july, 2014 rev. 02 powercrafttm 180i mig

IM7905-2 July, 2014

Rev. 02

PowerCRAFTTM

180i MIG

For use with machine Part Number：

PowerCRAFTTM

180i MIG K69020-3

THE LINCOLN ELECTRIC COMPANY PTY LTD

35 Byrant Street Padstow NSW 2211

www.lincolnelectric.com.au

Copyright © 2013 The Shanghai Lincoln Electric Company

Safety Depends on You PowerCRAFT machine is designed

and built with safety in mind.

However, your overall safety can be

increased by proper installation and

thoughtful operation on your part.

DO NOT INSTALL, OPERATE

OR REPAIR THIS EQUIPMENT

WITHOUT READING THIS

MANUAL AND THE SAFETY

PRECAUTIONS CONTAINED

THROUGHOUT. And, most

importantly, think before you act and

be careful.

http://www.lincolnelectric.com.au/

Thank you for selecting QUALITY PowerCRAFT®

products.

Please examine the packaging and equipment for damage. Claims for material damaged in shipment must

be notified immediately to the authorized dealer from whom you purchased the machine.

For future reference, please record your equipment identification information in the table below. Model

Name, Code & Serial Number can be found on the machine rating plate.

Declaration of conformity

THE SHANGHAI LINCOLN ELECTRIC COMPANY

Designed in conformance with the following norm:

AS 60974.1:2006

IEC 60974-1:2005

EN 60974-1:2005

GB15579.1:2004

A-1 CUSTOMER ASSISTANCE A-1

Read this Operators Manual completely before attempting to use this equipment. Save this manual and keep it handy for quick reference. Pay particular attention to the safety instruct ions we have provided for your protect ion. The level of seriousness to be applied to each is explained below:

A-2 CUSTOMER ASSISTANCE A-2

Master Table of Contents

Content

Page

Personal Safety …………………………………………………………………………. I - I I I

Electromagnetic Compatibility ………………………………………………………. IV-V

Customer Assistance Policy ……………… .……………………………… A-1

Master Table of Contents ……………………………………………………………… A-2

Product Description …………………………………………………………………….. B-1

Installation ……………………………………………………………………………….. C-1

Technical Specifications ………………………………………………………………. D-1

Technical Specification Data ……………………………………………………………. D-3

Graphics and their Meanings ……………………………………………………………. D-4

Power Source Placement ………………………………………………………………… D-5

Power Supply Configuration …………………………………………………………….. D-6

The Installation and Connection for MIG Welding …………………………………….. D-6

The Installation and Connection for Stick Welding ……………………………………. D-7

Operation …………………………………………………………………………………. E-1

Front Control Panel ……………………………………………………………………….. E-2

Welding Getting Started ………………………………………………………………….. E-4

Maintenance and Trouble Shooting …………………………………………………. F-1

Spare Parts List …………………………………………………………………………. G-1

Schematic Wiring Diagram …………………………………………………………….. H-1

Warranty …………………………………………………………………………………... I -1

B-1 PRODUCT DESCRIPTION B-1

PowerCRAFT 180i MIG is a multi-purpose 3 in 1 welding power source. It is capable of MIG welding

(both gas-shielded and gasless flux-cored welding), stick and TIG welding of mild and stainless steel

materials. Its characteristics are high production efficiency, excellent welding output and easy to carry

out all-position welding. The machine is light and portable which is very popular in DIY and

semi-professional market

The highlighted characteristics of PowerCRAFTTM

180i MIG Inverter MIG/Stick/TIG Welder:

Featured with compact size and light weight, it is widely used in maintenance and fieldwork.

Provided with input voltage compensation covering ±15% variation and a control circuit

reaction speed of less than 1 mSec,

Optimum arc characteristics are maintained over a broad range of operating conditions.

High working efficiency. Automatic Wire Feeding can realize high speed welding.

Both solid and flux-cored wires can be used. The wire diameter range is between

Φ0.6~Φ1.2mm

Synergic MIG single knob adjustment making easy for less skill operators to set the right

welding parameters.

Convenient connection mode. Outer connection makes it quick, safe, simple and reliable.

MMAW (stick welding) is also available which can also weld cellulosic electrodes.

Built-in VRD voltage reduction in Stick and TIG modes.

TIG Lift-ARC welding, program control, easy arc start, anti-sticking torch

Note:- We reserve the right to update the manual without notification

C-1 INSTALLATION C-1

SAFETY PRECAUTIONS

ELECTRIC SHOCK can kill.

Only qualified personnel should perform this installation.

Turn the input power OFF at the main switch or fuse box before working on this equipment.

Do not touch electrically live parts or electrode with skin or wet clothing.

Insulate yourself from work and ground.

Always wear dry insulating gloves.

FUMES AND GASES can be dangerous.

Keep your head out of fumes.

Use ventilation or exhaust to remove fumes from breathing zone.

WELDING SPARKS can cause fire or explosion.

Keep flammable material away.

Do not weld on closed containers.

