Page 1
058-9306-4
MIG 180 INVERTER WELDER
INSTRUCTION MANUAL
Page 2
Quick Start Guide
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.
MIG 180 INVERTER WELDER 058-9306-4
Page 3
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 1-12
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 1-3
1
2
MC-589306-34
WARNING / AVERTISSEMENT
ELECTRIC SHOCK can kill
UN CHOC ÉLECTRIQUE peut tuer.
MOUING PARTS can cause injury.
LES PIÉCES MOBILES peuvent causer des blessures.
•
We
lding
w
ire
a
n
d drive part
s
m
a
y
be
at
w
elding v
ol
tage.
•
Keep away
from
m
ov
ing p
a
rts.
• Ne
v
ous
approchez pas
de
s pièce
s
mo
bile
s
.
•
M
ain
t
ene
z
tous les
c
ouv
e
r
cles,
pan
ne
au
s et
port
es
f
ermés et
s
ol
ide
m
e
n
t
e
n
pla
ce
.
• Keep
a
ll
doors,
c
ov
ers a
n
d
panels
closed and
s
e
c
urely
in pla
c
e.
• Le
f
il
de
so
u
dure
e
t
les
pièces
motrices son
t
peut-être a la
t
ens
ion
de
s
ou
d
a
ge.
•
Ne tou
ch
e
z
p
a
s
le
fil oules
pa
r
ties motric
es
à
m
ain
s
n
ues
ou
av
e
c
de
s
outils lorsque la
de
tente es
t
s
ous, pre
ssion.
• Do no
t
to
uch
w
ire
or
driv
e
p
arts
with b
a
re ha
nds
or
too
l
s
w
hen
trigge
r
is
de
p
re
s
s
e
d.
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 AVEC ÂME EN FLUX
C
o
urant continu pol
arité normale
Polarity
s
witch s
et
ti
n
g
:
Régla
g
e du
c
ommuta
te
ur de
pol
a
r
it
é:
Direct
cur
rent
,
e
lectrod
e
n
agative
DCEP
DCEP
MIG
MIG
Direct cur
ren
t, e
l
ectro
de
po
si
ti
v
e
C
ou
r
ant continu, e
l
ectrode positive
Po
l
a
ri
ty
switch
s
etti
n
g
:
Régl
age du co
m
mu
ta
teu
r de po
l
ar
i
té:
ST
ICK
BAGUETTE
Polar
ity
s
wit
c
h
s
e
t
tin
g
:
Réglage
du commu
t
a
t
e
u
r
de p
ola
rit
é
:
+
+
+
-
-
-
NO GAS/PAS DE GAZ
GAS/GAZ
AVERTISSEMENT
SHOCK can kill
C ÉLECTRIQUE peut tuer.
PARTS can cause injury.
MOBILES peuvent causer des blessures.
e and drive parts may be at welding voltage.
from moving parts.
chez pas des pièces mobiles.
les couvercles, panneaus et portes fermés et
solidement en place.
rs, covers and panels closed and securely in place.
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, pression.
ch wire or drive parts with bare hands or tools when
trigger is depressed.
DCEN
DCEN
FLUX CORE WIRE
FIL AVEC ÂME EN FLUX
Courant continu polarité normale
Polarity switch setting:
Réglage du commutateur de polarité:
Direct current, electrode nagative
DCEP
DCEP
MIG
MIG
Direct current, electrode
Courant continu, electrode
Polarity switch setting:
Réglage du commutateur de polar
+
+
-
-
NO GAS/PAS DE GAZ
GAS/
1
MC-589306-39
Page 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 4-5
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
WI
RE
STICK
A
10
3
4
5
6
7
8
10
POWER
WA
RNING
W
ORK
V
A
ST
ICK
MIG
GA
S IN
ERTE
M
IG
V
GAS INERTE
ARC
ARC
F
IL
MAR
CH
E
058-9306-4
AVERTISSEMENT
INTENSITÉ
MIG 180 INVERTER WELDER
SOUDEUSE À ONDULEUR MIG 180
2
1
3
Page 5
STEP 2
Turn the mode selector switch (1) to the stick
welding mode. page 20, step 6
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
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
A
R
C
F
IL
MARCHE
058-9306-4
AVERTISSEMENT
INTENSITÉ
MIG 180 INVERTER WELDER
SOUDEUSE À ONDULEUR MIG 180
1
MC-589306-47
1/8"
2
1
Page 6
TABLE OF CONTENTS
2
MIG 180 INVERTER WELDER 058-9306-4
QUICK START GUIDE
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
TECHNICAL SPECIFICATIONS
3
MIG 180 INVERTER WELDER 058-9306-4
WELDER SPECIFICATION
SPOOL GUN (OPTIONAL) SPECIFICATION
POWER SUPPLY Single-phase, 230 V, 60 Hz
NO-LOAD VOLTAGE 78 V
OUTPUT CURRENT 30–200 A DC
DUTY CYCLE 30%
WIRE 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/CO
2
gas
140 A A/Ar gas
Page 8
SAFETY GUIDELINES
4
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.
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
serious injury or loss of life.
CAUTION!
Potential hazard that may result in
moderate injury or damage to equipment.
Page 9
SAFETY GUIDELINES
5
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.
Page 10
SAFETY GUIDELINES
6
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".
Page 11
SAFETY GUIDELINES
7
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.
Page 12
SAFETY GUIDELINES
8
MIG 180 INVERTER WELDER 058-9306-4
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.
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.
MC-OM-01
Page 13
KEY PARTS DIAGRAM
9
MIG 180 INVERTER WELDER 058-9306-4
No. Description No. Description
1
Voltage control (MIG mode) / Amperage
control (stick mode)
7 MIG gun trigger connection
2 Wire feed speed control 8 MIG gun cable
3 Power 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
STICK
A
10
3
4
5
6
7
8
10
POWER
WARNING
WORK
V
A
STICK
MIG
2
5
4
3
6
7
8
9
10
11
FIL
AVERTISSEMENT
1
GAS INERTE
ARC
ARC
MARCHE
058-9306-4
INTENSITÉ
MIG 180 INVERTER WELDER
SOUDEUSE À ONDULEUR MIG 180
Page 14
KEY PARTS DIAGRAM
10
MIG 180 INVERTER WELDER 058-9306-4
Welder upper front panel
No. Description No. Description
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
KEY PARTS DIAGRAM
11
MIG 180 INVERTER WELDER 058-9306-4
Welder back panel
No. Description No. Description
1 Primary power switch 3 Inert gas connection
2 Current overload circuit breaker
GAS INPUT
ENTRÊE DE GAZ
NORMAL
NORMAL
220V ~ 240V
1PH
OFF
ON
MARCHE
ARRÊT
POWER
PUISSANCE
OVER CURRENT
SURINTENSITEE
1
2
3
MC-589306-03
ELECTRICAL WARNING
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 only be performed by
a Qualified technician.
MIG
GAZ INERTE
STICK
ARC
／
0589306
OCV 78Vdc
OCV 78Vdc
160 A
22 V
140 A
25.6 V
230 V AC, 30 A max
Page 16
IMPORTANT INFORMATION
12
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.
Page 17
IMPORTANT INFORMATION
13
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.
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.
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.
12
3
4
MC-589306-35
1
MIG 180 INVERTER WELDER
SOUDEUSE À ONDULEUR MIG 180
WARN
IN
G /
AV
ER
TI
S
SEM
E
N
T
E
L
ECTRIC
SHOCK
c
a
n
k
ill
U
N C
H
O
C
É
L
EC
TR
IQUE
p
e
ut t
u
er.
MOUING PAR
TS
c
a
n
ca
u
se i
n
j
u
ry.
LE
S
P
IÉC
E
S
MO
BILE
S
p
euvent c
a
us
e
r d
e
s
b
l
e
ss
ur
es.
•
W
e
l
di
ng wi
r
e an
d
dri
v
e part
s
m
ay
be
at
w
el
d
i
n
g
v
o
l
t
ag
e.
•
Keep
aw
a
y fro
m
m
o
v
i
ng p
ar
t
s
.
•
Ne
v
o
u
s
appr
oc
he
z
p
as
d
es
piè
ces
m
ob
i
l
e
s
.
•
M
ai
n
t
en
ez
t
o
us
l
es
co
uv
ercl
es,
p
an
neau
s
e
t p
orte
s
f
erm
és
et
s
o
l
i
dem
e
n
t
e
n
p
lac
e
.
•
Keep
al
l
do
o
rs,
c
overs
a
n
d p
an
el
s
cl
o
s
ed
a
n
d
s
ecu
r
el
y
i
n pl
ac
e
.
• Le
fi
l
d
e s
o
udu
r
e et
l
e
s
pi
èces
m
o
t
r
i
ces
s
o
n
t
peu
t
-ê
t
re
a l
a
tens
i
o
n de s
o
udag
e.
• N
e tou
ch
ez p
a
s
l
e fil
o
ules
parti
es
mo
t
r
i
c
e
s à m
a
in
s
n
ues
o
u
av
ec de
s
o
u
til
s
l
o
rs
que l
a det
en
t
e es
t s
o
u
s
,
p
r
es
s
i
o
n.
•
D
o
not
to
uch
wi
r
e
or drive parts
wi
t
h
b
ar
e h
a
n
d
s
or
to
o
l
s
w
hen
t
r
i
g
g
e
r
i
s
depr
e
ss
ed.
MIG
SPOOL GUN/PISTOLET À BOBINE
When normal MIG welding,
this switch should be turned in “MIG” positio
n.
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 p
osit
ion « SPOOL GUN »
si vous utilisez un pistolet à bobine
.
