Campbell Hausfeld WF2034 User Manual

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.

IN970300AV 11/00

Operating Instructions & Parts Manual Model WF2034

Wire Feed Arc Welder

The Campbell Hausfeld WF2034 is a 70 amp, single phase 115 volt input, wire feed arc welding machine equipped with infinite wire speed control to accurately select the proper wire feed rate needed for various welding conditions. Internal components are thermostatically protected.

This welding system is designed for use with Flux Core Arc Welding (Gasless) only. As delivered from the factory, this welder can weld with .030” (.8mm) to .035” (.9mm) diameter flux-cored wire. A starter spool of .035” flux-cored wire is included.

Unpacking

Some welder components may be found in the wire feed compartment.

When unpacking, inspect carefully for any damage that may have occurred during transit. Report any damaged or missing items by calling (800) 746-5641.

Circuit Requirements

This equipment

requires a dedicated 115 volt circuit. Refer to the following chart 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.

Components and Controls

1. Ground Clamp - connect to work piece.

2. Wire Feed Gun

3. Power Cord - plug into 115 volt outlet.

4. On/Off Switch

5. Heat Selector - Selects welding power (high/low).

6. Infinite Wire Speed Control turn clockwise to increase wire speed and counterclockwise to decrease wire speed.

Heat Circuit Breaker or Selector Slow Blow Fuse

Danger means a

hazard that will cause death or serious injury if the warning is ignored.

Warning means a

hazard that could cause death or serious injury if the warning is ignored.

Caution means a

hazard that may cause minor or moderate injury if the warning is ignored. It also may mean a hazard that will only cause damage to property.

NOTE: Note means any additional information pertaining to the product or its proper usage.

Low 15 amp

High 20 amp

Description

General Safety

Figure 1

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CAUTION

DANGER

WARNING

CAUTION

Wire Feed Arc Welder

Always keep a fire extinguisher accessible while performing arc welding operations.

● 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.

● 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, wire feed gun, 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

wire or wire feed gun 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 cut off any excess wire from the wire feed gun.

● Never allow any part of the body to

touch the flux core wire and ground or grounded work piece at the same time.

● 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 at least shade 10 filter, flame resistant clothing, leather welding gloves, and full foot protection.

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.

● 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.

General Safety

(Con’t)

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WARNING

DANGER

WARNING

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.

● Store flux core wire in a clean, dry location with low humidity to preserve the flux wire coating.

● 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.

HANDLE ASSEMBLY

1. Pull rod on both sides of wire feed

door and lift to open.

2. Bolt plastic handle caps to cover as

shown (Figure 2).

3. Slide metal handle through caps and

attach with screws.

Ground Clamp

1. Loosen hex bolt on work clamp.

2. Insert cord (labeled work on the front

panel of the welder) through clamp handle and slide bare wire under the clamp block. Tighten hex bolt making sure bare wire is clamped securely (Figure 3).

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.

Model WF2034

● Never wrap arc welder cables around 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 equipment is turned off and excess wire is cut off. Be sure that cables are loosely coiled and out of the way. Be sure that all metal and slag has cooled.

ADDITIONAL SAFETY STANDARDS ANSI Standard Z49.1 from American

Welding Society, 550 N.W. LeJune Rd. Miami, FL 33126

Safety and Health Standards

OSHA 29 CFR 1910, from Superintendent of Documents, U.S. Government Printing Office, Washington, D.C. 20402

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

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

General Safety

(Con’t)

Installation

Assembly

Figure 2 - Handle Assembly

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WARNING

Flux Core Wire Installation

Welding power

is applied to the output terminals, feed roll, ground clamp, gun cable connection and welding wire even when the gun switch is not activated. Do not touch these parts when the welding machine is on.

NOTE: Before installing welding wire, be sure that the diameter of the welding wire matches the contact tip in the end of the gun. The wire size is marked on the contact tip in inches or

mm. (See chart below).

1. Verify the unit is off and lift the door

on the welder to expose the wire feed mechanism.

2. Remove the spool quick lock, by

pushing in and rotating 1/4 turn counterclockwise. The knob, spring, and spool spacer can now be removed.

3. Loosen the wire feed tensioning

screw on the drive mechanism. This allows initial feeding of the wire into the gun liner by hand.

4. Install the wire spool onto the

spindle so that the wire can come off the spool on the end closest to the wire feed guide tube. Do not cut the wire loose yet. Install the spool spacer, spring, and quick lock knob by pushing in and turning the knob 1/4 rotation clockwise.

5. Hold the wire and cut the wire end

from the spool. Do not allow the wire to unravel. Be sure that the end of the wire is straight and free of burrs.

6. Feed the wire through the wire feed guide tube, over the groove in the drive roll and into the gun liner. Tighten the wire feed tensioning screw so that it is snug. Do not over tighten.

