Campbell hausfeld WG3090, WG4130, WG3080 User Manual
Operating Instructions and Parts Manual
Wire Feed
Arc Welder
MODELS: WG3080, WG3090 and WG4130
3
5
6
4
2
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Figure 1 - Welder Components and Controls
Description
These Campbell Hausfeld wire feed welders are designed to be used on standard 120V
(WG3080 and WG3090) or 230V (WG4130) outlet. The welder 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) or
the Gas Metal Arc Welding (GMAW) process. As delivered from the factory, this welder
can weld with .030 in. (0.8mm) diameter flux core wire. A starter spool of .030 in.
(0.8 mm) flux cored wire is included.
To use the GMAW process with the WG3090 and WG4130, it is necessary to purchase
shielding gas and MIG wire only. With the WG3080, a regulator/hose kit must be
purchased in addition to the shielding gas and MIG wire.
CIRCUIT REQUIREMENTS
This equipment
requires a dedicated
120 volt or 230 volt circuit (depending
on model). Refer to the following chart
for correct circuit breaker or fuse
rating for 120 volt models. Do not run
other appliances, lights or tools on this
circuit while operating this equipment.
Extension cords are not recommended.
Blown fuses and tripped circuit breakers
can result from failure to comply with this
recommendation.
COMPONENTS AND CONTROLS
(FIGURE 1)
1. Work Clamp – connects to work
piece.
2. Torch with .030 in. tip.
3. Power Cord – plug into 120 volt or
230 volt outlet (depending on model).
4. Light – illuminates if thermostat has
automatically shut welder off.
5. Infinite Wire Speed Control – turn
clockwise to increase wire speed and
counterclockwise to decrease wire
speed.
6. Off/Heat Selector - Selects welding
power and turns welder on.
Five selections are possible:
1 – 2 – 3 – 4 – 5.
Circuit Breaker or
Heat
Selector
1-2-3 15 amp
4-5 20 amp
See page 8 for supply cable replacement
instructions.
Slow Blow Fuse for
120V Models
For parts, product & service information visit
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IN974201AV 11/13© 2013 Campbell Hausfeld/Scott Fetzer
Operating Instructions and Parts 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.
Unpacking
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.
READ & FOLLOW ALL INSTRUCTIONS
SAVE THESE INSTRUCTIONS
DO NOT DISCARD
Safety Guidelines
This manual contains information that is very important to know
and understand. This information is provided for SAFETY and
to PREVENT EQUIPMENT PROBLEMS. To help recognize this
information, observe the following symbols.
Danger indicates an imminently hazardous
situation which, if not avoided, WILL result
in death or serious injury.
Warning indicates a potentially hazardous
situation which, if not avoided, COULD
result in death or serious injury.
Caution indicates a potentially hazardous
situation which, if not avoided, MAY result
in minor or moderate injury.
Notice indicates important information,
that if not followed, may cause damage to
equipment.
NOTE: Note means any additional information pertaining to the
product or its proper usage.
General Safety Information
CALIFORNIA PROPOSITION 65
This product, when used for
welding, produces fumes
or gases which contain chemicals known to the
State of California to cause birth defects (or other
reproductive harm) and, in some cases, cancer
(California Health & Safety Code Section 25249.5 et seq.).
The power cord and other cables on
this product contain chemicals, including
lead, known to the State of California to cause cancer and birth
defects or other reproductive harm. Wash hands after handling.
GENERAL SAFETY
Always keep a fire extinguisher
welding operations.
u 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.
u All installation, maintenance, repair and operation
of this equipment should be performed by qualified persons
only in accordance with national, state, and local codes.
accessible while performing arc
MANUAL
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.
u Verify all components of the arc welder are clean and in
good condition prior to operating welder. Be sure insulation
on all cables, torch 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.
u Always wear dry, protective clothing, welding gloves and
insulated footwear when operating unit.
u Always operate welder in a clean, dry, well ventilated
area. Do not operate welder in humid, wet, rainy or poorly
ventilated areas.
u Be sure work piece is properly supported and grounded prior
to beginning any electric arc welding operation.
u Spread out coiled welding cable before use to avoid
overheating and damage to insulation.
Never immerse wire or torch in water. If
welder becomes wet for any reason, be
absolutely certain it is completely clean and dry before use!
u Always shut equipment off and unplug power cord prior to
moving the unit.
u Always attach the work lead first.
u Verify work piece is securely grounded.
u Always shut off electric arc welding equipment when not in
use and cut off any excess wire from torch.
u Never allow any part of the body to touch welding wire and
ground or grounded work piece at the same time.
u 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.
u Never attempt to use this equipment at current settings or
duty cycles higher than specified on equipment labels.
u 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.
u Wear ANSI approved face shield or safety glasses with side
shield protection when chipping or grinding metal parts.
u 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.
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General Safety Information
(Continued)
u 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.
u 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.
u 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.
u 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.
u Do not operate any electric arc welder in areas where
flammable or explosive vapors may be present.
u Take precautions to ensure 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
produced by arc welding
operation. These fumes are dangerous. If welding
area cannot be adequately ventilated, be sure to use
an air-supplied respirator.
u Keep head and face out of welding fumes.
u 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.
MODELS: WG3080, WG3090 and WG4130
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.
u Route torch and work cables together and secure with tape
when possible.
u Never wrap arc welder cables around the body.
u Always position torch and work leads on the same side of
the body.
u 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.
u Protect compressed gas cylinders from excessive heat,
mechanical shocks and arcs.
u Install and secure cylinders in an upright position by chaining
them to stationary support or equipment cylinder rack to
prevent falling or tipping.
u Keep cylinders away from any welding or other electrical
circuits.
u Never allow a welding electrode to touch any cylinder.
u Use only correct shielding gas cylinders, regulators,
hoses and fittings designed for the specific application;
maintain all parts properly.
u Turn face away from valve outlet when opening cylinder
valve.
u Keep protective cap in place over valve except when
cylinder is in use or connected for use.
u 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 non-flammable
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.
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Operating Instructions and Parts Manual
General Safety Information (Continued)
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
Safe Handling of Compressed Gases in Cylinders
CGA Pamphlet P-1, from Compressed Gas Association, 1235
Jefferson Davis Highway, Suite 501, Arlington, VA 22202
Refer to Material Safety Data Sheets and manufacturers
instructions for metals, wire, coatings and cleaners.
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
Installation
LOCATION
Selecting the proper location can significantly increase
performance, reliability and life of the arc welder.
u 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.
u 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.
u Store welding wire in a clean, dry location with low humidity
to prevent oxidation.
u 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.
u 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.
Assembly
TORCH INSTALLATION (See Figure 2)
1. Make sure unit is off and unplugged.
2. Feed the connectors for the torch switch through the hole
in the control panel. These leads are to be fed up over the
polarity studs and through the hanger on the center wall.
3. Insert the brass torch connector through the hole in the
control panel and into the drive deck. Make sure the
connector is inserted fully into the drive deck. Loosen the
torch clamp knob a few turns if the connector will not insert
fully. Tighten the torch clamp knob securely after the brass
torch connector is fully inserted.
4. Connect the torch switch connectors to the two 1/4 inch
terminals in the center wall. Polarity is not important. Make
sure these wires do not interfere with the polarity studs or
drive deck.
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Torch Switch
Connectors
Torch Switch
Terminals
Drive
Deck
Figure 2 - Torch Installation
Hex Nut
Ring Connector
Figure 3 - Clamp Installation
Hanger
Torch Clamp
Knob
Welding Cable
Work Clamp
Torch Switch
Leads
Torch
MODELS: WG3080, WG3090 and WG4130
WORK CLAMP INSTALLATION (See Figure 3)
1. Remove one hex nut from work clamp.
2. Slide welding cable with ring connector through hole in work
clamp.
3. Attach ring connector to work clamp with hex nut removed
in step 1.
WIRE INSTALLATION
NOTE: Before installing welding wire, be sure:
a. Diameter of welding wire matches groove in drive roller
on wire feed mechanism (See Figure 4).
b. Wire matches contact tip in end of torch (See Figure 5).
A mismatch on any item could cause the wire to slip and/or
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 lock by pushing in and rotating 1/4 turn
counterclockwise. Then remove lock, spring and retainer.
3. Flip tensioning knob down and swing arm up on drive
mechanism. This allows initial feeding of wire into torch liner
by hand.
4. Install wire spool onto spindle so wire can come off bottom
of spool. Do not cut the wire loose yet. Install retainer,
spring and lock by pushing in and turning lock 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.
Drive Deck
Spindle
Tension Knob
Swing Arm
Welding Wire
Retainer
Spring
Lock
Torch Diuser
Contact Tip
Nozzle
Figure 5 - Torch Nozzle
CONTACT TIP MARKINGS
Mark Wire Size
0.6 mm .024 in.
0.8 mm .030 in.
0.9 mm .035 in.
Driver Roller
Wire Guide
Figure 4 - Weld Wire Installation
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Operating Instructions and Parts Manual
Assembly (Continued)
6. Feed wire through wire guide, over the
groove in drive roller and back into
wire guide. Flip swing arm down and
tension knob up. Adjust tension by
rotating tension knob.
7. Unscrew nozzle and contact tip from
end of welding torch (See Figure 5).
Plug welder into a proper power supply
receptacle.
8. Turn on welder and set wire speed
to 10. Activate torch trigger until wire
feeds out past the torch end. Turn
welder off.
9. Carefully slip contact tip over wire,
screw tip into torch end and reinstall
nozzle (See Figure 5). Cut wire off
approximately 1/4 inch from nozzle
end.
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
Figure 6 - Polarity Control
protected from overheating with an
automatic thermal switch. A red lamp is illuminated on the
front panel if the duty cycle is exceeded. Do not switch
unit off. This will allow the internal fan to cool the unit quickly.
Welding operations may continue when the red lamp is no
longer illuminated.
OVERLOAD PROTECTION
The welder is equipped with a circuit breaker which protects the
machine if the maximum output is exceeded, such as when the
output is short-circuited. The circuit breaker button will extend
out when tripped. Manually push the button in to reset.
POLARITY
MIG welding wire requires the electrode to be positive.
Flux welding wire requires the electrode to be negative.
Always use the polarity recommended by the welding wire
manufacturer. The welder is factory set for flux welding wire.
TO CHANGE POLARITY (SEE FIGURE 6)
1. Unplug power cord from socket.
2. Open wire feed compartment door.
3. Remove two nuts from polarity studs.
4. Connect cable from drive deck to positive stud and cable
from work clamp to negative stud for electrode positive
polarity for MIG welding. Connect cable from drive deck to
negative stud and cable from work clamp to positive stud for
electrode negative polarity for flux core welding.
5. Reinstall two nuts and tighten securely.
Drive Deck Cable
NOTE: Electrode negative
polarity (typical for flux core
welding) shown in figure.
Reverse cables for electrode
positive polarity (typical for
MIG welding).
Ground Cable
Positive Stud
Negative Stud
Brass Nuts
If the nuts are not tightened properly,
excessive heat will be generated by
the loose connection and the insulators on the studs will be
damaged.
SHIELDING GAS PREPARATION
Improper handling and maintenance of
compressed gas cylinders and regulators
can result in serious injury or death! Always secure gas
cylinders to 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-core welding wire is
used.
GAS TYPES
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, nonflammable type of gas. Failure to do so will result in a very
hazardous situation.
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 to prevent it from falling over.
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MODELS: WG3080, WG3090 and WG4130
Assembly (Continued)
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”).
REGULATOR
An adjustable regulator with two gauges is supplied with the
WG3090 and WG4130. The WG3080 is not supplied with a
regulator (see parts list for optional regulator/hose kit). 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.
HOSE AND REGULATOR HOOKUP PROCEDURE
Cylinder gas is under high pressure. Point
cylinder outlet away from yourself and any
bystanders before opening.
1. With cylinder securely supported, stand on side of cylinder
opposite cylinder outlet then remove cylinder cap and open
valve slightly by turning 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 back of welder
and other end of hose to fitting on regulator. 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. Turn unit on and pull trigger on torch to allow gas to flow.
Adjust gas regulator to between 20 and 40 CFH. Release
trigger and turn unit off.
6. Remember to close gas cylinder valve when finished
welding.
Operation
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 non-metallic materials.
5. Rotate Wire Speed Control to setting per decal inside wire
feed compartment, then adjust as needed after test.
6. Plug power cord into a proper voltage receptacle with proper
circuit capacity (see circuit requirements on Page 1).
7. Switch welder on to desired heat setting per decal inside
wire feed compartment, then adjust as needed after test.
NOTE: These settings are general guidelines only. Heat setting
may vary according to welding conditions and materials.
8. Verify wire is extended 1/4 in. from contact tip. If not,
squeeze trigger to feed additional wire, release trigger, turn
welder off, and cut wire to proper length. Then, switch back
on to desired heat setting.
NOTE: The welder transformer is off and will not energize until
the trigger is pulled. This is a “cold torch” welding machine and
it will not weld until the trigger is pulled.
9. Position torch near work piece, lower welding helmet by
nodding head or positioning the hand shield, and squeeze
torch trigger. Adjust heat setting and wire speed as needed.
10. When finished welding, turn welder off and store properly.
MANUAL
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Operating Instructions and Parts Manual
Maintenance
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.
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 torch contact tip and nozzle.
Remove any weld slag. Replace torch contact tip or nozzle if
damaged.
Do not operate this welding machine with
cracked or missing insulation on welding
cables, torch 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 ventilation
openings.
3. Clean wire groove on drive roller. Remove drive roller and
use a small wire brush to clean. Replace if worn or damaged.
SUPPLY CABLE REPLACEMENT
1. Verify that welder is OFF and power cord disconnected.
2. Remove welder side panel to expose switches.
3. Disconnect the power cord leads per the diagram inside
the unit.
4. Disconnect the ground wire connected to welder base.
5. Loosen the cord strain relief screws and pull cord out of
strain relief.
6. Install new cord in reverse order per the diagram inside
the unit.
CONSUMABLE AND WEAR PARTS
The following parts require replacement:
• Wire feed drive roller
• Wire guide
• Torch liner
• Nozzle/contact tips
• Wire - This welder will accept either 4 in. or 8 in. 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. For
mild steel welding, AWS ER70S6 solid wire or AWS E71T-GS
Flux-Cored wire is recommended.
CHANGING WIRE SIZES
This welder is setup for .030 in. (0.8 mm) wire. If a different wire
size is used, the wire feed drive roller and contact tip may need
changing. There are two grooves in the drive roller. The small
groove is for .024 in. (0.6 mm) MIG wire and the large groove is
for .030 - .035 in. (0.8 - 0.9 mm) flux core and MIG wire. Rotate
the tension knob down and swing arm up and flip the drive roller
to choose the correct groove. Optional drive rollers for other
wire sizes are available (See parts breakdown). The contact tip
should also match the wire diameter used. The tip diameter is
marked on the contact tip in inches and/or millimeters.
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Welding Guidelines
General
This welding machine can utilize the Flux Cored Arc Welding
(FCAW) process or the Gas Metal Arc Welding (GMAW) process.
The weld must be protected (shielded) from contaminants in
the air while it is molten. The FCAW process uses a tubular wire
with a flux material inside. The flux creates a shielding gas when
melted. The GMAW 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 7).
Nozzle
Shielding Gas
Slag
Weld
Contact Tip
Flux (Gasless only)
Wire
MODELS: WG3080, WG3090 and WG4130
Base
Metal
Normal Heat,
Wire Speed,
Travel Speed
Heat Too Low
Heat Too High
Figure 8 - Weld Appearance
Travel
Speed
Too
Fast
Travel Speed
Too Slow
Wire Speed Too Slow
Wire Speed
Too Fast
Crater
Figure 7 - Weld Components
Work Piece
Arc Welding Basics
Six basic techniques affect weld quality. These are: wire
selection, heat setting, weld angle, wire speed, travel speed,
and electrode extension. 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 8.
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-cored 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.
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Operating Instructions and Parts Manual
Welding Guidelines (Continued)
5° - 45°
WORK ANGLE TRAVEL ANGLE
Figure 9 - Weld Angle
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 of
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 torch 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).
5° - 45°
too long, welding current will be reduced and the bead will be
high and narrow with less penetration.
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 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 than 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 the FCAW process.
TRAVEL SPEED
The travel speed is the rate at which the torch is moved across
the weld area. Factors such as diameter and type of weld wire,
amperage, position, and work piece material thickness all affect
the speed of travel necessary for completing a good weld (See
Figure 8). When the speed is too fast, the bead is narrow and
bead ripples are pointed as shown. When the speed is too slow,
the weld metal piles up and the bead is high and wide. For
Aluminum, travel speed is typically faster.
ELECTRODE EXTENSION
Electrode extension (or electrode stick-out) is the distance
between the end of the contact tip and and the end of the
welding wire. The recommended electrode extension is from
1/4 in to 1/2 in (6 mm to 13 mm). If the electrode extension is
10
www.campbellhausfeld.com
Cover
Filler
Root
Figure 10 - Weld Passes Figure 11 - Multiple Weld Passes
Welding Guidelines (Continued)
ALUMINUM WELDING
Any aluminum surface to be welded, must be cleaned
thoroughly with a 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 PTFE wire liner, smoothgroove drive roller and aluminum contact tips are recommended
when welding aluminum. Campbell Hausfeld offers these parts
in Kit WT2531. Call 1-800-746-5641 to order.
PUSH VS PULL TECHNIQUE
The type and thickness of the work piece dictates which way to
point the torch nozzle. For thin materials (18 gauge and smaller)
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 12).
Notes
MODELS: WG3080, WG3090 and WG4130
PULL PUSH
Figure 12
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11
Operating Instructions and Parts Manual
For Information About This Product Call 1-800-746-5641
Troubleshooting Chart - Welder
Symptom Possible Cause(s) Corrective Action
No output 1. Duty cycle exceeded 1. Allow welder to cool until lamp goes out
2. Poor work clamp connection 2. Be sure all connections are secure, and attaching
3. Tripped circuit breaker 3. Reset by pushing button on back of unit
4. Blown breaker or fuse 4. Reduce circuit load, reset breaker or replace fuse
Wire tangles at drive roller 1. Wrong size contact tip 1. Use proper size contact tip
2. Torch liner clogged or damaged 2. Clean or replace wire liner
3. Contact tip clogged or damaged 3. Clean or replace contact tip
4. Drive roller worn 4. Replace
5. Not enough tension 5. Tighten tension knob
Gun nozzle arcs to work surface 1. Slag inside gun nozzle 1. Clean slag from gun nozzle
2. Insulation ring melted/expired 2. Replace nozzle
Work clamp and/or cable gets hot 1. Poor contact 1. Be sure all connections are secure, and attaching
2. Using an extension cord with
excessive length
Wire does not feed 1. Wire jammed 1. Reload wire
2. Out of wire 2. Replace wire spool
3. Not enough tension 3. Tighten tension knob if wire is slipping
4. Wire liner worn 4. Replace liner
5. Wire disconnected internally 5. Call 1-800-746-5641 for assistance
6. Contact tip clogged 6. Replace contact tip
(Aluminum) Wire burns back into
tip or (Aluminum) Metal bubbles or
burns through
1. Wire speed too slow 1. Run speed in 7 - 10 range
2. Travel speed too slow or heat is
too high
Weld pops and sputters 1. Wire speed setting 1. Tune in correct setting (1-5 mild steel; 5-10
2. Contact tip size too large 2. Replace contact tip
3. Polarity set incorrectly 3. Reverse polarity
4. Drive roller slipping 4. Increase tension
5. Gas bottle empty 5. Replace gas bottle
Bead is intermittently too thin 1. Inconsistent travel speed 1. Decrease and maintain constant travel speed
2. Output heat setting too low 2. Increase output heat setting
Bead is intermittently too thick 1. Slow and/or inconsistent travel
speed
2. Output heat setting too high 2. Reduce output heat setting
Ragged depressions at edge of
1. Travel speed too fast 1. Decrease travel speed
weld
2. Wire speed too fast 2. Decrease wire speed
3. Output heat setting too high 3. Reduce output heat setting
Weld bead does not penetrate base
metal
1. Inconsistent travel speed 1. Decrease and maintain constant travel speed
2. Output heat setting too low 2. Increase output heat setting
3. No or low shielding gas 3. Use gas for MIG process or refill bottle
4. Wrong shielding gas (aluminum) 4. Use only 100% Argon gas
5. Extension cord is too long 5. Never use an extension cord longer than 20 ft
6. (Aluminum) Possible oxide buidup on surface
Wire sputters and sticks 1. Damp wire 1. Use dry wire and store in dry location
2. Wire speed too fast 2. Reduce wire speed
3. Wrong type of wire 3. Use flux-cored wire when not using gas
4. No or low shielding gas 4. Use gas for MIG process or refill bottle
surface is clean
surface is clean
2. Never use an extension cord longer than 20 ft
2. Increase the travel speed or reduce heat settings
aluminum)
1. Increase and maintain travel speed
6. Clean surface thoroughly with a stainless steel
brush only
12
www.campbellhausfeld.com
MODELS: WG3080, WG3090 and WG4130
Glossary of Welding Terms
AC or Alternating Current - electric current that reverses
direction periodically. Sixty cycle current travels in both
directions sixty times per second.
Arc Length - the distance from the end of the electrode to the
point where the arc makes contact with the work surface.
Base Metal - the material to be welded.
Butt Joint - a joint between two members aligned
approximately in the same plane.
Crater - a pool, or pocket, that is formed as the arc comes in
contact with the base metal.
DC or Direct Current - electric current which flows only in one
direction. The polarity (+ or -) determines which direction the
current is flowing.
DC Reverse Polarity - occurs when the electrode holder is
connected to the positive pole of the welding machine. Reverse
Polarity directs more heat into melting the electrode rather 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 nonconsumable 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.
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13
Operating Instructions and Parts Manual
For Replacement Parts or Technical Assistance, Call 1-800-746-5641
Please provide following information:
- Model number
- Serial number (if any)
- Part description and number as
shown in parts list
Address any correspondence to:
Campbell Hausfeld
Attn: Customer Service
100 Production Drive
Harrison, OH 45030 U.S.A.
22
14
21
23
7
6
5
Figure 13 - Replacement Parts
13
1
10
11
8
12
9
4
14
www.campbellhausfeld.com
MODELS: WG3080, WG3090 and WG4130
Replacement Parts List - Models WG3080, WG3090 and WG4130
Ref.
No. Description
1 Torch (MIG, 8 ft., WG3080) WC601810AJ 1
Torch (MIG, 10 ft., WG3090 &
WG4130)
2s Wire Liner – 0.024 in. - 0.035 in.
(0.6 mm - 0.9 mm), Cut to Length
s
Optional Wire Liner – 0.040 in. -
0.045 in. (1.0 mm - 1.2 mm), Cut to
Length (WG4130)
3s Contact Tip – 0.024 in. (0.6 mm) WT501200AV 1
s
Contact Tip – 0.030 in. (0.8 mm) WT501300AV 1
s
Contact Tip – 0.035 in. (0.9 mm) WT501400AV 1
s
Optional Contact Tip – 0.024 in. (0.6
mm) 4 Pack
s
Optional Contact Tip – 0.030 in. (0.8
mm) 4 Pack
s
Optional Contact Tip – 0.035 in.
(0.9 mm) 4 Pack
4 Nozzle WT502100AV 1
5 Drive Roller – 0.024 in. - 0.035 in.
(0.6 - 0.9 mm)
Optional Drive Roller – 0.040 in. -
0.045 in. (1.0 mm - 1.2 mm)
(WG4130 only)
6 Drive Deck Wire Guide WC500920AV 1
7 Drive Deck Assembly WC500900AV 1
8 Spool Spindle WC707430AV 1
9 Spool Retainer WC707023AV 1
10 Spool Spring WC707026AV 1
11 Spool Lock WC707024AV 1
12 Flux Weld Wire – 0.030 in. (0.8 mm)
2 lb. Spool (E71T-GS)
Flux Weld Wire – 0.030 in. (0.8 mm)
10 lb. Spool (E71T-GS)
Flux Weld Wire – 0.035 in. (0.9 mm)
2 lb. Spool (E71T-GS)
Flux Weld Wire – 0.035 in. (0.9 mm)
10 lb. Spool (E71T-GS)
MIG Weld Wire – 0.024 in. (0.6 mm)
2 lb. Spool (ER70S6)
MIG Weld Wire – 0.024 in. (0.6 mm)
11 lb. Spool (ER70S6)
MIG Weld Wire – 0.030 in. (0.8 mm)
2 lb. Spool (ER70S6)
MIG Weld Wire – 0.030 in. (0.8 mm)
11 lb. Spool (ER70S6)
MIG Weld Wire – 0.035 in. (0.9 mm)
2 lb. Spool (ER70S6)
MIG Weld Wire – 0.035 in. (0.9 mm)
11 lb. Spool (ER70S6)
Aluminum MIG Welding Wire –
0.030 in. (0.8 mm), 1 lb. Spool
Part
No. Qty.
WC601820AJ 1
WC601801AV 1
WC601802AV †
WT501200AJ †
WT501300AJ †
WT501400AJ †
WC500930AV 1
WC500932AV †
WE200001AV †
WE201000AV †
WE200501AV †
WE201500AV †
WE300001AV †
WE301500AV †
WE300501AV †
WE302000AV †
WE301001AV †
WE302500AV †
WE303001AV †
Ref.
No. Description
13 Safety Decal DK689105AV 1
14 Work Clamp WC100700AV 1
15s Gas Hose – 4 ft. (WG3090 & WG4130) WC803720AV 1
16s Regulator with 2 gauges (WG3090 &
WG4130)
17s Optional Regulator Kit (includes
items 15 & 16) (WG3080)
18 s Optional Welding Helmet WT100500AV †
19 s Optional Aluminum Welding Kit
[Includes PTFE Wire liner, U-groove
drive roller for 0.030 in. (0.8 mm)
aluminum wire and four 0.030 in. (0.8
mm) contact tips for aluminum wire]
20s Handle Assembly WC707405AJ †
21 MXW WC500900AV DD tensioner kit WC500960AV
22 MXW WC500900AV Arm kit WC500950AV
23 Knob 3-prong clamp WC500919AV
24s Fan motor-control power transformer-
115V-24V
25 s Fan shroud-motor mount WC405401AV
26 s Fan blade WC405402AV
27 s MIG solenoid valve kit WC405740SV
28 s Knob heat selector WC707370AV
29s CAM On Off heat knob WC707560AV
30s Fan motor-control power transformer-
230V-24V (WG413 only)
s
Not Shown
† Optional Accessory
Part
No. Qty.
WC803710AV 1
WC803700AJ †
WT253200AV †
WC405400AV
WC405500AV
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15
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