Campbell Hausfeld WG2040, WG2044, WG3000, WG2045 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.

IN971503AV 6/03

Operating Instructions & Parts Manual Model WG2040, WG2044, WG2045, WG3000

Wire Feed Arc Welder

This line of Campbell Hausfeld wire feed welders is designed to be used on standard 115V household current. The welders are 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 Core Arc Welding (FCAW) or the Gas Metal Arc Welding (GMAW) process. As delivered from the factory, this welder can weld with .024” (.6mm) to .035” (.9mm) diameter wire in MIG and .030” (.8mm) to .035” (.9mm) diameter wire in flux core. A starter spool of .035” (.9mm) flux core wire is included.

1. Work Clamp - connect to work piece.

2. Wire Feed Gun

3. Power Cord - plug into 115 volt outlet.

4. On/Off Switch - illuminates if thermostat has automatically shut unit off.

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

6. Heat Selector - Selects welding power. Four selections are possible; low 1, low 2, high 1 and high 2.

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.

Figure 1 - Welder Components and Controls

See page 7 for supply cable replacement instructions.

Unpacking

Welding accessories for the welder are packed inside the wire feed compartment. 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.

This equipment

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

Description

CIRCUIT REQUIREMENTS

COMPONENTS AND CONTROLS

General Safety

For parts, manuals, product & service information

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

Heat Circuit Breaker or Selector Slow Blow Fuse

Low 15 amp

High 20 amp

Assistance?

Need

Call Us First!

BUILT TO LAST

1-800-746-5641

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 all components of the arc

welder are clean and in good condition prior to operating welder. Be sure insulation on all cables, wire feed gun and power cord is not damaged. Always repair or replace damaged components before operating the welder. Always keep welder panels, shields, etc. in place when operating welder.

● Always wear dry, protective

clothing, welding gloves and insulated footwear when operating unit.

● Always operate welder in a clean,

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

● Be sure work piece is properly

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

● Spread out coiled welding cable

before use to avoid overheating and damage to insulation.

Never immerse

wire or wire feed gun in water. If welder becomes wet for any reason, be absolutely certain it is completely clean and dry before use!

● Always shut equipment off and

unplug power cord prior to moving the unit.

● Always attach the work lead first.

● Verify work piece is securely

grounded.

● Always shut off electric arc welding

equipment when not in use and cut off any excess wire from wire feed gun.

● Never allow any part of the body to

touch flux core 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 specified on 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.

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 all persons in 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 ensure flying

General Safety

(Continued)

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WARNING

MANUAL

DANGER

WARNING

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

● Keep head and face out of welding

fumes.

● Extremely toxic fumes are created

when galvanized or cadmium plated metals or metals which contain zinc, mercury or beryllium are heated. Complete the following precautions before performing electric arc welding operations on these metals:

a. Remove coating from base metal. b. Make sure welding area is well

ventilated.

c. Use an air-supplied respirator.

The electromagnetic field 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 wire gun and work cables

together and secure with tape when possible.

Never use

flammable gasses with MIG welders. Only inert or nonflammable gasses such as carbon dioxide, argon, helium or mixtures of one or more of these gasses are suitable for MIG welding.

Never lift cylinders

off the ground by their valves or caps or with chains or slings.

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

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 Material Safety Data Sheets and manufacturers instructions for metals, wire, coatings and cleaners.

● Never wrap arc welder cables around the body.

● Always position wire gun and work leads 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

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

Cylinders can explode if damaged. Shielding gas cylinders contain gas under high pressure. If damaged, a cylinder can explode. Since gas cylinders are normally part of the welding process, be sure to treat them carefully.

● Protect compressed gas cylinders

from excessive heat, mechanical shocks and arcs.

● Install and secure cylinders in an

upright position by chaining them to stationary support or equipment cylinder rack to prevent falling or tipping.

● Keep cylinders away from any

welding or other electrical circuits.

● Never allow a welding electrode to

touch any cylinder.

● Use only correct shielding gas

cylinders, regulators, hoses and fittings designed for the specific application; maintain all parts properly.

● Turn face away from valve outlet

when opening cylinder valve.

● Keep protective cap in place over

valve except when cylinder is in use or connected for use.

● Read and follow

instructions on compressed gas cylinders, associated equipment, and CGA publication P-1 listed in Safety Standards.

General Safety

(Continued)

Model WG2040, WG2044, WG2045, WG3000

ADDITIONAL SAFETY STANDARDS

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WARNING

DANGER

MANUAL

DANGER

WARNING

NOTE: Before installing welding wire,

be sure:

a. Diameter of welding wire matches

groove in drive roller on wire feed mechanism (See Fig. 5). 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. 6).

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

Wire Feed Arc Welder

LOCATION

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

● For best results locate welder in a clean and dry environment. Dust and dirt in the welder retain moisture and increase wear of moving parts.

● Place welder in an area with at least twelve inches (305 mm) of ventilation space at both the front and rear of unit. Keep all obstructions out of this ventilation space.

● Store welding wire in a clean, dry location with low humidity to prevent oxidation.

● Use a properly grounded receptacle for the welder and ensure welder is the only load on power supply circuit. Refer to chart on page 1 for correct circuit capacity.

● Use of an extension cord is not recommended for electric arc welding machines. Voltage drop in the extension cord may significantly degrade performance of the welder.

Welding accessories for the welder are inside wire feed compartment.

1. Place handle assembly on welder, aligning two holes in plastic ends with threaded holes in welder housing (Fig. 2).

2. Insert screws through cord wraps and handle ends and fasten into cabinet.

3. Attach cylinder base to unit as shown (Fig. 3).

1. Loosen hex bolt/nut on work clamp.

2. Insert cord (labeled ‘work clamp’ on the front panel of the welder) through clamp handle. Slide bare wire under clamp block. Tighten hex bolt/nut, making sure bare wire is clamped securely (Figure 4).

counterclockwise. Then remove knob, spring and spool spacer.

3. Loosen wire feed tensioning screw 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 roll and into gun liner. Snugly tighten wire feed tensioning screw. Do not over tighten. Three to four full turns is usually correct.

7. Remove nozzle by turning counterclockwise, then unscrew contact tip from end of welding torch (See Figure 6). 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 6). Cut wire off approximately 1/4 inch from nozzle end.

Figure 4a - Work Clamp Assembly (WG2040, WG2044, and WG2045)

Figure 3 - Base Assembly

Figure 2 - Handle Assembly

Assembly

Installation

HANDLE AND BASE ASSEMBLY

WORK CLAMP

WIRE INSTALLATION

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Figure 5 - Weld Wire Routing

Clamping Block

Figure 4b - Work Clamp Assembly (WG3000)

Clamping Block

Improper handling

and maintenance of compressed gas cylinders and regulators can result in serious injury or death! Always secure gas cylinders to tank bracket kit, a wall or other fixed support to prevent cylinder from falling over. Read, understand and follow all compressed gas and equipment warnings in the safety instructions.

NOTE: Shielding gas is not required if flux-cored welding wire is used.

There are 3 types of gas generally used for gas metal arc welding; 100% argon, a mixture of 75% argon and 25% carbon dioxide (C25) or 100% carbon dioxide.

Use ONLY the type

of gas recommended for your welder. Use ONLY an inert, non-flammable type of gas. Failure to do so will result in a very hazardous situation.

NOTE: 100% carbon dioxide is not recommended due to unsatisfactory weld beads.

The 75/25 mixture is recommended for general steel welding. For aluminum welding, use 100% argon. Cylinders of either type gas may be obtained at your local welding supply outlet. Secure cylinder in place on your welding machine or other support to prevent the cylinder from falling over.

Obtaining Correct Gas Type. The gas used in any welding application for your welder must be an INERT, NONFLAMMABLE TYPE. You can get the type of gas needed from a nearby welding gas distributor (often found in the yellow pages under “Welders” or ‘Welding Equipment”).

An adjustable regulator without gauges is supplied with this welder. The regulator provides a constant shielding gas pressure and flow rate during the welding process. Each regulator is designed to be used with a specific gas or mixture of gases. The argon and argon mixture use the same thread type. The 100% carbon dioxide uses a different thread type. An adapter is available at your local welding gas supplier to change between the two.

Cylinder gas is under high pressure. Point cylinder outlet away from yourself and any bystanders before opening.

1. With cylinder securely installed, stand on side of cylinder opposite cylinder outlet then remove cylinder cap and open valve slightly by turning

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 (on/off switch) if the duty cycle is exceeded. Welding operations may

continue when the yellow lamp is no longer illuminated.

To change between flux wire and MIG wire the polarity must be changed.

1. Open the wire feed door.

2. Locate red (+) and black (-) polarity connectors just above wire feed mechanism (See Figure 7).

3. For MIG welding with gas, connect torch cable from wire feed mechanism to red (+) polarity connector, then connect work cable to black (-) connector.

4. For flux-core welding, connect torch cable from wire feed mechanism to black (-) polarity connector, then connect work cable to red (+) connector.

Contact Tip Markings

Mark Wire Size

0.6 mm .024"

0.8 mm .030”

0.9 mm .035”

Assembly (Continued)

Model WG2040, WG2044, WG2045, WG3000

DUTY CYCLE / THERMOSTATIC PROTECTION

POLARITY

Shielding Gas Preparation

Figure 8 - Hookup

GAS TYPES

REGULATOR

HOOKUP PROCEDURE

Figure 7 - Cable connection

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Torch Diffuser

Contact Tip

Nozzle

Figure 6 - Torch Nozzle

DANGER

WARNING

4. To attach the handle, place shield on a flat surface and press handle into place (See Figure 10).

NOTE: If you have never welded before or have little experience, a full face helmet is recommended. Both hands are needed to stabilize and control the angle and arc length of the torch.

1. Remove the lens retainer from the

face shield with a regular screwdriver by prying against the shield and post of the lens retainer.

2. Remove the protective film covering

from both sides of each lens cover. Put one clear lens cover on each side of the shaded lens. Place these three lenses together into the face shield and secure with the lens retainer. The lens retainer should snap into the second notch in the face shield.

3. Position one of the holes in the

adjustment arm over the pins which are located in the ear area of the face shield. These adjustment arms control the closeness of fit and can be easily repositioned if necessary.

4. Position the headgear inside the face

shield. Assemble the helmet by inserting the stud screw through the headgear and shield into the tension nut as shown. Do not tighten tension nut completely.

5. Trial fit the welding helmet. Adjust

headgear ratchet band to a comfortable position and lower the face shield. If the shield is too far or

counterclockwise. When gas is emitted from cylinder, close valve by turning clockwise. This will blow out dust or dirt that may have accumulated around valve seat.

2. Install regulator onto cylinder valve. Tighten stem nut securely to gas valve.

3. Install one end of gas hose to fitting on the rear of welder and other end of hose to fitting on regulator using hose clamps on each connection. Make sure gas hose is not kinked or twisted.

4. While standing opposite cylinder outlet, slowly open cylinder valve. Inspect for leaks in the connections.

5. Pull trigger on gun to allow gas to flow. Adjust gas regulator to maximum flow by moving clockwise. Release trigger.

6. Remember to close gas cylinder valve when finished welding.

1. Cut retainer stiffeners and detachable

handle away from shield. Trim the excess plastic to remove sharp edges.

2. Insert filter lens.

3. Attach the stiffeners over the pins on

the lens retainers (See Figure 9).

Wire Feed Arc Welder

too close to the face, use a different hole in the adjustment arm. Adjust the tension nuts so that helmet can be easily lowered over the face by nodding the head.

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

2. Turn welder off.

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

4. Connect work clamp to work piece or

workbench (if metal). Make sure contact is secure. Avoid surfaces with paint, varnish, corrosion or nonmetallic materials.

5. Position Heat Selector on front panel

to desired setting.

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

Assembly

(Continued)

HOOKUP PROCEDURE (Continued)

Operation

Metal Heat

Thickness Setting

24 - 14 Gauge (MIG only) Low 1 or 2 18 - 14 Gauge (Flux Core)

Thicker Than 14 Gauge High 1 or 2

Figure 11

Headgear

Face Shield

Shaded Lens

Clear Lens Cover (2)

Post

Lens Retainer

Adjustment Arm (2)

Tension Nut (2)

Stud Screw (2)

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Figure 9

Lens

Lens Retainer

Retainer Stiffener

Figure 10

Handshield Assembly

Welding Helmet Assembly (Promotional

Models Only)

WARNING

MANUAL

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.

1. Replace any unreadable safety labels

on the welder.

2. Use compressed air to blow all dust

and lint from ventilation openings.

3. Clean wire groove on drive roll.

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

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

Welding Guidelines

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

7. Plug power cord into a proper voltage receptacle with proper circuit capacity (See circuit requirements on front page).

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

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

10. Position wire feed gun near work piece, lower welding helmet by nodding head or position the hand shield, and squeeze 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 wire compartment cover closed at all times unless wire needs to be changed.

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.

Model WG2040, WG2044, WG2045, WG3000

Maintenance

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

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.

6. Install new cord in reverse order.

MIG

WT5021

Figure 12 - Nozzle

Operation

(Con't.)

BEFORE EVERY USE:

EVERY 3 MONTHS:

Consumable and Wear Parts

General

This line of welding machines can utilize the Flux Cored Arc Welding (Gasless) process or the Gas Metal Arc Welding (MIG) 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. The MIG process uses inert gas to shield the weld while molten.

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 13).

Slag

Weld

Wire

Flux

(Gasless

only)

Work Piece

Shielding

Gas

Contact Tip

Crater

Nozzle

Figure 13 - Weld Components

approximately 6 months. For mild steel welding, AWS ER70S6 solid wire or AWS E71T-GS Flux-core wire is recommended.

This welder is setup for .035 (.9mm) wire. If a different wire size is used, the wire feed drive roll and contact tip may need changing. There are two grooves in the drive roll. The small groove is for .024 (.6mm) wire and the other is for .030-.035 (.8-.9mm) wire. Remove the roller cover and flip the drive roll to choose the correct groove (See parts breakdown). The contact tip should also match the wire diameter used. The tip diameter is marked on the contact tip in inches or millimeters.

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CHANGING WIRE SIZES

WARNING

Wire Feed Arc Welder

Welding Guidelines (Continued)

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. It is suggested that the welder practice with scrap metal to adjust settings, and compare welds with Figure 15.

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.

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.

SOLID WIRE ER - 70 S - 6

Weld strength, times 1,000 PSI

Solid wire Wire composition

ER-70S6 is recommended for this welder.

WELD ANGLE

Weld angle is the angle at which the 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.

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. 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. For Aluminum, wire speed is typically set higher (7-9 speed range).

TRAVEL SPEED

The travel speed is the rate at which the torch is moved across the weld area.

TRAVEL ANGLE

WORK ANGLE

5º - 45º

Figure 14 - Weld Angle

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 15 - Weld Appearance

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Model WG2040, WG2044, WG2045, WG3000

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. 15). 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. For Aluminum, travel speed is typically faster.

SLAG REMOVAL (FLUX-CORED WIRE ONLY)

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.

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.

Overhead welding is the least desirable position as it is the most difficult and dangerous. Heat setting and wire

Welding Guidelines (Continued)

stainless steel brush to eliminate any oxidation on the weld and grounding surface. 100% Argon shielding gas must be used when welding aluminum. If 100% Argon is not used, metal penetration is unlikely. A Teflon®wire liner, smooth-groove drive roller and aluminum contact tips are recommended when welding aluminum. Campbell Hausfeld offers these parts in Kit WT2530. Call 800-7465641 to order.

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) and all aluminum, 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 18).

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 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. 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 for gasless process.

ALUMINUM WELDING

Any aluminum surface to be welded, must be cleaned thoroughly with a

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Figure 16 - Weld Passes

Cover

Filler

Root

Figure 17 - Multiple Weld Passes

PUSH

PULL

Figure 18

WARNING

Wire Feed Arc Welder

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Figure 19 - Wiring Schematic

Troubleshooting Chart - Welder

Symptom Possible Cause(s) Corrective Action

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

Troubleshooting Chart - Welds

Symptom Possible Cause(s) Corrective Action

1. Duty cycle exceeded

2. Poor work 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

1. Slag inside gun nozzle

2. Insulation ring melted/expired

1. Poor contact

2. Using an extension cord with excessive length

1. Wire jammed

2. Out of wire

3. Not enough tension

4. Wire liner worn

5. Wire disconnected internally

6. Contact tip clogged

1. Wire speed too slow

2. Travel speed too slow or heat is too high

1. Wire speed setting

2. Contact tip size too large

3. Polarity set incorrectly

4. Drive roller slipping

5. Gas bottle empty

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

1. Clean slag from gun nozzle

2. Replace nozzle

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

2. Never use an extension cord longer than 20 ft

1. Reload wire

2. Replace wire spool

3. Tighten tensioning screws if wire is slipping

4. Replace liner

5. Call 1-800-746-5641 for assistance

6. Replace contact tip

1. Run speed in 7 - 10 range

2. Increase the travel speed or reduce heat settings

1. Tune in correct setting

2. Replace contact tip

3. Reverse polarity

4. Increase tension

5. Replace gas bottle

No output

Wire tangles at drive roller

Gun nozzle arcs to work surface

Work clamp and/or cable gets hot

Wire does not feed

(Aluminum) Wire burns back into tip or (Aluminum) Metal bubbles or burns through

Weld pops and sputters

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

3. No or low shielding gas

4. Wrong shielding gas (aluminum)

5. Extension cord is too long

6. (Aluminum) Possible oxide buid-up on surface

1. Damp wire

2. Wire speed too fast

3. Wrong type of wire

4. No or low shielding gas

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

3. Use gas for MIG process or refill bottle

4. Use only 100% Argon gas

5. Never use an extension cord longer than 20 ft

6. Clean surface thoroughly with a stainless steel brush only

1. Use dry wire and store in dry location

2. Reduce wire speed

3. Use flux core wire when not using gas

4. Use gas for MIG process or refill bottle

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Model WG2040, WG2044, WG2045, WG3000

Wire Feed Arc Welder

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1 Service torch – Universal WC600900AJ 1 2 Torch body, front and back WC600201AV 1 3 Hanger clip ▲ WC600003AV 1 4 Nozzle WT502100AJ 1 5 Trigger knob WC600202AV 1 6 Torch contact spring WC600203AV 1

7a Work clamp, all except WG3000

(Cord not included) WC100000AV 1

7b Work clamp, WG3000 (Cord not included) WC100100AV 1

8 Welding cable 6 mm

(6 ft) ❋ 1

9 Wire speed knob WC400201AV 1 10 Wire speed control board WC402900AV 1 11 Heat switch WC400300AV 2 12 On/off switch WC400000AV 1 13 Safety decal (1 of 2) DK670000AV 1 14 Safety decal (2 of 2) DK670001AV 1 15 Handle WC301800AV 1 16 Power cord 14-3 AWG (6 ft)

Type SJT ❋ 1 17 Spool spindle WC500300AV 1 18 #10-32 x .5” Pan head sheet

metal screw ❋ 2 19 Wire See Chart Below 1 20 Spool adapter WC500200AV 1 21 Spool spring WC500101AV 1 22 Spool locking hub WC500100AV 1 23 Drive deck assembly

(Includes Nos. 24-30) WC500000AV 1 24 Tension spring WC500003AV 1 25 Tension screw WC500002AV 1 26 Roller, .6-.9mm (.024-.035 in.) WC500001AV 1

Ref. Part No. Description Number Qty

Figure 20 - Replacement Parts

Model WG2040, WG2044, WG2045, WG3000

27 Roller cover WC500004AV 1 28 #8-36 x 1.5” Pan head screw ❋ 3 29 Swing arm WC500005AV 1 30 Swing arm roller WC500007AV 1 31 Strain relief ▲ WC102000AV 2 32 M6-1.0 x 25mm Machine screw ❋ 2 33 Handle caps WC301802AV 2 34 Liner, coated metal WC600208AV 1 35 Cylinder base ▲ WC704700AV 1

36 Polarity cap (Red) WC704000AV 1 37 Polarity cap (Black) WC704100AV 1 38 Torch ring WC600009AV 1 39 Valve body WC600204AV 1 40 Swan neck w/diffuser WC600701AV 1 41 Hose barb (external) WC802300AV 1 42 Hose barb (internal) WC802400AV 1 43 Regulator ▲ WC802500AV 1 44 Trumpet liner WC600305AV 1 45 Gas bottle strap WC802000AV 1 46 Gas liner ▲ WC802200AV 1 47 Handshield without lens ▲ WC801300AV 1 48 Lens for handshield ▲ WC801100AV 1 49 Welding helmet ▲ WT100500AV ✜ 50 Chipping hammer/brush ▲ WC803000AV 1 51 Aluminum welding kit ▲ WT253000AV ✜

(includes Teflon®wire liner, smooth-groove drive roller and 4 aluminum contact tips for .030” {0.8mm} wire)

❋ Standard hardware item, available at local hardware or welder

supply store

▲ Not shown ✜ Optional accessory, sold separately

Ref. Part No. Description Number Qty

Inside

OPTIONAL WIRE

Part Number Part Number

Type Description (2 pound) (10 pound)

Flux E71T-GS .030” WE200001AV WE201000AV Flux E71T-GS .035” WE200501AV WE201500AV MIG ER70S6 .024” WE300001AV WE301500AV MIG ER70S6 .030” WE300501AV WE302000AV MIG ER70S6 .035” WE301001AV WE302500AV

Aluminum MIG ER5356 .030” WE303001AV (1 lb) N/A

**OPTIONAL CONTACT TIPS (4/package)

Size

mm in. Part Number

0.6 0.024 WT501200AJ

0.8 0.030 WT501300AJ

0.9 0.035 WT501400AJ

13, 14

41, 42

9, 10

For Information About This Product

Call 1-800-746-5641

Operating Instructions and Parts Manual

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 than 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 work 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.

Glossary of Welding Terms

Model WG2040, WG2044, WG2045, WG3000

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Operating Instructions and Parts Manual

Limited Warranty

Limited 5-3-1 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 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 The Scott Fetzer Company 100 Production Drive Harrison, OH 45030 Telephone: (513)-367-4811

3. Who Receives This Warranty (Purchaser): The original purchaser of the Campbell Hausfeld product.

4. What is covered under this warranty: 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 limitations on how long an implied warranty lasts, so 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 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 the product.

E. Pre-delivery service, i.e. assembly and adjustment.

7. 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.

8. Responsibilities of purchaser under this warranty:

A. Deliver or ship the Campbell Hausfeld product or component to Campbell Hausfeld. Freight costs, if any, must be borne by

the purchaser.

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

9. 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.

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+ 30 hidden pages

Campbell Hausfeld WG2040, WG2044, WG3000, WG2045 User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual