travel speed:

The rate at which the torch is being moved along the weld joint.

MIG 180 INVERTER WELDER 058-9306-4

Packaging content list

No.

Material name

1 Portable MIG/flux core/stick welder

Quantity

2 Gas regulator 1

3 Ground cable with clamp 1

4 8" spool adaptor 1

5 MIG gun 1

Electrode holder with welding cable

MIG consumable kit (nozzle, contact tips, L shaped hexagonal wrench)

8 Gas hose

MIG 180 INVERTER WELDER 058-9306-4

Illustration

058-9306-

WARN

WORK

ING MENT

INTENSI

STICK ARC

GAS INER MIG

5 6

WIRE FIL

5 6

MIG GAS I

8 NER TE

ARC

MIG 180 INVER

TER WELDER

100 150

200

250

300

400

350

No.

Material name

Wire spool

Electrode

Owner’s manual

Quantity

Illustration

MIG 180 INVERTER WELDER 058-9306-4

Assembly Instructions

Installation for stick welding

DANGER!

Potential hazard that will result in serious injury or loss of life.

Do not use the welding unit near flammable materials.

1. Plug the ground cable (1) into the ground cable connection of the welding unit

(fig 1A).

fig 1A

058-9306-4

STICK

ARC

POWER

AVER

WARNI

TISSE NG

MENT

WORK

INTENSITÉ

MIG NE

5 6

8 WIRE

FIL

8 MIG

9 A

STIC

ARC

TER WELDER

2. Plug the electrode holder cable (1) into the electrode cable connection

(fig 1B)

MC-589306-10 fig 1B

ARC STIC

058-9306-4

POW

MARCHE ER

WA RNIN

AVERTISSEMENT

WORK

INTENSITÉ

8 WIRE

FIL

MIG

GAS INE

4 5 6

8 MIG

GAS INE

A RTE

10 STICK

ARC

MIG 180 INVER

TER WELDER

3. Attach the electrode (1) to the electrode holder (2)

(fig 1C)

fig 1C

STICK

ARC

058-9306-4

POWER

MARCH

WAR NING

WORK INTENSIT

MIG

GAS IN

4 5 6

FIL

WIRE

5 6

MIG

GAS INER

9 A

STICK

ARC

MIG 180 INVER

SOUDEUSE À ONDULEUR MIG 180

TER WELDER

MC-589306-11

1 2

MC-589306-12

MIG 180 INVERTER WELDER 058-9306-4

4. Attach the ground clamp (1) to the work surface (2) or to the work piece

(fig 1D)

5. Plug the power cord (1) of the welding unit into a suitable receptacle (2) and turn ON the power supply

(fig 1E)

Note: The plug of the power cord and the receptacle should adhere to NEMA 6 50 design

.

6. Turn the mode selector switch (1) to the stick welding mode

(fig 1F)

7. Turn ON the primary power switch (1) on the back panel of the welding unit

(fig 1G)

. Refer to Stick welding operation

page 33.

fig 1D

058-9306-4

STICK

ARC

AVER

POWER MARCHE

8 WIRE

FIL

INTENSITÉ WORK

GAS IN

MIG

GAS IN

ERTE

10 STICK ARC

MIG 180 INVER

TER WELDER

MC-589306-13 fig 1E

058-9306-4

STICK

ARC

POWER

MARCHE 3

8 WIRE

FIL

AVER WAR NING

TISSEME NT

GAS IN MIG

4 5 6

7 V

8 MIG

GAS IN ERT

9 A

10 STICK

ARC

MIG 180 INVER

SOUDEUSE À ONDULEUR MIG 180

TER WELDER

MC-589306-14 fig 1F

058-9306-4

POWER

MARCHE

RNIN

WIRE

FIL

WORK

INTENSITÉ

GAS INER

5 6

MIG

GAS INER

9 A

STICK

ARC

MIG 180 INVER

TER WELDER

MC-589306-15 fig 1G

／ 0589306

230 V AC, 30 A max

MIG

GAZ INERTE

STICK

ARC

160 A

22 V

140 A

25.6 V

ELECTRICAL WARNING

AVERTISSEMENT RELATIE À L’ÉLECTRICITÉ

• Disconnect from power supply before servicing.

• Do not operate with any panels or covers removed.

• Service on this machine should only be performed by

a Qualified technician.

• 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.

