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TABLE OF CONTENTS Safety Summary......................................4 Set the Wire Drive Tension ....................16 Safety Information..................................4 Installing Aluminium Wire ......................16 Shock Hazards ......................................5 Change Polarity......................................16 Flash Hazards ........................................5 Operation................................................17 Fire Hazards ..................................
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• When you see one of the symbols shown SAFETY SUMMARY here, be alert to the possibility of person- The warnings, cautions and instructions dis- al injury and carefully read the message cussed in this instruction manual can not cover that follows. all possible conditions or situations that could occur. It must be understood by the operator This symbol indicates that the pos- that common sense and caution are factors sibility of electric shock hazard which can not be built into this product, but
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SHOCK HAZARD into the power source if the ground prong on power cord plug is bent over, broken off, or missing. • Do not allow the welder to be connected WARNING to the power source or attempt to weld if the welder, welding cables, welding site, or welder power cord are exposed to any ELECTRIC SHOCK CAN KILL! To reduce the form of atmospheric precipitation, or salt risk of death or serious injury from shock, water spray. read, understand, and follow the following • Do not carry coiled welding ca
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welding shields and/or helmets in place. • Do not wear gloves or other clothing that • Do not wear a cracked or broken contains oil, grease, or other flammable helmet and replace any cracked or bro- substances. ken filter lenses IMMEDIATELY. • Do not wear flammable hair prepara- • Do not allow the uninsulated portion tions. of the wire feed gun to touch the ground • Do not weld in an area until it is checked clamp or grounded work to prevent an and cleared of combustible and/or flam- arc flash f
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prevent spatter or slag from falling into ear. can be decomposed by the heat of an • Make sure welding area has a good, electric arc or its ultraviolet radiation. solid, safe floor, preferably concrete or These actions can cause PHOSGENE, a masonry, not tiled, carpeted, or made of HIGHLY TOXIC gas to form, along with any other flammable material. other lung and eye-irritating gasses. Do • Protect flammable walls, ceilings, and not weld or cut where these solvent floors with heat resistant covers
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• Do not expose cylinders to electricity of harm. Wash hands after Handling. any kind. (California Health & Safety Code Sec. • Do not use a cylinder or its contents for 25249.5 et seq.) anything other than its intended use. Do not use as a support or roller. ADDITIONAL SAFETY INFORMATION • Do not locate cylinders in passageways For additional information concerning weld- or work area where they may be struck. ing safety, refer to the following standards • Do not use a wrench or hammer to open an
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Table 2. Duty Cycle Ratings WELDER SPECIFICATIONS Duty Maximum Required DESCRIPTION Cycle Welding Resting Your new MIG(GMAW) flux core (FCAW) Rating Time Time wire feed welder is designed for mainte- nance and sheet metal fabrication. The 20% 2 minutes 8 minutes welder consists of a single-phase power 25% 2.5 minutes 7.5 minutes transformer, stabilizer, rectifier, and a 40% 4 minutes 6 minutes unique built-in control/feeder. 60% 6 minutes 4 minutes Now you can weld sheet metal from 24 80% 8 mi
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(Refer to the Suggested Settings Chart on p.33 KNOW YOUR WELDER of this manual OR on the inside of the door of Voltage Selector Switch the welder.) Handle Power Switch – This switch turns the welder Wire ON and OFF. (Make sure the power switch is Speed in the OFF position before performing any maintenance on the welder.) Power Switch Power Cord – This is a standard, 230 volt power cord with a NEMA 6-50P 50 amp Voltage plug. (Make sure you are using a properly Selector Dial grounded 230 VAC, 60Hz
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use of adapters. Make certain that the exten- WELDER INSTALLATION sion is properly wired and in good electrical condition. Extension cords must be a #12 POWER SOURCE CONNECTION gauge cord at the smallest. Do not use an POWER REQUIREMENTS extension cord over 25 ft. in length. This welder is designed to operate on a proper- ly grounded 230 volt, 60Hz, single-phase alter- ASSEMBLING THE WELDER nating current (AC) power source fused with a The following procedures describe the process 50 amp time de
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3. Once the handle tabs are properly seat- ed in the face shield slots, install the handle cover by firmly pushing it into the recessed area on the face shield. 4. Install the dark glass by sliding it into place behind the glass retaining tabs. Note: if your face shield was supplied with a 3” x 3.8” dark glass you may choose to Figure 3. Handle Installation remove the extra material from the face SELECTING SHIELDING GAS shield to allow a larger field of vision when The shielding gas plays an ext
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Gas Selection For Aluminium Welding open cylinder valve port at yourself or with Aluminium Wire bystanders. Failure to comply with this warning Use only pure Argon when welding could result in serious personal injury. Aluminium. Note: If the cylinder you have is equipped with INSTALL THE SHIELDING GAS male regulator connecting threads instead of female, you will need to obtain a special com- pressed gas cylinder adaptor from your gas WARNING supplier to install between your gas cylinder and regu
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Change the drive roller according to the follow- that of the wire being installed (see Figure ing steps: 6). Push the drive roller onto the drive roller 1. Open the door to the welder drive com- shaft, with the side stamped with the partment. desired wire diameter facing you. 2. Remove the drive tension by loosening the tension adjusting screw and lifting the Drive Tension Adjustor up, away from the Drive Tension Arm. Pull the drive tension arm away from the drive roller. 3. If there is wire al
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7. After checking to make sure that your welder is disconnected from the ac power source, free the leading end of the wire from the spool, but do not let go of it until instructed to do so, or the wire will unspool itself. 8. Use a wire cutter, cut the bent end off the leading end of the wire so that only a straight leading end remains. 9. Flip down the screw holding the drive tension arm in place and lift the tension arm up off the drive roller. 10.Insert the leading end of the wire into Figu
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16.Set the WIRE SPEED control to the middle INSTALLING ALUMINIUM WIRE of the wire speed range. Install aluminium wire the same as steel 16.Straighten the gun cable and pull the wire, but with the following exceptions: trigger on the welding gun to feed the wire through the gun assembly. 1. Install a plastic liner (PN PRT 30900002) 17.When at least an inch of wire sticks out past in the welding gun. the end of the gun, release the trigger. 2. Adjust the drive tension VERY carefully. 18.Select a
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B. For MIG (GMAW) welding, mount the OPERATION Ground Clamp ring terminal to the “- ” mounting post and the Torch ring Operation of this welder consists of selecting terminal to the “+” mounting post. and adjusting operating controls for optimum See configuration shown in Figure 9. voltage (welding heat) and wire speed settings. CONTROLS AND INDICATORS POWER SWITCH - The power switch sup- plies electrical current to the welder. ALWAYS turn the power switch to the OFF position and unplug the weld
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piece farthest away from you, and at an tamination and enhance the welding capa- angle similar to that which will be used bilities of the electrical arc. when welding. (SEEHOLDINGTHEGUN on page 18 if you are uncertain of the Whether you have welded before or not, it is angle at which you will be welding) important that you become familiar with 4. With your free hand, turn the Wire Speed your new welder, its controls, and the results Dial to maximum and continue to hold achieved at different sett
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work piece and drag it along while welding. This can be very helpful to beginning welders to steady the gun, allowing the welder to concentrate on welding technique. If the nozzle is held off the work piece, the distance between the nozzle and the work piece should be kept constant and should not exceed 1/4 inch or the arc may begin sputtering, signaling a loss in welding per- formance. Angle A Figure 10. Gun Position, Angle A WELDING TECHNIQUES 2. Angle B (Figure 11) can be varied for two reaso
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Figure 12. Travel Direction Figure 13. Stringer Bead For most welding jobs you will pull the gun along the weld joint to take advantage of 2. The WEAVE BEAD (Figure 14) is used the greater weld puddle visibility. when you want to deposit metal over a wider space than would be possible with a 2. TRAVEL SPEED is the rate at which the stringer bead. It is made by weaving from gun is being pushed or pulled along the side to side while moving with the gun. It is weld joint. For a fixed heat setting,
