Campbell Hausfeld WF2058 User Manual 2

Heat Circuit Breaker or

Selector Slow Blow Fuse

Low 15 amp

High 20 amp

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.

IN972800AV 11/04

Operating Instructions & Parts Manual Models WF2050, WF2054, WF2057 & WF2058

Wire Feed Arc Welder

Description

This Campbell Hausfeld welder is a 70 amp, single phase 115 volt input, wire feed arc welding machine. This unit is 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 the Flux Cored Arc Welding (FCAW) process. As delivered from the factory, this welder can weld with .030” (.8 mm) or .035” (.9 mm) diameter flux-cored wire. A starter spool of .035” (.9 mm) wire is included.

Unpacking

All welding accessories for the welder are inside the wire feed compartment on side of welder.

When unpacking, inspect carefully for any damage that may have occurred during transit. Make sure any loose fittings and screws, etc. are tightened before putting unit into service. Report

any missing or damaged items by calling 1-800-746-5641.

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.

General Safety

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.

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

See page 5 for supply cable replacement instructions.

Components and Controls

1. Work Clamp - connects to work piece.

2. Wire Feed Gun with .035” tip.

3. Power Cord - plug into 115 volt outlet.

4. On/Off Switch.

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

6. Heat Selector - Selects welding power. Two selections are possible; low and high.

7. Light - illuminates if thermostat has automatically shut off unit.

8. Wire Feed Compartment.

For parts, manuals, product & service information

visit www.chpower.com

Figure 1 - Welder Components and Controls

REMINDER: Keep your dated proof of purchase for warranty purposes! Attach it to this manual or file it for safekeeping.

Service Record État de Service Registro de servicio

Models WF2050, WF2054, WF2057 & WF2058 Modèles WF2050, WF2054, WF2057 & WF2058 Modelos WF2050, WF2054, WF2057 & WF2058

Wire Feed Arc Welder Soudeur À L’Arc Alimenté En Fil Soldadora Con Arco Con Alambre Continuo

Date Date Fecha

Maintenance performed Entretien complété Mantenimiento realizado

Replacement components required Pièces de rechange exigées Repuestos requeridos

Operating Instructions and Parts Manual Manual de Instruccones y Lista de Repuestos Instructions D’Utilisation et Manuel de Pièces

www.chpower.com

BUILT TO LAST

Assistance?

Call Us First!

1-800-746-5641

CAUTION

DANGER

WARNING

CAUTION

WARNING

Need

39 Sp

Garantía Limitada 5-3-1

1. Duración: El fabricante garantiza que reparará, sin costo alguno por repuestos o mano de obra la soldadora o la pistola o

los cables que estén dañados bien en material o mano de obra, durante los siguientes periodos después de la compra original: Por 5 años: El transformador y rectificador de la soldadora Por 3 años: Toda la soldadora (se excluyen: pinzas, pistola,portaelectrodos, cables, o accesorios que vienen con la soldadora) Por 1 año: Pinzas, Pistola, Portaelectrodo, Acessorios y Cable para Soldar (de haberlos)

2. QUIEN OTORGA ESTA GARANTIA (EL GARANTE):

Campbell Hausfeld The Scott Fetzer Company 100 Production Drive Harrison, OH 45030 Teléfono: (513)-367-4811

3. BENEFICIARIO DE ESTA GARANTIA (EL COMPRADOR): El comprador original del producto Campbell Hausfeld.

4. Cobertura de la garantía: Defectos en material y fabricación que ocurran dentro del periodo de validez de la garantía. La

garantía cubre la soldadora, el transformador y rectificador, la pistola o el portaelectrodo y los cables sólamente.

5. Lo que no está cubierto por esta garantía:

A. Las garantías implicitas, incluyendo las garantías de comercialidad y conveniencia para un fin particular SON LIMITADAS A LA DURACION EXPRESA DE ESTA GARANTIA. Después de este periodo, todos los riegos de pérdida, por cualquier razón, serán la responsabilidad del propietario del producto. En algunos estados no se permiten limitaciones a la duración de las garantías implicitas, por lo tanto, en tal caso esta limitación o exclusión no es aplicable. B. CUALQUIER PERDIDA, DAÑO INCIDENTAL, INDIRECTO O CONSECUENTE O GASTO QUE PUEDA PUEDA RESULTAR DE UN DEFECTO, FALLA O MAL FUNCIONAMIENTO DEL PRODUCTO CAMPBELL HAUSFELD. En algunos estados no se permite la exclusión o limitación de daños incidentales o consecuentes, por lo tanto, en tal caso esta limitación o exclusión no es aplicable. C. Esta garantía no cubre aquellos accesorios que se desgastarán con el uso normal del producto; la reparación o reemplazo de los mismos será la responsabilidad del propietario. Ejemplos de los productos de desgaste por el uso son (lista parcial): Bqouillas de contacto, boquillas, forros internos de la pistola, bobinas, felpa para limpiar el alambre . Además, esta garantía no cubre daños que ocurran al reemplazar o darle servicio a las piezas arriba enumeradas. D. Cualquier falla que resulte de un accidente, abuso, negligencia o incumplimiento de las instrucciones de funcionamiento y uso indicadas en el(los) manual(es) que se adjuntan al producto. E. Servicio antes de entrega, por ejemplo ensamblaje y ajustes.

7. Responsibilidades del Garante bajo esta Garantía: Reparar o reemplazar, como lo decida el garante, los productos o componentes defectuosos durante el periodo de validez de la garantía.

8. Responsibilidades del Comprador bajo esta Garantía:

A. Entregar o enviar el producto o componente a Campbell Hausfeld. Los gastos de flete, si los hubiere, deben ser pagados por el comprador. B. Ser cuidadoso con el funcionamiento del producto, como se indica en el(los) manual(es) del propietario.

9. Cuando efectuará el garante la reparación o reemplazo cubierto bajo esta garantía: La reparación o reemplazo dependerá del flujo normal de trabajo del centro de servicio y de la disponibilidad de repuestos.

Esta garantía limitada le otorga derechos legales especificos y usted también puede tener derechos que varian de un estado a otro.

Modelos WF2050, WF2054, WF2057 & WF2058

Operating Instructions and Parts Manual

General Safety (Continued)

 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 work 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 cored wire 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 at least shade 10 lens, flame resistant clothing, leather welding gloves, and full foot protection.

The welding wire is

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

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, etc.

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.

www.chpower.com

WARNING

DANGER

WARNING

CAUTION

WARNING

38 Sp

Manual de Instruccones y Lista de Repuestos

Modelos WF2050, WF2054, WF2057 & WF2058

Notes

General Safety (Continued)

 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 wire gun and work cables

together and secure with tape when possible.

 Never wrap arc welder cables around

the body.

 Always position the wire gun 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 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. Le June 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

Assembly

WIRE INSTALLATION NOTE: Before installing welding wire,

be sure:

a. Diameter of welding wire matches

groove in drive roller on wire feed mechanism (See Fig. 2). The drive roller is marked with metric sizes: .6mm = .024”, .8 - .9mm = .030 – .035”

b. Wire matches contact tip in end of

gun. (See Fig. 3).

A mismatch on any item could cause the wire to slip and bind.

NOTE: Always maintain control of loose end of welding wire to prevent unspooling.

1. Verify unit is off and open door panel to expose wire feed mechanism.

2. Remove the spool quick lock by pushing in and rotating 1/4 turn counterclockwise. Then remove knob, spring and spool spacer.

3. Flip tensioning screw down on drive mechanism. This allows initial feeding of wire into gun liner by hand.

4. Install wire spool onto spindle so wire can come off spool on the end closest to the wire feed guide tube.

Do not cut the wire loose yet.

Install spool spacer, spring and quick lock knob by pushing in and turning knob 1/4 rotation clockwise.

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

6. Feed wire through wire feed guide tube, over the groove in drive roller and into gun liner. Flip tensioning screw up and adjust tension by rotating tensioning screw knob. Do not overtighten.

7. Remove nozzle by turning counterclockwise, then unscrew contact tip from end of welding torch (See Figure 3). Plug welder into a proper power supply receptacle.

8. Turn on welder and set wire speed rate to 10. Activate gun trigger until wire feeds out past the torch end. Turn welder off.

9. Carefully slip contact tip over wire and screw tip into torch end. Install nozzle by turning clockwise (See Figure 3). Cut wire off approximately 1/4 inch from nozzle end.

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, Quincy, 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, wire, coatings and cleaners.

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. 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 flux cored wire in a clean, dry

location with low humidity to reduce oxidation.

 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 on page 1 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.

Models WF2050, WF2054, WF2057 & WF2058

www.chpower.com

WARNING

37 Sp

Modelos WF2050, WF2054, WF2057 & WF2058

Figure 12 - Modèlos WF2050, WF2054,

WF2057 & WF2058

No. de Ref. Descripción No. del repuesto Ctd.

1 Ensamble de soplete y manguera (fundente revestido, 2,44 m, WF2050 & WF2057) WC403650AV 1

Ensamble de soplete y manguera (fundente revestido, 3,05 m, WF2054 & WF2058) WC404000AV 1

2 Punta de contacto - 0,035” (0,9 mm, 3,05 m, WF2054 & WF2058) WT501400AV 1

Punta de contacto opcional – 0,030” (0,8 mm) Paquete de 4 WT501300AJ †

Punta de contacto opcional – 0,035” (0,9 mm) Paquete de 4 WT501400AJ † 3 Boquilla WT502100AV 1 4 Portabobinas WC500805AV 1 5 Ensamble de la placa de conducción WC500800AJ 1

6 Vástago y rejilla WC707018AV 1 7 Retén de la bobina WC707024AV 1 8 Resorte del retén de la bobina WC707026AV 1 9 Anillo del retén de la bobina WC707023AV 1 10 Alambre de soldar c/fundente – 0,030” (0,8 mm) Bobina de 2 lb (0,9 kg) (E71T-GS) WE200001AV †

Alambre de soldar c/fundente – 0,030” (0,8 mm) Bobina de 10 lb. (4,54 kg) (E71T-GS) WE201000AV †

Alambre de soldar c/fundente – 0,035” (0,9 mm) Bobina de 2 lb. (0,9 kg) (E71T-GS) WE200501AV †

Alambre de soldar c/fundente – 0,035” (0,9 mm) Bobina de 10 lb. (4,54 kg) (E71T-GS) WE201500AV † 11  Máscara de mano (no se incluyen lentes) (WF2050 & WF2058) WC801700AV 1

12  Lentes oscuros (para máscara de mano) (WF2050, WF2054 & WF2058) WC801100AV 1 13  Martillo/cepillo cincelador WC803400AV 1 14  Etiqueta adhesiva de seguridad DK688509AV 1 15  Pinza de tierra (WF2050) WC100300AV 1

 Pinza de tierra (WF2054, WF2057 & WF2058) WC100600AV 1 16  Guantes para soldar (sólo WF2054, WF2057 & WF2058) WT200501AV 1 17  Casco de soldar (sólo WF2057) WT100500AV 1

 No se muestran

† Accesorio opcional

HANDSHIELD

1. Cut detachable handle (WF2050, WF2054 & WF2058 only; WF2057 is supplied with a fully assembled helmet) away from shield. Trim the excess plastic to remove sharp edges (See Figure 4).

2. To attach the handle, place shield on a flat surface and press handle into place (See Figure 4).

3. Insert filter lens exactly as shown in Figure 5.

NOTE: If you have never welded before or have little experience, a full face

Operating Instructions and Parts Manual

Assembly (Continued)

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 front panel if the duty cycle is exceeded.

Welding operations may continue when the yellow lamp is no longer illuminated.

POLARITY

This welder is configured for DCEN, direct current electrode negative.

helmet is recommended. Both hands are needed to stabilize and control the angle and arc length of the electrode.

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.

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.

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 work 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 (See decal inside wire feed compartment).

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 circuit requirements on front page).

Contact Tip Markings

Mark Wire Size

0.8 mm 0.030”

0.9 mm 0.035”

www.chpower.com

Torch Diffuser

Contact Tip

Nozzle

Figure 3 - Torch Nozzle

Spindle

Welding wire

Tensioner ring

Tension spring

Retainer

Tensioner knob

Guide tube

Tensioner arm

Drive deck

Roller support

Drive roller

Figure 2 - Weld Wire Routing

Figure 4

Figure 5

Metal Heat

Thickness Setting

14 - 18 Gauge Low

Thicker Than 14 Gauge High

WARNING

36 Sp

Manual de Instruccones y Lista de Repuestos

No funciona

El alambre se enrolla en la bobina

La boquilla se pega a la superficie de trabajo

La pinza de conexión a la pieza de trabajo y/o el cable se calientan

El alambre no circula

1. Excedio el ciclo de trabajo

2. Mala conexión a la pieza de trabajo

3. El interruptor ON/OFF está defectuoso

4. El fusible o cortacircuito está quemado

1. La boquilla de la pistola no es del tamaño adecuado

2. El forro interno de la pistola está atascado o dañado

3. La boquilla de la pistola está atascada o dañada

4. La bobina está desgastada

5. No tiene suficiente tensión

Hay escorias dentro de la boquilla de la pistola

Mala conexión

1. Está atascado

2. Se terminó el cable en la bobina

3. No tiene suficiente tensión

4. El forro está desgastado

1. Permita que la soldadora se enfríe hasta que la lámpara se apague.

2. Cerciórese de que todas las conexiones estén bien apretadas y de que las superficies estén limpias

3. Reemplace el interruptor

4. Reduzca la carga del circuito, active el cortacircuito o reemplace el fusible

1. Use una boquilla del tamaño adecuado

2. Limpie o reemplace el forro interno de la pistola

3. Limpie o reemplace la punta de la pistola

4. Reemplácela

5. Apriete el tornillo de tensión

Limpie la boquilla de la pistola

Cerciórese de que todas las conexiones estén bien apretadas y de que las superficies estén limpias

1. Instale el cable una vez más

2. Reemplácelo

3. Apriete el tornillo de tensión si el alambre se está saliendo

4. Reemplácelo

Reborde es muy delgado en algunos sitios

Reborde es muy grueso en algunos sitios

Los bordes de la soldadura están disparejos

El reborde no penetra el metal básico

El electrodo salpica y se pega

1. La velocidad de desplazamiento varia

2. El nivel del amperaje es muy bajo

1. La velocidad de desplazamiento varia o es muy lenta

2. El nivel del amperaje es muy alto

1. La velocidad de desplazamiento es muy rápida

2. La velocidad de alimentación es muy rápida

3. El nivel del amperaje es muy alto

1. La velocidad de desplazamiento varía

2. El nivel del amperaje es muy bajo

3. El cordón de extensión es demasiado largo

1. El alambre está húmedo

2. La velocidad del alambre está muy rápida

3. El alambre es del tipo incorrecto

1. Debe reducirla y mantenerla constante

2. Debe aumentarlo

1. Debe aumentarla y mantenerla constante

2. Debe bajarlo

1. Debe reducirla

2. Debe aumentarla

3. Debe bajarlo

1. Debe reducirla y mantenerla constante

2. Debe aumentarlo

3. Use un cordón de extensión que no sea de más de 6,10 m

1. Use un alambre seco y siempre debe almacenarlo e un sitio seco

2. Reduzca la velocidad del alambre

3. Use sólo alambre de fundente revestido (No use alambres para soldadoras MIG, o alambre de cobre)

Guía de diagnóstico de averías - Soldadora

Problema Posible(s) Causa(s) Acción a tomar

Guía de diagnóstico de problemas - Soldadura

Problema Posible(s) Causa(s) Acción a tomar

Operation (Continued)

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.