D
CEN
D
CE
N
FL
UX
COR
E
WIRE
FIL AVE
C ÂME
EN
FL
U
X
C
ou
r
a
nt
con
t
inu
po
la
ri
t
é no
r
ma
le
P
ol
a
rit
y
sw
it
c
h
se
t
tin
g
:
R
é
g
la
ge
du
c
o
mmut
a
t
e
u
r de polarit
é
:
D
i
r
e
ct
c
urrent
, e
lec
t
ro
d
e
nagat
i
ve
DC
E
P
DC
EP
M
IG
M
IG
D
i
rect cu
rren
t
,
el
ectro
de po
s
i
ti
ve
C
o
ur
an
t co
nt
in
u
, el
ectro
d
e
p
o
s
i
ti
v
e
P
o
l
ari
t
y
s
w
i
t
c
h
s
etti
n
g
:
Rég
l
a
g
e du
co
m
mu
tateu
r d
e
p
ola
ri
té
:
S
T
ICK
BAGUETTE
P
o
l
ari
t
y
sw
i
tch
se
ttin
g
:
R
é
glag
e
d
u c
om
mu
ta
t
e
u
r
d
e
p
o
larité
:
+
+
+
-
-
-
NO
GAS/P
A
S DE G
A
Z
G
A
S
/GA
Z
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.
1
Page 18
IMPORTANT INFORMATION
14
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.
NO
GAS
GAS
MC-589306-06
Page 19
IMPORTANT INFORMATION
15
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).
DCEN
DCEN
FLUX CORE WIRE
FIL AVEC ÂME EN FLUX
Courant continu polarité normale
Polarity switch setting:
Réglage du commutateur de polarité:
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 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 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.
Direct current, electrode nagative
DCEP
DCEP
MIG
MIG
Direct current, electrode positive
Courant continu, electrode positive
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
1
2
4
7
3
6
5
Page 20
IMPORTANT INFORMATION
16
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
2
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
2
.
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:
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.
Type of
electrode
Tensile strength Application
E6011 60,000 PSI Deep penetration process
E6013 60,000 PSI Poor fitup application
E7014 70,000 PSI
High deposition and fast travel speed with light
penetration process
E7018AC 70,000 PSI Tack welding and out of position application
Page 21
IMPORTANT INFORMATION
17
MIG 180 INVERTER WELDER 058-9306-4
Packaging content list
No. Material name
Quantity Illustration
1 Portable MIG/flux-core/stick welder 1
2 Gas regulator 1
3 Ground cable with clamp 1
4 8" spool adaptor 1
5MIG gun 1
6
Electrode holder with welding
cable
1
7
MIG consumable kit (nozzle,
contact tips, L shaped hexagonal
wrench)
1
8Gas hose 1
9
9
3
4
5
6
7
8
WIRE
STICK
A
10
3
4
5
6
7
8
10
PO
WE
R
W
A
RNING
WORK
V
A
ST
IC
K
MIG
GAS
I
NERT
E
MIG
V
GAS I
N
ERTE
A
RC
AR
C
FIL
M
AR
C
HE
0
5
8-9306-
4
AVERT
I
SSE
M
E
N
T
INTENSI
T
É
MIG 180 INVERTER WELDER
SOUDEUSE À ONDULEUR MIG 180
250
300
350
400
0
10
50
100
150
200
20
30
40
50
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
ASSEMBLY INSTRUCTIONS
19
MIG 180 INVERTER WELDER 058-9306-4
Assembly Instructions
Installation for stick welding
1. Plug the ground cable (1) into the
ground cable connection of the welding
unit
(fig 1A).
2. Plug the electrode holder cable (1) into
the electrode cable connection
(fig 1B)
.
3. Attach the electrode (1) to the electrode
holder (2)
(fig 1C)
.
DANGER!
Potential hazard that will result in serious injury or loss of life.
Do not use the welding unit near flammable materials.
MC-589306-10
9
9
3
4
5
6
7
8
WIRE
MI
G
V
STIC
K
A
10
3
4
5
6
7
8
10
POWER
W
ARNI
N
G
058-9306-4
W
O
RK
V
A
S
T
I
C
K
fig 1A
1
F
IL
AVERTIS
SE
MENT
MARC
HE
GAS INERTE
G
AS I
N
E
M
I
G
ARC
ARC
INTENSITÉ
MIG 180 INVERTER WELDER
SOUDEUSE À ONDULEUR MIG 180
MC-589306-11
9
9
3
4
5
6
7
8
WI
RE
MIG
V
STI
C
K
A
10
3
4
5
6
7
8
10
P
OW
ER
WARNING
WORK
V
A
S
TIC
K
fig 1B
1
F
IL
AVERTISSEMENT
MARCHE
G
AS INE
RT
E
M
I
G
GAS
I
N
E
AR
C
ARC
I
NT
ENSITÉ
058-9306-4
MIG 180 INVERTER WELDER
SOUDEUSE À ONDULEUR MIG 180
fig 1C
1
2
MC-589306-12
9
9
3
4
5
6
7
8
WIRE
STICK
A
10
3
4
5
6
7
8
10
P
O
WER
W
AR
N
ING
WORK
V
A
S
T
I
C
K
MI
G
GA
S
I
N
MIG
V
GAS INERTE
ARC
ARC
FIL
MARCHE
058-9306-4
AVERTIS
SEMENT
INTENSITÉ
MIG 180 INVERTER WELDER
SOUDEUSE À ONDULEUR MIG 180
Page 24
ASSEMBLY INSTRUCTIONS
20
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.
