Campbell Hausfeld WS0900, WS0950, WS1000, WS1020 User Manual

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Operating Instructions & Parts Manual Models WS0900, WS0950, WS1000 and WS1020

CAMPBELL
HAUSFELD

cause death or serious injury if the
warning is ignored.

Warning means a

hazard that could
cause death or serious injury if the
warning is ignored.

Caution means a

hazard that may
cause minor or moderate injury if the
warning is ignored. It also may mean a
hazard that will only cause damage to
property.

NOTE: Note means any additional
information pertaining to the product
or its proper usage.

1/16 15 amp

5/64 20 amp

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Call Us First!

1-800-746-5641

Description

General Safety

IN198903AV 4/97

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.

Shielded Metal
Arc Welder

This line of Campbell Hausfeld Arc
Welders is designed to be used on
standard 115V household current. These
welders are equipped with infinite
amperage control to accurately select the
proper current needed for various
welding conditions. Internal components
are thermostatically protected.

This welder can weld up to 1/8” steel in
a single pass. Recommended electrode
size is 1/16” diameter for 15 amp
circuits, up to 5/64” diameter for 20
amp circuits. For replacement
electrodes, call [phone] for the
nearest dealer.

MODEL

WS1020

ONLY

Unpacking

When unpacking, inspect carefully for
any damage that may have occurred
during transit. Report any damaged or
missing items by calling 1-800-746-5641.

Circuit Requirements

dedicated 115 volt circuit. Refer to the
following chart for the correct circuit
breaker or fuse rating. Do not run
other appliances, lights, or tools on
this circuit while operating this
equipment. Extension cords are not
recommended. Blown fuses or tripped
circuit breakers can result from failure
to comply with this recommendation.

Electrode Circuit Breaker or
Diameter Slow Blow Fuse

This equipment
requires a

Figure 1 - Welder Components

and Controls

Components and Controls

1. Work Clamp - connect to work piece

2. Electrode Holder - holds electrode
welding rod

3. Power Cord - plug into 115 volt outlet.

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

5. Infinite Amperage Control Knob ­turns clockwise to increase amperage
and counterclockwise to decrease
amperage.

6. Welding Amp Indicator - as the
amperage control knob (5) is rotated,
the amperage indicator moves
displaying approximate weld amps.

1

MODEL WS0900

Danger means a
hazard that will

Shielded Metal Arc Welder

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

General Safety (Con’t)

● Before starting or servicing any
electric arc welder, read and
understand all instructions. Failure
to follow safety precautions or
instructions can cause equipment
damage and or serious personal
injury or death.

● All installation, maintenance, repair
and operation of this equipment
should be performed by qualified
persons only in accordance with
national, state, and local codes.

Improper use of electric
arc welders can cause
electric shock, injury,
and death! Take all
precautions described in
this manual to reduce the possibility of
electric shock.

● Verify that all components of the

arc welder are clean and in good
condition prior to operating the
welder. Be sure that the insulation
on all cables, electrode holders, and
power cords is not damaged.
Always repair or replace damaged
components before operating the
welder. Always keep welder panels,
shields, etc. in place when operating
the welder.

● Always wear dry protective clothing

and welding gloves, and insulated
footwear.

● Always operate the welder in a

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

● Be sure that the work piece is

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

● Coiled welding cable should be spread

out before use to avoid overheating
and damage to insulation.

Never immerse the

electrode or
electrode holder 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, and
remove the electrode from the holder.

● Never allow any part of the body to

touch the electrode and ground or
grounded work piece at the same time.

● Awkward welding conditions and

positions can be electrically hazardous.
When crouching, kneeling or at
elevations, be sure to insulate all
conductive parts, wear appropriate
protective clothing, and take
precautions to prevent injury from falls.

● Never attempt to use this

equipment at current settings or
duty cycles higher than those
specified on the equipment labels.

● Never use an electric arc welder to

thaw frozen pipes.

Flying sparks and hot
metal can cause injury.
As welds cool, slag can
be thrown off. Take all
precautions described in
this manual to reduce the possibility of
injury from flying sparks and hot metal.

● Wear ANSI approved face shield or

safety glasses with side shield
protection when chipping or
grinding metal parts.

● Wear ear plugs when welding

overhead to prevent spatter or slag
from falling into ears.

Electric arc welding
operations produce
intense light and heat
and ultraviolet (UV)
rays. This intense light
and UV rays can cause injury to eyes

and skin. Take all precautions described
in this manual to reduce the possibility
of injury to eyes and skin.

● All persons operating this
equipment or in the area while
equipment is in use must wear
protective welding gear including:
welding helmet or shield with at
least shade 10, flame resistant
clothing, leather welding gloves,
and full foot protection.

Never look at arc

welding operations
without eye protection as described
above. Never use a shade filter lens
that is cracked, broken, or rated below
number 10. Warn others in the area not
to look at the arc.

Electric arc welding
operations cause sparks
and heat metal to
temperatures that can
cause severe burns! Use protective
gloves and clothing when performing
any metal working operation. Take all
precautions described in this manual to
reduce the possibility of skin and
clothing burns.

● Make sure that all persons in the
welding area are protected from
heat, sparks, and ultraviolet rays.
Use additional face shields and
flame resistant barriers as needed.

● Never touch work pieces until
completely cooled.

Heat and sparks
produced during electric
arc welding and other
metal working
operations can ignite
flammable and explosive materials!
Take all precautions described in this
manual to reduce the possibility of
flames and explosions.

● Remove all flammable materials
within 35 feet (10.7 meters) of
welding arc. If removal is not
possible, tightly cover flammable
materials with fire proof covers.

● Do not operate any electric arc
welder in areas where flammable or
explosive vapors may be present.

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Models WS0900, WS0950, WS1000 and WS1020

should consult with their physician
prior to performing any electric arc
welding operations.

● Route the electrode and work
cables together and secure with
tape when possible.

● Never wrap arc welder cables
around the body.

● Always position the electrode and
work leads so that they are on the
same side of the body.

● Exposure to electromagnetic fields
during welding may have other
health effects which are not known.

Always be sure

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

ADDITIONAL SAFETY STANDARDS
ANSI Standard Z49.1 from American

Welding Society, 550 N.W. 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

Installation

Assembly

General Safety (Con’t)

WS1000

GROUND

ELECTRODE

INFINITE

AMPERAGE SELECTOR

115 VOLT

OUTPUT 70 AMPS AC @ 23 V • 20% DUTY CYCLE • MAX OCV: 38 VOLTS • SINGLE PHASE

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ON

60HZ 23A

OFF

Figure 2 - Handle Assembly

● Take precautions to be sure that
flying sparks and heat do not cause
flames in hidden areas, cracks,
behind bulkheads, etc.

Fire hazard! Do not
weld on containers or
pipes that contain or
have contained
flammable materials or
gaseous or liquid combustibles.

Arc welding closed
cylinders or containers
such as tanks or drums
can cause explosion if
not properly vented! Verify that any
cylinder or container to be welded has
an adequate ventilation hole, so that
expanding gases can be released.

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

● Keep the head and face out of the
welding fumes.

● Do not perform electric arc welding
operations on metals that are
galvanized or cadmium plated, or
contain zinc, mercury, or beryllium
without completing the following
precautions:

a. Remove the coating from the

base metal.

b.Make sure that the welding area

is well ventilated.
c. Use an air-supplied respirator.
Extremely toxic fumes are created

when these metals are heated.

The electromagnetic
field that is generated
during arc welding may
interfere with the
operation of various electrical and
electronic devices such as cardiac
pacemakers. Persons using such devices

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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, electrodes,
coatings and cleaners.

Location

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

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

● Store electrodes in a clean, dry
location with low humidity to
preserve the flux 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 arc welding
machines. Extension cord use will
significantly degrade the
performance of the welder.

HANDLE ASSEMBLY-MODELS
WS0950, WS1000 AND WS1020 ONLY

1. Slide handle in slot toward rear of
unit.

Shielded Metal Arc Welder

2. Push forward and snap front of
handle in cutout in cabinet.

3. Fasten screw through handle and
into cabinet (See Figure 2).

WORK CLAMP (ALL MODELS)

1. Loosen hex bolt or nut on work
clamp.

2. Insert either

cable from the welder
through the clamp handle and slide
bare wire under the clamp block.
Tighten hex bolt or nut making sure
bare wire is clamped securely.

ELECTRODE HOLDER (ALL MODELS)

1. Remove insulation handle from the
holder body by pulling the two
pieces apart.

2. Slide the other weld cable through
the handle.

3. Loosen the wire clamping screw and
slide the bare cord wire under the
clamp block. Tighten the clamping
screw making sure the wire is secure.

4. Slide the handle over the electrode
holder body and press to stop. Make
sure the handle is secure and there
is no exposed metal on the holder.

HANDSHIELD (ALL MODELS EXCEPT
WS1020)

1. Cut retainer stiffeners and

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

protective welding gear including: eye
protection with proper shade as
specified in the following chart, flame
resistant clothing, leather welding
gloves, and full foot protection.

If heating, welding, or
cutting materials that
are galvanized, zinc
plated, lead, or
cadmium plated refer to the General
Safety Information Section for
instructions. Extremely toxic fumes are
created when these metals are heated.

4. Connect the work clamp to the
work piece. Make sure the contact is
on bare metal and not obstructed
by paint, varnish, corrosion, or non­metallic materials.

5. Insert the exposed part of the
electrode rod (the end with no flux)
into the jaws of the electrode holder.

6. Set the amperage adjustment knob
to the proper amperage for the
electrode rod diameter. Refer to
the following chart for proper
electrode current settings.

The electrode

holder and rod are
electrically “live” (current potential)
when the welder is on.

Grounding against

any metallic
surface may produce an arc which
could cause sparks and damage
eyesight.

7. Hold the electrode rod away from

the grounded work piece or
workbench. Turn on the welder.

8. Position the electrode to begin weld,

lower the welding helmet or position
the hand shield, and strike an arc.
Adjust weld amperage as needed.

9. When finished welding, turn welder

off and store properly.

Clamping

block

Figure 3 - Work Clamp Assemblies

Figure 4 - Electrode Holder Assembly

Operation

MANUAL

Electrode Current
Diameter Setting (Amps)

1/16" (1.6 mm) 35-80
5/64" (2 mm) 45-100

For specific settings, see weld guide
marked on welder

Assembly (Con’t)

Lens

Lens
Retainer

Retainer
Stiffener

Figure 5

Figure 6

2. Insert filter lens.

3. Attach the stiffeners over the pins on
the lens retainers (See Figure 5).

4. To attach the handle, place shield on
a flat surface and press handle into
place (See Figure 6).

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

1. Be sure to read,

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

2. Turn welder off and plug into

appropriate receptacle:
115v-15 amp - 1/16 electrodes
115v-20 amp - 5/64 electrodes

3. Verify that the surfaces of metals to

be joined are free from dirt, rust,
paint, oil, scale or other contaminants.
These contaminants make welding
difficult and cause poor welds.

All persons

operating this
equipment or in the area while
equipment is in use must wear

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