IM7905-1
September, 2012
Rev. 01
PowerCRAFTTM 180i MIG
For use with machine Part Number：
TM
PowerCRAFT 180i MIG
K69020-1
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.
Copyright © 2012 The Shanghai Lincoln Electric Company
THE LINCOLN ELECTRIC COMPANY PTY LTD
35 Byrant Street Padstow NSW 2211
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.
Model Name
□ PowerCRAFTTM 180i MIG
Code & Serial number
Date & Where Purchased
Authorized dealer’s shop
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 completel y before attempting to use this
equipment. Save this manual and keep it handy for quick reference. Pay
particular attention to the safety instructions we have provided for your
protection. 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-III
Electromagnetic Compatibility ……………………………………………………….
IV-V
Customer Ass istanc e Polic y ……………….………………………………
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
PRODUCT DESCRIPTION
B-1
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
INSTALLATION
C-1
SAFETY PRECAUTIONS
WARNING
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.
C-1
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
TM
PLEASE SEE ADDITIONAL WARNING INFORMATION
AT THE FRONT OF THIS OPERATOR’S MANUAL.
The PowerCRAFT 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.
SELECT A SUITABLE LOCATION
ENGINE DRIVEN GENERATOR
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.
CAUTION
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..
TM
Locate the PowerCRAFT 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.
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.
TECHNICAL SPECIFICATION
D-1
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)
Rectifier
Filter
Inverter
Drive
Protection
Inspect
Transformer
High
Frequency
Rectifier
Modulate
Trait
Control
Process
Control
Current
Adjustment
Sampling
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.
TECHNICAL SPECIFICATION
D-2
D-2
The Welding Machine Configuration
Th e PowerCRAFT
TM
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 SPECIFICATION
D-3
D-3
TECHNICAL SPECIFICATIONS
INPUT – SINGLE PHASE ONLY
PowerCRAFT
TM
180i
Standard
Voltage/Phase/
Frequency
240V(±15%)/ 1/50/60
Hz
Generator required
Maximum
Input
Current
Rated Input
Current
>7 KVA
28A
13A
RATED OUTPUT – DC ONLY
Duty Cycle
TM
180i
Amperes
20%
60%
100%
20%
60%
100%
20%
60%
100%
GMAW
PowerCRAFT
(1)
SMAW
GTAW
OUTPUT
180A
104A
80A
140A
80A
62A
180A
104A
80A
RANGE
Open Circuit
Voltage
Welding Current
Range
Welding Voltage
Range
20A ~ 180A
15.0V ~ 23.0V
20A~140A
20.8V ~ 25.6V
15A ~ 180A
10.6V ~ 17.2V
GMAW
PowerCRAFTTM
180i
SMAW
Volts at Rated
Amperes
23V
18.2V
18V
25.6V
23.2V
22.5V
17.2V
14.2V
13.2V
62V
GTAW
OTHER PARAMETERS
PowerCRAFT
TM
180i
Power Factor
Efficiency
Protection Class
Insulation Class
0.72
≥85%
IP21S
H
PHYSICAL DIMENSIONS
PowerCRAFT
TM
180i
Length
Width
Height
550mm
320mm
440mm
Weight
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
(2)
15.4Kg
TECHNICAL SPECIFICATION
D-4
D-4
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)
TECHNICAL SPECIFICATION
D-5
D-5
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.
TECHNICAL SPECIFICATION
D-6
D-6
Power supply configure of a welder:
Item
PowerCRAFT
Circuit breaker（A）(‘D’ Curve)
≥15
Fuse (Rated current）(Slow Blow)
15
Power cord（mm2）
TM
180i
≥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.
D-7
TECHNICAL SPECIFICATION
D-7
* 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.
OPERATION
E-1
19
E-1
18
20
21
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
18 Protection indicator
19 Wire Feed speed
20 Amperage display
21 MIG torch connector
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.
OPERATION
E-2
E-2
Front Panel Controls
1
13
2
3
4
5
6
7
12
10
11
9
8
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.
OPERATION
E-3

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 PowerCRAFTTM 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 positive (+) output
terminal, and work return lead to the negative (-) 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.
F-2
MAINTANCE AND TROUBLESHOOTING
F-2
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 3. RECOMMENDED COUSE OF
ACTION
This column provides a course of action for
the Possible Cause.
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.
If you do not understand or are unable to
perform the Recommended Course of Action
safely, contact your local Lincoln Authorized
Field Service Facility.
Step 2: POSSIBLE CAUSE
The third column labeled “POSSIBLE
CAUSE” lists the obvious external possibilities
that may contribute to the machine symptom.
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.
CAUTION
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.
MAINTANCE AND TROUBLESHOOTING
F-3
F-3
Troubleshooting Guide
No.
1
2
3
4
Problem
Yellow Thermal
Indicator is on
Wire feeding motor not
working
Cooling Fan not
working or turning very
slowly
Arc is not stable and
spatter is large
Possible Cause
Input voltage is too high
(≥15%)
Input voltage is too low
(≤15%)
Insufficient ventilation.
Ambient temperature is too
high.
Exceeding the rated
duty-cycle.
Arc will not start
6
No shielding gas
7
Others
Switch off power source; Check the main supply.
Restart welder when power recovers to normal
state.
Improve the ventilation.
It will automatically
temperature reduces.
It will automatically
temperature reduces.
recover
when
the
recover
when
the
Potentiometer faulty
Change potentiometer
Nozzle is blocked.
Change nozzle
Drive roll is loose.
Increase tension on drive roll
Switch broken
Fan broken
Wire broken or disconnected
Too large contact tip makes
the current unsteady
Replace the switch
Replace or repair the fan
Check the connection
Too thin power cable makes
the power unstable.
Too low input voltage
Change the power cable.
Wire feeding resistance is
too large
5
What to do
Work cable broken
Work piece has greasy, dirty,
rusty or painted
Torch is not connected
properly.
Gas pipe is crimped or
blocked.
Gas hose broken.
Change to proper contact tip and / or drive roll.
Correct the input voltage.
Clean or replace the liner and keep the gun
cable straight.
Connect / repair work cable
Clean work piece, ensure good electrical contact
between work clamp and job.
Re-connect the torch.
Check gas system.
Repair or replace
Please contact our Field Service Shop.
SPARE PARTS LIST
G-1
G-1
8 - Spare Parts List
1
Hinge
16
Work cable and clamp
31
Fan
2
Case cover, enclosure
17
MIG Gun (ROHS)
32
Main PCB
3
Wire retainer
18
Euro Connector (ROHS)
33
Rear Panel
4
Control transformer
19
MIG Gun receptacle
34
Power Cord retainer
5
Main PC Board
20
Wire feeder assembly
35
Power Cord（RoHS）
6
Door
21
Potentiometer Knob
36
Main Switch (ROHS)
7
Door lock (ROHS)
22
8
Spool holder
23
Cord retainer
38
Gas Valve connector
9
Vertical center sheet metal
24
Quick Connector, female
39
Gas solenoid valve
10
Main Transformer
25
Feet
40
Handle
11
Hall Effect Device
26
Output Inductance
12
Sheet metal case base
27
Loaded PCB
28
29
30
Capacitance PCB
Heat Sink
Rectifier
13
Plastic front panel
14
Front panel support
15 Front panel control board
Note: The list above is for reference only.
MIG Gun connector cable 37
Nut M14*1.5
SW101
PE
N
16A/250Vac
AC220~240V 50/60Hz
L
F
T101
1
2
3
4
5
CN101
B1
AC
AC
-
+
4
3
C15
C1 C2
R1
C3 C4
1 2
TH1
C6
1 2
CT1
CT1
T-
RG8
RG5
1 2 3 4
ZD8
ZD7
RG7
ZD6
ZD5
CN2
C5
Q4
RG6
CN5
DigiMIG-001
CN4
MIG 200 PWR
ZD4
ZD3 RG4
Q2
Q3
1
2
3
4
1
2
3
4
CN301
1 2 3 4
RG3
ZD2
ZD1 RG2
Q1
1 2
CN201
T3
CN203
220:23+23|19/15VA
FAN1
RLY101
R101
2
1
RG1
T+
1
2
C10
C9
1
2
YR2
YR1
D7
D6
D5
D4
R8
R7
L2
C12
C11
C13
C14
H-1
SCHEMATIC WIRING DIAGRAM
H-1
This diagram is for reference only, no notification of changes will be issued
DigiMIG-002
CN3
1
2
QF
M
WARRANTY
I-1
I-1
Warranty Terms & Conditions – Lincoln Electric Limited Warranty
STATEMENT OF LIMITED WARRANTY
®
®
This warranty is given by The Lincoln Electric Company (Australia) Pty Limited ("Lincoln "), 35 Bryant St, Padstow
NSW 2211, Tel: 1300 LINCOLN (1300 546 265).
®
®
Under this warranty, Lincoln warrants all new machinery and equipment ("goods") manufactured by Lincoln 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 or Lincoln'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's premises without written
®
authority from Lincoln 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 BRANDED GOODS"
®
Lincoln 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 Authorised Distributor or Lincoln
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 welding machines, wire feeders and plasma cutting machines unless listed below.
Two Years

®
®
Ranger 405D , Italian Invertec Welders & Plasmas machines unless listed below.
One Year





Kjellberg Plasma Cutting Equipment.
Fanuc Robotic Equipment.
Genesis Systems Group Equipment.
Weld Engineering Flux Recovery Equipment.
Binzel Robotic Cleaning Stations & Associated Equipment.
WARRANTY
I-2






I-2
PCA Profile Cutting Machines.
All PowerCRAFT Welding Machines
All water coolers (internal and external).
Arc welding and cutting robots and robotic controllers.
All stick electrodes, welding wires and fluxes.
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 ) and Spool guns.
All MIG, TIG and Plasma Torches.
All "Pro Torch" TIG Torches.
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 is not responsible for the replacement of any expendable part that is required due
to normal wear.

WARRANTY CLAIM PROCESS
®
The purchaser must contact Lincoln (see contact details above) within the applicable warranty period about any defect
®
claimed under this warranty. Lincoln may direct the purchaser to one of Lincoln's Authorised Service Facilities.
®
Determination of warranty on welding and cutting equipment will be made by Lincoln or one of Lincoln's Authorised
®
Service Facilities as directed by Lincoln .
®
At Lincoln's request, the purchaser must return, to Lincoln or Lincoln's Authorised Service Facility, at the purchaser's
®
cost, any goods claimed defective under this warranty, or permit Lincoln or Lincoln's Authorised Service Facility to
inspect the goods at the purchaser's premises.
®
Lincoln may at its absolute discretion repair or replace the goods at its own premises or at such other premises as
®
Lincoln may designate provided that all freight charges to and from Lincoln's premises or such other premises as
®
Lincoln may designate shall be paid by the purchaser.
®
If Lincoln or Lincoln'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's option.
CUSTOMER ASSISTANCE POLICY
Lincoln's 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 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 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 is a responsive manufacturer, but the selection and use of specific products sold by Lincoln is solely
®
within the control of, and remains the sole responsibility of the customer. Many variables beyond the control of Lincoln
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