Campbell Hausfeld WS4369, WS4469, IN973900AV User Manual

See Warranty on page 12 for important information about the use of this product.

Operating Instructions and Parts Manual WS4369 and WS4469

Please read and save these instructions. Read carefully before attempting to assemble, install, operate or maintain the product described. Protect yourself and others by observing all safety information. Failure to comply with instructions could result in personal injury and/or property damage! Retain instructions for future reference.

Shielded Metal

Arc Welder

Table of Contents

Descripion . . . . . . . . . . . . . . . . . . . . . . .1

Unpacking . . . . . . . . . . . . . . . . . . . . . . .1

Specifications. . . . . . . . . . . . . . . . . . . . .1

Circuit Requirements . . . . . . . . . . . . . .2

Components and Controls . . . . . . . . . .2

Safety Guidelines . . . . . . . . . . . . . . . . .2

General Safety Information . . . . . . 2 - 4

Glossary of Terms . . . . . . . . . . . . . . . . .5

Installation. . . . . . . . . . . . . . . . . . . . . . .6

Operation . . . . . . . . . . . . . . . . . . . . . . .6

Welding Guidelines. . . . . . . . . . . . . 7 - 9

General. . . . . . . . . . . . . . . . . . . . . . .7

Striking an Arc . . . . . . . . . . . . . . . . .7

Arc Welding Basics. . . . . . . . . . . . . .7

Electrode Type and Size. . . . . . . . . .7

AWS Electrode Classification. . . . . .7

Commonly Used Electrodes. . . . . . .8

Current . . . . . . . . . . . . . . . . . . . . . . .8

Weld Angle. . . . . . . . . . . . . . . . . . . .8

Arc Length . . . . . . . . . . . . . . . . . . . .8

Travel Speed . . . . . . . . . . . . . . . . . . .8

Slag Removal . . . . . . . . . . . . . . . . . .8

Welding Positions . . . . . . . . . . . . . .9

Weld Pass . . . . . . . . . . . . . . . . . . . . .9

Maintenance . . . . . . . . . . . . . . . . . . . .10

Troubleshooting Chart . . . . . . . . . . . .10

Replacement Parts List . . . . . . . . . . . .11

Warranty . . . . . . . . . . . . . . . . . . . . . . .12

Description

These Campbell Hausfeld electric arc (stick) welding machines run on 230 volt, single phase input power. These welders are equipped with infinite amperage control to accurately select the proper current needed for various welding conditions. Internal components are thermostatically protected. These welding systems are designed for use with the Shielded Metal Arc Welding (SMAW) process. As delivered from the factory, these welders can weld with up to 5/32 inch diameter electrodes. Model WS4369 is an AC output welder. Model WS4469 is an AC and DC output welder. There are two levels of AC output on each machine. The cable with the ground clamp is inserted into the AC COM socket and the cable with the electrode holder is inserted into the AC LO or AC HI socket, depending on the output current range needed. The WS4469 has two extra sockets labeled DC+ and DC-. The cables are connected to these sockets for DC welding. The polarity is dependent on the output needed. Do not try to use more than one pair of sockets at a time.

Unpacking

After unpacking the unit, inspect carefully for any damage that may have occurred during transit. Check for loose, missing or damaged parts. Make sure to tighten fittings, bolts, etc., before putting unit into service. Check to be sure all supplied accessories are enclosed with the unit. In case of questions, damaged or missing parts, please call 1-800-746-5641 for customer assistance.

Specifications

WS4369 Output

Weld Voltage . . . . . . . . . . . . 33 V AC

Weld Current . . . . . . . . . . . 225 A AC

Duty Cycle . . . . . . . . . . . . . . . . . . 20%

Maximum Open

Circuit Voltage . . . . . . . . . . . 75 V AC

WS4469 Output

Weld Voltage . . . . 33 V AC / 25 V DC

Weld Current . . 225 A AC / 160 A DC

Duty Cycle . . . . . . . . . . . . . . . . . . 20%

Maximum Open Circuit Voltage . . . 75 V AC / 70 V DC

Input Voltage . . . . . . . . . . . 230 V AC

Input Current . . . . . . . . . . . . . . . 50 A

Input Frequency . . . . . . . . . . . . 60 Hz

Circuit Breaker or

Slow Blow Fuse . . . . . . . . . . . . . . 50 A

Power Cord Length . . . . . . . . . . 6 FT

Electrode Cord Length . . . . . . . 14 FT

Grounding Cord Length . . . . . . . 6 FT

REMINDER: Keep your dated proof of purchase for warranty purposes!

Attach it to this manual or file it for safekeeping.

For parts, product & service information

visit www.chpower.com or call 1-800-746-5641

IN973900AV 6/09

Operating Instructions and Parts Manual

WS4369 and WS4469

Circuit Requirements

This equipment

requires a dedicated 230 volt circuit. Refer to the Speciﬁcations section for the correct circuit breaker or fuse rating. Do not run other appliances, lights, or tools on this circuit while operating this equipment. Extension cords are not recommended. Blown fuses and tripped circuit breakers can result from failure to comply with this recommendation.

The electrode holder

is "live" (has current potential) when machine is turned on.

Safety Guidelines

This manual contains information that is very important to know and understand. This information is provided for SAFETY and to PREVENT EQUIPMENT PROBLEMS. To help recognize this information, observe the following symbols.

Danger indicates

an imminently hazardous situation which, if not avoided, WILL result in death or serious injury.

Warning indicates

a potentially hazardous situation which, if not avoided, COULD result in death or serious injury.

Caution indicates

a potentially hazardous situation which, if not avoided, MAY result in minor or moderate injury.

Notice indicates

important information, that if not followed, may cause damage to equipment.

General Safety Information

CALIFORNIA PROPOSITION 65

The cables on this

product may contain chemicals, including lead, known to the State of California to cause cancer and birth defects or other reproductive harm. Wash hands after handling.

To request Material Safety Data Sheet (MSDS), visit the Internet at www. chpower.com or call 1-800-746-5641.

This product, when

used for welding, produces fumes or gases which contain chemicals known to the State of California to cause birth defects (or other reproductive harm) and, in some cases, cancer (California Health & Safety Code Section 25249.5 et seq.)