MC-589306-13
fig 1D
9
9
3
4
5
6
7
8
WIRE
MIG
V
STICK
A
10
3
4
5
6
7
8
1
0
POWER
WARNING
WORK
V
A
STICK
1
2
AVERT
I
SSEMENT
MARCHE
F
I
L
GAS
IN
ER
T
E
G
A
S
IN
MI
G
ARC
ARC
INTENSITÉ
058
-9306-4
MIG 180 INVERTER WELDER
SOUDEUSE À ONDULEUR MIG 180
MC-589306-14
fig 1E
9
9
3
4
5
6
7
8
WI
RE
M
I
G
V
ST
ICK
A
10
3
4
5
6
7
8
10
POWER
W
AR
N
I
N
G
W
O
RK
V
A
STI
CK
2
1
FI
L
AVERT
I
S
SEME
NT
MARCHE
G
A
S
IN
E
RTE
GAS
I
N
M
I
G
A
R
C
A
R
C
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
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
1
MC-589306-16
ELECTRICAL WARNING
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 only be performed by
a Qualified technician.
MIG
GAZ INERTE
STICK
ARC
／
0589306
OCV 78Vdc
OCV 78Vdc
160 A
22 V
140 A
25.6 V
230 V AC, 30 A max
fig 1G
GAS INPUT
ENTRÊE DE GAZ
NORMAL
NORMAL
OFF
ON
MARCHE
ARRÊT
POWER
PUISSANCE
OVER CURRENT
SURINTENSITEE
1
220V ~ 240V
1PH
Page 25
ASSEMBLY INSTRUCTIONS
21
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)
.
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)
.
MC-589306-17
fig 1H
1
9
9
3
4
5
6
7
8
WIRE
S
TICK
A
10
3
4
5
6
7
8
10
POWER
W
A
RNING
W
O
RK
V
A
STIC
K
MIG
G
A
S I
NE
R
TE
M
IG
V
G
A
S INER
T
E
A
RC
A
RC
F
IL
MA
RC
HE
058-9306-4
A
V
ERT
I
SSE
M
ENT
INTENSITÉ
MIG 180 INVERTER WELDER
SOUDEUSE À ONDULEUR MIG 180
MC-589306-18
fig 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.
• 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 only be performed by
a Qualified technician.
MIG
GAZ INERTE
STICK
ARC
／
0589306
OCV 78Vdc
OCV 78Vdc
160 A
22 V
140 A
25.6 V
230 V AC, 30 A max
1
220V ~ 240V
1PH
Page 26
ASSEMBLY INSTRUCTIONS
22
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.
MC-589306-21
fig 1L
1
2
MC-589306-22
250
300
350
400
0
10
50
100
150
200
20
30
40
50
9
9
3
4
5
6
7
8
WI
RE
STI
C
K
A
10
3
4
5
6
7
8
10
POW
ER
WA
RNI
NG
W
O
RK
V
A
S
TIC
K
MIG
GAS INERTE
MIG
V
GA
S
INERT
E
ARC
A
RC
FI
L
MAR
C
HE
058
-930
6
-4
AV
ERTISS
E
M
EN
T
IN
T
ENSITÉ
MIG 180 INVERTER WELDER
SOUDEUSE À ONDULEUR MIG 180
fig 1M
1
WAR
N
I
NG /
A
VE
RT
I
SSEMEN
T
E
LECTRIC SH
OC
K
can kill
UN CHOC ÉLECTRI
QU
E
peut tuer.
MOUING PA
R
TS ca
n
c
a
use
in
jur
y
.
LES PI
ÉCES MOBILES
peuvent cau
ser
des blessures.
• Weld
ing wire an
d
d
r
iv
e
parts may
be
at
w
eldin
g
vol
t
age
.
•
Keep
away
fr
o
m m
o
v
i
n
g
parts
.
•
N
e v
o
u
s approchez p
a
s des
pièces mobi
les
.
• Maint
e
n
ez tous les couv
e
r
cles,
pan
n
eau
s
et
po
r
t
es
fermés
et
s
olid
e
m
ent e
n
p
l
a
ce
.
•
Kee
p
a
ll
do
o
rs,
cove
rs and panels
clos
ed an
d securely
in p
lace
.
•
Le fil de s
o
u
dure et les
pièces m
o
trices
s
o
n
t
peu
t
-ê
t
re
a la
tension de s
oudage.
•
N
e
t
ouch
e
z
pas
l
e fil oules
p
ar
ties
motrices à main
s
n
ues
ou
a
ve
c
des
o
u
tils l
o
rsque
la deten
te
e
st sou
s
, pr
e
ssion.