PLEASE SEE ADDITIONAL WARNING INFORMATION AT THE FRONT OF THIS OPERATOR’S MANUAL.

SELECT A SUITABLE LOCATION This power source should not be subjected to rain, nor should any parts of it be submerged in water. Doing so may cause improper operation as well as pose a safety hazard. The best practice is to keep the machine in a dry, sheltered area.

The bottom of machine must always be placed on a firm, secure, level surface. There is a danger of the machine toppling over if this precaution is not taken.

Place the welder where clean cooling air can freely circulate in through the front louvers and out through the rear louvers. Water, dirt, dust or any foreign material that can be drawn into the welder should be kept to a minimum. Failure to observe these precautions can result in excessive operating temperatures and nuisance shutdowns..Locate the PowerCRAFT

TM machine away from radio

controlled machinery. Normal operation of the welder may adversely affect the operation of RF controlled equipment, which may result in bodily injury or damage to the equipment.

WARNING

CAUTION

INPUT CONNECTIONS ELECTRIC SHOCK can kill.

Have a qualified electrician install and service this equipment.

Disconnect input power by removing plug from receptacle before working inside machines. Allow machine to sit for 5 minutes minimum to allow the power capacitors to discharge before working inside this equipment.

Do not touch electrically live parts.

INPUT POWER CONNECTION Check the input voltage, phase, and frequency supplied to this machine before turning it on. The allowable input voltage is indicated in the technical specification section of this manual and on the rating plate of the machine. Be sure that the machine is earthed (grounded).

INPUT VOLTAGE The PowerCRAFT

TM 180i MIG machine is to be

provided with a 240V±10% input voltage, 50/60Hz. An output guide is provided in the technical specification section of this manual.

ENGINE DRIVEN GENERATOR The machine is designed to operate on engine driven generators as long as the auxiliary can supply adequate voltage, frequency and power as indicated in the “Technical Specification” Installation Section of this manual. The auxiliary supply of the generator must also meet the following conditions: Frequency: in the range of 50 and 60 Hz RMS voltage of the AC waveform: 180-260V Peak voltage max. 367V Generator Minimum 7kVA It is important to check these conditions because many engine driven generators produce high voltage spikes. Operation of this machine with engine driven generators not conforming to these conditions is not recommend and may damage the machine and is also NOT covered by warranty.

C-2 INSTALLATION C-2

Do not attempt to use this equipment until you have thoroughly read all operating

and maintenance manuals supplied with your machine. They include important

safety precautions, detailed operating and maintenance instructions and parts lists

ELECTRIC SHOCK can kill

Do not touch electrically live parts or electrode with skin or wet clothing

Insulate yourself from work and ground

Always wear dry insulating gloves.

Only qualified personnel should install, use or service this equipment.

Location and Ventilation

Whenever you use the PowerCRAFTTM

180i MIG Inverter MIG/Stick/TIG Welder be sure

that clean cooling air can flow around the front and rear louvres, (there should be

500mm clearance for good ventilation). Avoid dusty, dirty areas, particularly if

conductive particles are present in the cooling air. Also keep the machine away from

heat sources. If operation is to be outdoors protect from rain and do not sit in puddles

or otherwise submerge it in water. Such practices pose safety hazards and cause

improper operation and corrosion of parts.

Always operate the PowerCRAFTTM

180i MIG Inverter Welder with all panel work

installed to enable correct cooling air flow and protect you from possible electric shock.

Storing

Store the machine in the permissible range of -25 ~ +55℃, in a dry place when it is not in

use. Protect it from dust and dirt. Keep it were it cannot be .accidentally damaged

from construction activities, moving vehicles and other hazards.

Stacking

The PowerCRAFTTM

180i MIG Inverter Welder CANNOT be stacked.

Tilting

Place the PowerCRAFTTM

180i MIG Inverter Welder on a secure, level surface whenever

you use it or store it. Any surfaces you place it on other than the ground must be firm,

non-skid and structurally sound.

D-1 TECHNICAL SPECIFICATION D-1

The PowerCRAFTTM

180i MIG Inverter Welder permissible environment:-

The surrounding temperature range:

When welding: -10 ~ +40℃

During transport or in storage: -25 ~ +55℃

Relative humidity:

At 40℃ : ≤50%

At 20℃ : ≤90%.

Avoid excessive dust, acid and corrosive materials in the air as these will damage your machine.

Excessive vibration is not permissible.

Altitude – No more than 1,000m.

500mm space about the welding machine, including from walls and other similar obstructions, is

required to enable correct flow of cooling air.

Keep protected from rain and direct sun when in use outdoors.

The wind speed for all environments should less then 1m/s;

The Mains Input Voltage Requirement

The voltage wave form should be actual sine wave in shape with a maximum voltage variation of ±15%

of the rated value; the frequency of the voltage wave form should not exceed a variation of ± 10% of

the rated value.

