Harbor Freight Tools 225 Amp_AC, 240 Volt, Stick Welder Product manual
Contents
1. aai aae naa aia 7 Maintenance cccccceceeeeeeeeeeseccaeeeeeeeeees 13 SPOECIICATIONS seca OA 7 Parts List and Diagram 14 Basic Welding cccccecceeeeeeeeseceeteeeeeeees 8 Walranly cctccndtiadiitiieneuiaiianaiaiee 16 WARNING SYMBOLS AND DEFINITIONS This is the safety alert symbol It is used to alert you to potential personal injury hazards Obey all safety messages that follow this symbol to avoid possible injury or death Indicates a hazardous situation which if not avoided will result in death or serious injury A DANGER AWARNING Indicates a hazardous situation which if not avoided could result in death or serious injury Indicates a hazardous situation which if not avoided could result in minor or moderate injury ACAUTION NOTICE CAUTION IMPORTANT SAFETY INFORMATION AWARNING Read all safety warnings and instructions Failure to follow the warnings and instructions may result in electric shock fire and or serious injury Save all warnings and instructions for future reference Addresses practices not related to personal injury General Safety PROTECT yourself and others Read and understand this information 7 Never leave the Welder unattended while energized Turn power off if you have to leave 1 Before use read and understand manufacturer s instructions Material Safety Data Sheets MSDS s 8 The warnings precautions and instructions Page 2 employer s safety2. o 24 25 26 27 28 Note If product has no serial number record month and year of purchase instead Note Some parts are listed and shown for illustration purposes only and are not available individually as replacement parts Page 14 For technical questions please call 1 800 444 3353 SKU 69029 Assembly Diagram AONVNALNIVIN For technical questions please call 1 800 444 3353 Page 15 SKU 69029 Limited 90 Day Warranty Harbor Freight Tools Co makes every effort to assure that its products meet high quality and durability standards and warrants to the original purchaser that this product is free from defects in materials and workmanship for the period of 90 days from the date of purchase This warranty does not apply to damage due directly or indirectly to misuse abuse negligence or accidents repairs or alterations outside our facilities criminal activity improper installation normal wear and tear or to lack of maintenance We shall in no event be liable for death injuries to persons or property or for incidental contingent special or consequential damages arising from the use of our product Some states do not allow the exclusion or limitation of incidental or consequential damages so the above limitation of exclusion may not apply to you THIS WARRANTY IS EXPRESSLY IN LIEU OF ALL OTHER WARRANTIES EXPRESS OR IMPLIED INCLUDING THE WARRANTIES OF MERCHANTABILITY AND FITNESS To take ad
3. of such substances Welders create sparks which may ignite flammable substances or make reactive fumes toxic Welder Use and Care Do not use the welder if the switch does not turn 4 it on and off Any welder that cannot be controlled with the switch is dangerous and must be repaired Disconnect the plug from the power source before making any adjustments 5 changing accessories or storing welders Such preventive safety measures reduce the risk of starting the welder accidentally Prevent unintentional starting Ensure the switch is in the off position before connecting to power source or moving the welder Carrying or energizing welders that have the switch on invites accidents For technical questions please call 1 800 444 3353 If working on a metal wall ceiling etc prevent ignition of combustibles on the other side by moving the combustibles to a safe location If relocation of combustibles is not possible designate someone to serve as a fire watch equipped with a fire extinguisher during the cutting process and for at least one half hour after the cutting is completed Do not weld or cut on materials having a combustible coating or combustible internal structure as in walls or ceilings without an approved method for eliminating the hazard Do not dispose of hot slag in containers holding combustible materials After welding make a thorough examination for evidence of fire Be aware that easily visi
4. practices and ANSI Z49 1 Keep out of reach of children Keep children and bystanders away while operating Place the welder on a stable location before use If it falls while plugged in severe injury electric shock or fire may result discussed in this instruction manual cannot cover all possible conditions and situations that may occur It must be understood by the operator that common sense and caution are factors which cannot be built into this product but must be supplied by the operator 9 This product when used for welding and similar Do not overreach applications contains or produces a chemical Keep proper footing and balance at all times known to the State of California to cause cancer and birth defects or other reproductive harm Stay alert Watch what you are doling ahd Use California Health amp Safety Code 25249 5 et seq common sense when operating a welder Do not use a welder while you are tired or under 10 Handling the cord on this product will the influence of drugs alcohol or medication A moment of inattention while operating welders may result in serious personal injury Avoid unintentional starting Make sure you are prepared to begin work before turning on the Welder For technical questions please call 1 800 444 3353 expose you to lead a chemical known to the State of California to cause cancer and birth defects or other reproductive harm Wash hands after handling California
5. 6 50py and Outlet 6 507 for up to 250 V and up to 50 A 4 The plug shown NEMA 6 50p is for use on a 50 A circuit A different 250 V plug and outlet combination may be used provided it is rated to handle the electrical requirements of the tool and is installed by a certified electrician Note Although 125 V plugs may look similar the required plug is much larger see illustration SKU 69029 For technical questions please call 1 800 444 3353 Page 5 Extension Cords Do not use an extension cord on this welder gt Tl m j lt Replacement Cords 1 A qualified electrician can install a UL listed 3 3 Do not patch cords of any length together for this wire cords of the same thickness and length item patches may allow moisture to penetrate as the one already installed on this welder the insulation resulting in electric shock 2 Do not install a thinner or longer cord on this welder Symbology Workpiece Ground Cable Volts Alternating Current A fem O CV Open Circuit Voltage Mikam Electrode Cable ES Overheat Shutdown Indicator Housing Ground Point KVA Kilovolt Amperes Volts 1000 Amperes AW American Wire Gauge Specifications Power Input 240V 60Hz 47A A 50A dedicated circuit is required Output Current 60 225 A AC 270 A peak Capacity 1 16 to 1 4 thick and up mild steel Page 6 For technical questions please call 1 800 444 3353 SKU 69029 Read the ENTIRE
6. AUSES AND SOLUTIONS 1 Dirty workpiece or electrode Clean workpiece down to bare metal Make certain that fill material and electrode are clean and free from oil coatings and other residues TOP VIEW 2 Inconsistent welding speed Maintain steady weld speed Crooked Wavy Bead POSSIBLE CAUSES AND SOLUTIONS 1 Inaccurate welding Use two hands or rest hand on steady surface 2 Inconsistent welding speed TOP Maintain steady weld speed VIEW Excessive Spatter POSSIBLE CAUSES AND SOLUTIONS Fine spatter is normal Spatter that is grainy and large is a problem ane ne Dirty workpiece or electrode TOP Clean workpiece down to bare metal VIEW Make certain that electrode is clean and free eee from oil coatings and other residues mi m z Z Q wo Burn Through Base material melts away leaving a hole in the weld POSSIBLE CAUSES AND SOLUTIONS 1 Workpiece overheating Reduce current 2 Welding speed too slow Increase welding speed and ensure that welding speed is kept steady 3 Excessive material at weld Reduce amount of fill material TOP VIEW Page 12 For technical questions please call 1 800 444 3353 SKU 69029 Maintenance and Service AWARNING TO PREVENT SERIOUS INJURY FIRE AND BURNS Unplug the Welder rest the tool on a heat proof electrically non conductive surface and allow all parts of the Welder to cool thoroughly before service 1 Periodically remove the Rig
7. Health amp Safety Code 25249 5 et seq SKU 69029 Fume and Gas Safety FUMES AND GASES can be hazardous to your health 1 Exposure to welding or cutting exhaust fumes can increase the risk of developing certain cancers such as cancer of the larynx and lung cancer Also some diseases that may be linked to exposure to welding or cutting exhaust fumes are e Early onset of Parkinson s Disease e Heart disease e Ulcers e Damage to the reproductive organs e Inflammation of the small intestine or stomach e Kidney damage e Respiratory diseases such as emphysema bronchitis or pneumonia 2 Do not use near degreasing or painting operations 3 Keep head out of fumes Do not breathe exhaust fumes Arc Ray Safety 4 Use enough ventilation exhaust at arc or both to keep fumes and gases from breathing zone and general area If engineering controls are not feasible use an approved respirator SAFETY Work in a confined area only if it is well ventilated or while wearing an air supplied respirator Have a recognized specialist in Industrial Hygiene or Environmental Services check the operation and air quality and make recommendations for the specific welding situation Follow OSHA guidelines for Permissible Exposure Limits PEL s and the American Conference of Governmental Industrial Hygienists recommendations for Threshold Limit Values TLV s for fumes and gases ARC RAYS can injure