POWER

PUISSANCE

MARCHE

OFF

ARRÊT

GAS INPUT

ENTRÊE DE GAZ

NORMAL

OVER CURRENT

SURINTENSITEE

1PH

220V ~ 240V

MC-589306-16

MIG 180 INVERTER WELDER 058-9306-4

Installation for MIG welding

1. Place the shielding gas cylinder (1) (not included) close to the welding unit

(fig 1H).

2. Attach the regulator (1) to the shielding gas cylinder (2)

(fig 1I)

3. Connect one end of the gas hose (1) to the regulator (2)

(fig 1J)

fig 1H

STICK

ARC

058-93

06-4

POWER

MARC HE 3

5 6

WIRE

FIL

AVERTISSE

MENT

MIG GAS INERTE

4 5 6

9 A

STICK

ARC

MIG

GAS INER

MC-589306-17 fig 1I

100 150

200

400

350

250

300

MC-589306-18 fig 1J

100 150

200

250

300

400

350

4. Attach the other end of the gas hose (1) to the inert gas connection on the back panel of the welding unit

(fig 1K)

fig 1K

POWER

PUISSANCE

MARCHE

／ 0589306

230 V AC, 30 A max

160 A

22 V

140 A

25.6 V

ELECTRICAL WARNING

AVERTISSEMENT RELATIE À L’ÉLECTRICITÉ

• Disconnect from power supply before servicing.

• Do not operate with any panels or covers removed.

• Service on this machine should only be performed by

a Qualified technician.

• 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.

OFF

ARRÊT

GAS INPUT

ENTRÊE DE GAZ

NORMAL

OVER CURRENT

SURINTENSITEE

1PH

220V ~ 240V

MC-589306-19

100 150 200

250

300

400

350

MC-589306-20

MIG 180 INVERTER WELDER 058-9306-4

5. Open the valve (1) of the shielding gas cylinder and adjust the flow rate using the regulator (2) to 20 cubic feet/hour

(fig 1L)

Note: The red scale of the regulator denotes the flow rate.

Note: Gas flow can be heard at the end of the gun when the trigger is activated.

Note: If there is no gas flow, harsh arc with excessive spatter will occur and a smooth weld bead will not be obtained.

6. Plug the ground cable (1) into the ground cable connection of the welding unit

(fig 1M)

7. Open the wire drive compartment door (1) and loosen the gun securement screw (2)

(fig 1N)

8. Attach the MIG gun (1) and MIG gun trigger cable (2) to their designated connections

(fig 1O)

. Refer to Important information page 13.

fig 1L

MC-589306-21 fig 1M

1 058-930 6-4

POW

MAR ER CHE

AVERTISS NG WA RNI EMENT

WORK

INTENSITÉ

STICK ARC

MIG

GAS INER

4 5 6

8 WIRE

FIL

MIG

GAS INER

9 A

ARC STICK

TER WELDER

100 150 200

400 350

250

300

MC-589306-22 fig 1N

trigger is .

UN CHOC ÉL

• Le fil de soudure et les piè

tension de soudage.

• Ne touchez pas le fil oules parties

avec des outils lorsque la detente e

MOUING PARTS can caus

• Keep away from moving parts.

• Keep all doors, covers and panels closed

LES PIÉCES MOBILES peuve

• Ne vous approchez pas des pièces mobiles.

• Maintenez tous les couvercles, panneaus et po

solidement en place.

MIG

When normal MIG welding, this switch should be turned in “MIG” position.

this switch should be in “Spool gun” position.

si vous effectuez du soudage MIG normal et à la position « SPOOL GUN » si vous utilisez un pistolet à bobine.

SPOOL GUN/PISTOLET À BOBINE

WARNING / AVERTISSEMENT

• Welding wire and drive parts may be at welding voltage.

ELECTRIC SHOCK can kill

trigger is depressed.

• Do not touch wire or drive parts with bare hands or tools when

• Le fil de soudure et les pièces motrices sont peut-être a la UN CHOC ÉLECTRIQUE peut tuer.

• Ne touchez pas le fil oules parties motrices à mains nues ou tension de soudage.

avec des outils lorsque la detente est sous, pression.

MOUING PARTS can cause injury.

• Keep away from moving parts.

• Keep all doors, covers and panels closed and securely in place.

LES PIÉCES MOBILES peuvent causer des blessures.

• Maintenez tous les couvercles, panneaus et portes fermés et • Ne vous approchez pas des pièces mobiles.

solidement en place.

DCEN DCEN

Direct current, electrode nagative Courant continu polarité normale

FIL AVEC ÂME EN FLUX FLUX CORE WIRE

Réglage du commutateur de polarité: Polarity switch setting: -

DCEP DCEP

Courant continu, electrode positive Direct current, electrode positive

MIG MIG

Réglage du commutateur de polarité: Polarity switch setting:

BAGUETTE STICK

Réglage du commutateur de polarité: Polarity switch setting:

NO GAS/PAS DE GAZ GAS/GAZ

MC-589306-23

100 150

200 250

400 350

300 fig 1O

2 STICK

ARC

058-9306-4

AVER

MARC POW

WARNING

TISSEMENT

5 6

WIRE FIL

INTENSITÉ WORK

MIG

S INE GA

7 V

8 MIG

RTE

9 A

STICK ARC

TER WELDER

MC-589306-24

MIG 180 INVERTER WELDER 058-9306-4

9. Tighten the gun securement screw (1) by hand until it is snugly fit

(fig 1P)

10. Turn the mode selector switch (1) to the

MIG welding mode

(fig 1Q)

11. Attach the required spool of wire onto the hub in the wire drive compartment. Refer to Installing the wire page 26.

12. Draw the wire through the wire drive compartment. Refer to Installing the wire roller page 24.

13. Check the weld polarity for MIG welding operation. Refer to Important information page 15.

14. Fix the ground clamp (1) to the work surface (2) or to the work piece

(fig 1R)

fig 1P

trigger is .

UN CHOC ÉL

• Le fil de soudure et les piè

tension de soudage.

• Ne touchez pas le fil oules parties

avec des outils lorsque la detente e

MOUING PARTS can caus

• Keep away from moving parts.

• Keep all doors, covers and panels closed

LES PIÉCES MOBILES peuve

• Ne vous approchez pas des pièces mobiles.

• Maintenez tous les couvercles, panneaus et po

solidement en place.

MIG

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.

SPOOL GUN/PISTOLET À BOBINE

WARNING / AVERTISSEMENT

ELECTRIC SHOCK can kill

• Welding wire and drive parts may be at welding voltage.

trigger is depressed.

• Do not touch wire or drive parts with bare hands or tools when

UN CHOC ÉLECTRIQUE peut tuer.

tension de soudage.

• Le fil de soudure et les pièces motrices sont peut-être a la

• Keep away from moving parts.

MOUING PARTS can cause injury.

• Keep all doors, covers and panels closed and securely in place.

• Ne vous approchez pas des pièces mobiles.

solidement en place.

• Maintenez tous les couvercles, panneaus et portes fermés et

DCEN

Direct current, electrode nagative DCEN

DCEP

Direct current, electrode positive DCEP

Courant continu polarité normale Courant continu, electrode positive

FIL AVEC ÂME EN FLUX FLUX CORE WIRE

Réglage du commutateur de polarité: Polarity switch setting:

MIG

Réglage du commutateur de polarité: Polarity switch setting:

STICK BAGUETTE

NO GAS/PAS DE GAZ

GAS/GAZ

MC-589306-25

100 150 200

300 250

350

400 fig 1Q

STICK

WARNING

WORK

MIG

STICK BAGUETTE

POW ER

AVER WA RNIN

WORK

INTENSI TÉ

8 WIRE

FIL

4 5 6

7 V

MIG GAS I NE

9 A

STICK

ARC

RTE

TER WELDER fig 1R

MC-589306-26

058-9306-4

POW

MARC ER HE

AVER TISSE WA RNING

MENT

4 5 6

8 WIRE

FIL

ARC STICK

INTE WORK NSITÉ

GA MIG S INE

4 5 6

7 V

8 MIG

ERT

9 A

STICK

ARC

TER WELDER

MC-589306-27

15. Plug the power cord (1) of the welding unit into a suitable receptacle (2) and turn ON the power supply

(fig 1S)

Note: The plug of the power cord and the receptacle should adhere to NEMA 6

50 design and the receptacle should be a 230 V, 50 A receptacle.

fig 1S

ARC STICK

058-9306-4

AVER

POWER

MARCHE

TISSE WA RNIN

MENT

WORK INTENSITÉ

GAS MIG INE

4 5 6

8 WIRE

FIL

5 6

8 MIG

GAS

9 A

STICK

ARC

INER TE

TER WELDER

MC-589306-28

MIG 180 INVERTER WELDER 058-9306-4

16. Turn ON the primary power switch (1) on the back panel of the welding unit

(fig 1T)

. Refer to MIG welding operation page 30.

fig 1T

／ 0589306

230 V AC, 30 A max

MIG

GAZ INERTE

STICK

ARC

160 A

22 V

140 A

25.6 V

ELECTRICAL WARNING

AVERTISSEMENT RELATIE À L’ÉLECTRICITÉ

• Disconnect from power supply before servicing.

