ATD Tools 3175 User's Manual
Contents
1. ATD 3175 OPERATING MANUAL Manual Part No PRT3175 Manual e Professional Quality and Performance Effective Date Simple to Operate Can Be Used Right Out Of The Box With September 1 2009 Included Flux Core Wire FCAW Or Easily Converted to Shielding Gas Operation GMAW o Weld Steel Stainless Steel Aluminum amp Cast Iron Must use correct wire amp gas e Tweco Type Torch With Full On Off Safety Control e Multiple Power Settings Infinite Wire Speed For Accurate Welding Control Use With Standard Electrical Circuits e Fan Cooled Power Unit 8 Thermal Overload Protection e CSA Approved TABLE CONTENTS Safety 4 Safety 4 Shock Hazards iia 5 Flash Hazards u kann 5 Fire Hazards ee 6 F me Hazards er aan 7 Compressed Gasses and Equipment Hazards 7 Additional Safety Information 8 Welder Specifications 9 DESCUIDO AA 9 Welder Operating Characteristics 9 DUTY Anne 9 Internal Thermal Protection 9 Know Your Welder 10 Welder Installation 11 Power Source Connection 11 Power Requirements 11 Connect to Power Source 11 Extension Cords unse2. 19918 XVIN 6 0 ut GEO 09 NST 19918 XVIN sto 8 0 060 an Bois 90 ut 720 SJM 3109 XN 4 60 ut SEO SJM m xn 4 iu 80 urge SSITSVO 822 3Y4N0AIDO YA UL S Po ale Buipunos e analyoe peeds ay pue peeds De ay aun 4 sonsusjoeJeuo yooye sef pue aim sejqeueA dn jes 10 suyas JAIND ONILLAS GALSADONS dN LAS 60900922 33 34 35
3. When the wire speed is properly tuned in the welding wire will melt into the material you are welding as quickly as it is fed through the welding gun Voltage Selector The voltage selectors control the weld heat There are six voltage heat selections available on this welder Lower voltage less heat is achieved by setting the Voltage Selector Switch to the MIN position and or the Voltage Selector Dial to a lower number Higher voltage more heat is achieved by setting the Voltage Selector Switch to the MAX position and or the Voltage Selector Dial to a higher number Different materials and material thickness will require different voltage settings You will need to adjust your voltage accordingly for different welding conditions By properly adjusting your voltage settings and wire feed speed you will enable clean precision welds 10 Refer to the Suggested Settings Chart on p 33 of this manual OR on the inside of the door of the welder Power Switch This switch turns the welder ON and OFF Make sure the power switch 15 in the OFF position before performing any maintenance on the welder Power Cord This is a standard 230 volt power cord with a NEMA 6 50P 50 amp plug Make sure you are using a properly grounded 230 VAC 60Hz single phase 50 amp power source Ground Clamp Attaching the ground clamp to your work piece completes the welding current circuit You must attach the ground clamp to th
4. vides good puddle control when welding ver tically or overhead Gas Selection For Stainless Steel Welding The best shielding gas for stainless steel welding 15 a mixture of 90 Helium 7 5 Argon and 2 5 Carbon Dioxide However the 100 Argon can also be used but an increase in the area being heated by the arc will be experienced causing slightly greater distortion of the base metal Gas Selection For Steel Welding With Silicon Bronze Wire Use only pure Argon when welding steel with Silicon Bronze wire Gas Selection For Aluminium Welding with Aluminium Wire Use only pure when welding Aluminium INSTALL THE SHIELDING GAS WARNING IMPROPER HANDLING AND MAINTE NANCE OF COMPRESSED GAS CYLIN DERS AND REGULATORS CAN RESULT IN SERIOUS INJURY OR DEATH Always secure gas cylinders to the welding cart a wall or other fixed support to prevent the cylinder from falling over and rupturing Read understand and follow all the COM PRESSED GASSES AND EQUIPMENT HAZ ARDS in the SAFETY SUMMARY at the front of this manual Secure your gas cylinder to the welding cart or other fixed support 1 Remove the protective cap from the cylinder and inspect the regulator connecting threads for dust dirt oil and grease Remove any dust or dirt with a clean cloth DO NOT YOUR REGULATOR IF OIL GREASE OR DAMAGE ARE PRESENT 2 Open the cylinder valve FOR JUST AN INSTANT to blow out any foreig
5. welder Do not modify any wiring ground connections switches or fuses in this welding equipment e Wear welding gloves to help insulate hands from welding circuit Keep all liquid containers far enough away from the welder and work area so that if spilled the liquid can not possibly come in contact with any part of the welder or electrical welding circuit e Replace any cracked or damaged parts that are insulated or act as insulators such as welding cables power cord or electrode holder IMMEDIATELY FLASH HAZARDS WARNING ARC RAYS CAN INJURE EYES AND BURN SKIN To reduce the risk of injury from arc rays read understand and follow the fol lowing safety instructions In addition make certain that anyone else that uses this weld ing equipment or is a bystander in the welding area understands and follows these safety instructions as well Headshields and filter should conform to ANSI Z87 1 stan dards e Do not look at an electric arc without proper protection A welding arc is extremely bright and intense and with inadequate or no eye protection the retina can be burned leaving a perma nent dark spot in the field of vision A shield or helmet with a number 10 shade filter lens minimum must be used Do not strike a welding arc until all bystanders and you the welder have 5 welding shields and or helmets in place e Do not wear a cracked or broken helmet and replace any cracked or bro ken filte
6. 11 Assembling the Welder 11 Unpacking the Welder 11 Packing LAST NE 11 Assemble the Face Shield 11 Installing the Handle 12 Selecting Shielding Gas 12 Install the Shielding Gas 13 Check the Gas Flow 13 Align and Set the Drive Roller 13 Install the Welding Wire 14 Set the Wire Drive Tension 16 Installing Aluminium Wire 16 Change Polarity rrt ers 16 Operallon eoe re ERES I 17 Controls and Indicators 17 Power Switch 17 Voltage Selector 17 Wire Speed Control 17 Tuning in the Wire Speed 17 Learning to Weld 18 Holding the Gun 18 Welding Techniques 19 Moving the Gun 19 Types of Weld Beads 20 Welding Positions 20 Multiple Pass Welding 21 Special Welding Methods 22 Spot Welding werten 22 Maintenance 23 General sarao 23
7. 6 LISTEN As you decrease the wire speed the sound that the arc makes will change from a sputtering to a high pitched buzzing sound and then will begin sput tering again if you decrease the wire speed too much The wire speed that creates a smooth high pitched buzzing sound will achieve the best quality weld You can use the wire speed control to slightly increase or decrease the heat and penetration for a given heat setting by selecting hugher or lower wire speed settings Repeat this tune in procedure if you select a new heat setting a different diameter wire or a different type of welding wire LEARNING TO WELD MIG Metal Inert Gas welding is the process of uniting metallic parts by heating and allowing the metals to flow together through the use of an electrical arc The electrical arc is created between a continuous consum able wire electrode the welding wire and the work piece An shielding gas is used to protect the weld puddle from con 18 tamination and enhance the welding capa bilities of the electrical arc Whether you have welded before or not it is important that you become familiar with your new welder its controls and the results achieved at different settings We strongly recommend that you practice with your new welder on scrap metal trying different heat settings base metal thicknesses and weld ing positions for each type and size of wire you will be using By doing this you will gain
8. Consumable Maintenance 23 Maintaining the Contact 23 Maintaining the Nozzle 24 Testing for a Shorted Nozzle 24 Replace a Gun Liner 24 Preventive Maintenance 26 Troubleshooting 26 Wiring Diagram 28 29 Suggested Settings 33 SAFETY SUMMARY The warnings cautions and instructions dis cussed in this instruction manual can not cover all possible conditions or situations that could occur lt must be understood by the operator that common sense and caution are factors which can not be built into this product but must be supplied by the operator Reading this operator s manual before using the welder will enable you to do a better safer job Learn the welder s applications and limitations as well as the specific potential hazards peculiar to welding IMPORTANT SAFETY INFORMATION The following safety information is provided as guidelines to help you operate your new welder under the safest possible conditions Any equipment that uses electrical power can be potentially dangerous to use when safety or safe handling instructions are not known or not followed The following safety information is provided to give the user the information necessary for safe use and o
9. Standard 29 CFR Part 1910 Subpart Q WELDING CUTTING AND BRAZING obtainable from your state OSHA office or U S Dept of Labor OSHA Office of Public Affairs Room N3647 200 Constitution Ave Washington DC 20210 www osha gov CSA Standard W117 2 Code for SAFETY IN WELDING AND CUTTING obtainable from Canadian Standards Association 178 Rexdale Blvd Etobicoke Ontario M9W 1R3 WWW CSQ ca American Welding Society Standard A6 0 WELDING AND CUTTING CON TAINERS WHICH HAVE HELD COM BUSTIBLES obtainable from the American Welding Society 550 NW Le Jeune Road Miami FL 33126 Telephone 800 443 9353 Fax 305 443 7559 www amweld org or WWW AWS Org WELDER SPECIFICATIONS DESCRIPTION Your new MIG GMAW flux core FCAW wire feed welder is designed for mainte nance and sheet metal fabrication The welder consists of a single phase power transformer stabilizer rectifier and unique built in control feeder Now you can weld sheet metal from 24 gauge up to 1 4 inch thick with a single pass You can weld thicker steel with ing and multiple pass techniques Table 1 lists your MIG welder specifications Table 1 Welder Specifications Primary input Volts 230 VAC Primary input Amps 22 5 Phase Single Frequency 60Hz Secondary output volts 20 CSA rated output amps 120 Open Circuit Volts Max 30 VDC Duty Cycle Rating 25 MIG welders equipped with gas are capable of welding
10. Tighten gun or replace gun 7 Change to proper polarity 8 Replace spool of wire 1 Adjust drive tension See INSTALL THE WELDING WIRE 2 Replace gun liner 3 Replace contact tip 4 Trim liner to proper length Replace gun liner Trim liner to proper length Use correct size contact tip Replace contact tip Increase wire feed speed Ground clamp and or ground Bad connection from cable to clamp Tighten connection or replace cable gets hot Gun nozzle arcs to work surface Zle is shorted Slag building inside nozzle or noz Clean or replace nozzle as needed 27 WIRE FEED WELDER WIRING DIAGRAM IE d XL GAS NO GAS CHANGE K gt 21 4Vac 35 7Vac lt 7 1 2 THERMOSTAT THERMOSTATE THERMOSTAT TERMOSTATOS TERMOSTATI WIRE FEEDING DRAHTVORSCHUB MOTEUR EQUIPO MOTORE MOTOR MOTOR D ENTRAINEMENT DU FIL ARRASTRA HILO TRAINA FILO 1 FAN VENTILATOR VENTILATEUR VENTILADOR VENTILATORE N1 P C BOARD ELEKTRONIK PLATTE FICHE ELECTRONIQUE CIRCUITO ELECTRONICO SCHEDA ELETTRONICA RECTIFIER GLEICHRICHTER REDRESSEUR RECTIFICADOR PONTE RADDRIZZATORE INTERRUPTOR S1 ON OFF ON OFF ON OFF Nor ON OFF 52 53 SWITCH UMSCHALTER COMMUTATEUR CONMUTADOR COMMUTATORE BRENNER BOUTON PULSADOR DE LA PULSANTE 54 TORCH TRIGGER SCHALTER TORCHE ANTORCHA TORCIA 1 TRANSFORMER TRANSFORMATOR TRANSFORMATEUR TRANSFORMADOR TRASFORMATORE XL CHOKE IMPEDANZ I
11. a feel for how changes in these welding variables affect the weld Of course if you have not welded before you will need to develop welding skills and techniques as well The self taught welder learns through a process of trial and error The best way to teach yourself how to weld is with short peri ods of practice at regular intervals All prac tice welds should be done on scrap metal that can be discarded Do not attempt to make any repairs on valuable equipment until you have satisfied yourself that your practice welds are of good appearance and free of slag or gas inclusions What you fail to learn through practice will be learned through mistakes and re welds later on HOLDING THE GUN The best way to hold the welding gun is the way that feels most comfortable to you While practicing to use your new welder experiment holding the gun in different positions until you find the one that seems to work best for you Refer to WELDING POSI TIONS p 20 Position the Gun to the Work Piece There are two angles of the gun nozzle in relation to the work piece that must be con sidered when welding 1 Angle A Figure 10 can be varied but in most cases the optimum angle will be 60 degrees The point at which the gun handle is parallel to the work piece If angle A is increased penetration will increase angle A is decreased tration will decrease also 60 UII Angle Figure 10 Gun Position
12. any conductive material in contact with it b the ground clamp c the electrode or welding wire d any metal parts on the electrode holder or wire feed gun Do not weld in a damp area or come in contact with a moist or wet surface e Do not attempt to weld if any part of clothing or body is wet Do not allow the welding equipment to come in contact with water or moisture e Do not drag welding cables wire feed gun or welder power cord through or allow them to come into contact with water or moisture Do not touch welder attempt to turn welder on or off if any part of the body or clothing is moist or if you are in phys ical contact with water or moisture e Do not attempt to plug the welder into the power source if any part of body or clothing is moist or if you are in physical contact with water or moisture Do not connect welder work piece clamp to or weld on electrical conduit e Do not alter power cord or power cord plug in any way Do not attempt to plug the welder 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 to the power source or attempt to weld if the welder welding cables welding site or welder power cord are exposed to any form of atmospheric precipitation or salt water spray Do not carry coiled welding cables around shoulders or any other part of the body when they are plugged into the
13. connection inside machine 2 Too long improper extension cord 3 Wrong type or size wire 4 Poor ground connection 5 Wrong size contact tip 6 Loose gun connection or faulty gun assembly 7 Wrong welding polarity set 8 Dirty rusty welding wire Wire is jamming or birdnesting at 1 Too much tension on drive roller 2 Gun liner worn damaged 3 Contact tip is clogged or dam aged the drive roller 4 Liner stretched or is too long 1 Gun liner worn or damaged 2 Liner stretched or is too long 3 Wrong size contact tip Wire burns back to contact tip 4 Contact tip is clogged or dam aged 5 Wire feed speed is too slow POSSIBLE REMEDY 1 Clean or replace nozzle 2 Tank empty flow restricted or regulator set too low 3 See SELECTING SHIELDING gas section of manual 4 Replace spool of wire 1 Check ground and connections Tighten as necessary 2 Check connection to gun or replace gun 1 Replace wire speed control assembly 2 Adjust the drive tension 3 Replace drive motor 1 Replace gun trigger 2 Let welder cool at least 10 min utes observe and maintain proper duty cycle 3 Replace transformer 1 Blow inside of machine out with compressed air Clean and tighten all connections 2 See EXTENSION CORDS sec tion of manual 3 Use correct size wire 4 Reposition clamp and check cable to clamp connection 5 Use correct size contact tip 6
14. from the end of the weld ing gun If your regulator has no adjustment it has been preset at the factory for a flow of 20 cubic feet per hour If your gas regulator has an adjustment to control the gas flow rate turn the adjustment key clockwise to increase gas flow counterclockwise to reduce flow For most welding the gas flow should be set at 15 20 cubic feet per hour If no gas is heard or felt verify all steps involved in connecting the gas 3 Release the trigger Note If welding outside or in a draft it may become necessary to set up a wind break to keep the shielding gas from being blown from the weld area MAKE SURE TO TURN OFF THE GAS CYLINDER VALVE WHEN DONE WELD ING ALIGN AND SET THE DRIVE ROLLER Before installing any welding wire into the unit the proper sized groove must be placed into position on the wire drive mechanism Tension Adjustment Knob Figure 4 Feed Motor 13 Change the drive roller according to the follow Ing steps 1 Open the door to the welder drive com partment 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 already installed in welder roll it back onto the wire spool hand turning the spool counterclockwise Be careful not to allow the wire to come out of the rear end of the inlet guide tube without h
15. gun assembly 17 When at least an inch of wire sticks out past the end of the gun release the trigger 18 Select a contact tip stamped with the same diameter as the wire being used If stamped in metric see DESCRIPTION Note Due to inherent variances in flux cored welding wire it may be necessary to use a contact tip one size larger than your flux core wire if wire jams occur 19 Slide the contact tip over the wire pro truding from the end of the gun Thread the contact tip into the end of the gun and hand tighten securely 20 Install the nozzle on the gun assembly For best results coat the inside of the nozzle with anti stick spray or gel 21 Cut off the excess wire that extends past the end of the nozzle SET THE WIRE DRIVE TENSION y WARNING To reduce the risk of arc flash make certain that the wire coming out of the end of the gun does not come in contact with work piece ground clamp or any grounded mate rial during the drive tension setting process or arcing will occur 1 Pull the trigger on the gun 2 Turn the drive tension adjustment knob clockwise increasing the drive tension until the wire seems to feed smoothly without slipping When set correctly there should be no slip page between the wire and the drive roller under normal conditions If an obstruction occurs along the wire feed path the wire should then slip on the drive roller After the tension is properly adjusted the quick
16. it becomes free of the gun liner and remove wire from gun assembly Lay gun cable and gun handle straight out in front of unit Remove gun liner holding clamp by removing the three screws Take gun handle halves apart by remov ing five phillips head screws Remove gas hose from fast coupler fit ting on Gas Valve Depress lip on fast coupler fitting back towards fitting and pull gas hose out 9 Remove Fast Coupler Fitting from Gas Valve using a 9 millimeter wrench 10 Firmly hold the brass fitting on the end A n Drive Drive Gun Gun Tension Adjustment Arm Tension Liner Assembly Holding Tail End Inlet Guide Drive Gun Relief Tube Roller Liner Clamp Figure 22 Drive Assembly of the gun liner with a wrench and rotate Gas Valve counterclockwise to unscrew fitting Note Rotate Gas Valve Do not rotate brass fitting or gun liner twist inside gun cable and may cause damage to gun cable 11 The Live Wire Terminal is held in place on the Gas Valve by the brass fitting on the end of the gun liner When the brass fitting is removed slide the Live Wire Terminal off of the brass fitting 12 Firmly grip the gun cable and pull the gun liner all the way out 13 Install the new gun liner into gun cable starting from the end where the welding gun will be mounted and feeding the liner all the way through the gun cable to the wire feed roller Note It may be helpful to apply a small amount of liqui
17. symbol indicates that the pos sibility of being burned by hot slag exists during operation of the step s that follow This symbol indicates that the eye protection should be worn to pro tect against flying debris in the fol lowing step s This symbol indicates that the pos sibility of injury or death exists due to improper handling and mainte nance of compresses gas cylinders or regulators Published standards on safety are avail able They are listed in ADDITIONAL SAFETY INFORMATION at the end of this SAFETY SUMMARY The National Electrical Code Occupation Safety and Health Act regulations local industrial codes and local inspection requirements also provide a basis for equip ment installation use and service SHOCK HAZARD WARNING NE ELECTRIC SHOCK CAN KILL To reduce the risk of death or serious injury from shock read understand and follow the following safety instructions In addition make certain that anyone else who uses this welding equipment or who is a bystander in the welding area understands and follows these safety instructions as well IMPORTANT TO REDUCE THE RISK OF DEATH INJURY OR PROPERTY DAM AGE DO NOT ATTEMPT OPERATION of this welding equipment until you have read and understand the following safe ty summary Do not in any manner come into physi cal contact with any part of the welding current circuit The welding current cir cuit includes a the work piece or
18. 2 9005 LOWER PANEL PRT 21690226 PRT 05000180 PRT 04600114 PRT 21905041 PRT 21905007 PRT 21905039 PRT 04600361 DOOR LATCH SIDE DOOR W LABEL KIT GAS NO GAS CHANGE BOARD FACE SHIELD 50 105 75 98 DARK GLASS 75X98 DIN 11 WIRE BRUSH HAMMER SCREWS SET FOR HANDLE AND CABINET 29 SE AM INS INS _ D US P C RE an LI Ww Eh f 81 30 WIRE FEED WELDER GUN PARTS LIST PRT 04600163 PRT 23005332 PRT 23005145 PRT 23005091 PRT 23005285 PRT 23005146 PRT 23005018 PRT 23005019 PRT 23005020 PRT 23005147 PRT 21200010 PRT 33800032 PRT 30900021 PRT 23005254 PRT 30900002 PRT 22910001 PRT 22910001 PRT 30900020 PRT 04600063 PRT 23005148 PRT 23005318 HANDLE ASSY BLUE GAS VALVE SWAN NECK WITH INSULATING COVER SWAN NECK LINER ISOLATING COVER FOR TW1 TORCH DIFFUSER 0 023 CONTACT TIP 0 030 CONTACT TIP 0 040 CONTACT TIP TORCH GAS NOZZLE FAST ON CONTACT 6 3 0 8 TORCH CONTACT SPRING RUBBER OUTER SLEEVE 817 5 HOSES STEEL LINER 1 4XABLUE 2 2M W END FITTING PLASTIC LINER 1 5X4 2 5M FAST CONNECTION FOR HOSE 04 M6X0 75 PLASTIC LINER END FITTING 24 M6X0 75 TORCH GAS HOSE g2X4 4 6M KIT 2 PINS MALE CONNECTOR 2 CONTACTS NECK OUTER INSULATION DIFFUSER ALUMINIUM GAS VALVE NECK DIFFUSER 31 32 SUGGESTED SETTINGS GE 09 182
19. Angle A 2 Angle B Figure 11 can be varied for two reasons to improve the ability to see the arc in relation to the weld puddle and to direct the force of the arc 30 S INNAN Angle B Figure 11 Gun Position Angle B The force of the welding arc follows a straight line out of the end of the nozzle If angle B is changed so will the direction of arc force and the point at which penetration will be concentrated On a butt weld joint the only reason to vary angle B from perpendicular straight up to the work piece would be to improve visibili ty of the weld puddle In this case angle B can be varied anywhere from zero to 45 degrees with 30 degrees working about the best On a fillet weld joint the nozzle is generally positioned in such a manner so as to split the angle between the horizontal and verti cal members of the weld joint In most cases a fillet weld will be 45 degrees Distance from the Work Piece The end of the welding gun is designed with the contact tip recessed from the end of the nozzle and the nozzle electrically insulated from the rest of the gun This permits the operator to actually rest the nozzle on the 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
20. E WARNING AZ Electric shock can kill Always turn the POWER switch OFF and unplug the power cord from the ac power source before installing wire 1 Remove the nozzle and contact tip from the end of the gun assembly 2 Make sure the proper groove on the drive roller is in place for the wire being installed If the proper groove is not in place change the drive roller as described above 3 Unwrap the spool of wire and then find the leading end of the wire it goes through a hole in the outer edge of the spool and is bent over the spool edge to prevent the wire from unspooling BUT DO NOT UNHOOK IT YET 4 Place the spool on the spindle in such a manner that when the wire comes off the spool it will look like the top illustration in Figure 7 The welding wire should always come off the top of the spool into the drive mechanism 5 If you are installing a four inch spool of wire install the drive brake hardware on the top of the spool of wire according to Wrong Way Figure 7 Wire Installation figure 8A If you are installing an eight inch spool install the spindle adapter and drive brake hardware as shown in Figure 8B The purpose of the drive brake is to cause the spool of wire to stop turning at nearly the same moment that wire feeding stops Y Y gt T lt gt o MM Figure 8A Drive rov 8B Spindle Brake Hardware Adapter and Drive Installation Brake Installation 6 Once the drive b
21. ER REQUIREMENTS This welder is designed to operate on a proper ly grounded 230 volt 60Hz single phase alter nating current AC power source fused with a 50 amp time delayed fuse or circuit breaker It 15 recommended that a qualified electrician ver ify the ACTUAL VOLTAGE at the receptacle into which the welder will be plugged and confirm that the receptacle 15 properly fused and grounded The use of the proper circuit size can eliminate nuisance circuit breaker tripping when welding DO NOT OPERATE THIS WELDER if the ACTUAL power source voltage is less than 198 volts AC or greater than 240 volts AC Contact a qualified electrician if this problem exists Improper performance and or damage to the welder will result if operated on inadequate or excessive power CONNECT TO POWER SOURCE WARNING AZ High voltage danger from power source Consult a qualified electrician for proper instal lation of receptacle at the power source This welder must be grounded while in use to protect the operator from electrical shock If you are not sure if your outlet is properly grounded have it checked by a qualified electrician Do not cut off the grounding prong or alter the plug in any way and do not use any adapters between the welder s power cord and the power source receptacle Make sure the POWER switch is OFF then connect your welder s power cord to a properly grounded 230 VAC 60 Hz single phase 50 amp power source EXTENSIO
22. MPEDANCE IMPEDANCIA IMPEDENZA 28 22710076 PRT 04600146 PRT 21600035 22210014 PRT 04600286 PRT 21605036 PRT 21690425 PRT 21690422 PRT 22200038 PRT 04600337 PRT 22200035 PRT 04600002 PRT 21910048 PRT 21910050 PRT 05000182 PRT 44400019 PRT 33805074 PRT 21690424 20220120 PRT 05000177 PRT 05000181 PRT 04600257 22205143 PRT 44135018 22400038 PRT 44120178 22210016 PRT 05000184 PRT 23000124 PRT 04600234 PRT 21690442 PRT 21690443 43210161 22110007 PRT 21690426 WIRE FEED WELDER PARTS LIST E1292 P C BOARD CSA JOHNSON MOTOR 237 PINION HANDLE THERMOSTAT 100 10 FAN amp FAN MOTOR ASSY CABLE CLAMP W NUT PLASTIC TRIM TORCH GROMMET VOLTAGE SELECTOR SWITCH BLACK POTENTIOMETER KNOB 038 YELLOW POWER SWITCH 16A 250V COMPLETE SPOOL HOLDER 023 0 6 1 2LB 0 225KG SOLID CORE WIRE SPOOL 030 0 8MM 1 2LB 0 225KG FLUX CORE WIRE SPOOL DIVIDING PANEL W LABELS PLASTIC WIRE FEEDER 037 FEED ROLL g7X25 0 6 0 8 ACCESS PANEL SUPPORTS PINS POWER CORD 3XAWG12 8 2 5M W 50A PLUG FRONT PANEL UPPER PANEL W LABELS BLACK SWITCH KNOB 038 SWITCH 16A CHOKE 40X40 AL RECTIFIER PMS 8 4 1F TRANSFORMER 220V 60HZ 40X85 AL 127 16A THERMOSTAT REAR PANEL W LABELS 0 8 TORCH 10MM 7 3 2 2M G NG CABLE CLAMP 010 SCREW FRONT TRIM WITH LOUVER 0 36 EARTH CABLE 10 2 6 1 2 2M CL 200 0 8 EARTH CLAMP 200A BACK FRAME 220V PRT 3370024
23. N CORDS For optimum welder performance an exten sion cord should not be used unless absolutely necessary necessary care must be taken selecting an extension cord appropriate for use with your specific welder Select a properly grounded extension cord that will mate directly with the power source recep tacle and the welder power cord without the use of adapters Make certain that the exten sion is properly wired and good electrical condition Extension cords must be a 12 gauge cord at the smallest Do not use an extension cord over 25 ft in length ASSEMBLING THE WELDER The following procedures describe the process required to assemble install maintain and pre pare to weld with your new wire feed welder UNPACKING THE WELDER 1 Remove any cartons or bags containing parts accessories Most parts shipped INSIDE the welder door 2 Open the cartons or bags packed with your welder and inspect their contents for damage 3 Layout the parts and compare them to the the packing list in Table 3 to familiarize your self with the parts and what they are called This will help you when reading the manual PACKING LIST Table 3 contains a list of the items you will find packed in the carton Table 3 Packing List ITEM Welder Face Shield Face Shield Handle Face Shield Handle Cover Face Shield Retaining Clips Shaded Lens Welder Handle Wire Brush Hammer Parts Bag Handle Screws Contact
24. Tip 023 030 040 1 ea Nozzle 1 lt RQ gt gt NJ ml Wire 030 Flux Core 1 2 lb Wire 023 Solid Core 1 2 lb Manual Instruction 1 A THE FACE SHIELD Insert the upper tongue of the handle into the upper slot on the face shield 2 Align the second tab on the handle with the second slot in the face shield by push ing the bottom of the handle in towards the face mask while at the same time pushing upwards Alignment of the sec ond tab is made easier by applying pres sure to the point shown below 11 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 remove the extra material from the face shield to allow a larger field of vision when welding To remove the extra material remove the glass from the face shield and carefully cut the material out of the face shield with a utility knife 5 Once protective dark glass has been installed into face shield secure it in place with the retaining clips Align the holes on each of the retaining clips with the pins on the retaining tabs and firmly press into place Cover Retaining Clip Figure 2 Face Shield Assembly INSTALLING THE HANDLE 1 Insert
25. and should not exceed 1 4 inch or the arc may begin sputtering signaling a loss in welding per ormance WELDING TECHNIQUES y WARNING EXPOSURE TO A WELDING ARC IS EXTREMELY HARMFUL TO THE EYES AND SKIN Prolonged exposure to the welding arc can cause blindness and burns Never strike an arc or begin welding until you are adequately protected Wear flameproof welding gloves a heavy long sleeved shirt cuffless trousers high topped shoes and welding helmet WARNING AZ ELECTRIC SHOCK CAN KILL To prevent ELECTRIC SHOCK do not perform any weld ing while standing kneeling or lying direct ly on the grounded work MOVING THE GUN Gun travel refers to the movement of the gun along the weld joint and is broken into two elements Direction and Speed A solid weld bead requires that the welding gun be moved steadily and at the right speed along the weld joint Moving the gun too fast too slow or erratically will prevent proper fusion or create a lumpy uneven bead 1 TRAVEL DIRECTION 15 the direction the gun is moved along the weld joint in rela tion to the weld puddle The gun 15 either PUSHED see Figure 12 into the weld puddle or PULLED away from the weld puddle 19 Weld Puddle PUSH PULL Figure 12 Travel Direction For most welding jobs you will pull the gun along the weld joint to take advantage of the greater weld puddle visibility 2 TRAVEL SPEED 15 the rate at which the gun is b
26. andle Casing Switch Contact Wire Switch Contact Wire Gun Cable Figure 23 Gun Assembly 20 PREVENTIVE MAINTENANCE Except for internal and external cleaning cleaning the nozzle occasionally retightening screws there is no periodic maintenance recommended for your welder TROUBLESHOOTING The following TROUBLESHOOTING infor mation is provided as a guide to help resolve some of the more common problems that could be encountered Table 5 is a troubleshooting table provided to help you determine a possible remedy when you are having a problem with your welder This table does not provide all possi ble solutions only those possibilities consid ered to likely be common faults The table consists of a TROUBLE or symptom a POS SIBLE CAUSE for the symptom and a POSSI BLE REMEDY for that symptom 26 TABLE 5 TROUBLESHOOTING TROUBLE POSSIBLE CAUSE 1 Plugged welding nozzle 2 No shielding gas Dirty porous brittle weld 3 Wrong type of gas 4 Dirty or rusty welding wire Wire feed works but no arc 1 Bad ground or loose connection 2 Bad connection to gun or faulty gun 1 Faulty wire speed control assembly 2 No tension on drive roller 3 Faulty drive motor RARE Arc works but no feeding wire 1 Faulty trigger on gun 2 Exceeded duty cycle thermal protector opened Nothing works except fan 3 Faulty transformer RARE Low output or nonpenetrating weld 1 Loose
27. assing through it The more worn this hole becomes the less efficient is the transfer of welding current to the wire and even tually arc breakage and difficult arc starting will result Replace contact tips when signs of wear become apparent MAINTAINING THE NOZZLE The nozzle directs the shielding gas to the weld puddle determines the size of the shielding area and prevents the electrically hot contact tip from contacting the work piece CAUTION KEEP THE NOZZLE CLEAN During the welding process spatter and slag will build up inside the nozzle and must be cleaned out periodically Failure to clean and or replace the nozzle in a timely fashion WILL CAUSE DAMAGE TO THE FRONT END OF THE GUN ASSEMBLY For best results coat the inside of a new or freshly cleaned nozzle with anti stick spray or gel 1 Stop welding and clean any accumulated slag or spatter from the nozzle every 5 to 10 minutes of welding time 2 When welding overhead if any molten metal drips from the weld puddle and falls into the nozzle STOP WELDING IMMEDIATELY and clean the nozzle 3 If the slag cannot be thoroughly cleaned from the nozzle REPLACE THE NOZZLE Failure to keep the nozzle adequately cleaned can result in the following problems A SHORTED nozzle results when spatter buildup bridges the insulation in the nozzle allowing welding current to flow through it as well as the contact tip When shorted a nozzle will steal welding current from
28. d pieces of metal together by burning through the top piece and into the bottom piece With the burn through method larger wire diameters tend to work better than smaller diameters because they have greater current carrying capabilities allowing the arc to burn through very quickly while leaving a minimal amount of filler metal build up Wire diame ters that tend to work best with the burn through method are 0 030 inch diameter solid wire or 0 035 inch self shielding flux corewire Do not use 0 023 inch diameter solid or 0 030 inch self shielding flux core wires when using the burn through method unless the metal is VERY thin or excessive filler metal build up and minimal penetra tion is acceptable Always select the HIGH heat setting with the burn through method and tune in the wire speed prior to making a spot weld 2 The PUNCH AND FILL METHOD produces a weld with the most finished appearance of the three spot weld methods In this method a hole is punched or drilled into the top piece of metal and the arc is directed through the hole to penetrate into the bottom piece The puddle 15 allowed to fill up the hole leaving a spot weld that is smooth and flush with the surface of the top piece Select the wire diameter heat setting and tune in the wire speed as if you were weld ing the same thickness material with a con tinuous bead 3 The LAP SPOT METHOD directs the weld ing arc to penetrate the bottom and top p
29. d soap to the end of the gun liner to decrease resistance during installation process 14 Slide the eyelet of the Live Wire Terminal onto the threaded end of the gun liner brass fitting 15 Firmly hold the brass fitting on the end of the gun liner with a wrench and rotate Gas Valve clockwise to screw it onto fit ting Note Rotate Gas Valve Do not rotate brass fitting or gun liner will twist inside gun cable and may cause damage to gun cable 16 Return all components to the handle cas ing and realign them as they were origi nally 17 With both halves of the handle case in place tighten the five phillips head screws 18 Using wire cutters trim the new gun liner to approximately 3 16 inch beyond the edge of the Cable Holding Clamp The goal is to make sure that the end of the gun liner will be as close to the drive roller as possible after the Cable Holding Clamp 15 assembled This will make installing the welding wire much easier 19 Reinstall liner holding clamp at feeder 20 Reinstall the welding wire according to specifications in INSTALL THE WELDING WIRE section 21 Close side panel 22 Plug welder into power supply and turn POWER SWITCH to ON position Nozzle 5 Contact NT Gas Diffuser Up N Conductor Tube Conductor Tube Insulation Coupler Fitting Switch Contacts Trigger 1 Gas Valve i Live Wire Fast Terminal v Gas Hose Liner H
30. e metal you are welding If the ground clamp is not connected to the metal work piece you intend to weld the welder will not have a completed circuit and you will be unable to weld poor connec tion at the ground clamp will waste power and heat Scrape away dirt rust scale oil or paint before attaching the ground clamp Ground Cable The ground cable connects the ground clamp to the internal workings of the welder Welding Gun and Cable The welding gun controls the delivery of the welding wire to the material to be welded The welding wire 15 fed through the welding cable and welding gun when the welding gun trigger is pulled You will need to install a contact tip and welding nozzle to the end of the welding gun as described later in this manual prior to welding Welding Terms Now that you are familiar with the main parts of the welder make note of the follow ing terms You will see them used through out this manual weld puddle The localized volume of molten metal in a weld prior to its solidification weld angle The angle of the welding wire as it extends from the welding gun in rela tion to the item being welded slag The protective coating that forms on the surface of molten metal arc A sustained luminous discharge of elec tricity across a gap in a circuit welding bead The extended build up of a weld made by pushing or pulling the weld puddle WELDER INSTALLATION POWER SOURCE CONNECTION POW
31. e possible with a stringer bead is made by weaving from side to side while moving with the gun It is best to hesitate momentarily at each side before weaving back the other way Figure 14 Weave Bead WELDING POSITIONS There are four basic welding positions flat horizontal vertical and overhead 1 The FLAT POSITION Figure 15 is the easiest of the welding positions and is most commonly used It is best if you can weld the flat position if at all possible as good results are easier to achieve UV y lt pote Figure 15 Flat Position 2 The HORIZONTAL POSITION Figure 16 is next in difficulty level It is performed very much the same as the flat weld except that angle B see HOLDING THE GUN p 18 is such that the wire and therefore the arc force is directed more toward the metal above the weld joint This is to help prevent the weld puddle from running downward while still allowing slow enough travel speed to achieve good penetration A good start ing point for angle B is about 30 degrees DOWN from being perpendicular to the work piece Figure 16 Horizontal Position 3 The VERTICAL POSITION Figure 17 is the next most difficult position Pulling the gun from top to bottom may be easier for many people but in some instances it can be difficult to prevent the puddle from run ning downward Pushing the gun from bot tom to top may provide better puddle con trol and allow slower rates
32. eing pushed or pulled along the weld joint For a fixed heat setting the faster the travel speed the lower the pen etration and the lower and narrower the finished weld bead Likewise the slower the travel speed the deeper the penetra tion and the higher and wider the fin ished weld bead TYPES OF WELD BEADS The following paragraphs discuss the most commonly used welding beads Once you have the gun in position with the wire lined up on the weld joint lower your helmet pull the trigger and the arc will start In a second or two you will notice a weld puddle form and the base of the bead beginning to build It is now time to begin to move with the gun If you are just learning to weld simply move the gun in a straight line and at a steady speed along the weld joint Try to achieve a weld with the desired penetration and a bead that is fairly flat and consistent in width As you become more familiar with your new welder and better at laying some simple weld beads you can begin to try some dif ferent weld bead types There are two basic types of weld beads the stringer bead and the weave bead 1 The STRINGER BEAD Figure 13 is formed by traveling with the gun in a straight line while keeping the wire and nozzle centered over the weld joint This is the easiest type of bead to make 20 Figure 13 Stringer Bead 2 The WEAVE BEAD Figure 14 is used when you want to deposit metal over a wider space than would b
33. happen the wire could feed inside the cable casing or take a right angle and follow the wires and gas hose inside the welder It could also feed back on itself jamming up the mechanism 11 Line the wire up in the inside groove of the drive roller then allow the drive ten sion arm to drop onto the drive roller 12 Flip the quick release drive tensioner back up into position on the drive tensioner arm 13 Tighten turn clockwise the drive tension adjusting screw until the tension roller is applying enough force on the wire to prevent it from slipping out of the drive assembly 14 Let go of the wire 15 Connect the welder power cord to the ac power source Turn the welder ON by set ting the VOLTAGE switch to the voltage heat setting recommended for the gauge metal that is to be welded Refer to the label mounted on the cover inside the drive compartment for recommended volt age heat settings for your welding job The VOLTAGE selector controls the weld heat There are six voltage heat selections available on this welder Placing the volt age switch in MIN position and the voltage dial in position 1 provides the lowest volt age heat Placing the voltage switch in MAX position and the voltage dial in posi tion 3 provides the highest voltage heat 15 16 Set the WIRE SPEED control to the middle of the wire speed range 16 Straighten the gun cable and pull the trigger on the welding gun to feed the wire through the
34. ieces at the same time right along each side of the lap joint seam Select the wire diameter heat setting and tune in the wire speed as if you were weld ing the same thickness material with a con tinuous bead SPOT WELDING INSTRUCTIONS 1 Select the wire diameter and heat setting recommended above for the method of spot welding you intend to use 2 Tune in the wire speed as if you were going to make a continuous weld 3 Hold the nozzle piece completely perpen dicular to and about 1 4 inch off the work piece 4 Pull the trigger on the gun and release it when it appears that the desired penetra tion has been achieved 5 Make practice spot welds on scrap metal varying the length of time you hold the trigger until a desired spot weld is made 6 Make spot welds on the actual work piece at desired locations MAINTENANCE GENERAL This welder has been engineered to give many years of trouble free service providing that a few very simple steps are taken to properly maintain it 1 Keep the wire drive compartment lid closed at all times unless the wire needs to be changed or the drive tension needs adjusting 2 Keep all consumables contact tips nozzles and gun liner clean and replace when nec essary See CONSUMABLE MAINTENANCE and TROUBLESHOOTING later in this sec tion for detailed information 3 Replace power cord ground cable ground clamp or gun assembly when damaged or worn 4 Periodically clean du
35. ld until disconnecting the battery that is attached to the chassis ground Failure to do so may result in elec tronic component damage Operation of this welder consists of selecting and adjusting operating controls for opti mum voltage welding heat and wire speed settings OPERATION Operation of this welder consists of selecting and adjusting operating controls for optimum 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 welder before per forming any maintenance VOLTAGE SELECTOR The voltage selector switch and dial control the welding heat The voltage selector switch is label MIN MAX referring to minimum and maximum voltage output The voltage selector dial is num bered 1 3 Number 1 15 the lowest heat and number 3 15 the highest Refer to the label under the welder hood or on page 33 of this manual for recommended heat settings for your welding job WIRE SPEED CONTROL The wire speed control adjusts the speed at which the wire is fed out of the welding gun The wire speed needs to be closely matched tuned in to the rate at which it is being melted off Some things that affect wire speed selection are the type and diameter of the wire being used the heat setting selected and the welding position to be used Note The wire will feed faster withou
36. me as a result of rough handling Do not weld or cut in an area where the air may contain flammable dust such as grain dust gas or liquid vapors such as gasoline Do not handle hot metal such as the work piece or electrode stubs with bare hands Wear leather gloves heavy long sleeve shirt cuffless trousers high topped shoes helmet and cap As necessary use additional protective clothing such as leather jacket or sleeves fire resistant leggings or apron Hot sparks or metal can lodge in rolled up sleeves trouser cuffs or pockets Sleeves and collars should be kept buttoned and pockets eliminated from the shirt front Have fire extinguisher equipment handy for immediate use A portable chemical fire extinguisher type ABC is recom mended Wear ear plugs when welding overhead to prevent spatter or slag from falling into ear e Make sure welding area has a good solid safe floor preferably concrete or not tiled carpeted or made of any other flammable material e Protect flammable walls ceilings and floors with heat resistant covers or shields e Check welding area to make sure it is free of sparks glowing metal or slag and flames before leaving the welding area FUME HAZARDS WARNING a FUMES GASSES VAPORS CAUSE DISCOMFORT ILLNESS AND DEATH To reduce the risk of discomfort ill ness or death read understand and follow the following safety instructio
37. n matter inside the valve port Never aim the open valve cylinder port at yourself or bystanders 3 Screw the regulator into the cylinder valve and tighten with a wrench 4 Firmly push the gas hose over barbed fit tings on back of welder and regulator 5 Secure both ends of hose onto barbed fit tings with hose clamps CHECK THE GAS FLOW edi WARNING IMPROPER HANDLING AND MAINTE NANCE OF COMPRESSED GAS CYLINDERS AND REGULATORS CAN RESULT IN SERI OUS INJURY OR DEATH To reduce the risk of injury or death always stand to the side of the cylinder opposite the regulator when opening the cylinder valve keeping the cylinder valve between you and the regulator Never aim the open cylinder valve port at yourself or bystanders Failure to comply with this warning could result in serious personal injury Note If the cylinder you have is equipped with male regulator connecting threads instead of female you will need to obtain a special com pressed gas cylinder adaptor from your gas supplier to install between your gas cylinder and regulator The gas control function does not require the welder to be turned on or plugged in avoid damage to your regulator make sure you have the regulator valve closed before opening the cylinder valve 1 Slowly crack open the cylinder valve then turn open ALL THE WAY 2 Pull the trigger on the gun to allow the gas to flow KEEP THE TRIGGER PULLED Listen and feel for gas flowing
38. n that anyone else that uses this welding equip ment or is a bystander in the welding area understands and follows these safety instructions as well REMEMBER Arc welding by nature produces sparks hot spatter molten metal drops hot slag and hot metal parts that can start fires burn skin and damage eyes 6 WARNING Do not wear gloves or other clothing that contains oil grease or other flammable substances Do not wear flammable hair prepara tions Do not weld an area until it is checked and cleared of combustible and or flam mable materials BE AWARE that sparks and slag can fly 35 feet and can pass through small cracks and openings If work and combustibles cannot be sepa rated by a minimum of 35 feet protect against ignition with suitable snug fit ting fire resistant covers or shields Do not weld on walls until checking for and removing combustibles touching the other side of the walls Do not weld cut or perform other such work on used barrels drums tanks or other containers that had contained a flammable or toxic substance The tech niques for removing flammable sub stance and vapors to make a used con tainer safe for welding or cutting are quite complex and require special edu cation and training Do not strike an arc on a compressed gas or air cylinder or other pressure ves sel Doing so will create a brittle area that can result in a violent rupture imme diately or at a later ti
39. ns In addition make certain that anyone else that uses this welding equipment or is a bystander in the welding area understands and follows these safety instructions as well e Do not weld in an area until it is checked for adequate ventilation as described in ANSI standard 249 1 If ventilation is not adequate to exchange all fumes and gasses generated during the welding process with fresh air do not weld unless you the welder and all bystanders are wearing air supplied respirators e Do not heat metals coated with or that contain materials that produce toxic fumes such as galvanized steel unless the coating is removed Make certain the area is well ventilated and the operator and all bystanders are wearing air sup plied respirators e Do not weld cut or heat lead zinc cad mium mercury beryllium or similar metals without seeking professional advice and inspection of the ventilation of the welding area These metals pro duce EXTREMELY TOXIC fumes which can cause discomfort illness and death e Do not weld or cut in areas that are near chlorinated solvents Vapors from chlori nated hydrocarbons such as trichloroethylene and perchloroethylene can be decomposed by the heat of an electric arc or its ultraviolet radiation These actions can cause PHOSGENE a HIGHLY TOXIC gas to form along with other lung and eye irritating gasses Do not weld or cut where these solvent vapors can be drawn into the work area
40. of metal that will have to be welded closed In most cases more than one pass or bead will need to be laid into the joint to close the V Laying more than one bead into the same weld joint is known as multiple pass weld 21 illustrations in Figure 19 show the sequence for laying multiple pass beads into a single butt joint NOTE WHEN USING SELF SHIELDING FLUX CORE WIRE it 15 very important to thor oughly chip and brush the slag off each com pleted weld bead before making another pass or the next pass will be of poor quality Figure 19 Butt Joints Fillet Weld Joints Most fillet weld joints on metals of moderate to heavy thickness will require multiple pass welds to produce a strong joint The illustrations in Figure 20 show the sequence of laying multiple pass beads into a T fillet joint and a lap fillet joint Lap Joint Welded In Three Passes TJointin _ Three Passes Figure 20 Fillet Weld Joints 22 SPECIAL WELDING METHODS SPOT WELDING The purpose of a spot weld is to join pieces of metal together with a spot of weld instead of a continuous weld bead There are three methods of spot welding Burn Through Punch and Fill and Lap see Figure 21 Each has advantages and disadvantages depending on the specific application as LAP SPOT PUNCH AND FILL BURN THROUGH Figure 21 Spot Welding well as personal preference 1 The BURN THROUGH METHOD welds two overlappe
41. of travel speed to achieve deeper penetration When vertical welding angle B see HOLDING THE GUN p 18 is usually always kept at zero but angle A will generally range from 45 to 60 degrees to provide better puddle control PPELEEEDERERRRED Figure 17 Vertical Position WARNING Hot slag can cause fires and serious injury from burns Be sure to wear protective cloth ing and eye gear when using the Overhead Position 4 The OVERHEAD POSITION Figure 18 is the most difficult welding position because gravity is pulling at the weld puddle trying to make it drip off the work piece Angle A see HOLDING THE GUN p 18 should be maintained at 60 degrees the same as in the flat position Maintaining this angle will reduce the chances of molten metal falling into the nozzle should it drip from the weld puddle Angle B should be held at zero degrees so that the wire is aiming directly into the weld joint If you experience exces sive dripping of the weld puddle select a lower heat setting Also the weave bead tends to work better than the stringer bead when welding overhead t lt 0 S Figure 18 Overhead Position MULTIPLE PASS WELDING Butt Weld Joints When butt welding thick er materials you will need to prepare the edges of the material to be joined by grind ing a bevel on the edge of one or both pieces of the metal being joined When this Is done V 15 created between the two pieces
42. olding onto it or it will unspool itself Put the end of the wire into the hole on the outside edge of the wire spool and bend it over to hold the wire in place Remove the spool of wire from the drive compartment of the welder 4 Rotate the Drive Roller Cap counterclock wise and remove it from the Drive Roller Drive lension Drive Adjustment Tension Knob Arm Inlet Rotate Guide Counterclockwise Tube Figure 5 Drive Roller Adjustments 5 Pull the Drive Roller off of the Drive Roller Shaft Note The drive roller has two wire size grooves built into it When installing the drive roller the number stamped on the drive roller for the wire size you are using should be facing you Use only the proper size drive roller when using your welder Table 4 indicates which drive roller groove should be used with each wire diameter size Wire Diameter Drive Roller Groove 023 inch 0 6 030 inch 0 8 035 inch 0 8 Table 4 Drive Roller Sizing 6 Find the side of the drive roller that is stamped with the same wire diameter as 14 that of the wire being installed see Figure 6 Push the drive roller onto the drive roller shaft with the side stamped with the desired wire diameter facing you Drive Roller 4727 7 6mm t Motor Shaft Figure 6 Drive Roller 7 Reinstall the Drive Roller Cap and lock in place by turning it clockwise 8 Close the door to the welder drive compart ment INSTALL THE WELDING WIR
43. or where the ultraviolet radiation can penetrate to areas containing even very small amounts of these vapors e Do not weld in a confined area unless it is being ventilated or the operator and anyone else in the area is wearing an air supplied respirator e Stop welding if you develop momentary eye nose or throat irritation as this indi cates inadequate ventilation Stop work and take necessary steps to improve ven tilation in the welding area Do not resume welding if physical discomfort persists COMPRESSED GASSES AND EQUIPMENT HAZARDS WARNING I IMPROPER HANDLING AND MAINTENANCE OF COMPRESSED GAS CYLINDERS AND REGULATORS CAN RESULT IN SERIOUS INJURY OR DEATH To reduce the risk of injury or death from compressed gasses and equipment hazards read understand and follow the following safety instructions In addition make certain that anyone else who uses this welding equipment or a bystander in the welding area understands and follows these safety instructions as well e Do not use flammable gasses with MIG welders Only inert or nonflammable gasses are suitable for MIG welding Examples are Carbon Dioxide Argon Helium etc or mixtures of more than one of these gasses Do not attempt to mix gasses or refill a cylinder yourself Do not expose cylin ders to excessive heat sparks slag and flame etc Cylinders exposed to temper atures above 130 F will require water spray cooling e Do not expose c
44. peration procedure step preceded a WARNING 15 an indication that the next step contains a pro cedure that might be injurious to a person if proper safety precautions are not heeded A procedure preceded by a CAUTION is an indication that the next step contains a pro cedure that might damage the equipment being used A NOTE may be used before or after a pro cedure step to highlight or explain some thing in that step READ ALL SAFETY INSTRUCTIONS CARE FULLY before attempting to install operate or service this welder Failure to comply with these instructions could result in personal injury and or property damage RETAIN THESE INSTRUCTIONS FOR FUTURE REFERENCE Note The following safety alert symbols identify important safety messages in this manual 4 When you see one of the symbols shown here be alert to the possibility of person al injury and carefully read the message that follows This symbol indicates that the pos sibility of electric shock hazard exists during the operation of the step s that follow This symbol indicates that the pos sibility of fire hazard exists during the operation of the step s that follow This symbol indicates that the hel met must be worn during the step s that follow to protect against eye damage and burns due to flash hazard This symbol indicates that the pos sibility of toxic gas hazard exists during operation of the step s that follow This
45. r lenses IMMEDIATELY e Do not allow the uninsulated portion of the wire feed gun to touch the ground clamp or grounded work to prevent an arc flash from being created on contact e Provide bystanders with shields or hel mets fitted with a 10 shade filter lens e Wear protective clothing The intense light of the welding arc can burn the skin in much the same way as the sun even through light weight clothing Wear dark clothing of heavy material The shirt worn should be long sleeved and the collar kept buttoned to protect chest and neck e Protect against REFLECTED ARC RAYS Arc rays can be reflected off shiny surfaces such as a glossy painted surface alu minum stainless steel and glass It is possible for your eyes to be injured by reflected arc rays even when wearing a protective helmet or shield If welding with a reflective surface behind you arc rays can bounce off the surface then off the filter lens on the inside of your helmet or shield then into your eyes If a reflec tive background exists in your welding area either remove it or cover it with something non flammable and non reflective Reflective arc rays can also cause skin burn in addition to eye injury FIRE HAZARDS FIRE OR EXPLOSION CAUSE DEATH INJURY AND PROPERTY DAMAGE To reduce the risk of death injury or property damage from fire or explosion read under stand and follow the following safety instructions In addition make certai
46. rake hardware 15 installed set the spool tension With one hand turn the wire spool and continue turning it while adjusting the tension on the spool With your free hand tighten turn clockwise the knob that holds the spool in place Stop tightening when drag is felt on the wire spool that you are turn ing then stop hand turning the wire spool Note If TOO MUCH tension is applied to the wire spool the wire will slip on the drive roller or will not be able to feed at all If TOO LITTLE tension is applied the spool of wire will want to unspool itself Readjust the drive brake ten sion as necessary to correct for either problem 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 the inlet guide tube Then push it across the drive roller and into the gun assem bly about six inches CAUTION Make certain that the welding wire is actual going into the gun liner Be very sure it has not somehow been accidentally routed alongside the liner or even in some other direction If this should
47. release drive tensioner may unlocked and relocked and no radjustment of the drive tension adjustment knob will be neces sary unless the diameter or type of wire is changed 16 INSTALLING ALUMINIUM WIRE Install aluminium wire the same as steel wire but with the following exceptions 1 Install a plastic liner PN PRT 30900002 in the welding gun 2 Adjust the drive tension VERY carefully Aluminium wire is very sensitive to slight changes in drive tension Note For welding aluminium with this unit 5356 alloy wire is recommended because of its superior feedability A plastic liner is need ed When welding with softer aluminium alloys you may experience feed problems CHANGE POLARITY This welder allows you to change the welding current polarity Select straight polarity for welding with flux core wire FCAW Select reverse polarity for MIG welding GMAW when using mild steel stainless steel or silicon bronze wire Reverse polarity is also suggested with some flux core wire used in hard facing Change the polarity of your welder according to the following procedure steps Figure 8 shows what the polarity block should look like for each polarity setting WARNING NE Electric shock can kill Always turn the power OFF and unplug the power cord from the ac power source before changing polarity CAUTION Do not use a ratchet crescent or other lever type wrench to tighten knobs on the polarity block The nu
48. st dirt grease etc from your welder Every six months or as necessary remove the side panels from the welder and air blow any dust and dirt that may have accumulated inside the welder WARNING NL Electric shock can kill To reduce the risk of electric shock always unplug the welder from its ac power source before removing side panels CONSUMABLE MAINTENANCE IT IS VERY IMPORTANT TO MAINTAIN THE CONSUMABLES TO AVOID THE NEED FOR PREMATURE REPLACEMENT OF THE GUN ASSEMBLY The GUN LINER is intended to provide an unrestricted path for the welding wire to flow through the gun assembly Over time the liner will accumulate dust dirt and other debris Replacement is necessary when these accumulations begin to restrict the free flow of wire through the gun assembly MAINTAINING THE CONTACT TIP The purpose of the CONTACT TIP is to trans fer welding current to the welding wire while allowing the wire to pass through it smoothly Always use a contact tip stamped with the same diameter as the wire it will be used with 23 Note Due to inherent variances flux cored welding wire it may be necessary to use a contact tip one size larger than your flux core wire if wire jams occur 1 Ifthe wire burns back into the tip remove the tip from the gun and clean the hole running through it with an oxygen acety lene torch tip cleaner or tip drill 2 Over time the hole in the contact tip will become worn by the wire p
49. t an arc When an arc is being drawn the wire speed will slow down TUNING IN THE WIRE SPEED This is one of the most important parts of MIG welder operation and must be done before starting each welding whenever any of the following variables are changed heat set ting wire diameter or wire type 1 Set up and ground a scrap piece of the same type of material which you will be welding lt should be equal to or greater that the thickness of the actual work piece and free of oil paint rust etc 2 Select a heat setting 3 Hold the gun in one hand allowing the nozzle to rest on the edge of the work 17 piece farthest away from you and at an angle similar to that which will be used when welding SEE HOLDING THE GUN on page 18 if you are uncertain of the angle at which you will be welding 4 With your free hand turn the Wire Speed Dial to maximum and continue to hold onto the knob WARNING EXPOSURE TO A WELDING ARC IS EXTREMELY HARMFUL TO THE EYES AND SKIN Prolonged exposure to the welding arc can cause blindness and burns Never strike an arc or being welding until you are adequately protected Wear flameproof welding gloves a heavy long sleeved shirt cuffless trousers high topped shoes and welding helmet 5 Lower your welding helmet and pull the trigger on the gun to start an arc then begin to drag the gun towards you while simultaneously turning the Wire Speed Dial counter clockwise
50. the wire whenever it contacts the grounded work piece This causes erratic welds and 24 reduced penetration In addition a shorted nozzle overheats the end of the gun which can DAMAGE the front end of the gun A RESTRICTED nozzle 15 created when enough slag builds up in the nozzle to affect the direction concentration and or rate of the shielding gas flow This problem can cause porous brittle welds and reduce penetration TESTING FOR A SHORTED NOZZLE Arcing between the nozzle and the work piece ALWAYS means the nozzle is shorted but this can be hard to detect through the lens of a welding helmet The following test ing method is another way to tell if a nozzle is shorted With the welder unplugged from the ac power source touch the probes of an ohm meter or continuity tester to the end of the contact tip and the outside of the nozzle If there is any continuity at all the nozzle IS shorted Clean or replace as needed REPLACE A GUN LINER When installing a new gun liner care must be taken not to kink or otherwise damage the gun liner See Figure 22 for the drive assem bly and Figure 23 for the gun assembly 1 Turn OFF welder POWER SWITCH and unplug welder from power supply 2 Open the welder side panel 3 Loosen the tension arm and lift it up off the drive roller 4 Turn the wire spool counter clockwise be sure to hold onto the wire itself while turn ing the spool or the wire will unspool itself when
51. the tabs of the welder handle into the slots provided on the top of the welder 2 Insert a large flat head screw included in the accessories bag into each hole on the top of the welder handle 3 With a flat tip screwdriver securely tight en both screws see Figure 3 12 Figure 3 Handle Installation SELECTING SHIELDING GAS The shielding gas plays an extremely impor tant role in the MIG welding process 15 crit ical that the molten weld puddle be shielded from the atmosphere The shielding gas cre ates a protective pocket around the weld pud dle which keeps impurities in the air from con taminating the weld Inadequate shielding will result in porous brittle welds Although there are many gasses and gas mix tures available for MIG welding the following recommendations are based on the electrical output characteristics and metal thickness capabilities of this specific MIG welder Gas Selection For Steel Welding With Steel Wire For either mild or low carbon High Strength Structural steel use a gas mixture of 75 Argon and 25 Carbon Dioxide DO NOT USE Argon gas concentrations higher than 75 on steel The result will be extremely poor penetration porosity and brittleness of weld This gas mixture helps to prevent burn through and distortion on very thin steel yet provides good penetration on thicker steel lts ability to minimize spatter results in clean smooth weld appearances In addition it pro
52. ts must be hand tightened only Too much torque applied to one of the knobs could cause the knob to break off 1 Remove the retaining knobs from the and mounting posts on the Gas No Gas Board located just below the drive motor on the inside of your welder A For Gasless FCAW welding mount the Ground Clamp ring terminal to the mounting post and the Torch n ring terminal to the mounting post For GMAW welding mount the Ground Clamp ring terminal to the mounting post and the Torch ring terminal to the mounting post See configuration shown in Figure 9 DI GAS Figure 9 Changing Polarity 2 Attach the ground clamp to the work piece making sure that it is cleaned of dirt oil rust scale oxidation and paint at the point of connection Note is best to connect the ground clamp directly to the work piece and as close to the weld as possible If it is impractical to con nect the ground clamp directly to the work piece connect it to the metal that is secure ly attached to the work piece but not elec trically insulated from it Make certain this other metal is of equal or greater thickness than that of the workpiece CAUTION le Risk of electric component damage the ground clamp 15 being connected to an automobile or other equipment with on board computer systems solid state elec tronic controls solid state sound systems etc do not we
53. ulator from service for repair if any of the fol lowing conditions exist e 205 leaks externally e Delivery pressure continues to rise with down stream valve closed The gauge pointer does not move off the stop pin when pressurized or fails to return to the stop pin after pressure 15 released WARNING This product contains chemicals including lead or otherwise produces chemicals known to the State of California to cause cancer birth defects and other reproductive 8 harm Wash hands after Handling California Health 8 Safety Code Sec 25249 5 et seq ADDITIONAL SAFETY INFORMATION For additional information concerning weld ing safety refer to the following standards and comply with them as applicable ANSI Standard 249 1 SAFETY IN WELDING AND CUTTING obtainable from the American Welding Society 550 NW Le Jeune Road Miami FL 33126 Telephone 800 443 9353 Fax 305 443 7559 www amweld org or WWW AWS Org ANSI Standard Z87 1 SAFE PRACTICE FOR OCCUPATION AND EDUCATION AL EYE AND FACE PROTECTION obtainable from the American National Standards Institute 11 West 42nd St New York NY 10036 Telephone 212 642 4900 Fax 212 398 0023 www ansi org NFPA Standard 518 CUTTING AND WELDING PROCESS obtainable from the National Fire Protection Association 1 Batterymarch Park Box 9101 Quincy MA 02269 9101 Telephone 617 770 3000 Fax 617 770 0700 www nfpa org OSHA
54. unctions except the cooling fan If this happens DO NOT SHUT OFF THE WELDER Leave the welder turned on with the fan running After cooling the thermal protector will automatically reset and the welder will function normally again However you should wait at least ten min utes after the thermal protector opens before resuming welding You must do this even if the thermal protector resets itself before the ten minutes is up or you may experience less than specified duty cycle performance If you find that the welder will not weld for two minutes without stopping reduce the wire speed slightly and tune in the welder at the lowest wire speed setting that still pro duces a smooth arc Welding with the wire speed set too high causes excessive current draw and shortens the duty cycle KNOW YOUR WELDER Volt lect itch oltage Selector Switc Handle Wire Speed Power Switch Voltage Selector Dial Ground Clamp FE lt lt Ground Cable Gun Cable Power Welding Gun Cable Figure 1 Model Cat 3175 Handle Rugged top mounted handle allows for easy transport of your welder Wire Speed Control Use this dial to adjust the speed at which the welder feeds wire to the gun 1 is the slowest wire feed speed 10 is the highest You will need to adjust or tune in your wire speed for different welding conditions thickness of metals gas vs gasless welding metal type wire size
55. with 0 023 0 6mm and 0 030 0 8mm solid steel wire on DC reverse polar ity and with 0 030 0 8mm self shielding flux core wire on DC straight polarity Larger 0 035 inch 0 9mm diameter solid steel wire on dc reverse polarity may also be used on this welder The use of larger diameter wire makes welding difficult and the results cannot be guaranteed Use of larger than 035 diam eter wire is not recommended WELDER OPERATING CHARACTERISTICS DUTY CYCLE The duty cycle rating of a welder defines how long the operator can weld and how long the welder must be rested and cooled Duty cycle is expressed as a percentage of 10 minutes and represents the maximum welding time allowed The balance of the 10 minute cycle is required for cooling Your new welder has a duty cycle rating of 25 at the rated output This means that you can weld for two and a half 2 5 min utes out of 10 with the remaining seven and a half 7 5 minutes required for cooling See Table 2 Table 2 Duty Cycle Ratings Duty Maximum Required Cycle Welding Resting Rating Time Time 20 2 minutes 8 minutes 25 2 5 minutes 7 5 minutes 40 4 minutes 6 minutes 60 6 minutes 4 minutes 80 8 minutes 2 minutes 100 10 minutes O minutes INTERNAL THERMAL PROTECTION CAUTION Do not constantly exceed the duty cycle or damage to the welder can result If you exceed the duty cycle of the welder an inter nal thermal protector will open shutting off all welder f
56. ylinders to electricity of any kind e Do not use a cylinder or its contents for anything other than its intended use Do not use as a support or roller e Do not locate cylinders in passageways or work area where they may be struck Do not use a wrench or hammer to open a cylinder valve that cannot be opened by hand Notify your supplier e Do not modify or exchange gas cylinder fittings e Do not deface or alter name number or other markings on a cylinder Do not rely on cylinder color to identify the contents Do not connect a regulator to a cylinder containing gas other than that for which the regulator was designed e Do not attempt to make regulator repairs Send faulty regulators to manufacturer s designated repair center for repair e Do not attempt to lubricate a regulator Always change cylinders carefully to pre vent leaks and damage to their walls valves or safety devices e Always secure cylinders with a steel chain so that they cannot be knocked over e Always protect a cylinder especially the valve from bumps falls falling objects and weather Remember that gasses in the cylinders are under pressure and damage to a regulator can cause the regulator or portion of the regulator to be explosively ejected from the cylinder e Always make certain the cylinder cap is securely in place on the cylinder when ever the cylinder is moved e Always close the cylinder valve and immediately remove a faulty reg
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