•
D
o
n
o
t
t
o
u
ch
wire
o
r drive
par
ts with bare h
a
n
ds
o
r tools
w
h
e
n
trig
ger is
depr
e
s
s
e
d
.
MIG
SPOOL GUN/PISTOLET À BOBINE
Whe
n normal MIG welding,
this switch should be turned in “MIG” position.
when using spool gun.
this switch should be in “Spool gun”
position.
Ce commutate
ur doit être placé à la position « MIG »
si vous effectuez du soudage MIG n
o
rmal
et à la position « SPOOL GUN »
si vou
s
utilisez un pistolet à bobine.
D
C
EN
DC
E
N
F
L
UX
C
O
RE
WIRE
FIL AVEC ÂME
E
N
F
LU
X
C
o
u
r
an
t
cont
i
nu
p
ol
ar
i
t
é
n
or
m
a
l
e
Pol
ar
i
t
y
swi
t
ch
s
e
tt
i
n
g:
Régl
a
ge
d
u
commu
tate
u
r
d
e
pola
r
i
té:
Di
r
e
ct
c
ur
re
nt,
e
lectrod
e
n
agat
i
v
e
DCE
P
DC
EP
MIG
MIG
Direct
current,
ele
ctrode
positive
C
o
urant
con
tinu,
elec
trode
posit
iv
e
Pola
r
i
t
y
s
w
itch
s
et
ting:
R
églag
e du commuta
teu
r
de pol
arité:
ST
IC
K
BAGUETTE
Po
larity
switch setti
ng
:
R
é
glage
d
u
c
o
mm
ut
a
t
e
ur d
e
po
larité
:
+
+
+
-
-
-
NO GAS/PAS DE GAZ
GAS/GAZ
UN CHOC ÉL
MOUING PARTS can caus
LES PIÉCES MOBILES peuve
• Keep away from moving parts.
• Ne vous approchez pas des pièces mobiles.
• Maintenez tous les couvercles, panneaus et po
solidement en place.
• Keep all doors, covers and panels closed
• Le fil de soudure et les piè
tension de soudage.
• Ne touchez pas le fil oules parties
avec des outils lorsque la detente e
trigger is .
1
2
MC-589306-23
fig 1N
MC-589306-24
250
300
350
400
0
10
50
100
150
200
20
30
40
50
9
9
3
4
5
6
7
8
WIRE
MIG
V
STICK
A
10
3
4
5
6
7
8
10
POW
E
R
W
A
RNING
WORK
V
A
ST
I
CK
F
IL
GAS INE
R
TE
M
IG
GA
S
INE
ARC
AR
C
fig 1O
1
2
AVERTISSEMENT
MARC
H
E
INTENSITÉ
058-9306-4
MIG 180 INVERTER WELDER
SOUDEUSE À ONDULEUR MIG 180
Page 27
ASSEMBLY INSTRUCTIONS
23
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)
.
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.
MC-589306-25
fig 1P
W
ARN
IN
G
/ AVERTISSEM
E
NT
ELE
CTRI
C
SHOCK can kil
l
U
N
CHOC ÉLE
C
T
RIQU
E
peut
tuer
.
MO
U
I
NG PAR
T
S can ca
u
se inj
u
ry.
LES
P
IÉ
CES
MO
BILE
S
p
e
u
v
e
nt cau
s
er de
s
b
l
ess
u
r
es.
• We
lding
wi
re
a
n
d d
ri
v
e
p
art
s
m
a
y b
e
at we
ld
ing
vo
lt
a
g
e.
•
Keep away
f
rom m
ov
i
ng p
a
r
t
s.
•
Ne vous app
r
o
c
hez pas des p
iè
c
e
s
mobile
s
.
•
Ma
in
t
e
n
ez
t
o
u
s
le
s couv
e
rcles, panneaus
e
t portes fer
m
é
s e
t
s
o
lidem
e
n
t
e
n
p
l
ace.
•
Keep a
l
l
d
oors, covers and panels closed and
securely
i
n
p
la
c
e.
•
L
e
fi
l
de
so
u
dure et les p
iè
ce
s
m
o
tric
e
s
s
ont
p
eut-être
a
la
tension de souda
g
e
.
•
N
e
touch
ez
pas
le f
il
oul
e
s
p
a
r
t
i
es
m
otrice
s
à ma
i
n
s
n
u
e
s
ou
a
ve
c
d
e
s o
u
t
i
ls
lo
r
sque
la
d
e
tent
e
e
s
t
so
u
s
,
p
r
es
sion.
•
Do
no
t
touc
h w
ir
e
o
r
d
r
iv
e par
t
s
w
ith
bare han
d
s or tools when
trigger is depress
e
d.
MIG
SPOOL GUN/PISTOLET À BOBINE
W
he
n
nor
mal MIG weld
i
n
g,
this
sw
itc
h
s
hould
b
e
t
u
rne
d
i
n
“
MIG”
position.
w
he
n
usi
n
g
s
po
ol
gun.
this
swi
t
c
h should be
in “
Spo
o
l g
u
n”
position.