• Do not operate with any panels or covers removed.

• Service on this machine should only be performed by

a Qualified technician.

• 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.

POWER

PUISSANCE

MARCHE

OFF

ARRÊT

GAS INPUT

ENTRÊE DE GAZ

NORMAL

OVER CURRENT

SURINTENSITEE

1PH

220V ~ 240V

MC-589306-29

Installing the wire roller

1. Open the wire drive compartment.

2. Remove the drive tension by loosening the drive tension adjusting knob (1) and lifting the drive tension adjustor and drive tension arm (2) away from the drive roll (3)

(fig 1U)

Note: Proper sized drive roll must be used before installing the wire.

3. Insert the end of the wire (1) into the hole on outside edge of the wire spool and bend the wire to hold the wire in place.

Remove the wire spool from the wire drive compartment

(fig 1V).

Note: If the wire is already installed in 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. fig 1U fig 1V

MC-589306-30

MC-589306-31

MIG 180 INVERTER WELDER 058-9306-4

4. Loosen the set screw of the drive roll (1) using L shaped hexagonal wrench (2)

(fig 1W)

. fig 1W

5. Remove the drive roll (1) from the drive roll shaft (2)

(fig 1X)

. fig 1X

Refer the below chart to select the roll groove based on the wire diameter:

Wire diameter

0.023"

0.030"

0.035"

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.

Roll groove

0.6

0.9

MC-589306-32

MC-589306-33

MIG 180 INVERTER WELDER 058-9306-4

Installing the wire

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 burn the work piece.

• Before installing, remove the old wire from the MIG gun assembly to prevent the wire from being jammed inside the gun liner.

• Do not remove the welding nozzle when the MIG gun trigger is pulled due to risk of an electric shock. Turn the power OFF before removing the welding nozzle.

Refer to the chart below for wire selection based on type of welding:

Welding Type

MIG welding

Flux

core welding

Note: MIG wire can be either mild steel, stainless steel, or aluminium solid wire.

1. Remove the nozzle (1) and contact tip (2) from the end of the MIG gun assembly

(fig 1Y)

Note: Ensure that the groove on the drive roll matches with the size of the wire being installed.

2. Unwrap the wire spool from its packaging and do not unhook the wire from the spool at this time.

3. Remove the wing nut, bushing and washer from the hub in the wire compartment.

Note: If a 4" spool is used, proceed to step 4 and then follow step 7. If an 8" spool is used, skip to step 5.

Wire diameter

0.023"

–

0.035" MIG wire

0.030"

–0.035" flux-core wire fig 1Y

MC-589306-34

MIG 180 INVERTER WELDER 058-9306-4

4" spool installation

4. Slide a 4" spool (1) on the hub and secure the washer (2), bushing (3) and the wing nut (4) sequentially

(fig 1Z).

Go to step 7

.

Note: Ensure the spool is not firmly tightened.

It should be able to move easily.

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).

fig 1Z

2 fig 2A

3 fig 2B

MC-589306-35

MC-589306-36

MC-589306-37

7. Place the spool on the hub with the wire passing from the bottom of the spool into the drive mechanism

(fig 2C)

. fig 2C

MC-589306-38

MIG 180 INVERTER WELDER 058-9306-4

8. Setting the wire spool tension: a. Turn the wire spool clockwise with one hand.

b. Increase the spool tension by tightening the wing nut while turning the spool. Tighten the wing nut until turning becomes harder.

c. Stop tightening the wing nut. Repeat the steps a c until proper spool tension is achieved.

Note: If high tension is applied to the wire spool, the wire slips off the drive roll or the wire gets stuck. If low tension is applied, the wire spool unspools itself when the trigger is released. Readjust the spool tension using the wing nut if the tension is high or low.

9. Disconnect the welder from the power source, and remove the leading end of the wire from the spool.

10. Cut off any bent portion of the wire using a wire cutters.

11. Loosen the tension adjusting knob and lift up the tension arm off the drive roll.

12. Insert about 6" of the wire into the inlet guide tube, and across the drive roll and into the MIG gun assembly.

13. 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 set up chart inside the wire drive compartment.

17. Set the wire feed speed control . Straighten the MIG gun cable and pull the trigger in the gun handle to feed the wire through the torch assembly .

18. Turn the power switch to the OFF position. Select a contact tip having the diameter same as the wire being used .

Note: Due to inherent variances in flux

cored welding wire, it is necessary to use a contact tip larger than the wire.

19. Slide the contact tip over the wire, thread the contact tip into the end of the gun and tighten securely.

20. Install the nozzle on the gun assembly, and use anti

spatter spray or gel to keep the spatter from sticking to the inside of the nozzle.

21. Cut off the excess wire that extends past the nozzle leaving 1/4" of the wire to stick out.

22. Turn ON the power switch.

MIG 180 INVERTER WELDER 058-9306-4

Setting the wire tension

WARNING!

Potential hazard that could result in serious injury or loss of life.

• To reduce the risk of arc flash, ensure that wire passing out of the end of the torch does not contact with the work piece, ground clamp or any grounded material during the drive tension setting process. If not followed, arcing will occur.

• Do not apply back pressure on the wire without a glove. Failure to comply may result in injury.

1. Press the trigger on the gun.

2. Turn the drive tension adjustment knob

(1) clockwise, and increase the drive tension until the wire feeds smoothly without slipping

(fig 2D)

fig 2D

AVERTISSEMENT

SHOCK can kill e and drive parts may be at welding voltage.

C ÉLECTRIQUE peut tuer.

pas le fil oules parties motrices à mains nues ou

avec des outils lorsque la detente est sous, pr ession.

PARTS can cause injury.

from moving parts.

rs, covers and panels closed and securely in place.

MOBILES peuvent causer des blessures.

chez pas des pièces mobiles.

les couvercles, panneaus et portes fermés et

solidement en place.

DCEN

Direct current, electrode nagative

Courant continu polarité normale

FLUX CORE WIRE

FIL AVEC ÂME EN FLUX

Polarity switch setting:

Réglage du commutateur de polarité:

DCEP

Direct current, electrode

Courant continu, electrode

MIG

Polarity switch setting:

Réglage du commutateur de pola

+ +

MIG 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 » et à la position « SPOOL GUN » si vous utilisez un pistolet à bobine.

SPOOL GUN/PISTOLET À BOBINE

WARNING / AVERTISSEMENT

ELECTRIC SHOCK can kill

• Do not touch wire or drive parts with bare hands or tools when • Welding wire and drive parts may be at welding voltage.

trigger is depressed.

UN CHOC ÉLECTRIQUE peut tuer.

tension de soudage.

• Le fil de soudure et les pièces motrices sont peut-être a la

avec des outils lorsque la detente est sous, pression.

• Ne touchez pas le fil oules parties motrices à mains nues ou

• Keep away from moving parts.

MOUING PARTS can cause injury.

• Keep all doors, covers and panels closed and securely in place.

• Ne vous approchez pas des pièces mobiles.

• Maintenez tous les couvercles, panneaus et portes fermés et

solidement en place.

DCEN DCEN

Direct current, electrode nagative Courant continu polarité normale

DCEP DCEP

Courant continu, electrode positive Direct current, electrode positive

MIG MIG FIL AVEC ÂME EN FLUX FLUX CORE WIRE

Réglage du commutateur de polarité: Polarity switch setting:

BAGUETTE STICK

Réglage du commutateur de polarité: Polarity switch setting:

NO GAS/PAS DE GAZ GAS/GAZ

NO GAS/PAS DE GAZ

GAS/

MC-589306-39

3. Apply slight back pressure against the wire by curling the wire. If wire continues to feed smoothly, the wire tension is set correctly.

MIG 180 INVERTER WELDER 058-9306-4

MIG welding operation

Holding the torch (MIG gun):

• Before starting the welding operation, try holding the torch in different positions until you identify a suitable position.

Distance from the work piece:

• The distance between the nozzle and the work piece should be kept constant and should not exceed 1/4".

Tuning in the wire speed:

Wire speed must be tuned in before starting each welding job or whenever any of the variables such as heat setting, wire diameter and wire type are changed.

WARNING!

Potential hazard that could result in serious injury or loss of life.

• Prolonged exposure to the welding arc can cause blindness and burns.

• Never strike the arc or start welding until the user is adequately protected.

• Wear flameproof welding gloves, a heavy long sleeved shirt, trousers without cuffs, high

topped shoes and ANSI

approved welding helmet.

Connect the ground clamp 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.

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 on the need.

MIG 180 INVERTER WELDER 058-9306-4

There are two angles of the torch nozzle in relation to the work piece that must be considered when welding.