8. IMPORTANT SAFETY INFORMATION section at the beginning of this manual including all text under subheadings therein before set up or use of this product AWARNING TO PREVENT SERIOUS INJURY FROM ACCIDENTAL OPERATION Turn the Power Switch off and unplug the welder before assembly Face Shield Assembly 1 Attach the handle to the Face Shield by lining up the two rectangular tabs on the handle with the corresponding holes in the face shield and A press the tabs through the holes and then B slide the tabs forward from the back locking the round tab in place Face Shield viewed from front 2 Wear heavy duty work gloves the edges of the filter lens may be sharp Remove any protective film from both sides of the filter lens Slide the filter lens into the helmet behind the holding tabs Make sure that the filter lens fits securely and that light cannot leak around its edges Filter Lens Face Shield viewed from back Components and Controls Power Current Light Indicator Overload omen Light Power Switch Current Knob Grounding Clamp Electrode Holder SKU 69029 For technical questions please call 1 800 444 3353 U gt m m Z A Basic Welding AWARNING To Prevent Serious Injury and Permanent Eye Damage Wear protective gear during use an ANSI approved welding mask shade 10 ear protection welding gloves and apron NIOSH approved respirator and fire resista
9. Loose Electrode Handle Check to ensure that all connections are tight cable or Ground cable Damaged Electrode Have a qualified technician inspect and Welding Arc Not Stable Handle or loose repair or replace as necessary connection within Electrode Handle Adjust current setting Make sure setting matches recommended setting SKU 69029 For technical questions please call 1 800 444 3353 Page 13 MAINTENANCE 2 m gt Z 2 m Parts List and Diagrams PLEASE READ THE FOLLOWING CAREFULLY THE MANUFACTURER AND OR DISTRIBUTOR HAS PROVIDED THE PARTS DIAGRAM IN THIS MANUAL AS AREFERENCE TOOL ONLY NEITHER THE MANUFACTURER NOR DISTRIBUTOR MAKES ANY REPRESENTATION OR WARRANTY OF ANY KIND TO THE BUYER THAT HE OR SHE IS QUALIFIED TO MAKE ANY REPAIRS TO THE PRODUCT OR THAT HE OR SHE IS QUALIFIED TO REPLACE ANY PARTS OF THE PRODUCT IN FACT THE MANUFACTURER AND OR DISTRIBUTOR EXPRESSLY STATES THAT ALL REPAIRS AND PARTS REPLACEMENTS SHOULD BE UNDERTAKEN BY CERTIFIED AND LICENSED TECHNICIANS AND NOT BY THE BUYER THE BUYER ASSUMES ALL RISK AND LIABILITY ARISING OUT OF HIS OR HER REPAIRS TO THE ORIGINAL PRODUCT OR REPLACEMENT PARTS THERETO OR ARISING OUT OF HIS OR HER INSTALLATION OF REPLACEMENT PARTS THERETO Parts List Description 5 Sprin i y O Qty 5 6 8 Grommet 1 9 Record Product s Serial Number Here Base Nylon Cover Grommet 23 Nylon Cover 20 22 ROTM
10. Owner s Manual amp Safety Instructions Save This Manual Keep this manual for the safety warnings and precautions assembly operating inspection maintenance and cleaning procedures Write the product s serial number in the back of the manual near the assembly diagram or month and year of purchase if product has no number Keep this manual and the receipt in a safe and dry place for future reference CHICAGOS eiee WELDING POWER 225 AMP ARC WELDER jJ WD Visit our website at http www harborfreight com Email our technical support at tech harborfreight com ITEM 69029 When unpacking make sure that the product is intact and undamaged If any parts are missing or broken AWARNING please call 1 800 444 3353 as soon as possible Copyright 2011 by Harbor Freight Tools All rights reserved No portion of g this manual or any artwork contained herein may be reproduced in any shape Read this material before using this product or form without the express written consent of Harbor Freight Tools Diagrams Failure to do so can result in serious injury within this manual may not be drawn proportionally Due to continuing SAVE THIS MANUAL improvements actual product may differ slightly from the product described herein Tools required for assembly and service may not be included wn gt A m lt Table of Contents DANGLY PI E 2 Welding TIPS sdsacedisisccacaevvssaccacedvsacnredivvaaccese 9 SEP nd iaa
11. ase call 1 800 444 3353 Do not expose welders to rain or wet conditions Water entering a welder will increase the risk of electric shock Do not abuse the cord Never use the cord for carrying pulling or unplugging the welder Keep cord away from heat oil sharp edges or moving parts Damaged or entangled cords increase the risk of electric shock Do not use outdoors Insulate yourself from the workpiece and ground Use nonflammable dry insulating material if possible or use dry rubber mats dry wood or plywood or other dry insulating material large enough to cover your full area of contact with the work or ground Page 3 wn gt TI m lt Page 4 Fire Safety ARC AND HOT SLAG can cause fire Clear away or protect flammable objects 5 Remove or make safe all combustible materials for a radius of 35 feet 10 meters around the work area Use a fire resistant material to cover or block all open doorways windows cracks and other openings Keep ABC type fire extinguisher near work area and know how to use it Maintain a safe working environment 6 Keep the work area well lit Make sure there is adequate surrounding workspace Keep the work area free of obstructions grease oil trash and other debris Do not operate welders in atmospheres containing dangerously reactive or flammable liquids gases vapors or dust 8 Provide adequate ventilation in work areas to prevent accumulation
12. ble smoke or flame may not be present for some time after the fire has started Do not apply heat to a container that has held an unknown substance or a combustible material whose contents when heated can produce flammable or explosive vapors Clean and purge containers before applying heat Vent closed containers including castings before preheating welding or cutting Store idle welders out of the reach of children and do not allow persons unfamiliar with the welder or these instructions to operate the welder Welders are dangerous in the hands of untrained users Use the welder and accessories in accordance with these instructions taking into account the working conditions and the work to be performed Use of the welder for operations different from those intended could result in a hazardous situation SKU 69029 Maintenance 1 Maintain welders Check for misalignment or 3 Maintain labels and nameplates on the Welder binding of moving parts breakage of parts These carry important information and any other condition that may affect the If unreadable or missing contact welder s operation If damaged have the Harbor Freight Tools for a replacement ps welder repaired before use Many accidents Lu are caused by poorly maintained welders 4 Unplug before maintenance Unplug the Welder LL from its electrical outlet before any inspection lt x 2 Have your welder serviced by a qualified maintenance or cleaning procedure
13. d ensure 2 Insufficient weld heat that welding speed is kept steady Slow down so fill material has time to melt into the weld location Increase current 3 Workpieces too thick close Bevel thick workpieces allow slight gap and weld in several passes 4 Insufficient weld material Increase amount of fill material WELDING TIPS Weld Not Adhering Properly Gaps present between weld and previous bead or between weld and workpiece See areas below POSSIBLE CAUSES AND SOLUTIONS 1 Incorrect welding technique Place stringer bead at correct place in joint Adjust workpiece position or weld angle to permit proper welding to bottom of piece Keep arc on leading edge of weld puddle Hold gun at proper angles 2 Insufficient weld heat Increase current 3 Dirty workpiece Clean workpiece down to bare metal PROFILE VIEW SKU 69029 For technical questions please call 1 800 444 3353 Page 11 Bend at Joint POSSIBLE CAUSES AND SOLUTIONS 1 Improper clamping Clamp workpieces securely PROFILE Make tack welds to hold workpieces VIEW 2 Excessive heat Weld a small portion and allow to cool before proceeding Coat of Slag Over Weld EN esac peer TOP Slag is a necessary part of a stick weld It shields VIEW the weld from impurities Clean off the slag with the Chipping Hammer and Wire Brush after welding PARTIALLY CHIPPED AWAY TO SHOW WELD Porosity Small cavities or holes in the bead POSSIBLE C
14. ded 8 240V outlet and turn the Welder on WARNING TO PREVENT SERIOUS INJURY AND DEATH If the operator is not holding 9 the Electrode Holder it must be sitting on a nonconductive nonflammable surface 10 The Stick Welder will immediately turn on when the Power Switch is turned on A good way to test welding technique is to examine a weld s appearance after it has cooled and the slag has been removed Then better welding can be learned by adjusting your weld technique to remedy any problems found Cleaning the Weld AWARNING TO PREVENT SERIOUS INJURY Continue to wear ANSI approved safety goggles and protective wear when cleaning a weld Sparks or chips may fly when cleaning 1 A weld will be covered by slag use a Chipping Hammer to knock this off Be careful not to damage the weld or base material 2 Then use a Wire Brush to further clean the weld or use an angle grinder sold separately to shape the weld SKU 69029 For technical questions please call 1 800 444 3353 Stroke the workpiece lightly to ignite the arc Tips for igniting the arc a Stroke the surface with the electrode b Strike the surface like a match with the electrode c Tap the surface with the electrode When the arc ignites tilt the electrode forward and hold it near the workpiece After practice welding for a few seconds STOP and examine your weld using the guidelines starting below When finished welding lift t
15. eyes and burn skin 1 Wear ANSI approved welding eye protection featuring at least a number 10 shade lens rating 2 Wear leather leggings fire resistant shoes or boots during use Do not wear pants with cuffs shirts with open pockets or any clothing that can catch and hold molten metal or sparks 3 Keep clothing free of grease oil solvents or any flammable substances Wear dry insulating gloves and protective clothing Electrical Safety 4 Wear an approved head covering to protect the head and neck Use aprons cape sleeves shoulder covers and bibs designed and approved for welding and cutting procedures When welding cutting overhead or in confined spaces wear flame resistant ear plugs or ear muffs to keep sparks out of ears ELECTRIC SHOCK can KILL 1 Turn off disconnect power and discharge electrode to ground before setting down torch electrode holder and before service 2 Do not touch energized electrical parts Wear dry insulating gloves Do not touch electrode holder electrode welding torch or welding wire with bare hand Do not wear wet or damaged gloves 3 Connect to grounded GFCl protected power supply only 4 Do not use near water or damp objects 5 People with pacemakers should consult their physician s before use Electromagnetic fields in close proximity to heart pacemaker could cause pacemaker interference or pacemaker failure SKU 69029 6 For technical questions ple
16. he electrode from the workpiece and turn the Welder off Place the handle down on a nonflammable nonconductive surface To prevent accidents disconnect the tool from its power supply after use Allow the tool to cool down clean then store the tool indoors out of children s reach Welding Tips Oo Z m al z S p g A typical Weld before cleaning ia weld bead g ip E wee base metal WELDING TIPS Page 9 Strike Test clamp A test weld on a PIECE OF SCRAP can be tested by using the following procedure WEAR ANSI APPROVED SAFETY GOGGLES DURING THIS PROCEDURE dead blow hammer SCRAP workpiece 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 GOOD WELD 1 After two scraps have been welded together and the bends and is not brittle weld has cooled clamp one scrap in a sturdy vise clamp dead blow hammer SCRAP workpiece 2 Stay clear from underneath while you strike the opposite scrap with a heavy hammer preferably a dead blow hammer 3 AGOOD WELD will deform but not break as shown on top A POOR WELD will be brittle and snap at the weld as shown on bottom POOR WELD snaps or cracks Example Weld Diagrams CLEAN WELDS FIRST Stick welds will have a coat of slag over them until cleaned Good Current Current Weld Speed Weld Speed Arc Length Arc Length Weld Too Lo
17. ht and Left side panels and using compressed air blow out all dust from the interior 2 Store in a clean and dry location 3 For optimal weld quality clean and inspect the Contact points before each use Troubleshooting IMPORTANT Be CERTAIN to shut off the Welder disconnect it from power and discharge the Electrode Holder to ground before adjusting cleaning or repairing the unit Possible Cause J sowon o oo O 1 Tripped thermal Reduce duration or frequency of welding periods Power Switch Lights but protection device to help reduce wear on the welder Welder Does Not Function Refer to Duty Cycle Duration of Use When Switched ON on page 8 2 Faulty connection 2 Qualified technician must check connection Unit is not connected Verify the voltage at the outlet and the connection to to outlet properly or the outlet Power Switch Does Not outlet is unpowered If voltage is not present at outlet check circuit Light When Switched On breaker GFCI devices if any are tripped determine and remedy cause before resetting Verify that the circuit is designed to supply the required input Incorrect line voltage Check the line voltage and if insufficient have a licensed electrician remedy the situation Weak Arc Strength Improper gauge or length 2 Extension cords are not recommended of extension cord If possible eliminate the use of an extension cord If an extension cord is needed refer to the guidelines on page 5
18. nt work clothes without pockets Light from the arc can cause permanent damage to the eyes and skin Do not breathe arc fumes Duty Cycle Duration of Use 20 RATED 225A DUTY CYCLE 2 minutes welding followed by at least 8 minutes of rest Avoid damage to the Welder by not welding for more than the prescribed duty cycle time The duty cycle defines the number of minutes within a 10 minute period during which a given welder can produce a particular welding current without overheating For example this Welder at its rated output has a 20 duty cycle and must be allowed to rest for at least 8 minutes after every 2 minutes of continuous welding Failure to carefully observe duty cycle limitations can easily over stress a welder s power generation system contributing to premature welder failure Setting up the Weld 1 Make practice welds on pieces of scrap the same thickness as your intended workpiece to practice technique before welding anything of value Clean the weld surfaces thoroughly with a wire brush or angle grinder there must be no rust paint oil or other materials on the weld surfaces only bare metal 2 Use clamps not included to hold the workpieces in position so that you can concentrate on proper welding technique The distance if any between the two workpieces must be controlled properly to allow the weld to hold both sides securely while allowing the weld to penetrate fully into the joint The edges
19. of thicker workpieces may need to be chamfered or beveled to allow proper weld penetration Page 8 For technical questions please call 1 800 444 3353 Thermal Overload Protection This Welder has an internal thermal protection system to help prevent this sort of over stress When the unit overheats it automatically shuts down and the Overload Light turns on The Welder automatically returns to service after cooling off Rest the Electrode Holder on an electrically non conductive heat proof surface such as a concrete slab well clear of the ground clamp while allowing the welder to cool with the Power Switch on so that the internal fan will help cool the Welder When the Welder can be used again use shorter welding periods and longer rest periods to prevent needless wear clamps workpieces mn Clean surfaces to bare metal A Chamfer thick workpieces SKU 69029 Basic Welding Technique 1 Place the Welder on a level surface that 6 can bear its weight near the work area 2 Secure the Grounding Clamp to a clean exposed metal part of the workpiece 3 Place the uncoated end of the electrode inside the jaws of the Electrode Holder Electrode types vary for welding different metals 4 Turn the Current Knob to adjust the welding current The approximate current setting can be read on the Current Indicator IMPORTANT A 50A dedicated circuit is required 5 Plug the power cord into a groun
20. s N repair person using only identical replacement parts This will ensure that the safety of the welder is maintained A SAVE THESE INSTRUCTIONS AWARNING TO PREVENT ELECTRIC SHOCK AND DEATH FROM INCORRECT GROUNDING WIRE CONNECTION Check with a qualified electrician if you are in doubt as to whether the outlet is properly grounded Have a plug installed by a certified electrician Do not use the welder if the power cord or plug is damaged If damaged have it repaired by a service facility before use If the plug will not fit the outlet have a proper outlet installed by a qualified electrician do not use adapter plugs 1 The green wire inside the cord is connected to DO NOT USE the grounding system in the welder The green 125 V PLUG wire in the cord must be the only wire connected NOTE SIZE DIFFERENCE to the welder s grounding system and must never be attached to an electrically live terminal Never leave the grounding wire disconnected or modify the Power Cord Plug in any way 2 Make sure the tool is connected to an outlet having the same configuration as the plug If the tool must be reconnected for use on a different type of electric circuit the reconnection should be made by qualified service personnel and after reconnection the tool should comply with all local codes and ordinances 3 A250 V plug will need to be installed by a certified electrician before use 230 V 2 Prong Plug
21. vantage of this warranty the product or part must be returned to us with transportation charges prepaid Proof of purchase date and an explanation of the complaint must accompany the merchandise If our inspection verifies the defect we will either repair or replace the product at our election or we may elect to refund the purchase price if we cannot readily and quickly provide you with a replacement We will return repaired products at our expense but if we determine there is no defect or that the defect resulted from causes not within the scope of our warranty then you must bear the cost of returning the product This warranty gives you specific legal rights and you may also have other rights which vary from state to state CHICAGOG ana WELDING 3491 Mission Oaks Blvd PO Box 6009 Camarillo CA 93011 800 444 3353
22. w Too High Too Fast Too Slow Too Short Too Long SOP g f gt Ry h TO CORRECT TO CORRECT TO CORRECT TO CORRECT TO CORRECT TO CORRECT mi g Z Q a J wo U Weld slower Weld faster Increase Decrease se Use Current Knob Current Knob distance distance to increase to decrease Current Current Page 10 For technical questions please call 1 800 444 3353 SKU 69029 Diagnosis Workpiece Heat Control Weld Penetration EXCESS PENETRATION OR INADEQUATE PENETRATION PROPER PENETRATION BURN THROUGH Not hot enough Ideal heat Too hot 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 current b Weld more slowly a Decrease current b Weld more quickly Penetration Workpiece Heat Control EXCESS PENETRATION OR PROPER PENETRATION INADEQUATE PENETRATION BURN THROUGH Weld is visible underneath and Weld does not contact the joint Weld droops on top and bulges slightly on top fully just on the surface underneath or falls through entirely making a hole D J PROFILE VIEWS POSSIBLE CAUSES AND SOLUTIONS POSSIBLE oe AND SOLUTIONS 1 Workpiece overheating 1 Incorrect welding technique Reduce current Keep arc on leading edge of weld puddle 2 Welding speed too slow Hold electrode at proper angles Increase welding speed an
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