C
e
co
m
mutateur
d
oit
ê
tre
pl
a
c
é
à
l
a posi
ti
on
«
MIG
»
si v
o
us
e
f
fect
u
ez
d
u s
o
ud
a
ge MIG normal
et à la position « SPOOL GUN »
si
v
ou
s
uti
lis
e
z un
p
i
s
to
le
t
à
b
ob
ine
.
DC
EN
DCEN
FLU
X
C
ORE WIRE
FI
L
A
VE
C
Â
ME EN
FL
U
X
C
ourant co
nt
i
nu polarité normale
P
olarity
sw
it
ch
se
tt
ing:
R
é
gla
g
e
d
u commutateu
r de
p
olar
ité:
Di
r
ect
c
u
rr
e
n
t
, elec
t
ro
de
na
g
at
i
ve
D
C
E
P
D
CE
P
MI
G
MI
G
Dire
c
t current, electrode positive
Cou
r
ant contin
u
,
e
le
ctro
d
e
posi
t
ive
Polarity
s
w
it
c
h set
t
ing:
Réglage du
c
o
mmut
a
t
e
ur d
e
p
ol
a
ri
té:
S
T
I
C
K
BAGU
E
TTE
P
o
l
arity sw
i
tch se
t
tin
g:
R
ég
l
age d
u
comm
utateur d
e
p
o
larité:
+
+
+
-
-
-
NO
G
A
S/
PAS DE GAZ
G
AS/
G
AZ
UN CHOC ÉL
MOUING PARTS can caus
LES PIÉCES MOBILES peuve
• Keep away from moving parts.
• Ne vous approchez pas des pièces mobiles.
• Maintenez tous les couvercles, panneaus et po
solidement en place.
• Keep all doors, covers and panels closed
• Le fil de soudure et les piè
tension de soudage.
• Ne touchez pas le fil oules parties
avec des outils lorsque la detente e
trigger is .
1
B
AG
U
ETTE
MC-589306-26
250
300
350
400
0
10
50
100
150
200
20
30
40
50
9
9
3
4
5
6
7
8
W
I
RE
M
I
G
V
ST
ICK
A
10
3
4
5
6
7
8
10
POW
ER
WARNI
N
G
W
ORK
V
A
STICK
WARNING
WORK
A
STICK
MIG
G
A
S
INE
R
TE
G
A
S
I
NE
MIG
AR
C
fig 1Q
1
F
I
L
AVER
TIS
SEME
N
T
MARCHE
MIG 180 INVERTER WELDER
SOUDEUSE À ONDULEUR MIG 180
INTENSI
T
É
MC-589306-27
fig 1R
9
9
3
4
5
6
7
8
WI
RE
MIG
V
STICK
A
10
3
4
5
6
7
8
10
P
O
W
ER
WARN
I
NG
WORK
V
A
STICK
1
2
FIL
AVER
T
ISSE
M
E
NT
M
ARCHE
GAS IN
E
RTE
MI
G
GAS
INE
ARC
A
RC
INTE
N
SITÉ
058-9306-4
MIG 180 INVERTER WELDER
SOUDEUSE À ONDULEUR MIG 180
MC-589306-28
fig 1S
2
1
9
9
3
4
5
6
7
8
WIRE
MIG
V
STI
C
K
A
10
3
4
5
6
7
8
10
POWER
WARNING
WORK
V
A
S
TICK
FIL
AVERTISSEME
NT
MARCHE
GAS INERTE
MIG
G
AS
IN
E
ARC
ARC
INTENSITÉ
058-9306-4
MIG 180 INVERTER WELDER
SOUDEUSE À ONDULEUR MIG 180
Page 28
ASSEMBLY INSTRUCTIONS
24
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.
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.
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 R
E
LATIE À L’ÉLECTRICITÉ
• Disconnect fr
o
m p
o
we
r
supply b
ef
or
e s
erv
i
cing.
• Do not operate w
ith
any
panels or co
v
ers
r
emo
v
ed.
• Dé
b
ra
n
chez
l
e c
o
rd
on de la
s
ou
r
ce
d
’
a
limen
t
at
io
n avant l
’en
t
ret
i
en.
•
Ne fait
es
pas fonctionner ce
t
app
a
reil avec les panneaux ou le
s
co
u
vercl
e
s
r
etirés.
•
L’entretien
d
e cet appareil doit
to
ujo
ur
s ê
tr
e effect
ué
par
un t
echnic
i
en
Q
ua
l
ifie.
• Servic
e
on th
i
s machine sho
u
ld onl
y
b
e
perf
o
rm
ed by
a Q
u
alified
t
ec
h
nician.
MIG
GAZ INERTE
STICK
ARC
／
0589306
OCV 78Vdc
OCV 78Vdc
160 A
22 V
140 A
25.6 V
230 V AC, 30 A max
220V ~ 240V
1PH
MC-589306-30
3
1
2
fig 1U
1
MC-589306-31
fig 1V
Page 29
ASSEMBLY INSTRUCTIONS
25
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)
.