Angle A (60 degrees) Angle B (30

45 degrees)

fig 2E fig 2F

30 45

MC-589306-40

• Angle A is the angle between the nozzle and the work piece and can be varied, but in most cases the optimum angle will be

60 degrees (the point at which the torch handle is parallel to the work piece). If angle A is increased, penetration will increase, and if decreased penetration will decrease

(fig 2E)

MC-589306-41

• Angle B is the angle between the perpendicular of the work piece and the nozzle and can be varied to improve the visibility of the arc in relation to the weld puddle and to direct the force of the arc

(fig 2F)

Turn the wire feed speed control with the other hand to its maximum position and continue to hold onto the speed control.

Pull the trigger (1) on the torch to start an arc. Drag the torch toward the user while simultaneously turning the wire feed speed control counterclockwise

(fig 2G)

fig 2G

MC-589306-42

When the wire speed decreases, the sound that the arc makes will change from a sputtering sound to a high pitched buzzing sound. The correct setting is the point where the high pitched buzzing sound is achieved. Use 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.

MIG 180 INVERTER WELDER 058-9306-4

Welding techniques

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 grounded area. Failure to comply could result in serious injury or loss of life.

• Do not perform any welding without adequate protection, helmet and gloves.

Failure to comply could result in serious injury or loss of life.

1. For a solid weld bead, move the welding torch steadily and at the right speed along the weld joint.

Note: Moving the torch too fast, too slow, or erratically prevents proper fusion and/or creates a lumpy, uneven bead.

2. Move the torch (1) towards the weld puddle or away from the weld puddle

(fig 2H)

Note: For most welding jobs, move the torch along the weld joint 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.

fig 2H

MC-589306-43

MIG 180 INVERTER WELDER 058-9306-4

Stick welding operation

Selection of electrode

1. Determine the type and thickness of the metal to be welded and the position of the work piece.

2. Select the appropriate type of electrode and the amount of heat required for the welding process.

3. Set higher amperage 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 electrode:

• The bead will be high and irregular

(fig 2J).

• The arc will be difficult to maintain.

fig 2I fig 2J

MC-589306-44

MC-589306-45

MIG 180 INVERTER WELDER 058-9306-4

On selection of a large electrode:

• The arc will burn through light metals

.

• The bead will undercut the work.

• The bead will be flat and porous.

• The rod may stick to the work piece

(fig 2K).

Note: Rate of travel over the work piece also affects the weld. To ensure proper penetration and enough rod deposit, the arc must be moved slowly and evenly along the weld seam.

Setting the amperage control

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 electrode perpendicular to the work piece when striking the initial arc.

3. To allow good penetration with minimal spatter, hold the electrode at an angle of

10 °

–

30 ° between the electrode and the work piece once the initial arc is struck.

fig 2K

MC-589306-46

MIG 180 INVERTER WELDER 058-9306-4

Striking the arc

DANGER!

Potential hazard that will result in serious injury or loss of life.

• Do not expose self to a welding arc.

• Do not weld without adequate protection.

• Wear recommended safety equipment and clothing before welding.

1. Scratch the work piece (1) with the end of electrode (2) to start the arc and then raise it to a gap of 1/8" between the rod and the work piece

(fig 2L).

fig 2L

1/8"

MC-589306-47

2. Maintain the constant gap between the welding rod and the work piece during welding.

Note: If the gap is too narrow, the rod will stick to the work piece. If the gap is too wide, the arc will extinguish.

3. Gently 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).

fig 2M

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MIG 180 INVERTER WELDER 058-9306-4

Weld bead formation

The formation of weld bead depends on the welding speed and arc conditions.

Ideal weld:

• The bead will lay smoothly over the work without ragged 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.

fig 2N fig 2O

MC-589306-49

MC-589306-50

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)

fig 2P

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MIG 180 INVERTER WELDER 058-9306-4

Arc too long:

• The arc will result in a flat, wide weld

(fig 2Q)

• The arc will result in a lot of splatter.

• The arc will be unstable

.

fig 2Q

Guidelines for a good weld bead

• A solid weld bead requires that the electrode be moved slowly and steadily along the weld seam.

• Moving the electrode rapidly or erratically will prevent 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 chipping process not only removes the slag off the weld but also relieves the internal strains developed by the heating and cooling processes of welding.