Circuit Block Diagram

(Also refer to Section 9 – Schematic Diagram)

The welder acquires 230V (220 ~ 240V) single phase 50/60Hz AC power source through the

power switch SW 101 and then rectified through a single phase rectifier bridge B1, then filtered

through capacitors (C1, C2, C3, C4) to get the DC current. The 20 KHz AC current is derived

through the IGBTs (Q1, Q2, Q3, and Q4) full bridge inverter. Then this alternating current,

transformed by the intermediate frequency transformer and rectified by the quick recovery diodes (D4,

D5, D6, D7), the stable DC current is filtered by the reactor L2 and then outputted. The wire feed

speed can be steplessly adjusted through the Speed Control Knob. The welding current is easily

adjusted by the wire feed speed control, usually the faster the wire feed speed the higher the current

for the same voltage.

Rectifier Filter Inverter Transformer High

Frequency

Rectifier

Drive Modulate Trait

Control

Protection

Inspect

Process

Control

Current

Adjustment

Sampling


The Welding Machine Configuration

The PowerCRAFTTM

180i MIG welding machines consist of:-

The upper part of the front panel is equipped with, a wire feed speed knob, an output voltage control

knob, an electronic reactance control, a VRD indicator light (green), a power indicator light (white),

abnormal indicator light (yellow), an amperage and voltage digital display, a mode selection button, a

welding mode switch, 2T/4T/Spot selector, and a wire size selector. While the lower part is furnished

with a Euro style torch quick connector, “+” &“-” quick connectors and polarity selection. The back

side is installed with power switch, gas valve connection, cooling fan, input cable and an on/off switch.

On the top there is a handle for the convenient of easy transport.Internally there is the primary

transformer, printed circuit board, output reactor, and the heatsink with the power semiconductors.

The package consists of:

PowerCRAFTTM

180i MIG power source

MB15 MIG torch

Work return lead and clamp

Electrode lead and holder

Flowmeter

Drive rolls 0.6-0.8mm solid, 0.9-1.2mm cored

Instruction manual


TECHNICAL SPECIFICATIONS

INPUT – SINGLE PHASE ONLY

Standard

Voltage/Phase/ Frequency

Generator required Maximum

Input Current

Rated Input Current

PowerCRAFTTM

180i 240V(±15%)/ 1/50/60

Hz >7 KVA 28A 13A

RATED OUTPUT – DC ONLY

Duty Cycle(1)

Amperes Volts at Rated

Amperes

PowerCRAFTTM

180i

GMAW

20% 60%

100%

180A 104A 80A

23V 18.2V 18V

SMAW

20% 60%

100%

140A 80A 62A

25.6V 23.2V 22.5V

GTAW

20% 60%

100%

180A 104A 80A

17.2V 14.2V 13.2V

OUTPUT RANGE

Open Circuit

Voltage Welding Current

Range Welding Voltage

Range

PowerCRAFT

TM 180i

GMAW

62V

20A ~ 180A 15.0V ~ 23.0V

SMAW 20A~140A 20.8V ~ 25.6V

GTAW 15A ~ 180A 10.6V ~ 17.2V

OTHER PARAMETERS

Power Factor Efficiency Protection Class Insulation Class

PowerCRAFTTM

180i 0.72 ≥85% IP21S H

PHYSICAL DIMENSIONS

Length Width Height Weight

PowerCRAFTTM

180i 550mm 320mm 440mm 15.4Kg(2)

Temperature Range

Operating Temperature Range -10°C ~ +40°C(14°F~104°F)

Storage Temperature Range -25°C ~ +55°C(-13°F~131°F)

(1) Based upon 10 minute time period(i.e., for 30% duty cycle, it is 3 minutes on and 7 minutes off)

(2) Power Source only.

Note: The above parameters are subject to change with the improvement of machine


MB15 MIG Torch (Gun) Illustration

The MB15 MIG torch is composed of the Euro connector, connecting cable and handle.

There is a gooseneck installed in the handle of the torch. The gas diffuser distributes shielding gas

in the nozzle to provide even shield for the welding arc. A switch on the handle controls the welding

output.

* Turn off the power before assemble/disassemble or replacement of the torch components. * The cable, nozzle and tip need to be replaced as required.

Graphics and their meanings

Earth / Ground

Descending

MMAW (Stick) welder

GMAW (MIG) welder

GTAW (TIG) welder

1 Single phase AC power source

Single phase inverter---transformer---rectifier

DC current

＋: “＋” Output connector

－: “－” Output connector

X: Duty Cycle

I1: Rated Input Current

I2: Rated Welding Current

P1: Rated Input Power

U0: Rated Open Circuit Voltage

U1: Rated Input Voltage

U2: Rated Load V

~50/60 Hz: AC, Rated frequency 50 Hz, workable frequency 60 Hz.

V: Voltage (V)

A: Current (A)


kVA: Power (kVA)

%: Percentage

A/V ~ A/V: Output range. Rated min and rated max welding current and related load

voltage.

Duty Cycle: The rated duty cycle of a Welding Power Source, is a statement of the time it

may be operated at its rated welding current output without exceeding the temperature

limits of the component parts.

IP21S: Case protection class. IP is the code of International Protection.

