Campbell Hausfeld WG3090, WG4130, WG3080, IN974200AV User Manual

Operating Instructions & Parts Manual	Models WG3080, WG3090 and WG4130

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

Arc Welder

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Description

These Campbell Hausfeld wire feed welders are designed to be used on standard 120V (WG3080 & 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" (0.8mm) diameter flux core wire. A starter spool of .030" (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.

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.

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5

6

4

2

1

Figure 1 - Welder Components and Controls

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" 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	Slow Blow Fuse for
Selector	120V Models
1-2-3	15 amp
4-5	20 amp

See page 8 for supply cable replacement instructions.

REMINDER: Keep your dated proof of purchase for warranty purposes!

Attach it to this manual or file it for safekeeping.

© 2009 Campbell Hausfeld/Scott Fetzer

For parts, product & service information

IN974200AV 11/09

visit www.chpower.com or call 1-800-746-5641

Wire Feed Arc Welder

General Safety

● Always wear dry, protective

● Wear ANSI approved face shield or

clothing, welding gloves and

safety glasses with side shield

Danger

insulated footwear when operating

protection when chipping or

indicates

unit.

grinding metal parts.

an imminently hazardous situation

which, if not avoided, will result in

● Always operate welder in a clean,

● Wear ear plugs when welding

death or serious injury.

dry, well ventilated area. Do not

overhead to prevent spatter or slag

Warning

operate welder in humid, wet, rainy

from falling into ears.

indicates

or poorly ventilated areas.

a potentially hazardous situation

which, if not avoided, COULD result in

● Be sure work piece is properly

death or serious injury.

supported and grounded prior to

Electric arc welding

Caution

beginning any electric arc welding

operations produce intense

light and heat and ultraviolet

indicates

operation.

a potentially hazardous situation

(UV) rays. This intense light

and UV rays can cause injury to eyes and

which, if not avoided, MAY result in

● Spread out coiled welding cable

skin. Take all precautions described in

minor or moderate injury.

before use to avoid overheating and

this manual to reduce the possibility of

NOTE: Note means any additional

damage to insulation.

injury to eyes and skin.

information pertaining to the product

Never

● All persons operating this equipment

or its proper usage.

immerse

or in the area while equipment is in

wire or torch in water. If welder

use, must wear protective welding

becomes wet for any reason, be

gear including: welding helmet or

absolutely certain it is completely clean

Always keep a fire

and dry before use!

shield with at least shade 10 lens, flame

extinguisher accessible while

● Always shut equipment off and

resistant clothing, leather welding

performing arc welding

operations.

unplug power cord prior to moving

gloves and full foot protection.

● Before starting or

the unit.

Never

servicing any electric arc

● Always attach the work lead first.

look at

welder, read and

MANUAL

● Verify work piece is securely

arc welding operations without eye

protection as described above. Never

understand all

grounded.

use a shade filter lens that is cracked,

instructions. Failure to

● Always shut off electric arc welding

broken, or rated below number 10.

follow safety precautions or

Warn others in the area not to look at

equipment when not in use and cut off

the arc.

instructions can cause equipment

any excess wire from torch.

damage and/or serious personal

● Never allow any part of the body to

injury or death.

Electric arc welding

touch welding wire and ground or

● All installation, maintenance, repair

operations cause sparks and

grounded work piece at the same

heat metal to temperatures

and operation of this equipment

time.

that can cause severe burns!

should be performed by qualified

Use protective gloves and clothing when

● Awkward welding conditions and

persons only in accordance with

performing any metal working

positions can be electrically hazardous.

operation. Take all precautions

national, state, and local codes.

described in this manual to reduce the

When crouching, kneeling or at

possibility of skin and clothing burns.

elevations, be sure to insulate all

● Make sure all persons in welding

conductive parts, wear appropriate

Improper use of electric arc

area are protected from heat, sparks

protective clothing and take

welders can cause electric

and ultraviolet rays. Use additional

shock, injury, and death! Take

precautions to prevent injury from falls.

all precautions described in

face shields and flame resistant

● Never attempt to use this equipment

this manual to reduce the possibility of

barriers as needed.

electric shock.

at current settings or duty cycles

● Never touch work pieces until

● Verify all components of the arc

higher than specified on equipment

completely cooled.

labels.

welder are clean and in good

condition prior to operating welder.

● Never use an electric arc welder to

Be sure insulation on all cables,

thaw frozen pipes.

Heat and sparks produced

torch and power cord is not

during electric arc welding

damaged. Always repair or replace

and other metal working

damaged components before

operations can ignite

Flying sparks and hot metal

flammable and explosive materials!

operating the welder. Always keep

can cause injury. As welds

Take all precautions described in this

cool, slag can be thrown off.

welder panels, shields, etc. in place

manual to reduce the possibility of

Take all precautions described

when operating welder.

flames and explosions.

in this manual to reduce the possibility

of injury from flying sparks and hot metal.

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Models WG3080, WG3090 and WG4130

General Safety

(Continued)

●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 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 torch and work cables together and secure with tape when possible.

●Never wrap arc welder cables around the body.

●Always position torch 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.

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 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.

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.

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

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

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Wire Feed Arc Welder

General Safety

(Continued)

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.

Installation

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.

Assembly

TORCH INSTALLATION (See Fig. 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" terminals in the center wall. Polarity is not important. Make sure these wires do not interfere with the polarity studs or drive deck.

WORK CLAMP INSTALLATION

(See Fig. 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.

	Torch switch	Hanger
	connectors
		Torch clamp knob
	Torch switch
	terminals
		Torch switch leads
	Drive deck
		Torch
	Figure 2 - Torch Installation

Hex Nut

Ring connector

Welding cable

Work clamp

Figure 3 - Clamp Installation

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Models WG3080, WG3090 and WG4130

Tension knob	Swing arm
Drive deck
	Welding wire	Drive
	Retainer	roller
	Spring	Wire guide
Spindle	Lock
Figure 4 - Weld Wire Installation

Assembly (Continued)

WIRE INSTALLATION

NOTE: Before installing welding wire, be sure:

a.Diameter of welding wire matches groove in drive roller on wire feed mechanism (See Fig. 4).

b.Wire matches contact tip in end of torch (See Fig. 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.

Torch Diffuser

Contact Tip

	Nozzle
	Figure 5 - Torch Nozzle
	Contact Tip Markings
	Mark	Wire Size
	0.6 mm	.024"
	0.8 mm	.030"
	0.9 mm	.035"

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 spool bottom of spool. Do not cut the wire loose yet. Install spool 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.

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 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.

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Wire Feed Arc Welder

Assembly (Continued)

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.

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.

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.

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.

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.

NOTE: Electrode negative polarity (typical for flux core welding) shown in figure.

Reverse cables for electrode positive polarity (typical for MIG welding).

Ground cable

Drive deck cable

Positive stud

Negative stud

Brass nuts

Figure 6 - Polarity control

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.

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Models WG3080, WG3090 and WG4130

Operation

1. Be sure to read, understand

and comply with all precautions in the General MANUAL 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.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" 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.

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.

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.

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" or 8" diameter spools. Flux-Cored welding wire is susceptible to moisture and oxidizes over time, so it is important to select a spool size that will be used within approximately 6 months. 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" (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" (0.6 mm) MIG wire and the large groove is for .030 - .035" (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.

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.

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Wire Feed Arc Welder

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	Contact
	Shielding	Tip
	Gas	Flux
	Slag	(Gasless
		only)
	Weld	Wire
	Crater	Work Piece
	Figure 7 - Weld Components

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 9.

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.

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.

5º - 45º

WORK ANGLE

5º - 45º

TRAVEL ANGLE

Figure 8 - Weld Angle

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).

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 9). 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.

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Models WG3080, WG3090 and WG4130

Welding Guidelines (Continued)

ELECTRODE EXTENSION

Electrode extension (or electrode stickout) 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 to 1/2 in (6 to 13 mm). If the electrode extension is 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.

Base

Metal

Normal Heat,	Travel
Wire Speed,	Speed
Travel Speed	Too Fast
Heat Too Low	Travel Speed
Heat Too High	Too Slow
	Wire Speed Too Slow
	Wire Speed
Figure 9 - Weld Appearance	Too Fast

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.

Cover

Filler

Root

Figure 11 - Multiple Weld Passes

Figure 10 - Weld Passes

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Wire Feed Arc Welder

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 Teflon® wire liner, smooth-groove drive roller and aluminum contact tips are recommended when welding aluminum. Campbell Hausfeld offers these parts in Kit WT2532. 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).

Figure 12

PULL

PUSH

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 surface
		3. Tripped circuit breaker	is clean
			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	2. Clean or replace wire liner
		damaged
		3. Contact tip clogged or	3. Clean or replace contact tip
		damaged
		4. Drive roller worn	4. Replace
		5. Not enough tension	5. Tighten tension knob
	Gun nozzle arcs to work	1. Slag inside gun nozzle	1. Clean slag from gun nozzle
	surface	2. Insulation ring melted/expired	2. Replace nozzle
	Work clamp and/or cable	1. Poor contact	1. Be sure all connections are secure, and attaching surface
	gets hot	2. Using an extension cord with	is clean
			2. Never use an extension cord longer than 20 ft
		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	1. Wire speed too slow	1. Run speed in 7 - 10 range
	into tip or (Aluminum) Metal	2. Travel speed too slow or heat	2. Increase the travel speed or reduce heat settings
	bubbles or burns through	is too high
	Weld pops and sputters	1. Wire speed setting	1. Tune in correct setting (1-5 mild steel; 5-10 aluminum)
		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
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Models WG3080, WG3090 and WG4130

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

Troubleshooting Chart - Welds

Symptom	Possible Cause(s)	Corrective Action
Bead is intermittently	1. Inconsistent travel speed	1. Decrease and maintain constant travel speed
too thin	2. Output heat setting too low	2. Increase output heat setting
Bead is intermittently	1. Slow and/or inconsistent travel speed	1. Increase and maintain travel speed
too thick	2. Output heat setting too high	2. Reduce output heat setting
Ragged depressions at	1. Travel speed too fast	1. Decrease travel speed
edge of 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	1. Inconsistent travel speed	1. Decrease and maintain constant travel speed
penetrate base metal	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 buid-up on	6. Clean surface thoroughly with a stainless steel brush
	surface	only
Wire sputters and	1. Damp wire	1. Use dry wire and store in dry location
sticks	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

Notes

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