7. Remove the nozzle by turning counterclockwise. Then, unscrew the contact tip from the end of the welding torch. (See Figure 6). Plug the welder into the proper power supply receptacle.

8. Turn on the welder and set the wire speed rate to 8. Activate the gun switch until the wire feeds out past the torch end. (See Figure 5.) Turn

welder off.

9. Carefully slip the contact tip over the wire and screw it into the torch diffuser. (See Figure 6.) Install the nozzle by twisting clockwise. Cut the wire off approximately 1/4 inch from the end of the nozzle.

Wire Feed Arc Welder

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 10% duty cycle, actual welding can occur for one minute, then the welder must cool for nine minutes.

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

1. Be sure to read, understand, and comply with all precautions in the General Safety Information section and Welding Guidelines prior to using this equipment.

2. Verify welder is off.

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, flame resistant clothing, leather welding gloves, and full foot protection.

The welding wire is

live whenever the welder is turned on — whether or not the trigger is pulled.

Figure 4 - Weld Wire Routing

Torch Diffuser

Contact Tip

Nozzle

Figure 6 - Torch Nozzle

Figure 3 - Ground Clamp Assembly

Contact Tip Markings

Wire Size mm

.030” or .8

.035” or .9

Figure 5 - Wire Feed Gun

Operation

Spool Lock

Spool Spring

Spacer

Guide Tube

Tension Screws

Tension Screw

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WARNING

CAUTION

MANUAL

Metal Heat Thickness Setting

Model WF2034

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. Avoid surfaces with paint, varnish, corrosion, or non-metallic materials.

5. Position the Heat Selector on the front panel to the desired setting.

NOTE: These settings are general guidelines only. Heat setting may vary according to welding conditions and materials.

6. Rotate the Wire Speed Control to setting number 5 to start with, then adjust as needed after test weld.

7. Plug the input cord into a proper voltage receptacle with proper circuit capacity. (See Chart under circuit requirements on page 1).

8. Switch the welder ON/OFF switch to the ON position.

9. Verify that the wire is extended 1/4” from the contact tip. If not, squeeze the trigger to feed additional wire, release the trigger, and cut wire to proper length.

10. Position the wire feed gun near the work piece, lower the welding helmet by nodding the head, or position the hand shield, and squeeze the gun trigger. Adjust heat setting and wire speed as needed.

11. When finished welding, turn welder off and store properly.

Disconnect power

supply and turn machine off before inspecting or servicing any components. Keep the wire compartment cover closed at all times unless the wire needs replacement.

Before every use:

1. Check condition of weld cables and immediately repair or replace any cables with damaged insulation.

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

3. Inspect the condition of the gun tip and nozzle. Remove any weld slag. Replace gun tip or nozzle if damaged.

Do not operate this

welding machine with cracked or missing insulation on welding cables, wire feed gun, or power cord.

Every 3 months:

1. Replace any unreadable safety

labels on the welder.

2. Use compressed air to blow all dust

and lint from the ventilation openings.

3. Clean the wire groove on the drive

roll. Remove wire from the feed mechanism, remove screws from the drive roll housing. Use a small wire brush to clean the drive roll. Replace if worn or damaged.

Consumable and Wear Parts

The following parts require routine maintenance:

• Wire feed drive roller

• Gun liner - replace if worn

• Nozzle/contact tips

• Wire - This welder will accept either 4” or 8” diameter spools. Flux-cored welding wire is susceptible to moisture and oxidizes over time, so it is important to select a spool size that will be used within approximately 6 months. Use AWS type AWS E71T-GS or E71T-11, .030" (.8mm) or .035" (.9mm) diameter.

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for replacement parts

Operation

(Con’t)

14 -18 Gauge Low

Thicker than 18 Gauge High

Maintenance

Welding Guidelines

General

This line of welding machines utilizes the Flux Cored Arc Welding (Gasless) process. The weld must be protected (shielded) from contaminates in the air while it is molten. The gasless process uses a tubular wire with a flux material inside. The flux creates a shielding gas when melted.

When current is produced by a transformer (welding machine) and flows through the circuit to the weld wire, an arc is formed between the end of the weld wire and the work piece. This arc melts the wire and the work piece. The melted metal of the weld wire flows into the molten crater and forms a bond with the work piece as shown (Figure 7).

Arc Welding Basics

Five basic techniques affect weld quality. These are: wire selection, heat setting, weld angle, wire speed, and travel speed. An understanding of these techniques is necessary for effective welds.

HEAT SETTING

The correct heat involves the adjustment of the welding machine to the required setting. The heat setting used depends on the thickness of the work piece. Consult specifications listed on the welder. It is suggested that the welder practice with scrap metal to adjust settings, and compare welds with Figure 12.

Slag

Weld

Wire

Flux

Work Piece

Contact Tip

Crater

Nozzle

Figure 7 - Weld Components

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WARNING

WIRE TYPE AND SIZE

The correct choice of wire 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 wire.

The AWS classification for self-shielding wire (Gasless process) is a multi digit number preceded by the letter E.

FLUX-CORED WIRE E - 7

0 T

- GS Weld strength, times

10,000 pounds per square inch

Welding positions (0 for flat or horizontal, 1 for any position)

Tubular flux core wire Flux type

AWS E71T-GS or E71T-11 is recommended for this welder.

WELD ANGLE

Weld angle is the angle at which the nozzle is held during the welding process. Weld angle involves two positions - travel angle and work 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.

Wire Feed Arc Welder

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.

WIRE SPEED

The wire speed is controlled by the knob on the front panel. The speed needs to be “tuned” to the rate at which the wire is being melted in the arc. Too slow of speed will cause sputtering and the wire will burn up into the contact tip. Too fast a speed will also cause a sputtering sound and the wire will push into the plate before melting.

TRAVEL SPEED

The travel speed is the rate at which the torch is moved across the weld area. Factors such as diameter and type of weld wire, amperage, position, and work piece material thickness all effect the speed of travel necessary for completing a good weld (See Fig. 12). When the speed is too fast, the bead is narrow and bead ripples are pointed as shown. When the speed is too 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

Welding Guidelines (Continued)

clean-up is done with a wire brush. When making multiple weld passes, remove the slag before each pass.

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 wire 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.

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

WELD PASSES

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.

TRAVEL ANGLE

WORK ANGLE

5º - 45º

Figure 8 - Weld Angle

Figure 9 - Weld Passes

Cover

Filler

Root

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WARNING

Model WF2034

Welding Guidelines (Continued)

Figure 10 - Multiple Weld Passes

PUSH VS PULL TECHNIQUE

The type and thickness of the work piece dictates which way to point the gun nozzle. For thin materials (18 gauge and up), the nozzle should point out in front of the weld puddle and push the puddle across the workpiece. For thicker steel, the nozzle should point into the puddle to increase weld penetration. This is called backhand or pull technique (See Figure 11).

PUSH

PULL

Figure 11

Normal Heat, Wire Speed, Travel

Speed

Heat Too Low

Heat Too High

Wire Speed Too Fast

Wire Speed Too Slow

Travel Speed Too Slow

Travel Speed Too Fast

Base Metal

Figure 12 - Weld Appearance

Supply Cable Replacement

1. Unplug welder.

2. Remove the right side panel.

3. Disconnect the black and white power cord wires connected to the ON/OFF switch.

4. Disconnect the green power cord wire connected to the frame.

5. Loosen the cord strain relief screw and pull cord through front panel.

6. Install new cord in reverse order.

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Wire Feed Arc Welder

Troubleshooting Chart - Welder

Symptom Possible Cause(s) Corrective Action

1. Duty cycle exceeded

2. Poor ground clamp connection

3. Defective power switch

4. Blown breaker or fuse

1. Wrong size gun tip

2. Gun liner clogged or damaged

3. Gun tip clogged or damaged

4. Feed roller worn

5. Not enough tension

Slag inside gun nozzle

Poor contact

1. Wire jammed

2. Out of wire

3. Not enough tension

4. Wire liner worn

5. Fuse blown

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Bead is intermittently too thin

Bead is intermittently too thick

Ragged depressions at edge of weld

Weld bead does not penetrate base metal

Wire sputters and sticks

1. Inconsistent travel speed

2. Output heat setting too low

1. Slow and/or inconsistent travel speed

2. Output heat setting too high

1. Travel speed too fast

2. Wire speed too fast

3. Output heat setting too high

1. Inconsistent travel speed

2. Output heat setting too low

1. Damp wire

2. Wire speed too fast

1. Allow welder to cool until ON/OFF Switch lamp goes out

2. Be sure all connections are secure, and attaching surface is clean

3. Replace switch

4. Reduce circuit load, reset breaker or replace fuse

1. Use proper size gun tip

2. Clean or replace gun liner

3. Clean or replace gun tip

4. Replace

5. Tighten tensioning screw

Clean slag from gun nozzle

Be sure all connections are secure, and attaching surface is clean

1. Reload wire

2. Replace wire spool

3. Tighten tensioning screws if wire is slipping

4. Replace liner

5. Replace fuse on wire feed control board inside welder, (1.6 amp time delay)

No output

Wire tangles at drive roller

Gun nozzle arcs to work surface

Ground clamp and/or cable gets hot

Wire does not feed

Troubleshooting Chart - Welds

Symptom Possible Cause(s) Corrective Action

1. Decrease and maintain constant travel speed

2. Increase output heat setting

1. Increase and maintain travel speed

2. Reduce output heat setting

1. Decrease travel speed

2. Decrease wire speed

3. Reduce output heat setting

1. Decrease and maintain constant travel speed

2. Increase output heat setting

1. Use dry wire and store in dry location

2. Reduce wire speed

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Campbell Hausfeld WF2034 User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual