Campbell Hausfeld WG3013 User Manual

280.85 Kb
Loading...
! WARNING
! DANGER

Operating Instructions & Parts Manual

Model WG3013

 

 

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.

 

 

Wire Feed

 

TM

Arc Welder

BUILT TO LAST

 

 

 

 

 

 

 

URAN

CE

 

 

 

 

 

 

SS

P

 

 

 

 

A

 

 

 

 

 

Y

 

 

 

R

 

 

 

 

 

 

O

 

T

 

 

 

 

G

AL

I

 

 

 

Need

R

 

 

 

 

 

A

U

 

Assistance?

M

Q

 

 

Call Us First!

1-800-746-5641

Description

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.

These welders are designed for use with Flux Core Arc Welding (Gasless) or Gas Metal Arc Welding (Mig) process. As delivered from the factory, this welder can weld with .024” (.6 mm) to .035” (.9 mm) diameter wire. A starter spool of .035” (.9 mm) flux-cored wire and a

.040 tip are 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 ! CAUTION requires a dedi-

cated 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.

 

Heat

Circuit Breaker or

 

Selector

Slow Blow Fuse

 

 

 

 

 

 

 

 

Low

15 amp

 

 

 

 

 

 

 

 

High

20 amp

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

4

1

6 5 3

FARMHAND 125

7

2

Figure 1

Components and Controls

1.Ground Clamp - connect to work piece.

2.Wire Feed Gun with .040 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. Four selections are possible

7.Polarity Hook-up - Attach torch cable to (+) for MIG and (-) for flux core wire.

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 ! CAUTION 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.

© 2000 Campbell Hausfeld / Scott Fetzer

For parts, product & service information

IN970400AV 11/00

visit www.chpower.com

! WARNING
! WARNING

Wire Feed Arc Welder

General Safety

(Continued)

Torch is “live” (has ! WARNING current potential)

at all times when machine is turned on.

! WARNING

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.

! WARNING

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.

! DANGER

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 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.

!WARNING 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, 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.

! WARNING

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.

!WARNING

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 m) 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.

! WARNING

Fire hazard! Do not weld on containers or pipes that contain or have contained

flammable materials or gaseous or liquid combustibles.

! WARNING

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.

www.chpower.com

2

! DANGER

WG3013

General Safety

(Continued)

! WARNING

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.

! WARNING

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 ! WARNING 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.

! DANGER

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 them and associated parts in good condition.

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.

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 ! WARNING off the ground by

their valves, caps, or with chains or slings.

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

Code for Safety in Welding and Cutting

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

Cutting And Welding Processes

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

Safe Practices For Occupational And Educational Eye And Face Protection

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

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

Installation

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 12” (30,48 cm) of ventilation space at both the front and rear of the unit. Keep all obstructions away from this ventilation space.

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

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.

Assembly

Welder components listed below are in the wire feed compartment. Open and remove.

HANDLE ASSEMBLY

1.Remove screws from handle. Slide handle between welder front panel

www.chpower.com

3

! WARNING

Wire Feed Arc Welder

Assembly (Continued)

and top cover aligning the holes in handle with holes in top cover.

2.Fasten screws through top cover and into handle.

WHEEL AND AXLE ASSEMBLY

1.Insert axle supports into slots in the welder housing.

2.Insert axle through the axle supports and firmly push wheels onto axle.

3.Secure wheel with e-clips and wheel caps.

GAS CYLINDER BRACKET ASSEMBLY

1.Place bracket on welder aligning the holes in welder housing.

2.Fasten screws through bracket and into cabinet.

FOOT ASSEMBLY

1.Place foot on welder and align holes in the welder housing.

2.Fasten screws through foot into cabinet.

Figure 2 - WG3013 Assembly

Ground Clamp

1.Loosen hex nut on work clamp.

2.Insert cord through clamp handle and slide bare wire under the clamp block. Tighten hex nut making sure bare wire is clamped securely (Figure 3).

Clamping

Block

Figure 3 - Work Clamp Assembly

Wire Installation

Welding power may be applied to

the output terminals, feed roll, work clamp, gun cable connection and

welding wire even when the 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 groove in the drive roller on the wire feed mechanism and the wire matches the contact tip in the end of the gun. A mismatch on any item could cause the wire to slip or bind.

1.Verify the unit is off and open the panel 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.

NOTE: Spool spacer and spindle spacer act as an 8” spool spindle adapter. Purchase of an adapter is not necessary.

* See Figure 4 for assembly.

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

Tension

 

 

Screw

Panel

 

 

 

Guide

Drive Roller

Tube

 

 

Spindle

 

 

Spacer

 

Spool

 

 

 

 

Spacer

 

 

Spool

 

 

Lock

Spindle

 

 

 

*Reverse

 

4” or 8”

position and

 

insert into 8”

 

Spool

Spring

spool

 

Figure 4 - Weld Wire Routing

 

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 5). Plug the welder into the proper power supply receptacle.

Torch Neck

Contact Tip

 

Nozzle

Figure 5 - Torch Nozzle

HINT: Keep torch cable straight when feeding wire.

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

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

Contact Tip Markings

 

Wire Size

 

mm

 

 

 

 

 

 

.024”

or

.6

 

 

 

 

 

 

 

.030”

or

.8

 

 

 

 

 

 

 

.035”

or

.9

 

 

 

 

 

 

 

.040”

or

1.0

 

 

 

 

 

 

 

 

 

 

 

POLARITY

For gas shielded welding, connect the cable coming out of the torch to the (+) socket and the ground clamp cable to the (-) socket on the front panel. For flux-core (no-gas) welding, connect torch to (-) and work clamp to (+).

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

www.chpower.com

4

+ 12 hidden pages