2 - Means preventing the user’s finger from accessing dangerous parts; preventing solid

material with the diameter no less than 12.5 mm entering into the cabinet.

1 – Means water dropping vertically remains harmless.

S – Means water protection test is conducted while the movable parts are at standstill.

H: H insulation grade.

Notice: The temperature rise test of the welding power source had been carried out in the room

temperature. The rated duty cycle of 40℃ is obtained by simulation.

Power Source Placement

* Avoid excessive dust, acid and corrosive materials in the air.

* Keep protected from rain and direct sun when in use outdoors.

* There should be 500 mm space about for the welding machine to have good ventilation.

* Use adequate ventilation when in confined areas.

Connection between Power Source and Input Power Supply

Connect the input cable, (located in the rear panel of the welder), into the single phase 220~240

voltage power receptacle of appropriate current capacity and with an appropriately sized circuit

breaker.


Power supply configure of a welder:

Item PowerCRAFT

TM 180i

Circuit breaker（A）(‘D’ Curve) ≥15

Fuse (Rated current）(Slow Blow) 15

Power cord（mm2） ≥2.5

Notice: The melting current of the fuse is 1.2~1.5 times its rated current.

The installation and connection for MIG welding

* Select a suitable filler wire according to process being used (Lincoln Ultramag S6 for MIG and

Innershield NR211MP for gasless flux cored welding). The wire diameter must be matched to the

drive roll, the liner and contact tip.。

* Open the side panel of wire feeder and mount the wire spool on the spool post. The end of the wire

must be at the bottom of the wire spool, opposite wire feeder inlet guide tube.

* The spool post is fitted with a brake; the wing nut in the centre of the spool post adjusts the brake

tension. Pull the wire from the reel by hand and adjust the tension to provide some drag -

clockwise will increase the braking and anticlockwise reduces it.


* Release the wire tensioning device on the drive rolls, insert the filler wire end into the inlet guide

tube of wire feeder, align wire with the drive roll groove and feed a short length into the torch

connector so that it protrudes out of the front panel, then replace the tensioner over the wire. (The

filler wire is feed through the torch cable once the input power is switched on.)

Connection between Power Source and Torch

* Insert the torch connector over the protruding wire and into the Euro connector on the front panel of

the welder and rotate the screw cap firmly.

Connection between Power Source and Work Piece

Insert the quick connector of work return cable into the current output (-) terminal on the lower

section of the front panel and then screw in clockwise. The earth clamp is connected with work piece.

The short welding power lead connected to the power source needs to be connected into (+) output

terminal.

* For correct arc performance when using flux-cored gasless wire the polarity needs to be reversed,

connect the (+) and (-) in the opposite way, that is the torch will be (-) and the work lead will be (+).

Do not use steel plate or similar materials which are high resistance to connect between welder and work piece.

The installation and connection for stick welding.

a) Connection of electrode lead to the welder.

Connect the quick connector of electrode lead to the (+) output quick connect terminals on the front

panel, turn clockwise and ensure the connection is tight.

b) Connection of the work return lead to the welder.

Connect the quick connector of work return lead to the (-) output quick connect terminals on the front

panel, turn clockwise and ensure the connection is tight.

Do not use steel plate or similar materials which are high resistance to connect between welder and work piece.

E-1 OPERATION E-1

1 VRD indicator LED 2 Power indicator 3 Current display 4.Wirefeeding/amperage

5 Welding mode selection 6 2T/4T change 7 Voltage display 8 Voltage adjustment

9 Electronic inductance 11 Wire diameter 12 Euro torch socket

13 Output socket 14 Rating plate 15 Gas input 16 Power switch

17 Cable holder

21 MIG torch connector

18 Protection indicator 19 Wire Feed speed 20 Amperage display

Note:-

* The ‘protection indicator light’ will come on if the duty cycle is exceeded. It shows that the inner

temperature is over the permitted level, the machine should be stopped being used to allow it cool

down. Welding can continue after the ‘protection indicator light’ is off.

* The power source should be switched off when not in use.

* Welders should wear protective clothing and welding helmet to prevent injury from arc and thermal

radiation.

* Care should be taken so as not to expose others to the welding arc. Use of screening is

recommended.

* Do not weld near Inflammable or explosive materials.

E-2 OPERATION E-2

Front Panel Controls

1. 【Power Light】

This pilot lamp illuminates when the power source is on.

2. 【VRD Light】

The machine is working in VRD voltage range when light is on.

3. 【Thermal Light】

This indicator will turn on when the machine is overheated and the output has been disabled. This normally occurs when the duty cycle of the machine has been exceeded. Leave the machine on to allow the internal components to cool. When the indicator turns off, normal operation is again.

4. 【Amp/WFS display】

Stick, TIG & MIG synergic mode:

For amp preset before welding, and display actual amperage in welding.

MIG manual mode:

For WFS preset before welding, and display actual amperage in welding.

5. 【Voltage display】

MIG mode: For voltage preset before welding, and display actual voltage in welding.

Stick &TIG mode: Display actual voltage in welding.

6. 【Voltage Knob】

Function1：Rotary this knob for voltage adjustment in MIG mode

Function2：Press this knob for gas flow check and choose.

short press once will display "GAS” “ON-", and machine will turn into gas check status with

15sec continuous flow.

1 2

13 1 2 3 4 5 6 7

12

11 10 9 8

E-3 OPERATION E-3

Continually press twice, machine will turn into gas selection status, and display “CO2”

“AR-“for using mix gas; press again, will display “ CO2” “---“for using Co2.

7. 【Inductance Knob】

For inductance adjustment in MIG mode. Reduce to soften the arc or increase for crisp arc

8. 【Synergic Switch】

Select the wire size, choose in MIG synergic mode. Synergic mode allows adjustment of the

welding parameters by adjusting (11) amp knob. Switch to “Manual” for synergic off and into

manual adjustment, welding parameters are then set by adjusting (6) voltage knob and (11)

wire feed knob.

9. 【2/4T Switch】

In 2T MIG torch trigger functions in 2 step on/off. In 4T the MIG torch trigger functions in 4 step

on / let the trigger go welding will continue until the trigger is closed again and released / off.

10. 【Mode switch】

For switching welding mode:

Stick welding

MIG welding

TIG welding

11. 【Amp/WFS knob】

Stick & TIG mode: for welding amperage adjustment

MIG Synergic mode: for welding amperage adjustment

MIG Manual mode: for wire feeder speed / amperage adjustment

12. 【Amp light】

When amp light is on, the amp display shows amps.

13. 【WFS light】

When WFS light is on, the current display shows wire feeder speed for preset.

E-4 OPERATION E-4

Welding Getting started Work Piece cleaning Before Welding

The joint to be welded must be clean, remove existing rust, greasy dirt, water and paint etc.

MIG welding steps

a) Before welding

* Install the MIG torch, gas and welding wire, and then turn on the power switch. The power indicator

is on and fan works.

* Set the welding mode button on MIG

* Turn on the gas regulator on the gas cylinder, the gas pressure is shown on the gauge.

* Release the drive roll pressure, press the gun trigger, and then adjust the gas flow to meet the

specification requirement, (turn the gas regulator anticlockwise to reduce the flow rate). Then

re-engage the drive roll pressure.

* Press the gun trigger till the wire exits the nozzle. (The nozzle may need to be removed from the

gun to allow this function).

* When wire feeding, keep the gun cable straight.

* When wire feeding, make sure the wire is located on the drive roll groove and the feeding speed

should be smooth. If the wire feeding speed is not smooth, please adjust the tension of the drive

roll.

* When using MIG wire, the V groove wire roller should be used.

MIG operation mode: press Amp/WFS adjustment knob, this gives wire inch function. Press the

voltage adjustment knob, gives a gas purge function.

b) Welding

There are five options for wires: 0.6mm, 0.8mm, 0.9mm, 1.0mm, and manual. In the manual function,

operator needs to set up welding voltage and wire feeding speed. The other four options are synergic

adjustment; operator only needs to select the wire diameter being used and adjust wire feeding

speed. The PowerCRAFTTM

180i will match relevant voltage automatically, and also operator can

make micro adjustment of voltage to fine tune the output. Inductance can be adjusted hard and soft

welding arc.

Welding methods: 2 step and 4 step.

Welding material the PowerCRAFTTM

180i is designed to weld mild steel and stainless steel. (Note: the

welding voltage pre-display will show peak voltage).

* pressing voltage adjustment knob，following data will be showed：

When showing“Gas On-”， release the knob, gas valve will open and supply the gas

When showing“Gas CH-”release the knob, and turning the knob, you can choose the shielding

gas to be used.

* When welding, adjust the welding current and welding voltage to match the wire being used.

* Point the wire into the joint to be welded, press the gun trigger, the wire feeds automatically. The

arc is started once the wire touches the work piece.

E-5 OPERATION E-5

Gasless (Innershield) Wire welding steps

a) Before welding * Change the polarity on the front of the PowerCRAFT

TM 180i, connect MIG torch lead to “-” and the

work cable lead to “+”. * Set the welding mode button on MIG * Install the gun, and welding wire, and then turn on the power switch. The power indicator is on and fan works.

* Press the gun trigger till the wire extends to the nozzle. (The nozzle may need to be removed from

the gun to allow this function).

* When wire feeding, keep the cable straight.

* When wire feeding, make sure the wire is located on the drive roll groove and the feeding speed

should be smooth. If the wire feeding speed is not smooth, adjust the tension of the drive roll.

* When using flux cored wire, the knurled drive roll should be used.

b) Welding

* When welding, adjust the welding current and welding voltage to match the wire being used.

* Point the wire into the joint to be welded, press down the gun trigger, the wire feeds automatically.

The arc is started once the wire is touched the work piece.

Stick welding steps

a) Before welding * Set the “welding mode button” on “stick”. * Set the welding amperage with the Amp knob. * Connect the Electrode lead to the (+) output terminal on the front of the machine * Connect the work return lead to the (-) output terminal on the front of the machine b) Welding * Take up the electrode holder, install the electrode - point the electrode into the joint to be welded, scratch the work piece to start the arc.

TIG Lift-ARC welding steps, (Optional TIG torch required).

a) Before welding * Set the welding mode button on Lift-ARC, welding torch should connect to negative (-) output terminal, and work return lead to the positive (+) output terminal. * Set the welding amperage with the Amp knob.

* Turn on the gas regulator on the gas cylinder, the gas pressure is shown on the gauge. b) Welding * Turn the gas valve located on the TIG torch to start the flow of shielding gas * Touch the tungsten electrode to the work piece, then lift the tungsten and the welding arc will start. * To stop welding lift the TIG torch away from the work piece. * Turn the gas valve located on the TIG torch off to stop the flow of shielding gas.

Error code

a）【PAS tE】 Machine in Anti-sticking status

b）【OL oad】 Machine is over load

F-1 MAINTANCE AND TROUBLESHOOTING F-1

MAINTENANCE In order to guarantee the arc welding machine works efficiently and safely, it must be maintained regularly.

Refer to the maintenance items in the following table.

● Warning: For safety while maintaining the machine, please disconnect the supply power and

wait for 5 minutes, until capacitor voltage drops to safe voltage. All service work should be conducted by an authorised Lincoln Electric field service agent

Maintenance items

Daily examination

Check operation of the panel knob’s and switch’s on the front and at the back of arc welding machine are operational and operate correctly. If the switch is not operational, replace immediately. Check the function of the LED display. If it doesn’t work, maintain or replace the display PCB. Check fan is operating normally. If the fan is damaged, change immediately. If the fan does not rotate after the arc welding machine is overheated, check if something blocking the fan blade, if it is blocked, remove the obstruction. If the fan still does not rotate try to spin the blade in the rotation direction of fan. If the fan rotates normally, the start capacitor should be replaced; If not, change the fan. Check the output terminals for overheating, if so change output terminals. Ensure welding lead plugs are connected tightly. Check welding leads for damage. If damaged replace leads.

Monthly examination

Using dry compressed air to clear the inside of arc welding machine. Especially remove dust from heat sinks, main voltage transformer, inductance, IGBT module, the fast recover diode and PCB, etc.

Yearly examination

Have a Lincoln Field service ship perform an insulation resistance test.


HOW TO USE TROUBLESHOOTING GUIDE

WARNING

Before arc welding machines are dispatched from the factory, they have already been tested. Therefore no unauthorised modifications are allowed. Unauthorised repairs performed on this equipment may result in danger to the technician and machine operator and will invalidate your factory warranty. For your safety and to avoid Electric Shock, please observe all safety notes and precautions detailed throughout this manual.

This Troubleshooting Guide is provided to help you locate and repair possible machine malfunctions. Simply follow the three-step procedure listed below.

Step 1: LOCATE PROBLEM (SYMPTOM). Look under the column labeled “PROBLEM (SYMPTOMS)”. This column describes possible symptoms that the machine may exhibit. Find the listing that best describes the symptom that the machine is exhibiting.

Step 2: POSSIBLE CAUSE The third column labeled “POSSIBLE CAUSE” lists the obvious external possibilities that may contribute to the machine symptom.

Step 3. RECOMMENDED COURSE OF ACTION This column provides a course of action for the Possible Cause. If you do not understand or are unable to perform the Recommended Course of Action safely, contact your local Lincoln Authorized Field Service Facility.

WARNING ELECTRIC SHOCK can kill. 1. Have an electrician install and

service this equipment. 2. Turn the input power off at the fuse

box before working on equipment. 3. Do not touch electrically hot parts.

If for any reason you do not understand the test procedure or are unable to perform the tests/repairs safely, contact your Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed.

CAUTION


Troubleshooting Guide

No. Problem Possible Cause What to do

1 Yellow Thermal

Indicator is on

Input voltage is too high

(≥15%) Switch off power source; Check the main supply.

Restart welder when power recovers to normal

state. Input voltage is too low

(≤15%)

Insufficient ventilation. Improve the ventilation.

Ambient temperature is too

high.

It will automatically recover when the

temperature reduces.

Exceeding the rated

duty-cycle.

It will automatically recover when the

temperature reduces.

2 Wire feeding motor not

working

Potentiometer faulty Change potentiometer

Nozzle is blocked. Change nozzle

Drive roll is loose. Increase tension on drive roll

3

Cooling Fan not

working or turning very

slowly

Switch broken Replace the switch

Fan broken Replace or repair the fan

Wire broken or disconnected Check the connection

4 Arc is not stable and

spatter is large

Too large contact tip makes

the current unsteady Change to proper contact tip and / or drive roll.

Too thin power cable makes

the power unstable. Change the power cable.

Too low input voltage Correct the input voltage.

Wire feeding resistance is

too large

Clean or replace the liner and keep the gun

cable straight.

5 Arc will not start

Work cable broken Connect / repair work cable

Work piece has greasy, dirty,

rusty or painted

Clean work piece, ensure good electrical contact

between work clamp and job.

6 No shielding gas

Torch is not connected

properly.

Re-connect the torch.

Gas pipe is crimped or

blocked.

Check gas system.

Gas hose broken. Repair or replace

7 Others Please contact our Field Service Shop.

G-1 SPARE PARTS LIST G-1

8 - Spare Parts List

1

2

3

4

5

6

7

8

9 10 11 12

16

15

21

17

14

18

19

20

13

Item Description Part Number

1 Case Cover with hinge L15712-20

2 Gas Solenoid Assembly M22745-1

3 Strain Relief S28302-10

4 Input Cord with AU plug Assembly M22276-10

5 Rocker Switch S28343-5

6 Rear Panel L15715-10

7 Fan Assembly M22416-10

8 Bottom Plate L15713-16

9 Rubber Feet S26787-9

10 Wire Feeder Motor Assembly S26214-1

11 Socket with Housing M22415-8

12 Gun Connector (Euro) S28783

13 Front Panel Nameplate M21801-66

14 Front Panel L15714-9

15 Knob T10491-7

16 Front Panel Metal Board L15716-24-B

17 Front PC Board L15712-21

18 Handle M22544-4

19 Wire Spool M22743-1

20 Door Latch S29438

21 Torch Socket with Harness S29836

Note: The list above is for reference only.

H-1 SCHEMATIC WIRING DIAGRAM H-1

This diagram is for reference only, no notification of changes will be issued

43

21

43

21

FFA

N1

CT

121

CN

201

21

CN

101 54321

220:

23+2

3|19

/15V

A

T101

PENL

16A

/250

Vac

SW

101

RLY

101

R10

1

C14

C13

C12

C11

C15

TH1

CT1

L2

YR

2

YR

1

R8

R7

C10

C9

D6

D7

D5

D4

T3B

1

4-

3+

2A

C

1A

C

C4

C3

C2

C1

RG

7

RG

5

RG

3

RG

1

ZD8

ZD7

ZD6

ZD5

ZD4

ZD3

ZD2

ZD1

T-

T+

RG

8

RG

6

RG

4

RG

2

R1

C5

C6

Q4

Q3

Q2

Q1

MIG

200

PW

R

Dig

iMIG

-001

AC

220~

240V

50/

60H

z

4

123

21

4

123

12

CN3

CN

4

M

QF

CN

2C

N5

CN

301

DigiMIG-002

21

CN203

1 2

NOTE

Limited Warranty

STATEMENT OF LIMITED WARRANTY

This warranty is given by The Lincoln Electric Company (Australia) Pty Ltd (“Lincoln Electric”),

35 Bryant St, Padstow NSW 2211, Tel: 1300 LINCOLN (1300 546 265).

Under this warranty, Lincoln Electric® warrants all new machinery and equipment (“goods”) manufactured by Lincoln Electric® against defects in workmanship and material subject to certain limitations hereinafter provided.

The benefits to the purchaser given by this warranty are in addition to other rights and remedies of

the purchaser under a law in relation to the goods. Our goods come with guarantees that cannot

be excluded under the Australian Consumer Law. You are entitled to a replacement or refund

for a major failure and compensation for any other reasonably foreseeable loss or damage.

You are also entitled to have the goods repaired or replaced if the goods fail to be of

acceptable quality and the failure does not amount to a major failure.

This warranty is void if Lincoln Electric or Lincoln Electric’s Authorised Service Facility finds that the

equipment has been subjected to improper installation, improper care or abnormal operations.

Further, this warranty does not apply to:

• cable wear and consequential damage resulting from cable wear due to flexing and

abrasion. The purchaser is responsible for routine inspection of cables for possible wear and to

remedy the issue prior to cable failure;

• engines and engine accessories;

• any batteries supplied with the goods;

• repairs done to the goods and undertaken by the purchaser outside Lincoln

Electric’s premises without written authority from Lincoln Electric obtained prior to any such repair;

or

• any damage or failure of the goods as a result of normal wear and tear or the neglect

misuse abuse or failure to properly service goods by any purchaser.

PERIOD OF WARRANTY “LINCOLN ELECTRIC BRANDED GOODS”

Lincoln Electric will assume both the parts and labour expense of correcting defects during this

warranty period. All warranty periods under this warranty start from the date of purchase from

a Lincoln Electric Authorised Distributor or Lincoln Electric Authorised Service Facility to the original

end user or from the date of manufacture if proof of purchase is not available and are as follows:

Three Years

• All Lincoln Electric® welding machines, wire feeders and plasma cutting machines unless

listed in 1 Year or Two Years

Two Years

• All Invertec®, Tomahawk® Welders & Plasmas machines unless listed below (exclude V350, TPX,

TX, SX & ASPECT Models which are 3 years)

• VIKING™ Helmets (Electronic ADF Lens Only).

One Year

• VRTEX™ 360 Virtual Reality Welder Trainer (not including items listed under 90 day

warranty)

• Kjellberg Plasma Cutting Equipment.

• Fanuc Robotic Equipment.

• Genesis Systems Group Equipment.

• Torchmate Cutting Systems

• Weld Engineering Flux Recovery Equipment.

• Binzel Robotic Cleaning Stations & Associated Equipment.

• PCA Profile Cutting Machines.

• All water coolers (internal and external).

• Arc welding and cutting robots and robotic controllers.

• All stick electrodes, welding wires and fluxes.

NOTE

• All Environmental Systems equipment, including portable units, central units and

accessories. (Does not include consumable items listed under 30-day warranty).

• All welding and cutting accessories including wire feed modules, undercarriages, field installed options that are sold separately, unattached options, welding supplies, standard accessory sets, replacement parts. (Does not include expendable parts and guns/ torches listed under 90 and 30 day warranties).

90 Days

• All Gun and Cable Assemblies (manufactured by Lincoln Electric®) and Spool guns.

• All MIG, TIG and Plasma Torches.

• All “Pro Torch” TIG Torches.

• VRTEX™ 360 Guns and VR Helmet

30 Days

• All consumable items that may be used with the environmental systems described above.

This includes hoses, filters, belts and hose adapters.

• Expendable Parts - Lincoln Electric® is not responsible for the replacement of any

expendable part that is required due to normal wear.

PERIOD OF WARRANTY “POWERCRAFT BRANDED GOODS”

Lincoln Electric will assume both the parts and labour expense of correcting defects during this

warranty period. All warranty periods under this warranty start from the date of purchase from a

Lincoln Electric Authorised Distributor or Lincoln Electric Authorised Service Facility to the original

end user or from the date of manufacture if proof of purchase is not available and are as follows:

Three Year Limited Warranty*

• All PowerCraft® welding power sources, wire feeders and plasma cutting machines with a Code

number 76205 or higher. *

PowerCRAFT welding power sources Parts Labour

Original main transformer, inductors, rectifiers 3 year 2 year

Original printed circuit boards 2 year 1 year

All other circuits and components including, but not limited to relays, switches, contactors, solenoids, fans and electric motors

1 year 1 year

One Year

• All PowerCRAFT™ Welding power sources with a Code number lower than 76205. • All welding and cutting accessories including wire feed modules, undercarriages, field installed options that are sold separately, unattached options, welding supplies, standard accessory sets, replacement parts. (Does not include expendable parts and guns/ torches listed under 90 and 30 day warranties).

• PowerCRAFT™ Welding Helmet (Electronic ADF Lens Only).

90 Days

• All MIG, TIG and Plasma Torches.

30 Days

• Expendable Parts - Lincoln Electric® is not responsible for the replacement of any expendable

part that is required due to normal wear.

NOTE

WARRANTY CLAIM PROCESS The purchaser must contact Lincoln Electric (see contact details above) within the applicable

warranty period about any defect claimed under this warranty. Lincoln Electric may direct the

purchaser to one of Lincoln Electric’s Authorised Service Facilities. Determination of warranty on

welding and cutting equipment will be made by Lincoln Electric or one of Lincoln Electric’s

Authorised Service Facilities as directed by Lincoln Electric. At Lincoln Electric’s request, the

purchaser must return, to Lincoln Electric or Lincoln Electric’s Authorised Service Facility, at the

purchaser’s cost, any goods claimed defective under this warranty, or permit Lincoln Electric or

Lincoln Electric’s Authorised Service Facility to inspect the goods at the purchaser’s premises.

Lincoln Electric may at its absolute discretion repair or replace the goods at its own premises

or at such other premises as Lincoln Electric may designate provided that all freight charges to

and from Lincoln Electric’s premises or such other premises as Lincoln Electric® may designate

shall be paid by the purchaser.

If Lincoln Electric or Lincoln Electric’s Authorised Service Facility confirms the existence of a

defect covered by this warranty; the defect will be corrected by repair or replacement at Lincoln

Electric’s option.

CUSTOMER ASSISTANCE POLICY

Lincoln Electric® business is manufacturing and selling high quality welding equipment,

consumables, and cutting equipment. Our challenge is to meet the needs of our customers and to

exceed their expectations. On occasion, purchasers may ask Lincoln Electric® for advice or

information about their use of our products. We respond to our customers based on the best

information in our possession at that time. Lincoln Electric® is not in a position to warrant or

guarantee such advice and to the extent permitted by law assumes no liability, with respect to

such information or advice. As a matter of practical consideration, we also cannot assume any

responsibility for updating or correcting any such information or advice once it has been given.

The provision of information or advice does not create, expand or alter this warranty.

Lincoln Electric® is a responsive manufacturer, but the selection and use of specific products sold

by Lincoln Electric® is solely within the control of, and remains the sole responsibility of the

customer. Many variables beyond the control of Lincoln Electric® affect the results obtained in

applying this type of fabrication methods and service requirements.

NOTE

THE LINCOLN ELECTRIC COMPANY PTY LTD 35 Bryant Street Padstow NSW

www.lincolnelectric.com.au

http://www.lincolnelectric.com.au/

july, 2014 rev. 02 powercrafttm 180i mig

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