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MIG 180 INVERTER WELDER 058-9306-4

Types of welding beads:

Stringer bead

fig 2R

Weave bead

fig 2S

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• 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)

Welding positions

1. Flat position: This position is the easiest and most commonly used position. It is best to weld in the flat position to achieve good results

(fig 2T)

MC-589306-54

• The weave bead is made by weaving the wire from side to side while moving with the torch

(fig 2S)

fig 2T

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2. Horizontal position: This position 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)

fig 2U

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MIG 180 INVERTER WELDER 058-9306-4

3. Vertical position: The torch can be easily moved from top to bottom in this position, though it is difficult to prevent the puddle from running downward.

Moving the torch from bottom to top provides better puddle control and allows slower rates of travel speed to achieve deeper penetration. For this position, angle B should be zero and angle A will vary from 45 to 60 degrees to provide better puddle control

(fig 2V)

4. Overhead position: This is the most difficult welding position. For this position, angle A should be maintained at 60 degrees

.

Maintaining this angle will reduce falling 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 process is done, a "V" is created between the two metal pieces. In most cases, more than one pass or bead will need to be laid into the joint to close the "V"

(fig 2X)

Note: When using self -shielding flux core wire, it is necessary to thoroughly chip and brush the slag off each completed weld bead before making another pass.

fig 2V fig 2W

MC-589306-57

MC-589306-58 fig 2X

First or

Root Pass

Second

Pass

Third

Pass

Finished

Weld

MC-589306-59

MIG 180 INVERTER WELDER 058-9306-4

2. Fillet weld joint: Most fillet weld joints on metals of moderate to heavy thickness will require multiple pass welds to produce strong joint. The multiple pass beads can be laid in three passes into a

T fillet joint and a lap fillet joint

(fig 2Y)

Spot welding

There are three methods of spot welding:

1. Burn

through method: In this method, two overlapped metal pieces are welded together by burning through the top piece and into the bottom piece.

Self shielding, flux core wire of 0.035" 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 of metal and the arc is directed through the hole to penetrate into the bottom piece. The puddle is allowed to fill up the hole leaving a spot weld that is smooth and flush with the surface of the top piece

(fig 3A)

fig 2Z fig 3A fig 2Y

Lap Joint Welded

In Three Passes

1 2

T Joint in

Three Passes

MC-589306-60

MC-589306-61

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MIG 180 INVERTER WELDER 058-9306-4

3. Lap spot method: The welding arc is directed to penetrate the bottom and top pieces at the same time, and along each side of the lap joint seam. Select the wire diameter, wire feed speed, and tune in the wire speed for welding a continuous bead

(fig 3B)

Instructions to be followed for spot welding

Select the wire diameter and heat setting recommended above for the intended method of spot welding.

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 duration of time of holding the trigger until a desired spot weld is made.

6. Make spot welds on the actual work piece at desired locations.

fig 3B

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MIG 180 INVERTER WELDER 058-9306-4

Maintenance

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 damaged parts or accessories.

• Use only recommended and properly rated replacement parts. Failure to comply could lead to serious injury or loss of life.

MAINTENANCE

REQUIRED

depth inspection

Repair or replacement

DESCRIPTION

Worn or broken parts

MAXIMUM SERVICE INTERVAL

Monthly

As Needed

The welder needs regular maintenance as following:

• Clean the dust, dirt, and grease periodically from the welder.

• Every six months, remove the front panel from the welder to clear the accumulated dust and dirt.

• Replace power cord, ground cable, ground clamp or electrode assembly when damaged or worn.

• Repairs must be performed by a qualified service technician only.

Storage

• Store the welder in a clean and dry location away from corrosive gas and excess dust 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.

MIG 180 INVERTER WELDER 058-9306-4

Troubleshooting

The following chart lists common issues and solutions. Please read it carefully and follow all instructions closely.

WARNING!

Potential hazard that could result in serious injury or loss of life.

• If any of the following symptoms appears while the welder is in use, turn unit off and disconnect it from the power supply immediately. Failure to heed this warning will result in serious personal injury or loss of life.

• Repairs must be performed by a qualified service technician only.

PROBLEM

The welder does not work when the main switch is turned on.

The welder does not weld.

POSSIBLE CAUSES

1. No power input.

2. Power cord or power plug is broken.

3. Main switch is broken.

4. Transformer is broken.

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.

SOLUTIONS

1. Check the circuit or fuse of the power supply.

2. Replace the power cord.

3. Replace the main switch.

4. Replace the transformer.

1. Check the power source.

2. Check for proper grounding to the work piece.

3. Check the output connection.

4. Clean the components.

5. Use the correct wire.

6. Set the mode selector switch in accordance to the type of welding.

Blown fuse or tripped circuit breaker.

1. Inadequate fuse or circuit breaker.

1. Check whether the fuse in power supply is 50 A.

Arc is hard to start.

1. Wrong welding wire or electrode.

2. Base metal is not grounded properly.

1. Use the correct wire or electrode.

2. Make sure the connection is good.

MIG 180 INVERTER WELDER 058-9306-4

PROBLEM POSSIBLE CAUSES

1. Not enough drive roll pressure.

SOLUTIONS

1. Tighten the drive tension adjustor on wire feeder.

2. Adjust the wing nut on the spool holder.

Inconsistent arc or wire feed.

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.

3. Replace the contact tip.

4. Replace the wire.

5. Use correct or undamaged electrode.

Note: For further assistance on installation and repairs, please contact 1 800 689 9928.

MIG 180 INVERTER WELDER 058-9306-4

XXXXXXX CN202 CN201

XXXXXXX

CN207

MIG 180 INVERTER WELDER 058-9306-4

MC-589306-65

10 11

1 2

22 23

24 25

37 36

MC-589306-64

MIG 180 INVERTER WELDER 058-9306-4

No.

Description

1 Hinge

Case cover

Wire retainer

Control transformer

Main PC board

Door

Door lock

Spool holder

Spring

10 Board

Holder

Spool adaptor

Spool fixed cover

Washer

Butterfly nut

Vertical centre sheet metal

Connection terminal (red)

Connection terminal (black)

Main transformer

Rectifier heat sink

Reactor assembly

Plastic front panel

Front panel support

Qty.

No.

Description

Indicator

Wire speed potentiometer

Voltage potentiometer

Potentiometer knob

Ground cable and clamp

MIG Torch

American Connector

MIG torch receptacle

Wire feeder assembly

Welding mode (MIG/Stick) selector

Quick connector, female

Trigger lead receptacle

Feet

Sheet metal case base

Loaded PCB

Capacitance PCB

Heat sink

Rectifier

Fan

Middle board

Back Panel

Power cord retainer

46 Power cord

Qty.

MIG 180 INVERTER WELDER 058-9306-4

No.

Description

47 Circuit breaker

48 Main switch

Copper nut 49

50 Gas valve connector

51 Gas solenoid valve

Qty.

No.

Description

52 Handle

53 Dual gas regulator

Gas hose

Fuse board

Spool gun function selector switch

Qty.

MIG 180 INVERTER WELDER 058-9306-4

3 Year Limited Warranty

INDUSTRY LEADING GUARANTEE

This Mastercraft Maximum product is guaranteed for a period of three (3) years from the date of original retail purchase against defects in workmanship and materials.

Subject to the conditions and limitations described below, this product, if returned to us with proof of purchase within the stated warranty period and if covered under this warranty, will be repaired or replaced (with the same model, or one of equal value or specification), at our option. We will bear the cost of any repair or replacement and any costs of labour relating thereto.

These warranties are subject to the following conditions and limitations:

a) a bill of sale verifying the purchase and purchase date must be provided; b) this warranty will not apply to any product or part thereof which is worn or broken or which has become inoperative due to abuse, misuse, accidental damage, neglect or lack of proper installation, operation or maintenance (as outlined in the applicable owner’s manual or operating instructions) or which is being used for industrial, professional, commercial or rental purposes; c) this warranty will not apply to normal wear and tear or to expendable parts or accessories that may be supplied with the product that are expected to become inoperative or unusable after a seasonable period of use; d) this warranty will not apply to routine maintenance and consumable items such as, but not limited to, fuel, lubricants, vacuum bags, blades, belts, sandpaper, bits, fluids, tune ups or adjustments; e) this warranty will not apply where damage 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 alterations have been made or attempted by unauthorized persons; h) this warranty will not apply to normal deterioration of the exterior finish, such as, but not limited to, scratches, dents, paint chips, or to any corrosion or discolouring by heat, abrasive and chemical cleaners; and

MIG 180 INVERTER WELDER 058-9306-4

i) this warranty will not apply to component parts sold by and identified as the product of another company, which shall be covered under the product manufacturer’s warranty, if any.

Additional limitations

This warranty applies only to the original purchaser and may not be transferred. Neither the retailer nor the 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 warranty are not intended to limit, modify, take away from, disclaim or exclude any statutory warranties set forth in any applicable provincial or federal legislation.

MIG 180 INVERTER WELDER 058-9306-4

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