5. Remove the drive roll (1) from the drive
roll shaft (2)
(fig 1X)
.
Refer 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" 0.9
0.035" 0.9
Page 30
ASSEMBLY INSTRUCTIONS
26
MIG 180 INVERTER WELDER 058-9306-4
Installing the wire
Refer to the chart below for wire selection based on type of 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.
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.
Welding Type
Wire diameter
MIG welding 0.023"–0.035" MIG wire
Flux-core welding 0.030"–0.035" flux-core wire
fig 1Y
1
2
MC-589306-34
Page 31
ASSEMBLY INSTRUCTIONS
27
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).
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
4
MC-589306-36
fig 2A
1
2
3
4
fig 2B
MC-589306-37
1
X
fig 2C
MC-589306-38
Page 32
ASSEMBLY INSTRUCTIONS
28
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.
Page 33
ASSEMBLY INSTRUCTIONS
29
MIG 180 INVERTER WELDER 058-9306-4
Setting the wire tension
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)
.
3. Apply slight back pressure against the
wire by curling the wire. If wire
continues to feed smoothly, the wire
tension is set correctly.
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
2
MC-589306-39
fig 2D
WARNING
/ AV
E
RT
I
SSE
M
E
NT
EL
ECT
RIC SHOC
K
can kill
UN CHO
C ÉL
ECT
RIQUE
peut
t
uer.
MOUING PARTS can cause inju
r
y
.
LES PIÉCES MO
B
IL
E
S
p
eu
vent
c
aus
e
r
de
s
b
le
s
s
u
r
e
s.
•
W
e
lding w
i
r
e
and drive parts may
be
a
t
welding
volta
ge
.
• Kee
p
a
w
a
y
f
rom m
o
vin
g
par
t
s.
• N
e
v
ous
approchez p
a
s
d
e
s
p
i
è
ces mobiles.
• M
a
in
tenez tous
l
es couv
e
rcles, panneaus et portes ferm
é
s
et
s
olide
m
en
t
e
n
place.
•
Keep a
l
l doors, covers
a
nd
p
a
ne
ls
c
los
e
d
a
nd
s
e
c
ure
ly
in p
la
c
e
.
• Le
f
il de soudure
et les p
i
èc
es m
o
trices sont pe
u
t
-
ê
tre
a
la
tension de soud
a
ge.
• Ne touchez pas le fil oul
e
s
p
a
r
ties motric
e
s
à
m
a
ins
nues ou
a
ve
c
des
outil
s lorsq
ue
la
d
e
te
nte est sous, pression.
•
D
o
not touch wire or drive
pa
rts
with b
a
re hands or tools when
trigger is depressed.
MIG
SPOOL GUN/PISTOLET À BOBINE
W
hen
nor
ma
l M
IG welding,
this switch should be tu
rne
d in “
M
IG”
po
sit
i
o
n.
when using
spo
ol g
u
n
.
this switch
should be in “
S
p
ool g
un”
p
osi
ti
o
n.
C
e commutat
eur doit être
placé
à la position « MIG »
si
vous e
ffe
ctue
z
du so
u
dage
MIG
norma
l
et
à
l
a
position « SPOO
L
G
UN
»
si vo
us utilise
z
un pistolet à bobine.
DC
E
N
D
C
EN
F
L
U
X
C
ORE WIR
E
FIL AVEC ÂM
E
E
N
FL
U
X
Cour
ant
c
o
ntinu
p
olari
t
é
normale
P
ol
arity switch setting:
R
églage du commut
at
eur
de
p
olari
t
é:
Direct
c
u
r
r
en
t,
e
lec
t
rode
n
a
g
a
t
ive
DCE
P
DCE
P
MIG
MIG
D
ire
ct current, electrode p
o
s
iti
v
e
C
o
urant
con
tin
u,
electrode p
o
s
iti
v
e
Polari
t
y switch settin
g
:
R
égl
age
d
u
commutateur d
e
p
o
larité:
S
T
ICK
BA
GUE
TTE
P
o
larity
s
witc
h
sett
ing:
Réglage
d
u c
ommutateu
r
d
e
po
la
rité:
+
+
+
-
-
-
N
O
GAS/
P
AS DE
GAZ
GA
S
/GAZ
1
AVERTISSEMENT
SHOCK can kill
C ÉLECTRIQUE peut tuer.
PARTS can cause injury.
MOBILES peuvent causer des blessures.
e and drive parts may be at welding voltage.
from moving parts.
chez pas des pièces mobiles.
les couvercles, panneaus et portes fermés et
solidement en place.
rs, covers and panels closed and securely in place.
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, pression.
ch wire or drive parts with bare hands or tools when
trigger is depressed.
DCEN
DCEN
FLUX CORE WIRE
FIL AVEC ÂME EN FLUX
Courant continu polarité normale
Polarity switch setting:
Réglage du commutateur de polarité:
Direct current, electrode nagative
DCEP
DCEP
MIG
MIG
Direct current, electrode
Courant continu, electrode
Polarity switch setting:
Réglage du commutateur de pola
+
+
-
-
NO GAS/PAS DE GAZ
GAS/
Page 34
OPERATING INSTRUCTIONS
30
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.
1. 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.
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 on the need.
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.
Page 35
OPERATING INSTRUCTIONS
31
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.
4. Turn the wire feed speed control with
the other hand to its maximum position
and continue to hold onto the speed
control.
5. 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)
.
6. 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.
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 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)
.
• 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)
.
60
fig 2E
MC-589306-40
30
45
fig 2F
MC-589306-41
MC-589306-42
1
fig 2G
Page 36
OPERATING INSTRUCTIONS
32
MIG 180 INVERTER WELDER 058-9306-4
Welding techniques
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.
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.
fig 2H
MC-589306-43
1
Page 37
OPERATING INSTRUCTIONS
33
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.
MC-589306-44
fig 2I
MC-589306-45
fig 2J
Page 38
OPERATING INSTRUCTIONS
34
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.
MC-589306-46
fig 2K
Page 39
OPERATING INSTRUCTIONS
35
MIG 180 INVERTER WELDER 058-9306-4
Striking the arc
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).
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).
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.
1/8"
MC-589306-47
1
2
fig 2L
MC-589306-48
fig 2M
1
Page 40
OPERATING INSTRUCTIONS
36
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.
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 2O
MC-589306-51
fig 2P
Page 41
OPERATING INSTRUCTIONS
37
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
.
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.
MC-589306-52
fig 2Q
Page 42
OPERATING INSTRUCTIONS
38
MIG 180 INVERTER WELDER 058-9306-4
Types of welding beads:
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)
.
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)
.
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 torch
(fig 2S)
.
fig 2R
MC-589306-53
fig 2S
MC-589306-54
fig 2T
MC-589306-55
fig 2U
MC-589306-56
Page 43
OPERATING INSTRUCTIONS
39
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
MC-589306-57
fig 2W
MC-589306-58
fig 2X
1
2
1
1
23
First or
Root Pass
Second
Pass
Third
Pass
Finished
Weld
MC-589306-59
Page 44
OPERATING INSTRUCTIONS
40
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 2Y
1
1
2
3
2
3
Lap Joint Welded
In Three Passes
T Joint in
Three Passes
MC-589306-60
fig 2Z
MC-589306-61
fig 3A
MC-589306-62
Page 45
OPERATING INSTRUCTIONS
41
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
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 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
MC-589306-63
Page 46
MAINTENANCE
42
MIG 180 INVERTER WELDER 058-9306-4
Maintenance
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.
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
DESCRIPTION
MAXIMUM SERVICE INTERVAL
Monthly As Needed
In-depth inspection Worn or broken parts X X
Repair or replacement Worn or broken parts X
Page 47
TROUBLESHOOTING
43
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 POSSIBLE CAUSES SOLUTIONS
The welder does not
work when the main
switch is turned on.
1. No power input.
2. Power cord or power plug is
broken.
3. Main 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. 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.
Page 48
TROUBLESHOOTING
44
MIG 180 INVERTER WELDER 058-9306-4
Note: For further assistance on installation and repairs, please contact 1-800-689-9928.
Inconsistent arc or
wire feed.
1. Not 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
MAIN CIRCUIT CHART
45
MIG 180 INVERTER WELDER 058-9306-4
+
+
+
+
AC220-240V 50/60HZ
Circuit Breaker
FAN1
SW101
S101
R101
13
4
2
AC
AC
XXXX
C1
C15
C2
R1
C3 C4
RG1
RG3
RG4
RG2
Q2
Q4
Q3
C5
CT1
CT1
C4
ZD5
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
123
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
EXPLODED VIEW
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
PARTS LIST
47
MIG 180 INVERTER WELDER 058-9306-4
No. Description Qty. No. Description Qty.
1 Hinge 2
24
Indicator
1
2 Case cover 1
25 Wire speed potentiometer 1
3 Wire retainer 2
26 Voltage potentiometer 1
4 Control transformer 1
27 Potentiometer knob 2
5 Main PC board 1
28
Ground cable and clamp
1
6 Door 1 29 MIG Torch 1
7 Door lock 1 30 American Connector 1
8 Spool holder 1 31 MIG torch receptacle 1
9 Spring 1 32 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 Rectifier 1
19
Main transformer
1 42 Fan 1
20 Rectifier heat sink 1 43
Middle board 1
21 Reactor assembly 1
44 Back Panel 1
22 Plastic front panel 1
45 Power cord retainer 1
23
Front panel support
1
46
Power cord
1
Page 52
PARTS LIST
48
MIG 180 INVERTER WELDER 058-9306-4
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
WARRANTY
49
MIG 180 INVERTER WELDER 058-9306-4
3-Year Limited Warranty
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
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.
INDUSTRY LEADING GUARANTEE
**
Page 54
WARRANTY
50
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.
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