Maintenance

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 to be changed.

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 - The WF2050 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 E71T-GS or E71T-11, .030” (.8mm) or .035” (.9mm) diameter.

Models WF2050, WF2054, WF2057 & WF2058

www.chpower.com

Supply Cable Replacement

1. Verify that welder is OFF and power cord disconnected.

2. Remove welder cover to expose the ON/OFF switch.

3. Disconnect the black power cord wire connected to the ON/OFF switch and the white power cord wire from the transformer windings.

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

5. Loosen the cord strain relief screw(s) and pull cord out of strain relief and wire post.

6. Install new cord in reverse order.

WARNING

35 Sp

Modelos WF2050, WF2054, WF2057 & WF2058

General

This line of welding machines utilizes a process called Flux Cored Arc Welding (FCAW). The FCAW process uses a tubular wire with a flux material inside. Shielding is obtained from the decomposition of the flux within the tubular wire. 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 in Figure 6.

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. Heat or voltage is regulated by a switch on the welder. The heat setting used depends on the size (diameter) and type of wire, position of the weld, and the thickness of the work piece. Consult specifications listed on the welder or generalized chart in the Operation section. It is suggested that the welder practice with scrap metal to adjust settings, and compare welds with Figure 11.

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 (FCAW process) is a multi digit number preceded by the letter E.

WELD ANGLE

Weld angle is the angle at which the diffuser nozzle 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, nozzle angle becomes an increasingly important factor in obtaining a satisfactory weld. Weld angle involves two positions - travel angle and work angle.

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 cored wire Flux type

AWS E71T-GS or E71T-11 is recommended for these welders.

Operating Instructions and Parts Manual

Welding Guidelines

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.

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. Tuning is one of the most critical functions in wire feed welding. Tuning should be performed on a scrap piece of metal the same type and thickness as that to be welded. Begin welding with one hand “dragging” the gun nozzle across the scrap piece while adjusting the wire speed with the other hand. Too slow of speed will cause sputtering and the wire will burn up into the contact tip (See Figure 11). Too fast a speed will also cause a sputtering sound and the wire will push into the plate before melting. A smooth buzzing sound indicates the wire speed is properly tuned. Repeat the tuning procedure each time there is a change in heat setting, wire diameter or type, or work piece material type or thickness.

TRAVEL SPEED

The travel speed is the rate at which the wire 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. 11). 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

www.chpower.com

Slag

Weld

Wire

Flux

Work Piece

Diffuser Nozzle

Contact Tip

Crater

Figure 6 - Weld Components

Travel Angle

Work Angle

5º - 45º

Figure 7 - Weld Angle

CA o Corriente Alterna - corriente

eléctrica que cambia de dirección periódicamente. Corriente de 60 ciclos se desplaza en ambas direcciones 60 veces por segundo.

Longitud del Arco - la distancia entre el extremo del electrodo y el punto de contacto con la superficie de trabajo.

Metal Básico - el material que se va a soldar.

Unión a tope - la unión de dos miembros alineados aproximadamente en el mismo plano.

Cráter - el vacio que se forma cuando el arco hace contacto con el metal básico.

CD o Corriente Directa - corriente eléctrica que se deplaza en un sólo sentido. La polaridad (+ o -) determina el sentido del desplazamiento.

CD Polaridad Reversa - ocurre cuando el portaelectrodo está conectado al polo positivo de la soldadora. Esta tecnica dirije más calor para derretir el electrodo en vez de la pieza de trabajo. Generalmente esta técnica se usa con piezas delgadas.

CD Polaridad Directa - oocurre cuando el portaelectrodo está conectado al polo negativo de la soldadora. Con esta tecnica la mayoría del calor se dirije a la pieza de trabajo para lograr una mayor penetración en piezas gruesas.

Electrodo - un alambre de metal con una capa que tiene aproximadamente la misma composición del material que se va a sol-dar.

Soldadura de Filete - soldadura triangular, para unir dos superficies en ángulo recto, en T o en las esquinas.

Fundente - un material, que al calentarse, emite un gas que cubre el área donde va a soldar. Este gas protege los metales que va a soldar contra las impurezas presentes en el aire.

Soldar con Arcos de Fundente también se conoce como soldar sin gas, esta técnica para soldar usa una soldadora con alambre. El alambre es tubular y lleno de fundente.

Soldar con Arcos de Metal Gaseoso ,

es un proceso para soldar usado con una soldadora con alambre. El alambre es sólido y se usa un gas inerte.

Soldar con Arcos de Tungsteno - es un proceso para soldar usado con soldadoras con generadores de alta frecuencia. El arco se crea con un electrodo no-consumible de tugnsteno. No necesariamente se usa metal de relleno.

Unión de superposición - la unión de dos miembros superpuestos en planos parale-los.

Voltaje de circuito abierto - el voltaje entre el electrodo y la pinza de conexión a tierra de la soldadora cuando no hay flujo de corriente (no se está soldando). Esto determina la rápidez con que se enciende el arco.

Sobremonta - ocure si el amperaje es demasiado bajo. En este caso, el metal derretido se cae del electrodo sin haberse unido al metal básico.

Porosidad - cavidad que se forma durante la solidificación del área soldada. Las porosidades debilitan la unión.

Penetración - la profundidad que el arco se penetra dentro de la pieza de trabajo durante el proceso de soldar. Para soldar bien se debe lograr 100% de penetración, es decir todo el grosor de la pieza de trabajo se debe derretir y solidificar. El área afectada por el calor se debe ver facilmente desde el otro lado.

Soldar con arcos protegidos - es un proceso de soldar que usa un electrodo consumible para sostener el arco. La protección se logra al derretir el fundente del electrodo .

Escoria - una capa de residuo de fundente que protege la unión de óxidos y otros contaminantes mientras los metales se solidifican (enfrian). Este se debe limpiar una vez que el metal se haya enfriado.

Salpiqueo - las particulas de metal que salpican durante el proceso de soldar y que se solidifican en la superficie de trabajo. Esto se puede minimizar al rociar un repelente adecuado antes de comenzar a soldar.

Soldadura de puntos - una unión hecha para mantener las piezas alineadas hasta que se haya completado el proceso de soldar.

Angulo de desplazamiento - el angulo del electrodo con respecto a la línea a soldar. Este varia entre los 5º y 45º según sean las condiciones.

Unión en T - es la unión del borde de una pieza de metal con la superficie de otra en un ángulo de 90º .

Socavación - el resultado de soldar con un amperaje demasiado alto. Esto ocasiona ranuras en ambos lados de la reborde que reduce la resistencia de la unión.

Sedimento - el volumen de metal derretido al soldar antes de que se solidifique como metal soldado.

Reborde - una capa delgada o capas de metal depositado en el metal básico cuando el electrodo se derrite. Generalmente su grosor es el doble del diámetro del electrodo.

Angulo de trabajo- el ángulo del electrodo con respecto a la línea horizontal, medido en ángulos rectos a

Glosario de Terminología Usada por Soldadores

WARNING

+ 14 hidden pages

Campbell Hausfeld WF2058 User Manual 2

Specifications and Main Features

Frequently Asked Questions

User Manual