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PrimeWeld MIG180 Assembly And Operating Instructions Manual

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MIG180
WELDER
r:!}
Need Hei
Please Call
856-500-2000
ASSEMBLY AND
OPERATING
INSTRUCTIONS

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  • Page 1 MIG180 ASSEMBLY AND OPERATING WELDER INSTRUCTIONS r:!} Need Hei Please Call 856-500-2000...

  • Page 2: Table Of Contents

    CONTENTS SAFETY WARNINGS AND PRECAUTIONS UNPACKING SPECIFICATIONS AND PARAMETERS SETUP BASIC WELDING BASIC WELDING TECHNIQUE WELDING TIPS WELD DIAGNOSIS WELD PROBLEMS INSTALLATION SET-UP FOR SMAW (STICK) WELDING OPERATION FOR SMAW (STICK) WELDING SMAW (STICK) WELDING GENERAL DESCRIPTION SMAW (STICK) WELDING FUNDAMENTALS MAINTENANCE PARTS LIST AND DIAGRAM...
  • Page 3 MIG180 MIG WELDER Save This Manual You will need the manual for safety warnings and precautions, assembly instructions, operating and maintenance procedures, parts list and diagram. Keep your invoice with this manual. Write invoice number and date of purchase on the inside of the manual. Keep the manual and invoice in a safe and dry place for future reference.

  • Page 4: Safety Warnings And Precautions

    SAFETY WARNINGS AND PRECAUTIONS WARNING: When using welder, basic safety precautions should always be followed to reduce the risk of personal injury and damage to equipment. Read all instructions before using this welder. Cluttered areas invite injuries. Keep work area clean. Do not use machines or power tools in damp Observe work area conditions.
  • Page 5 SAFETY WARNINGS AND PRECAUTIONS Always wear Use eye and ear protection. ANSI approved, arc shaded, impact safety face shield(welding helmet). Always use full-face shield when welding. Always wear ANSI approved eyewear under face shield and while in the workplace. Wear a NIOSH approved dust mask or respirator when working around metal, chemical dusts, fumes and mists.
  • Page 6 Use of any other parts will void warranty. Only use accessories intended for use with this welder. Approved accessories are available from"PRIMEWELD". Do not operate tool if under the influence of alcohol or Read warning labels on prescriptions to determine drugs.
  • Page 7 SAFETY WARNINGS AND PRECAUTIONS • Avoid electrical shock. Do not permit electrically live parts, cables, or electrodes to contact skin, clothing or gloves. Protective clothing should be hole free, dry and ANSI approved. This unit draws enough current to cause serious injury or death. Before turning the welder on, check the welder gun to be sure that there are no protruding screw heads and that all insulation is secure.
  • Page 8 Improper use of electric arc welders can cause electric shock, injury and death! Take all precautions described in this manual to reduce the possibility of electric shock. The MIG180 power switch is to be in the OFF ("O")position when installing work cable and gun and when connecting power cord to input power.
  • Page 9 SAFETY WARNINGS AND PRECAUTIONS ARC RAYS can burn. Use a shield with the proper filter and cover plates to protect your eyes from sparks and the rays of the arc when welding or observing open arc welding. Use suitable clothing made from durable flame resistant material to protect your skin and that of your helpers from the rays.

  • Page 10: Unpacking

    (See Figure A-1 ) FIGURE A-1 11111a 4 Electrode Holder 3 Work Clamp 1 MIG180 Welder 2 Torch 7 Hand-hold Mask and Hammer Brush s Gas Regulator 6 Gas Hose 9 .030" (0.8mm) ,.040" (1.0mm) Contact Tip 8 2 lb.Spool of .030"...

  • Page 11: Specifications And Parameters

    SPECIFICATIONS AND PARAMETERS MIG 180 � 1 phase 1 phase Supply voltage 110V±15% 220V±15% Frequeency (Hz) No-load voltage (V) MIG:30-120 MIG:30-180 Output current (A) MMA:30-120 MMA:30-170 MIG:15.5-20 M IG:15.5-23 Output voltage (V) MMA:21.2-24.8 M MA:21.2-26.8 Duty cycle (%) �0.73 Power factor Efficiency(%) �80 Wire speed {in/min)

  • Page 12: Setup

    SETUP Read the ENTIRE IMPORTANT SAFETY INFORMATION section at the beginning of this manual including all text under subheadings therein before set up or use of this product. TO PREVENT SERIOUS INJURY FROM ACCIDENTAL � WARNING OPERATION: Turn the Power Switch off and unplug the Welder before setup.
  • Page 13 SETUP �SpoolK"ob 10-12 Pound Wire Spool Installation: Remove the Spool Knob. Place the new Wire Spool over the Adapter and line up pin on Adapter 10-12 lb with hole in Spool. To prevent wire Spool ­ feed problems, set the Spool so that Adapter it will unwind counterclockwise.
  • Page 14 SETUP DCEN Direct Current Electrode Negative Wire Setup for Flux Cored (gasless) welding: Connect the Wire Feed Connector to the Negative Terminal on front of the Welder. Connect the Ground Cable to the Positive Terminal on the front of the connect connect Welder.
  • Page 15 SETUP D Remove the cylinder's cap. Stand to the side of the valve opening, then open the valve briefly to blow dust and dirt from valve opening. Close the cylinder valve. E Locate the Regulator (included) and close its valve until it is loose, then thread Regulator onto cylinder and wrench tighten connection.
  • Page 16 SETUP A Unscrew the Feed Roller Knob Feed Roller Knob counterclockwise. B Remove the Feed Roller Knob to expose the Feed Roller. C Flip or replace the Feed Roller as needed and confirm that it is the correct Roller for the type of wire being used and that the number showing is the same as the wire diameter...
  • Page 17 SETUP Loosen the Knob on the Wire Wire Feed Gun Ca b le K no b Mechanism Connector Feed mechanism, then insert the Gun Cable Connector through the hole on the Welder front and into the socket on the Wire Feed. Ensure that the Gun Cable Connector is full inserted into the socket on the Wire Feed...
  • Page 18 SETUP Cut off all bent and crimped wire. The cut end must have no burrs or sharp edges; cut again if needed. Keep tension on the wire and Welding guide at least 12 inches of wire Wire Inlet Wire Liner into the Wire Inlet Liner and Feed Guide.
  • Page 19 SETUP IMPORTANT Stainless steel wire is less flexible than other welding wire. Therefore, it is more diffcult to feed through the liner and gun. It is especially important to keep the gun cable straight while feeding stainless steel wire. Turn the Power Switch off and do not touch the Gun's Trigger and before connecting Power Cord: If using 11 0VAC, connect the...
  • Page 20 SETUP Set the MIG Flux/ Spool Gun MIG Flux/ Spool Gun Switch Switch to MIG Flux Gun. MIG Gun Point the Gun away from all objects. Press and hold the Trigger until the wire feeds Welding through the end of the Gun two Wire inches.
  • Page 21 SETUP Select a Contact Tip that is compatible with the welding wire used. Slide the Contact Tip over the wire and thread it clockwise into the MIG Gun. Tighten the Contact Tip. Replace the Nozzle and cut the wire off at 1 /2" from tip (1 /2" stickout).

  • Page 22: Basic Welding

    BASIC WELDING Read the ENTIRE IMPORTANT SAFETY INFORMATION section at the beginning of this manual including all text under subheadings therein before welding. AWARNING TO PREVENT SERIOUS INJURY: Protective gear must be worn when using the Welder; minimum shade number 10 full face shield (or welding mask), ear protection, welding gloves, sleeves and apron, NIOSH approved respirator, and fire resistant work clothes without pockets should be worn when welding.
  • Page 23 BASIC WELDING Make practice welds on pieces of scrap to practice technique before welding anything of value. AWARNING TO PREVENT SERIOUS INJURY, FIRE AND BURNS: Keep welding tip clear of grounded objects whenever unit is plugged in and turned on. Practice your welding technique on scrap pieces before welding anything of value.
  • Page 24 BASIC WELDING Front Panel Controls MIG/MMA Selector Voltage Display Abnormal Indicator 2T/4T Selector Current/Wire Speed Display MIG Gun/ Spool Gun Cable Socket Positive Output Terminal Wire Feed Control Socket Negative Output Terminal OW N ER 'S M A N UA L Prlmeweld...
  • Page 25 BASIC WELDING Display voltage Provide selection Voltage Display: MIG/MMA Selector: setting status. of MIG or MMA (Stick) welding modes. Selecting MIG position provides for Under Current/ Wire Speed Display: MIG welding function. Selecting MMA MIG Mode: display wire speed setting position provides for Stick welding status under no-load and actual current function.
  • Page 26 BASIC WELDING Interior Controls MIG Flux/ Spool Gun Switch Feed Tensioner Spool Knob Idler Arm Wire Spool Wire Inlet Liner Wire Feed Mechanism Note: When using an optional Spool Gun (included), disconnect input power to the machine and place the MIG Flux/Spool Gun Switch on the Spool Gun setting. Fully insert gun cable into the socket, plug the 4pin plug into the wire feed control socket.
  • Page 27 BASIC WELDING Back View · Gas Inlet Fitting Power Switch Power Supply Input Weld Settigs Refer to the Settings Chart on the inside of the Welder door for Flux-Cored and MIG Weld settings. The chart is only intended to show general guidelines for different wire sizes and for different thicknesses of material.
  • Page 28 BASIC WELDING Duty Cycle (Duration of Use) Avoid damage to the Welder by For example, a welder with a 30% duty not welding for more than the cycle at 180 A welding current must be prescribed duty cycle time. The Duty allowed to rest for at least 7 minutes Cycle defines the number of minutes, after every 3 minutes of continuous...
  • Page 29 BASIC WELDING When the Abnormal Indicator is no MIG Gun longer lit and the Welder can be used again, use shorter welding periods and longer rest periods to prevent needless wear. concrete slab (or other heat-proof, non-conductive surface) Setting Up The Weld Make practice welds on pieces of scrap the same thickness as your intended workpiece to practice...
  • Page 30 BASIC WELDING When welding equipment on a vehicle, disconnect the vehicle battery Notice: power from both the positive connection and the ground before welding. This prevents damage to some vehicle electrical systems and electronics due to the high voltage and high frequency bursts common in welding. Clamp Ground Cable to bare metal on the workpiece near the weld area, or to metal work bench where...
  • Page 31 BASIC WELDING Gas shielded, solid-core wire only: A: Open gas cylinder valve all the way. B: Set Flow Gauge to 20-30 cubic ft per hour(CFH), (10-14L/min). Turn the Power Switch off and do not touch the Gun's Trigger and before connecting Power Cord: If using 11 0VAC, connect the included adapter to the end of the...

  • Page 32: Basic Welding Technique

    BASIC WELDING TECHNIQUE Press (and hold) Trigger and contact the area to be welded with electrode wire to ignite a re. stringer bead weave bead For a narrow weld, you can usually draw the wire in a steady straight line. This is called a stringer bead. For a wider weld, draw the wire back and forth across the joint.
  • Page 33 BASIC WELDING TECHNIQUE The Contact Tip should remain within 1 /2"of the work surface. This distance is called stick out. stick out 1/2") (up to Note: If Welder is used too long, the Abnormal Indicator lights up and the unit automatically shuts down.
  • Page 34 BASIC WELDING TECHNIQUE MIG Gun When welding is complete, set the MIG Gun down on a heat­ proof, electrically non-conductive Turn the Power Switch OFF. surface. (or other heat-proof, non-conductive surface) Allow Welder to cool down, then unplug the Power Cord. Remove Ground Clamp from workpiece or table and disconnect MIG Gun.

  • Page 35: Welding Tips

    WELDING TIPS A typical flux-cored wire (FCAW)weld A good way to test welding technique is to before cleaning. examine a weld's appearance after it has weld bead slag spatter cooled and the slag has been removed. Then, better welding can be learned by adjusting your weld technique to remedy any problems found.
  • Page 36 WELDING TIPS Strike Test A test weld on a PIECE OF SCRAP can be tested by using the following procedure. WEAR ANSI-APPROVED SAFETY GOGGLES DURING THIS PROCEDURE. WARNING! This test WILL damage the weld it is performed on. This test is ONLY an indicator of weld technique and is not intended to test working welds.

  • Page 37: Weld Diagnosis

    WELD DIAGNOSIS Workpiece Heat control / Weld penetration EXCESS PENETRATION OR INADEQUATE PENETRATION PROPER PENETRATION BURN-THROUGH How to increase workpiece heat How to reduce workpiece heat and increase penetration: and limit penetration: (to weld THICKER workpieces properly) (to weld THINNER workpieces properly) a.Increase weld current c.Use faster wire feed a.Decrease weld current c.Use slower wire feed...

  • Page 38: Weld Problems

    WELD PROBLEMS Penetration(Workpiece Heat Control) EXCESS PENETRATION OR PROPER PENETRATION INADEQUATE PENETRATION BURN-THROUGH Weld is visible underneath and Weld does not penetrate the Weld droops on top and bulges slightly on top. joint fully, just on the surface. underneath, or falls through entirely, making a hole.
  • Page 39 WELD PROBLEMS Bend at Joint Weld Not Adhering Properly Gaps present between weld and previous bead or between weld and workpiece. See areas below. PROFILE VIEW PROFILE POSSIBLE CAUSES AND SOLUTIONS VIEW Improper clamping: Clamp workpieces securely. POSSIBLE CAUSES AND SOLUTIONS Make tack welds to hold 1.
  • Page 40 WELD PROBLEMS Porosity Excessive Spatter Small cavities or holes in the bead. Fine spatter is normal. Spatter that is grainy and large is a problem. VIEW VIEW POSSIBLE CAUSES AND SOLUTIONS POSSIBLE CAUSES AND SOLUTIONS Incorrect polarity: Dirty workpiece or welding Check that polarity is set wire: Clean workpiece down to correctly for type of welding.
  • Page 41 WELD PROBLEMS Crooked/Wavy Bead Burn-Through Base material melts away, leaving a hole in the weld. VIEW VIEW POSSIBLE CAUSES AND SOLUTIONS POSSIBLE CAUSES AND SOLUTIONS Inaccurate welding: Workpiece overheating: Use two hands or rest hand on Reduce current and/or wire feed steady surface.

  • Page 42: Installation Set-Up For Smaw (Stick) Welding

    INSTALLATION SET-UP FOR SMAW (STICK) WELDING INSTALLATION SET UP FOR SMAW (STICK) WELDING Turn the power source on and select the MMA function with the MIG/MMA selector switch. Connection of Output Cables Two weld output receptacles are available on this welding machine. For Stick welding the electrode holder is connected to the positive receptacle, while the ground lead (work piece) is connected to the negative receptacle, this is known as DC+ polarity.

  • Page 43: Operation For Smaw (Stick) Welding

    OPERATION FOR SMAW (STICK) WELDING Set the welding current relevant to the electrode type and size being used as recommended by the electrode manufacturer. Place the electrode into the electrode holder and clamp tight. Scratch the electrode against the work piece to create an arc and hold the electrode steady to maintain the arc.

  • Page 44: Smaw (Stick) Welding General Description

    SMAW (STICK) WELDING GENERAL DESCRIPTION One of the most common types of arc welding is shielded metal arc welding (SMAW) or stick welding. An electric current is used to strike an arc between the base material and a consumable electrode rod or 'stick'. The electrode rod is made of a material that is compatible with the base material being welded and is covered with a flux that gives off gaseous vapors that serve as a shielding gas and provide a layer of slag, both of which protect the weld area from atmospheric...
  • Page 45 SMAW (STICK) WELDING GENERAL DESCRIPTION The metal core works as conductor of the current that maintains the arc. The metal core melts and is deposited into the weld pool. Protective The covering on a shielded metal arc welding electrode is called flux. The flux on the electrode performs many "---Arc different functions.

  • Page 46: Smaw (Stick) Welding Fundamentals

    SMAW (STICK) WELDING FUNDAMENTALS ELECTRODE SELECTION As a general rule, the selection of an electrode is straight forward, in that it is only a matter of selecting an electrode of similar composition to the parent metal. However, for some metals there is a choice of several electrodes, each of which has ELECTRODE SIZE particular properties to suit...
  • Page 47 SMAW (STICK) WELDING FUNDAMENTALS ARC LENGTH To strike the arc, the electrode should be gently scraped on the work until the arc is established. There is a simple rule for the proper arc length; it should be the shortest arc that gives a good surface to the weld. An arc too long reduces penetration, produces spatter and gives a rough Excessive travel surface finish to the weld.

  • Page 48: Maintenance

    MAINTENANCE AWARNING TO PREVENT SERIOUS INJURY, FIRE AND BURNS: Unplug the Welder, rest the MIG Gun on a heat-proof, electrically non­ conductive surface, and allow all parts of the Welder to cool - --- • thoroughly before service. inspect Periodically, have a qualified BEFORE EACH USE, the general condition of the technician remove the Rear Panel...
  • Page 49 MAINTENANCE Nozzle and Contact Tip Inspection and Cleaning Make sure that the entire Mig gun is completely cool and that the power cord is unplugged from the electrical outlet before proceeding. Pull the Nozzle to remove it. Scrub the interior of the Nozzle clean with a wire brush.
  • Page 50 MAINTENANCE Troubleshooting IMPORTANT! Be CERTAIN to shut off the Welder, disconnect it from power, and discharge the MIG Gun to ground before adjusting, cleaning, or repairing the unit. Likely Solutions Problem Possible Causes 1. Insufficient wire feed tension. 1. Increase wire feed tension properly. Follow step 25 on page 20.
  • Page 51 MAINTENANCE Troubleshooting IMPORTANT! Be CERTAIN to shut off the Welder, disconnect it from power, and discharge the MIG Gun to ground before adjusting, cleaning, or repairing the unit. Problem Possible Causes Likely Solutions 1. Wire not feeding properly. 1. See first Troubleshooting section above. 2.
  • Page 52 MAINTENANCE Troubleshooting (continued) IMPORTANT! Be CERTAIN to shut off the Welder, disconnect it from power, and discharge the MIG Gun to ground before adjusting, cleaning, or repairing the unit. Likely Solutions Problem Possible Causes 1. Improper ground connection. 1. Make certain that the workpiece is contacted properly by the Ground Clamp and that the 2.

  • Page 53: Parts List And Diagram

    PARTS LIST AND DIAGRAM Parts List Description Description Part Part Divider Left Front Plastic Part MIG Gun Copper Connector Kit Left Front Iron Part Front Fillet MIG Gun Cable Socket Fixed Board Control Board Door Panel Decorative Strip Right Back Iron Part Door Door Latch Right Back Plastic Part...

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