GENERAL

• Before starting or

servicing any electric arc welder, read and understand all instructions. Failure to follow safety precautions or instructions can cause equipment damage and or serious personal injury or death. For additional safety information, obtain a copy of ANSI Standard Z49.1 - Safety in Welding and Cutting. This publication may be ordered from the American Welding Society, 550 NW LeJeune Road, Miami, FL 33126

MANUAL

Components and Controls

1. Work Clamp – connect to work piece

2. Electrode Holder – holds welding electrode.

3. Power Cord – plug into 230 volt outlet.

4. ON / OFF Switch

5. Infinite Amperage Control Knob – turns clockwise to increase amperage and counterclockwise to decrease amperage.

6. Welding Amp Indicator – as the amperage control knob (5) is rotated, the amperage indicator moves, displaying approximate weld amps.

7. Overload Indicator Light – lights when duty cycle exceeded.

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Figure 1

Operating Instructions and Parts Manual

WS4369 and WS4469

General Safety Information (Continued)

Always

keep a fire extinguisher accessible while performing arc welding operations.

• All installation, maintenance, repair

and operation of this equipment should be performed by qualified persons only in accordance with national, state, and local codes.

Improper

use of electric arc welders can cause electric shock, injury, and death! Take all precautions described in this manual to reduce the possibility of electric shock.

• Verify that all components of the

arc welder are clean and in good condition prior to operating the welder. Be sure that the insulation on all cables, electrode holders, and power cords is not damaged. Always repair or replace damaged components before operating the welder. Always keep welder panels, shields, etc. in place when operating the welder.

• Always wear dry protective clothing

and welding gloves, and insulated footwear.

• Always operate the welder in a

clean, dry, well ventilated area. Do not operate the welder in humid, wet, rainy, or poorly ventilated areas.

• Be sure that the work piece is

properly supported and grounded prior to beginning any electric arc welding operation.

• Coiled welding cable should be

spread out before use to avoid overheating and damage to insulation.

Never immerse

the electrode or electrode holder in water. If the welder becomes wet for any reason, be absolutely certain that it is completely clean and dry prior to attempting use!

• Always shut the equipment off and

unplug the power prior to moving the unit.

• Always attach the ground lead first.

• Verify that the work piece is

securely grounded.

• Always shut off electric arc welding

equipment when not in use and remove the electrode from the holder.

• Never allow any part of the body to

touch the electrode and ground or grounded work piece at the same time.

• Awkward welding conditions

and positions can be electrically hazardous. When crouching, kneeling or at elevations, be sure to insulate all conductive parts, wear appropriate protective clothing, and take precautions to prevent injury from falls.

• Never attempt to use this

equipment at current settings or duty cycles higher than those specified on the equipment labels.

• Never use an electric arc welder to

thaw frozen pipes.

Flying

sparks and hot metal can cause injury. As welds cool, slag can be thrown off. Take all precautions described in this manual to reduce the possibility of injury from flying sparks and hot metal.

• Wear ANSI approved face shield

or safety glasses with side shield protection when chipping or grinding metal parts.

• Wear ear plugs when welding

overhead to prevent spatter or slag from falling into ears.

Electric arc welding operations produce intense light and heat and ultraviolet (UV) rays. This intense light and UV rays can cause injury to eyes and skin. Take all precautions described in this manual to reduce the possibility of injury to eyes and skin.

• All persons operating this

equipment or in the area while equipment is in use must wear protective welding gear including: welding helmet or shield with

proper shade as specified in the following chart, flame resistant clothing, leather welding gloves, and full foot protection.

Current (Amps) Filter Shade

Up to 160 Amps 10

160 to 250 Amps 12

Never look at arc

welding operations without eye protection as described above. Never use a shade filter lens that is cracked, broken, or rated below number 10. Warn others in the area not to look at the arc.

Electric

arc welding operations cause sparks and heat metal to temperatures that can cause severe burns! Use protective gloves and clothing when performing any metal working operation. Take all precautions described in this manual to reduce the possibility of skin and clothing burns.

• Make sure that all persons in the

welding area are protected from heat, sparks, and ultraviolet rays. Use additional face shields and flame resistant barriers as needed.

• Never touch work pieces until

completely cooled.

Heat and

sparks produced during electric arc welding and other metal working operations can ignite flammable and explosive materials! Take all precautions described in this manual to reduce the possibility of flames and explosions.

• Remove all flammable materials

within 35 feet (10.7 meters) of welding arc. If removal is not possible, tightly cover flammable materials with fire proof covers.

• Do not operate any electric arc

welder in areas where flammable or explosive vapors may be present. Take precautions to be sure that flying sparks and heat do not cause flames in hidden areas, cracks, behind bulkheads, etc.

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Operating Instructions and Parts Manual

General Safety Information (Continued)

Fire

hazard! Do not weld on containers or pipes that contain or have contained flammable materials or gaseous or liquid combustibles.

Arc

welding closed cylinders or containers such as tanks or drums can cause explosion if not properly vented! Verify that any cylinder or container to be welded has an adequate ventilation hole, so that expanding gases can be released.

Do not

breathe fumes that are produced by the arc welding operation. These fumes are dangerous. If the welding area cannot be adequately ventilated, be sure to use an air-supplied respirator.

• Keep the head and face out of the

welding fumes.

• Do not perform electric arc welding

operations on metals that are galvanized or cadmium plated, or contain zinc, mercury, or beryllium without completing the following precautions:

a. Remove the coating from the

base metal.

b. Make sure that the welding area

is well ventilated.

c. Use an air-supplied respirator. Extremely toxic fumes are created when these metals are heated.

The electromagnetic field that is generated during arc welding may interfere with the operation of various electrical and electronic devices such as cardiac pacemakers. Persons using such devices should consult with their physician prior to performing any electric arc welding operations.

• Route the electrode and work

cables together and secure with tape when possible.

• Never wrap arc welder cables

around the body.

• Always position the electrode and

work leads so that they are on the same side of the body.

• Exposure to electromagnetic fields

during welding may have other health effects which are not known.

Always be sure that

the welding area is secure and free of hazards (sparks, flames, glowing metal or slag) prior to leaving. Be sure that the equipment is turned off and electrode is removed. Be sure that cables are loosely coiled and out of the way. Be sure that all metal and slag has cooled.

