SPEEDWAY 7644 Use and Care Manual
Contents
1. caused by moist ding or Make sure clothing and work area are dry Welder overheats blows fuses or trips creut use of extension cora use of extension cor If not possible use thicker lower gauge number extension cord breaker diameter T Overioadez creut wrong type of electrode verify electrode i for aernatng current use lectrode ciameter too large use smater ameter electrode ar dict to Verf proper grounding No paint varnish oF Heavy loads making poer line voltage ow n meeer on Saeed Soa Problem Possible Cause s Bend is intermittentiy to inconsistent trave speed Watch contrai tne wictn of the matien wed think oF ie amp setting incorrect adjust output amp setting or change smaller Travel speed to fast Jwaten orange weld puddle and contro Ragged depressions at Jae length too short Pracice running elecrode across workpiece weider OFF edge of wale too large Recommend ether 1 16 or 5 64 inch diameter E Lt electrode ta correct arc length as soon Bectrode sticks to work AE length too short ma lama increase amp setting or changa to smaller 5 pamp secreces use ery electrodes and store in dry location nmi Tesdback ratitools com 4 800 348 5004 Limited Manufac2. low setting The amperage required depends on the size diameter of electrode used and the thickness of the piece Excessive currents burn through light metals and the weld bead is fiat and porous The bead appears high and irregular ifthe current is too low Weld Angle Weld angle is the angle at which the electrode is held during the welding process Using the correct angle ensures proper penetration and bead formation Electrode angle involves two positions travel angle and work angle Travel angle is the angle in the line of welding and varies from 5 degrees to 45 degrees from the vertical depending upon welding conditions Work angle is the angle from the horizontal measured at right angles to the line of welding For most applications a 45 degree travel angle and 45 degree work angle is sufficient For specific applications consult an arc welding handbook Right handed welders should work from leftto right Left handed welders should weld from rightto left Arc length Arc length is the distance from the work piece to the tip ofthe electrode the distance which the arc must travel Aproper arc length is essential to generate the heat needed for welding An arc that is too long produces an unstable arc reduces penetration increases spatter and causes flat and wide beads Too shortan arc does not create enough heat to melt the work piece the electrode has a tenden
3. E The electrode holder and rode are electrically Ie when the welderis on 5 Hold the electrode away from the grounded work piece or bench Tum on the welder to either high or low Electrode diameter 1 16in Output setting Low Electrode diameter 5 64in Output setting High 6 Position the electrode to begin weld lower the welding helmet or position the shield and strike an arc Adjust the output setting as needed 7 When finished welding tum weider off and store properly Dutycycle Thermostalic protection Welder duty cycle is the percentage of actual weld time that can occur in a ten minute interval 10 duty cycle 1 minute of actual welding and 9 minutes cool down time The internal components of the welder are protected from overheating with an automatic thermal switch MAINTENANCE Disconnect the power supply and tum machine off before inspecting or servicing any components Before everyuse 1 Check the condition of the weld cables and repair or replace any cables with damaged insulation before use 2 Check the condition of the power cord and immediately repair or replace the cord if damaged before use Check the condition of the electrode holder insulating pieces and immediately replace any cracked or missing insulators Verify that all fasteners are tight and insulated Every3 months Replace any unreadable labels the welder Use compressed ai
4. I approved face shield or safely glasses with side shield protection when chipping or grinding metal parts Wear ear plugs when welding overhead to prevent spatter slag from falling into the ears WARNINING Arc welding operations produce intense light heat and ultraviolet UV rays Intense light and UV rays can cause injury to eyes and Skin Take all precautions to reduce the possibility of injury to the eyes andor skin All persons operating this weider or in the vicinity of this equipment while itis being used must wear proper protective welding gear including a welding helmet or shield with at least shade 10 flame resistant clothing leather welding gloves and full foot protection WARNINING Never look directly nto arc welding operations without proper eye protection Do notuse a shade filter lens that is cracked broken or rated below number 10 Warn others in the area not to look at the arc WARNINING Arc welding operations cause sparks and heat metal to temperatures that can cause severe burns Use protective clothing and gloves while performing any metal working operations and be sure to take all precautions to reduce the possibilty of clothing and skin burns Make sure that any person in the welding area is protected from heat ultraviolet rays and sparks Use flame resistant barriers and additional face shields as needed Never touch any work piece until ithas c
5. Please carefully read and save these instructions before attempting to assemble maintain install or operate this product Observe safety information to protect yourself and others Failure to observe the instructions may result in property damage and or personal injury Please keep instructions for future reference 100 AMP ARC WELDER Important Operating Instruction Model 7644 CALIFORNIA PROPOSITION 65 WARNING You can create dust when you cut sand drill or grind materials such as wood paint metal concrete cement other masonry This dust often contains chemicals known to cause cancer birth defects or other reproductive harm Wear protective gear WARNING This product or its power cord may contain chemicals including lead known to the State of California to cause cancer and birth defects or other reproductive harm Wash hands after handling Important When using equipment a few safety precautions must be accidents which arise due to non observance of these instructions and the safety information herein SPECIFICATIONS Input 230V Single Phase 22 Amps Open Circuit Voltage 48 Volts Welding Current 40 100 Amps Duty Cycle 10 70 Amps 50 100 Amps Any failures made in following SAFETY INSTRUCTIONS WARNING Aways keep a fire extinguisher accessible while using an arc welder Before staring or servicing any electric arc welder read and understand al
6. a 1 800 348 5004 or ema feedbacknatiiools com 8007644 04 11
7. cy to stick penetration will be poor and uneven beads with irregular nipples result Aproper arc should be no longer than the diameter of the rod The sound ofa proper arcis a stead crisp size Travel speed Weld appearance diagram on page The travel speed is the rate at which the electrode is moved across the arc weld area When the speed is too fast the bead is narrow and ripples are pointed When the speed is too low the weld metal piles up and the bead is high and wide To control travel speed watch the width of the weld beat not the arc when welding The weld bead is the orange molten metal behind the arc The width should be approximately twice the diameter of the welding rod Control the travel speed to obtain a consistent bead width After completing the weld wait for the heated sections to cool Aprotective coating called slag now covers the weld beat which prevents contaminants in the air from reacting with the molten metal Once the weld cools to the point itis no longer Tesdbsck natitools com 5 4 800 348 5004 glowing red the slag can be removed Removal is done with a chipping hammer Lightly tap the slag with the hammer and break it loose from the bead The final clean up is done with Wire brush When making multiple weld passes remove the slag between each pass Welding positions Four basic welding positions be used fat horizontal vertical and ove
8. e use of an extension cord is not recommended for arc welding machines because the cord will significantly decrease the performance of the welder ASSEMBLY Handshield optional 1 Cutthe detachable handie away ftom the shield Trim the excess plastic to remove the sharp edges 2 Insert fiter lens 3 To attach the handle place the shield on a flat surface and press the handle in place Ifyou have never welded or have litle experience welding TesdbsckGnatitoolscom 4 800 348 5004 a full face helmet is recommended to allow both hands to stabilize and control the angle and arc length ofthe electrode OPERATION WARNING Any person operating this equipment or in the area ofits use must wear protective welding gear Including eye protection with a minimum shade 10 lens flame resistant clothing leather welding gloves and full foot protection 1 Ensure welder is off Plug into appropriate receptacle 115v 15amp Low 114 20amp High 2 Verity thatthe surfaces of metals to be joined are free from dirt rust paint oll scale or other contaminants These contaminants will make welding difficult and cause poor welds 3 Connect the work clamp to the work piece Ensure the contact is on bare metal and ot obstructed by paint varnish corrosion or non metallic materials 4 Insert the exposed part of the electrode rod the end with no flux into the jaws of the electrode holder NOT
9. g from the base metal 2 Ensure the welding area is well ventilated 3 Use an air supplied respirator Exremely toxic fumes created when these metals are heated WARNING The electromagnetic field that is generated during arc welding may interfere with operations of various electrical and electronic devices such as cardiac pacemakers Persons with Such a device should consult their physician before using an electric arc welder Route the electrode and work cables together and secure with tape when possible Never wrap arc welder cables around the body Always position the electrode and work leads so that they are the same side of the body WARNING Always ensure the welding area is secure and free of hazards prior to leaving Ensure all equipmentis tumed off and the electrode is removed Ensure all metal and slag has cooled an that the cables are loosely coiled and outof the way INSTALLATION Location Selecting the proper location increase performance reliability and the life ofthe arc welder For the best results locate the welder in a clean and dry environment Dust and dirt can cause the welder to retain moisture and increase wear of moving parts Store electrodes in a ci Jow humidity dry location preserve the coating The receptacle used for the welder must be properly grounded and the welder must be the onlyload on the power Supply circuit Th
10. l instructions and warnings Failure to follow the Safety guidelines or instructions cause damage to the equipment or personal injury or death Al installation maintenance repair and operation of this welder should be performed by qualified users onlyin accordance with local state and national law codes WARNINING Improper use of the safety regulations and electric arc welders can cause observed to avoid injuries and instructions may result inan electric shock injury and death Gamage Please read the electric shock fire andlor complete operating manual with Serious injury Before using this welder be sure due care Keep this manual in a that all components are clean safe place so thatthe information and in proper working order is available at all imes Ifyou give Check the insulation on all the equipmentto anyother cables electrode holders and person give them these power cords for damage Aways operating instructions as well We repair or replace damaged parts accept no liability for damage or before operating the welder For warranty purchases please keep your dated proof of purchase File or attach to the manual for safekeeping For customer service ca 1 800 348 5004 or ema feedbackgnatitools com T 8B07644 04 11 Always keep the welder panels shields etc in place while operating the welder Always wear protective closing and welding gloves and insulated f
11. ompletely cooled WARNINING Heat and sparks produced byany metal working operation can ignite flammable and explosive materials Be sure to take all precautions to reduce the possibility of explosions and flames Tesdbsck natitools com 4 800 348 5004 Remove all flammable materials within 35 feet 10 7 meters of the welding arc If removal is not possible be sure to tightly cover any flammable materials with fire proof covers Do not operate any arc welder in areas where explosive or flammable vapors maybe present sure that ying sparks and heat do not cause flames in hidden areas cracks behind WARNINING Do not weld on containers or pipes that have or have had contained flammable materials or gaseous or liquid combustibles WARNINING Arc welding closed cylinders or containers tanks or drums can explosions if not properly vented Make sure any cylinder or container to be welded has adequate ventilation hole that expanding gases can be released WARNING Do not breathe fumes that are produced by the arc welding operation The fumes are dangerous Ifthe welding area cannot be ventilated use an air supplied respirator Keep head and face outof the welding fumes Do not perform electric arc welding operations on metals that are galvanized or cadmium plated or contain zinc mercury or beryllium without completing the following precautions 1 Remove the coatin
12. ootwear Do not operate the welder in wet humid rainy or poor ventilated areas Ensure that the work piece is properly supported and grounded before beginning any welding process Acolled welding cable should be spread out before use to avoid overheating and damage to the insulation Never immerse the electrode or electrode holder in water Ifthe welder becomes wet for any reason do notuse the welder again until certain itis completely dry and clean Always shut the equipment off and unplug the power cord before moving the welder Always attach the work lead first Always shutofthe welding equipment when itis notin use and remove the electrode from the holder Do not allow any part of the bodyto touch the electrode and ground or grounded work piece atthe same time Awkward welding conditions and positions can be hazardous When working in a crouching kneeling or elevated position ensure all parts are insulated wear appropriate protective clothing and take precautions to prevent injury from falling Never attempt to use this welder at current settings or duty cycles higher than specified on the equipment labels Never use an arc welder to thaw frozen pipes Flying sparks and hot metal can cause personal injury and property damage As weld cools slag can be thrown off Take all precautions to reduce the possibility of injury from flying sparks and hot metal Wear ANS
13. r to blow all dust and debris from the ventilation openings sag Pe crater Striking an arc Attach work clamp to work piece The jaws of the work clamp must make good contact with clean bare metal of the work piece for good welding results Place the bare end ofthe electrode in the holder Grip the holder tightly to reduce tiring of the hand and arm Note Always keep the jaw of the holder clean to ensure good electrical contact with the electrode Tesdbsck natitools com 4 4 800 348 5004 Be careful not to touch the work plece or welding bench with the electrode as this causes arc flashes The best method for striking an arcis the scratching method Drag the electrode at an angle along the surface like striking a match Upon contact with the plate lift the electrode slightly off the surface or it will stick If the electrode sticks break it loose by quickly turning or bending atthe holder while pulling upward ifthe electrode does not break loose disengage the electrode by releasing itfrom the holder ARC WELDING BASICS Four basic techniques affect weld quality These ar amperage setting weld angle arc length and travel speed Proper use of these techniques is necessary for good weld quality Amperage Setting The correct amperage involves the adjustment of the welding machine to the required amp setting This is regulated by selecting the appropriate high or
14. rhead Welding In the flat position is the easiest because the welding speed can be increased molten metal h less tendency o run better penetration can be achieved the work is less fatiguing Other positions require different technique pass circular pass and Jogging Ahigher skill level is required to complete these welds All work should be performed in the flat position if possible For more specific welding instructions consult an arc welding handbook Weld passes Sometimes itis necessary for more than one pass to fill the Joint The root pass is frst followed byfiller passes and lastly the cover pass Ifthe are thick itmay be necessary to bevel the edges that are joined ata 60 degree angle Remember to remove the slag between each pass Teodback natitols com 4 800 348 5004 Troubleshooting Guide Welder Problem Possible Cause s Solutions Welder does not hum wher NE power at receptacle check dreut fuse or crevit breaker tured on Broken or damages power core Power cable requires service Wilder hums but does not weld linadequite current at electrode work and electrode camp work and eecrode cable connection t work pece elder gives trickle shocks Pose connections at weider em Che si welder external connect void contact wit work piece Accidental contact wn work Current leackage
15. turer Warranty North American Tool NAT Industries makes every effort to ensure that this product meets high quality and durability standards NAT warrants to the original retail consumer a 1 year limited warranty from the date the product was purchased at retail and each product is free from defects in materials Warranty does not apply to defects due directly or indirectly to misuse abuse negligence or accidents repairs or alterations or a lack of maintenance NAT shall in no event be liable for death injuries to persons or property or for incidental special or consequential damages arising from the use of our products To receive service under warranty the original manufacturer must be retumed for examination by an authorized service center Shipping and handling charges may apply Ifa defect is found NAT will either repair or replace the product at its discretion DO NOT RETURN TO STORE For Customer Service Email feedback natitools com or Call 1 800 348 5004 NOTE Weld bead width M Je Se epe Normal Amps Are Length Speed Amperage Too Low Amperage Too High Speed Too Fas Speed Siow Arc Length Too Long Tesdback atitools com 1800 348 5004 100 AMP ARC WELDER Model 7644 y 1 Power Switch 2 Current Switch 3 Current Scale 4 Over Temp Indicator 5 Power Cable 6 Electrode Holder 7 Ground Clamp 8 Air Vent For customer service c
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