WS4369 and WS4469

ADDITIONAL SAFETY STANDARDS

ANSI Standard Z49.1 from American Welding Society, 550 NW LeJeune Road, Miami FL 33126

Safety and Health Standards

OSHA 29 CFR 1910, from U.S. Government Printing Office, 732 North Capital Street NW, Washington DC 20401

National Electrical Code

NFPA Standard 70, from National Fire Protection Association, Batterymarch Park, Quincy, MA 02269

Safe Handling of Compressed Gases in Cylinders

CGA Pamphlet P-1, from Compressed Gas Association, 1235 Jefferson Davis Highway, Suite 501, Arlington, VA 22202

Code for Safety in Welding and Cutting

CSA Standard W117.2, from Canadian Standards Association, Standards Sales, 178 Rexdale Boulevard, Rexdale, Ontario, Canada M9W 1R3

Cutting And Welding Processes

NFPA Standard 51B, from National Fire Protection Association, Batterymarch Park, Quicy, MA 02269

Safe Practices For Occupational And Educational Eye And Face Protection

ANSI Standard Z87.1, from American National Standards Institute, 1430 Broadway, New York, NY 10018

Refer to the Material Safety Data Sheets and the manufacturers instructions for metals, electrodes, coatings and cleaners.

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Operating Instructions and Parts Manual

WS4369 and WS4469

Glossary of Terms

AC or Alternating Current - electric

current that reverses direction periodically. Sixty cycle current travels in both directions sixty times per second.

Arc Length - the distance from the end of the electrode to the point where the arc makes contact with the work surface.

Base Metal - the material to be welded.

Butt Joint - a joint between two members aligned approximately in the same plane.

Crater - a pool, or pocket, that is formed as the arc comes in contact with the base metal.

DC or Direct Current - electric current which flows only in one direction. The polarity (+ or -) determines which direction the current is flowing.

DC Reverse Polarity - occurs when the electrode holder is connected to the positive pole of the welding machine. Reverse Polarity directs more heat into melting the electrode rather then the work piece. It is used on thinner material.

DC Straight Polarity - occurs when the electrode holder is connected to the negative pole of the welding machine. With straight polarity more heat is directed to the work piece for better penetration on thicker material.

Electrode - a coated metal wire having approximately the same composition as the material being welded.

Fillet Weld - approximately a triangle in cross-section, joining two surfaces at right angles to each other in a lap, T or corner joint.

Flux - a coating, when heated, that produces a shielding gas around the welding area. This gas protects the parent and filler metals from impurities in the air.

Flux Cored Arc Welding (FCAW) -

also called Gasless, is a welding process used with a wire-feed welding machine. The weld wire is tubular with flux material contained inside for shielding.

Gas Metal Arc Welding (GMAW) -

also called MIG, is a welding process used with a wire feed welding machine. The wire is solid and an inert gas is used for shielding.

Gas Tungsten Arc Welding (GTAW) -

also called TIG, is a welding process used with welding equipment with a high frequency generator. The arc is created between a non-consumable tungsten electrode and the work piece. Filler metal may or may not be used.

Lap Joint - a joint between two overlapping members in parallel planes.

Open Circuit Voltage (OCV) - the voltage between the electrode and the ground clamp of the welding machine when no current is flowing (not welding). The OCV determines how quickly the arc is struck.

Overlap - occurs when the amperage is set too low. In this instance, the molten metal falls from the electrode without actually fusing into the base metal.

Porosity - gas pockets, or cavities, formed during weld solidification. They weaken the weld.

Penetration - the depth into the work piece that has been heat effected by the arc during the welding process. A good weld achieves 100% penetration meaning that the entire thickness of the work piece has been heated and resolidified. The heat effected area should be easily seen on the opposite side of the weld.

Shielded Metal Arc Welding (SMAW) - also called Stick, is a welding

process with uses a consumable electrode to support the arc. Shielding is achieved by the melting of the flux coating on the electrode.

Slag - a layer of flux soot that protects the weld from oxides and other contaminants while the weld is solidifying (cooling). Slag should be removed after weld has cooled.

Spatter - metal particles thrown from the weld which cool and harden on the work surface. Spatter can be minimized by using a spatter resistant spray on the work piece before welding.

Tack Weld - weld made to hold parts in proper alignment until final welds are made.

Travel Angle - the angle of the electrode in the line of welding. It varies from 5º to 45º depending on welding conditions.

T Joint - made by placing the edge of one piece of metal on the surface of the other piece at approximately a 90º angle.

Undercut - a condition that results when welding amperage is too high. The excessive amperage leaves a groove in the base metal along both sides of the bead which reduces the strength of the weld.

Weld Pool or Puddle - a volume of molten metal in a weld prior to its solidification as weld metal.

Weld Bead - a narrow layer or layers of metal deposited on the base metal as the electrode melts. Weld bead width is typically twice the diameter of the electrode.

Work Angle - the angle of the electrode from horizontal, measured at right angles to the line of welding.

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Operating Instructions and Parts Manual

WS4369 and WS4469

Installation

LOCATION

Selecting the proper location can significantly increase performance, reliability and life of the arc welder.

• For best results locate the welder

in an environment that is clean and dry. Avoid locations exposed to high temperature, high humidity, dust and corrosive fumes. High humidity causes moisture condensation on electrical components. Moisture can contribute to corrosion and short electrical components. Dust and dirt in the welder retain moisture and increase wear of moving parts.

• Place the welder in an area that

provides at least twelve inches (305 mm) of ventilation space at both the front and rear of the unit.

Keep all obstructions away from

this ventilation space.

• Store electrodes in a clean, dry

location with low humidity to preserve the flux coating.

• The welder control panel contains

information regarding proper input voltage and amperage. Follow the specifications on the welder front panel.

• The receptacle used for the welder

must be properly grounded and the welder must be the only load on the power supply circuit. Refer to the Circuit Amps chart under Specifications for correct circuit capacity.

• The use of an extension cord is

not recommended for electric arc welding machines. The voltage drop in the extension cord may significantly degrade the performance of the welder.

Operation

1. Be sure to read, understand, and

comply with all precautions in the General Safety Information section. Be sure to read the entire section entitled Welding Guidelines prior to using this equipment.

2. Turn welder off and plug into

appropriate receptacle: 230V-50 Amp

3. Verify that the surfaces of metals

to be joined are free from dirt, rust, paint, oil, scale or other contaminants. These contaminants make welding difficult and cause poor welds.

All persons

operating this equipment or in the area while equipment is in use must wear protective welding gear including: eye protection with proper shade (minimum shade 10), flame resistant clothing, leather welding gloves, and full foot protection.

If heating, welding,

or cutting materials that are galvanized, zinc plated, lead, or cadmium plated refer to the General Safety Information Section for instructions. Extremely toxic fumes are created when these metals are heated.

4. Connect the ground clamp to the

work piece or workbench (if metal). Make sure the contact is secure, and not obstructed by paint, varnish, corrosion, or non-metallic materials.

5. Insert the exposed part of the

electrode (the end with no flux) into the jaws of the electrode holder.

6. Set the amperage adjustment knob to the proper amperage for the electrode diameter. Refer to the following chart for proper electrode current settings.

Electrode Diameter

Current Setting

(Amps)

3/32 inch (2.5 mm) 60-110

1/8 inch (3.2 mm) 110-160

5/32 inch (4.0 mm) 150-230

The electrode

holder and rod are electrically "hot"(have current potential) when the welder is on. Grounding against any metallic surface may produce an arc which could cause sparks and damage eyesight.

7. Hold the electrode and holder away

from the grounded work piece or workbench. Turn on the welder.

8. Position the electrode to begin

weld, lower the welding helmet or position the hand shield, and strike an arc. Adjust weld amperage as needed.

9. When finished welding, turn

welder off and store properly.

DUTY CYCLE / THERMOSTATIC PROTECTION

Welder duty cycle is the percentage of actual weld time that can occur in a ten minute interval. For example, at a 20% duty cycle, actual welding can occur for two minutes, then the welder must cool for eight minutes.

Internal components of this welder are protected from overheating with an automatic thermal switch. A yellow lamp is illuminated on the control panel if the duty cycle is exceeded. Welding operations may continue when the yellow lamp is no longer illuminated.

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Operating Instructions and Parts Manual

WS4369 and WS4469

Welding Guidelines

GENERAL

This line of welding machines utilizes a process known as Shielded Metal-Arc Welding (SMAW). This process is used to bond metals by heating them with an electric arc created between the electrode and the work piece.

Electrodes used for shielded metal arc welding have two parts. The inner core is a metal rod or wire that should be similar in composition to the base metal. The outer coating is called flux. Various types of flux exist. Each coating is used for a particular welding situation.

While the metal is molten, it can be contaminated by elements in the air. This contamination could weaken the weld. The flux coating creates a protective barrier called slag that protects the molten metal from contaminants.

When current (amperage) flows through the circuit to the electrode, an arc is formed between the end of the electrode and the work piece. The arc melts the electrode and the work piece. The melted metal of the electrode flows into the molten crater and forms a bond with the work piece as shown in Figure 5.

STRIKING AN ARC

Place the bare end of the electrode in the holder. Grip the holder lightly to reduce tiring of the hand and arm.

NOTE: Always keep the jaws of the holder clean to insure good electrical contact with the electrode.

Be careful not to

touch the work piece or welding bench with the electrode as this causes arc flashes.

There are two methods which can be used to start or strike the arc; the tapping method and the scratching method. In the tapping method, the electrode is brought straight down and tapped on the work piece. With the scratching method, drag the electrode at an angle along the surface much like striking a match. Regardless of method, upon contact with the plate, immediately raise the electrode a distance equal to the diameter of the electrode or it will stick to the surface. Always hold the electrode pointed into the weld (See Figure 6).

Same as electrode diameter

ARC WELDING BASICS

Five basic techniques affect weld quality. These are: electrode selection, current setting, weld angle, arc length, and travel speed. Proper implementation of these techniques is necessary for good weld quality.

ELECTRODE TYPE AND SIZE

The correct choice of electrode type involves a variety of factors, such as welding position, work piece material type, thickness, and condition of surface to be welded. The American Welding Society, AWS, has set up certain requirements for each type of electrode.

All electrodes are classified into five main groups: mild steel, high-carbon steel, special alloy steel, cast iron, and nonferrous such as aluminum. The majority of arc welding is done with the electrodes in the mild steel group. The electrode material should corres- pond with the work piece material.

Flux coatings are made for use with either AC (alternating current), DC (direct current) reverse polarity, or DC straight polarity, although some function well on both AC and DC current.

AWS ELECTRODE CLASSIFICATION

E - 6 0 1 3

Wire

Flux

Weld

Slag

Crater

Figure 5

Work Piece

NOTE: Discontinue using and discard electrodes that burn down to 1 to 2 inches from the electrode holder.

Same as electrode diameter

Figure 6

NOTE: Should the electrode stick to the work piece, break it loose by quickly twisting or bending at the holder while pulling upward. If the electrode does not break loose, disengage the electrode by releasing it from the holder.

E = Electrode

60 = Mild steel

70 = High strength Steel

1 = Electrode can be used in all positions

2 = Electrode is restricted for use in flat or horizontal position only

Flux type

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Operating Instructions and Parts Manual

WS4369 and WS4469

Welding Guidelines (Continued)

COMMONLY USED ELECTRODES

1. E-6011 Deep Penetrating

• The strong arc force and rapid solidification of the metal makes vertical and overhead welding easier with this rod.

• Where time does not permit rust, scale or paint removal, this rod penetrates rapidly and easily.

• Acceptable for AC or DC welding current (reverse polarity).

2. E-6013 General Purpose

• All position, smooth deposit rod with low spatter.

• For all mild steel and general purpose work.

• Acceptable for AC or DC welding current (straight or reverse polarity).

3. E-7014 Iron Powder

• A general purpose "drag" rod for all positions.

• Ideal for situations where fit between metal pieces is poor.

• The iron powder in the flux coating combines with the filler rod to make a smooth deposit with very little spatter.

• Ideal for ornamental work.

• Acceptable for AC or DC welding

current (reverse polarity).

4. E-7018 Low Hydrogen

• An all position high strength electrode designed to produce low hydrogen content combined with excellent mechanical properties.

• Acceptable for AC or DC welding current (reverse polarity).

CURRENT

The correct current involves the adjustment of the welding machine to the required amperage setting. Current represents the actual flow of electricity and is regulated by a knob on the welder. The current used depends on the size (diameter) and type of electrode used, position of the weld, and the thickness of the work piece.

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Consult specifications listed on the electrode package or generalized chart in the Operation section. Excessive current burns through light metals, and the weld bead is flat and porous or the bead undercuts the work piece (See Figure 8). The bead appears high and irregular if the current is too low.

WELD ANGLE

Weld angle is the angle at which the electrode is held during the welding process. Using the correct angle ensures proper penetration and bead formation. As different welding positions and weld joints become necessary, electrode angle becomes an increasingly important factor in obtaining a satisfactory weld. Electrode angle involves two positions - travel angle and work angle (See Figure 7).

5º - 45º

Travel Angle

Work Angle

Figure 7 - Weld Angle

Travel angle is the angle in the line of welding and may vary from 5º to 45º from the vertical, depending on welding conditions.

Work angle is the angle from horizontal, measured at right angles to the line of welding.

For most applications, a 45º travel angle and 45º work angle is sufficient. For specific applications, consult an arc welding handbook.

NOTE: Right handed welders should weld from left to right. Left handed

welders should weld from right to left. The electrode should always point into the weld puddle as shown.

ARC LENGTH

Arc length is the distance from the work piece to the tip of the electrode, the distance which the arc must travel. A proper arc length is essential to generate the heat needed for welding (See Figure 8). An arc that is too long produces an unstable arc, reduces penetration, increases spatter, and causes flat and wide beads. Too short an arc does not create enough heat to melt the work piece, the electrode has a tendency to stick, penetration will be poor, and uneven beads with irregular ripples result. A proper arc should be no longer then the diameter of the rod. The sound of a proper arc is a steady, crisp sizzle, similar to bacon frying.

TRAVEL SPEED

The travel speed is the rate at which the electrode is moved across the weld area. Factors such as diameter and type of electrode, amperage, position, and work piece material thickness all effect the speed of travel necessary for completing a good weld (See Figure 8). When the speed is too fast, the bead is narrow and bead ripples are pointed as shown. When the speed is to slow, the weld metal piles up and the bead is high and wide.

SLAG REMOVAL

Wear ANSI approved

safety glasses (ANSI Standard Z87.1) and protective clothing when removing slag. Hot, flying debris can cause personal injury to anyone in the area.

After completing the weld, wait for the welded sections to cool. A protective coating called slag now covers the weld bead which prevents contaminants in the air from reacting with the molten metal. Once the weld cools to the point that it is no longer glowing red, the slag can be removed. Removal is done with a chipping hammer. Lightly tap the slag with the hammer and break it loose from the weld bead. The final clean-up is done with a wire brush. When making multiple weld passes, remove the slag before each pass.

Operating Instructions and Parts Manual

WS4369 and WS4469

Welding Guidelines (Continued)

WELDING POSITIONS

Four basic welding positions can be used; flat, horizontal, vertical, and overhead. Welding in the flat position is easier than any of the others because welding speed can be increased, the molten metal has less tendency to run, better penetration can be achieved, and the work is less fatiguing. Welding is performed with the electrode at a 45º travel angle and 45º work angle.

Other positions require different techniques such as a weaving pass, circular pass, and jogging. A higher skill level is required to complete these welds.

Overhead welding is the least desirable position as it is the most difficult and dangerous. Heat setting and electrode selection will vary depending upon the position.

All work should be performed in the flat position if possible. For specific applications, consult an arc welding handbook.

WELD PASS

Sometimes more then one pass is necessary to fill the joint. The root pass is first, followed by filler passes and the cover pass (See Figures 9 and 10). If the pieces are thick, it may be necessary to bevel the edges that are joined at a 60º angle. Remember to remove the slag before each pass.

Cover

Filler

Root

Figure 9 - Multiple Weld Passes

Figure 10 - Fillet Welds

NOTE: Weld bead

width (W) should be approximately twice the diameter of the electrode rod used.

Normal Current,

Arc Length,

Speed

Current Too Low

Current Too High

Figure 8 - Weld Appearance

Arc Length Too Short

Work Piece

Base Metal

Speed Too Fast

Speed Too Slow

Arc Length Too Long

www.chpower.com

Operating Instructions and Parts Manual

WS4369 and WS4469

Maintenance

Disconnect power

supply and turn machine off before inspecting or servicing any components.

BEFORE EVERY USE:

1. Check condition of weld cables and

immediately repair or replace any cables with damaged insulation.

3. Check condition of electrode holder insulating pieces and immediately replace cracked or missing insulators. Verify that all fasteners are tight and insulated.

Do not operate this

welding machine with cracked or missing insulation on welding cables, electrode holder, or power cord.

EVERY 3 MONTHS:

Replace any unreadable labels on the welder. Use compressed air to blow all dust and lint from the ventilation openings.

2. Check condition of power cord and immediately repair or replace any cord if damaged.

Troubleshooting Chart

Symptom Possible Cause(s) Corrective Action

Welder does not hum when turned on

Welder hums but does not weld

Welder gives trickle shocks 1. Accidental contact with work piece

Welder overheats - blows fuses, trips circuit breaker

Arc difficult to strike 1. Electrode diameter too large

Bead is intermittently too thin

Bead is intermittently too thick

Ragged depressions at edge of weld

Weld bead does not penetrate base metal

Electrode sticks to work piece

Electrodes sputter and stick Damp electrodes Use dry electrodes and store in dry location

1. No power at receptacle

2. Broken or damaged power cable

1. Inadequate current at electrode

2. Poor connections at welder

2. Current leakage caused by moist clothing or work area

1. Use of extension cord

2. Electrode diameter too large

3. Overloaded circuit

2. Work piece not properly grounded

3. Heavy loads making power line voltage low

1. Inconsistent travel speed

2. Output amp setting too low

1. Slow and/or inconsistent travel speed

2. Output amp setting too high

1. Travel speed too fast

2. Arc length too short

3. Output amp setting too high

1. Inconsistent travel speed

2. Output amp setting too low

Electrode is held in contact with work piece while arc is struck

1. Check circuit fuse or circuit breaker

2. Power cable requires service

1. Check ground clamp, cable and connection to work piece. Check electrode cable and clamp.

2. Check all welder external connections

1. Avoid contact with work piece

2. Make sure clothing and work area are dry

1. If possible, relocated welder to avoid use of extension cord. If relocation of welder is not possible, use thicker (lower gauge number) extension cord

2. Use smaller diameter electrode

3. Welder requires a dedicated 230v circuit

1. Use smaller diameter electrode

2. Verify proper grounding. (No paint, varnish or corrosion)

3. Run welder on dedicated 230v circuit

1. Decrease and maintain travel speed

2. Increase output amp setting or change to smaller diameter electrode

1. Increase and maintain travel speed

2. Reduce output amp setting

1. Decrease travel speed

2. Increase arc length

3. Reduce output amp setting

1. Decrease and maintain constant travel speed

2. Increase output amp setting

Lift electrode to correct arc length as soon as arc is struck

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For Information About This Product Call 1-800-746-5641

Operating Instructions and Parts Manual

WS4369 and WS4469

For replacement parts or technical assistance, call 1-800-746-5641

Please provide following information:

- Model number

- Serial number (if any)

- Part description and number as shown in parts list

Figure 11

Address parts correspondence to:

Campbell Hausfeld Attn: Customer Service 100 Production Drive Harrison, OH 45030 USA

Replacement Parts List

Ref. Part No. Description Number Qty.

1 Decal, Warning DK689175AV 1 2 Connector, Dinse WC000200AV 2 3 Cordset, Power – 230V, 50A (NEMA 6-50P), 7 ft (213 cm), 12AWGX3C, Type SJT * 1 4 Cable, Welding – 6 AWG (15 mm 5 Clamp, Work – 250A WC100100AV 1 6 Holder, Electrode – 300A WC200200AV 1

7 Crank Kit (includes crank, knob, post, and pin) WC707645AV 1

8 s Cart, Welder (Optional Accessory) WT720000AJ Optional * Standard hardware item, available at local hardware or welder supply store.

s Not shown

) * 2

www.chpower.com

Operating Instructions and Parts Manual

WS4369 and WS4469

Limited Warranty

1. DURATION: The manufacturer warrants that it will repair, at no charge for parts or labor, the welder, welding gun, or cables, proven defective in material or workmanship, during the following time period(s) after date of original retail purchase:

For 5 Years: The Welder Transformer and Rectifier For 3 Years: The Entire Welder (excluding clamps, welding gun, electrode holder, cables, or accessories packed with the

welder)

For 1 Year: The Welding Clamps, MIG Gun, Electrode Holder, Accessories, and Welding Cables (as applicable)

2. WHO GIVES THIS WARRANTY (WARRANTOR): Campbell Hausfeld / Scott Fetzer Company 100 Production Drive Harrison, Ohio, 45030 Telephone: 1-800-746-5641

3. WHO RECEIVES THIS WARRANTY (PURCHASER): The original purchaser (other than for purposes of resale) of the Campbell Hausfeld product.

4. WHAT IS COVERED UNDER THIS WARRANTY: Substantial defects in material and workmanship which occur within the duration of the warranty period. This warranty extends to the Welder, the Welders Transformer and Rectifier, Welding Gun or Electrode holder, and cables only.

5. WHAT IS NOT COVERED UNDER THIS WARRANTY:

A. Implied warranties, including those of merchantability and FITNESS FOR A PARTICULAR PURPOSE ARE LIMITED IN

DURATION TO THIS EXPRESS WARRANTY. After this period, all risks of loss, from whatever reason, shall be on the purchaser. Some States do not allow limitation on how long an implied warranty lasts, so the above limitations may not apply to you.

B. ANY INCIDENTAL, INDIRECT, OR CONSEQUENTIAL LOSS, DAMAGE, OR EXPENSE THAT MAY RESULT FROM ANY

DEFECT, FAILURE, OR MALFUNCTION OF THE CAMPBELL HAUSFELD INDUSTRIAL PRODUCT. Some States do not allow limitations on how long an implied warranty lasts, so above limitations may not apply to you.

C. This warranty does not apply to any accessory items included with the product which are subject to wear from

usage; the repair or replacement of these items shall be at the expense of the owner. These MIG items include but are not limited to; Contact Tips, Nozzles, Gun Liners, Drive Rollers, Felt Wire Cleaner. In addition, this warranty does not extend to any damage caused by the untimely replacement or maintenance of any of the previously listed CONSUMABLE parts.

D. Any failure that results from accident, purchaser’s abuse, neglect or failure to operate products in accordance with

instructions provided in the owner’s manual(s) supplied with product. E. Pre-delivery service, i.e. assembly, oil or lubricants, and adjustment. F. Gasoline engine components are expressly excluded from coverage under this limited warranty. Such components

should be returned by the purchaser to the original manufacturer or to its authorized repair stations for service.

6. RESPONSIBILITIES OF WARRANTOR UNDER THIS WARRANTY: Repair or replace, at Warrantor’s option, products or components which have failed within duration of the warranty period.

7. RESPONSIBILITIES OF PURCHASER UNDER THIS WARRANTY:

A. Please call 1-800-746-5641 for warranty assistance. B. Provide dated proof of purchase and maintenance records. C. All welders must be delivered or shipped to the nearest Campbell Hausfeld Authorized Service Center. Freight costs,

if any, must be borne by the purchaser.

D. Use reasonable care in the operation and maintenance of the products as described in the owner’s manual(s).

8. WHEN WARRANTOR WILL PERFORM REPAIR OR REPLACEMENT UNDER THIS WARRANTY:

Repair or replacement will be scheduled and serviced according to the normal work flow at the servicing location, and depending on the availability of replacement parts.

This Limited Warranty gives you specific legal rights and you may also have other rights which vary from state to state.

www.chpower.com

Voir la Garantie à la page 24 pour de l’information importante sur l’utilisation de ce produit.

Instructions d’Utilisation et Manual de Pièces WS4369 et WS4469

Veuillez lire et conserver ces instructions. Lire attentivement avant de commencer à assembler, installer, faire fonctionner ou entretenir l'appareil décrit. Protégez-vous et les autres en observant toutes les informations sur la sécurité. Négliger d'appliquer ces instructions peut résulter en des blessures corporelles et/ou en des dommages matériels ! Conserver ces instructions pour références ultérieures.

Soudeur À L’Arc Au

Métal Enrobé

Table des Matières

Descripion . . . . . . . . . . . . . . . . . . . . . .13

Déballage . . . . . . . . . . . . . . . . . . . . . .13

Spécifications. . . . . . . . . . . . . . . . . . . .13

Exigences De Circuit . . . . . . . . . . . . . .14

Commandes et Pièces Détachées. . . .14

Directives de Sécurité . . . . . . . . . . . . .14

Généralités Sur la Sécurité . . . . . 14 - 16

Glossaire des Termes. . . . . . . . . . . . . .17

Installation. . . . . . . . . . . . . . . . . . 17 - 18

Fonctionnement . . . . . . . . . . . . . . . . .18

Directives de Soudage . . . . . . . . 18 - 21

Généralités . . . . . . . . . . . . . . . . . . .18

Amorçage d’Un Arc . . . . . . . . . . . .19

Éléments Fondamentaux du

Soudage à l’Arc . . . . . . . . . . . . . . .19

Type et Taille d’Électrode . . . . . . .19

Classement d’Électrodes AWS. . . .19

Électrodes Communes . . . . . . . . . .19

Courant. . . . . . . . . . . . . . . . . . . . . .19

Angle de Soudure . . . . . . . . . . . . .20

Longueur de l’Arc . . . . . . . . . . . . .20

Vitesse de Déplacement . . . . . . . .21

Retrait des Scories . . . . . . . . . . . . .21

Positions de Soudage. . . . . . . . . . .21

Passes de Soudage . . . . . . . . . . . . .21

Entretien . . . . . . . . . . . . . . . . . . . . . . .21

Guide de Dépannage . . . . . . . . . . . . .22

Liste de Pièces de Rechange. . . . . . . .23

Garantie. . . . . . . . . . . . . . . . . . . . . . . .24

Description

Ces appareils de soudure à l'arc électrique (bâtonnet) de Campbell Hausfeld fonctionnent avec un courant d'entrée monophasé à 230 volts.

MÉMENTO: Gardez votre preuve datée d'achat à fin de la garantie!

Joignez-la à ce manuel ou classez-la dans un dossier pour plus de sécurité.

Ces soudeurs sont dotés d'un contrôle à ampérage infini pour choisir avec exactitude le bon courant nécessaire pour diverses conditions de soudage. Les composants internes sont protégés thermostatiquement.

Ces systèmes de soudure sont conçus pour une utilisation avec le processus de soudage avec électrodes enrobées Shielded Metal Arc Welding (SMAW). Ces appareils tels que livrés de l'usine peuvent souder avec des électrodes jusqu'à 3,9 mm (5/32 po) de diamètre.

Le modèle WS4369 est un soudeur à sortie de c.a. Le modèle WS4469 est un soudeur à sortie de CA et de CC Il y a deux niveaux de sortie de c.a. pour chaque appareil. Le câble à prise de masse est inséré dans la douille AC COM et le câble avec le porte-électrode est inséré dans la douille AC LO ou AC HI selon la plage de courant de sortie voulue. Le WS4469 a deux douilles supplémentaires portant la mention DC+ (CC+) et DC- (CC-). Les câbles sont branchés dans ces douilles pour la soudure à CC. La polarité dépend de la sortie nécessaire. Ne pas essayer d'utiliser plus d'une paire de douilles à la fois.

Déballage

Dès que l’appareil est déballé, l’inspecter attentivement pour tout signe de dommages en transit. Vérifier s’il y a des pièces desserrées, manquantes ou endommagées. S’assurer de resserrer tous les raccords, boulons, etc. avant de le mettre en service. Vérifier pour s’assurer que tous les accessoires fournis sont inclus avec l’appareil. Pour toutes questions, pièces endommagées ou manquantes, appeler le 1-800-746-5641 pour le service à la clientèle.

13-Fr

Spécifications

Sortie WS4369

Tension de soudure . . . . . . . . .33 V CA

Courant de soudure . . . . . . .225 A CA

Cycle de service . . . . . . . . . . . . . . . 20%

Ouverture maximale

Tension du circuit . . . . . . . . . . . 75 V CA

Sortie WS4469 Tension de

soudure . . . . . . . . . . 33 V CA / /25 V CC

Courant de

soudure . . . . . . . . 225 A CA / /160 A CC

Cycle de service . . . . . . . . . . . . . . . 20%

Ouverture maximale Tension du circuit . . .75 V AC / 70 V DC

Tension d'entrée . . . . . . . . . . 230 V AC

Courant d'entrée . . . . . . . . . . . . . .50 A

Fréquence d'entrée . . . . . . . . . . .60 Hz

Disjoncteur ou

Fusible à action retardée . . . . . . .50 A

Longueur de cordon

d'alimentation . . . . . . . . . . 1,8 m (6 pi)

Longueur de cordon

d'électrode . . . . . . . . . . . . 4,3 m (14 pi)

Longueur de cordon de

mise à la terre . . . . . . . . . . 1,8 m (6 pi)

IN973900AV 6/09

Instructions d’utilisation et manual de pièces

WS4369 et WS4469

Exigences De Circuit

Cet équipement exige un circuit spécialisé de 230 volts. Se reporter à la section de Spéciﬁcations pour la bonne valeur nominale du fusible ou du disjoncteur. Ne pas faire fonctionner d'autres appareils électroménagers, lumières ou outils sur ce circuit en utilisant cet équipement. Les rallonges ne sont pas recommandées. Les fusibles grillés et les disjoncteurs déclenchés peuvent découler du non-respect de cette recommandation.

Le porte-électrode

est “électrisé” (porte une charge électrique) quand le modèle est en marche (ON).

Directives de Sécurité

Ce manuel contient de l’information très importante qui est fournie pour la SÉCURITÉ et pour ÉVITER LES PROBLÈMES D’ÉQUIPEMENT. Rechercher les symboles suivants pour cette

information.

Danger indique

une situation dangereuse imminente qui MÈNERA à la mort ou à des blessures graves si elle n’est pas évitée.

Avertissement

indique une situation potentiellement dangereuse qui, si elle n’est pas évitée, POURRAIT mener à la mort ou à de graves blessures.

Attention indique une situation potentiellement dangereuse qui, si elle n’est pas évitée, PEUT mener à des blessures mineures ou modérées.

Avis indique

de l’information importante qui pourrait endommager

l’équipement si elle n’est pas respectée.

Généralités Sur la Sécurité

PROPOSITION 65 CALIFORNIE

Les câbles sur ce

produit peuvent contenir des produits chimiques incluant le plomb, qui de l'avis de l'État de Californie peut causer le cancer et des anomalies congénitales ou autres problèmes reproductifs. Se laver les mains après toute manipulation.

Pour demander la ﬁche signalétique de sécurité du produit (FSSP), visiter Internet à www.chpower.com ou appeler le 1-800-746-5641.

This product,

Ce produit utilisé pour la soudure produit des émanations ou des gaz qui contiennent des produits chimiques qui de l'avis de l'État de Californie causent des anomalies congénitales (ou autres problèmes de reproduction) et, dans certains cas, le cancer (section du code de Californie California Health & Safety Section

25249.5 et seq.)

Commandes et Pièces Détachées

1. Bride de serrage - connecter au travail

2. Porte-électrode - tient l'électrode de soudage.

3. Cordon D’Alimentation - brancher dans une prise de courant de 230 volts.

4. Interrupteur ON/OFF - Tourner à la droite pour c.a. haut ou à la gauche pour c.a. bas ou pour c.c.

5. Bouton De Réglage De L’Ampérage Infini - tourne dans le sens des aiguilles d’une montre pour augmenter l’ampérage, et dans le sens contraire pour réduire l’ampérage.

6. Indicateur d’Amp de Soudage - quand le bouton de réglage de l’ampérage (5) est tourné, l’indicateur d’ampérage bouge et indique les amps approx. de soudage.

7. Indicateur lumineux de surcharge - s’allume si le facteur d’utilisation est dépassé.

Figure 1

14-Fr

Instructions d’utilisation et manual de pièces

WS4369 et WS4469

Généralités Sur la Sécurité (Suite)

GÉNÉRALITÉ

• Lire et comprendre toutes instructions avant de démarrer un soudeur à l’arc ou de procéder à son entretien. Ne pas suivre les précautions et instructions de sécurité peut mener à des blessures graves, perte de vie ou dommage matériel. Pour plus d’information concernant la sécurité, obtenir la publication ANSI Standard Z49.1

- Safety in Welding and Cutting. Cette publication est disponible à l’American Welding Society, 550 NW. LeJune Rd., Miami, FL 33135.

Toujours

avoir un extincteur d’incendie disponible pendant le soudage à l’arc.

• Toute installation, entretien,

réparation et utilisation de cet équipement doivent être effectués par des personnes qualifiées conformément aux codes nationaux, provinciaux et locaux.

La mauvaise utilisation des soudeurs à l’arc peut mener à des chocs électriques, blessures, et perte de vie! Suivre toutes les précautions indiquées dans ce manuel afin de réduire le risque de choc électrique.

• S’assurer que toutes les pièces du

soudeur à l’arc sont propres et en bon état avant d’utiliser le soudeur. S’assurer que l’isolation sur tous les câbles, porte-électrodes et cordons d’alimentation n’est pas endommagée. Toujours réparer ou remplacer les pièces détachées qui sont endommagées avant d’utiliser le soudeur. Toujours maintenir les panneaux et couvercles de soudage en place pendant l’uilisation du soudeur.

• Toujours porter des vêtements

protecteurs et gants de soudage secs, et des chaussures isolantes.

• Toujours utiliser le soudeur dans un

endroit propre, sec et bien ventilé. Ne jamais utiliser de soudeur dans un endroit humide, trempé, pluvieux, ou mal-ventilé.

MANUEL

• S’assurer que l’objet sur lequel

vous travaillez est bien fixé et mis à la terre correctement avant de commencer votre soudage électrique à l’arc.

• Le câble de soudage roulé devrait

être déroulé avant l’utilisation afin d’éviter le surchauffage et les dommages à l’isolation.

Ne jamais immerger

l’électrode ou le porte-électrode dans l’eau. Si le soudeur devient trempé, il est nécessaire qu’il soit complètement sec et propre avant l’utilisation!

• Toujours mettre l’équipement hors

circuit et le débrancher avant de le déplacer.

• Toujours brancher d’abord le

conducteur de terre.

• Vérifier que l’objet sur lequel

vous travaillez soit mis à la terre correctement.

• Toujours mettre l’équipement de

soudage électrique à l’arc hors circuit s’il n’est pas utilisé et enlever l’électrode du porte-électrode.

• Ne jamais permettre que votre

corps touche l’électrode et le contact à la terre, ou l’objet sur lequel vous travaillez en même temps.

• Les conditions et positions de

soudage difficiles peuvent poser des risques électriques. Si vous êtres accroupis, à genoux ou surélevé, s’assurer que toutes les pièces conductrices sont isolées. Porter des vêtements protecteurs convenables et prendre des précautions contre les chutes.

• Ne jamais essayer d’utiliser cet

équipement aux réglages de courant ou facteurs d’utilisation plus hauts que ceux indiqués sur les étiquettes de l’équipement.

• Ne jamais utiliser de soudeur

électrique à arc pour dégeler les tuyaux congelés.

Les

étincelles volantes et le métal chaud peuvent causer des blessures. La scorie peut s’échapper quand les soudures refroidissent. Prendre toutes les précautions indiquées dans ce manuel pour réduire la possibilité de blessure par les étincelles volantes et le métal chaud.

• Porter un masque de soudure

approuvé par ANSI ou des lunettes protectrices avec écrans protecteurs latéraux pendant le burinage ou l’ébarbage des pièces en métal.

• Utiliser des protège-tympans pour

le soudage aérien afin d’éviter que la scorie ou la bavure tombe dans les oreilles.

soudage électrique à l’arc produit une lumière intense, de la chaleur et des rayons ultraviolets (UV). Cette lumière intense et ces rayons UV peuvent causer des blessures aux yeux et à la peau. Prendre toutes les précautions indiquées dans ce manuel afin de réduire la possibilité de blessure aux yeux et à la peau.

• Toutes les personnes qui utilisent

cet équipement ou qui sont sur place pendant l’utilisation de l’équipement doivent porter des vêtements de soudage protecteurs y compris: masque ou casque de soudeur ou écran avec filtre indiqué sur le tableau suivant, vêtements incombustibles, gants de soudeur en cuir, et protection complète pour les pieds.

Courant

(Amps)

Lentille

Filtrante

Jusqu’à 160 Amps 10

160 à 250 Amps 12

Ne jamais observer

le soudage sans protection pour les yeux indiqué cidessus. Ne jamais utiliser de lentille filtrante fendue, cassée, ou classifiée moins que 10. Avertir les autres personnes sur place de ne pas regarder l’arc.

soudage électrique à l’arc produit des étincelles et chauffe le métal à des températures qui peuvent causer des brûlures graves ! Utiliser des gants et des vêtements protecteurs pendant tout travail de métal. Prendre toutes les précautions indiquées dans ce manuel afin de réduire la possibilité de brûlures de peau ou de vêtements.

15-Fr

+ 33 hidden pages

Campbell Hausfeld WS4369, WS4469, IN973900AV User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual