Campbell Hausfeld WS2100 User Manual

Please read and save these instructions. Read carefully before attempting to assemble, install, operate or maintain the product described. Protect yourself and others by observing all safety information. Failure to comply with instructions could result in personal injury and/or property damage! Retain instructions for future reference.

IN971600AV 4/03

Operating Instructions & Parts Manual Model WS2100

Arcitech Inverter Technology Arc Welder

Description

The future of welding has arrived! The Campbell Hausfeld Arcitech

™

arc welder uses inverter technology to eliminate the mass and weight of traditional transformer welders, giving you amazing power in a tiny portable package. This constant-current power source delivers smooth DC power for high quality welds with the SMAW (shielded metal arc welding) process using stick electrodes. It can also be converted to a TIG (tungsten inert gas) welder with the optional TIG torch (WT6100) and a bottle of inert gas with a regulator.

The Campbell Hausfeld Arcitech

™

welder runs on 115 Volt – 20 Amp single phase input power. It is equipped with infinite amperage control to accurately select the proper current needed for various welding conditions. Internal components are thermostatically protected.

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.

Circuit Requirements

This equipment

requires a 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.. See chart for proper extension cord use. Blown fuses and tripped circuit breakers can result from failure to comply with this recommendation.

Specifications

The electrode

holder is "live" (has current potential) when machine is turned on.

Components (See Figure 1)

1. Work Clamp with 10’ lead and dinse

plug connector

2. Electrode Holder with 15’ lead and dinse plug connector

3. Power Cord – 7.5’ – 14AWGX3C-SJT

Controls – Front Panel (See Figure 2)

1. Infinite amperage control knob – controls 5-110 Amps DC output

2. Positive Dinse plug connector: a) Connect electrode holder for “reverse” (DCEP) polarity. b) Connect work clamp for “straight” (DCEN) polarity.

3. Negative Dinse plug connector: a) Connect work clamp for “reverse” (DCEP) polarity. b) Connect electrode holder for “straight” (DCEN) polarity.

4. Yellow LED – Normally off. When lit it means that welding current is shut off due to: a) Thermal overload – duty cycle is exceeded – allow to cool for 15 minutes. b) Input voltage outside of safe

For parts, manuals, product & service information

visit www.chpower.com

or call 800-746-5641

Extension Cords – Length at Rated Output

Weld Output Amps 55 65 90

Cord Gauge Cord Length – Feet

14 Gauge Cord 65 50 25 12 Gauge Cord 100 75 50 10 Gauge Cord 150 125 100

Figure 1 - Welder Components and Controls

Input Current at Rated Output

Input Amps AC 16 19 24 Output Amps DC 55 65 90 Weld Volts DC 22 23 24 Duty Cycle 100% 60% 35%

Power Specifications

Single Phase 50/60 Hz 115 Volts

™

BUILT TO LAST

CAUTION

WARNING

Operating Instructions and Parts Manual

Inverter Technology Arc Welder

parameters. (115 volts +/- 10%)

5. Green LED – On = ready to weld.

Controls – Back Panel (See Figure 3)

1.On/Off Switch: O = Off I = On

2.Power Cord input

General Safety

Danger means a

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

Warning means a

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

Caution means a

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.

Always

keep a fire extinguisher accessible while performing arc welding operations.

● Before starting or servicing any

electric arc welder, read and understand all instructions. Failure to follow safety precautions or instructions can cause equipment damage and or serious personal injury or death. For additional safety information, obtain a copy of ANSI Standard Z49.1 - Safety in Welding and Cutting. This publication may be ordered from the American Welding Society, 550 NW LeJune Rd., Miami, FL 33135.

● All installation, maintenance, repair

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

Im-

proper 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 ground lead first.

● Verify that the work piece is

securely grounded.

● Always shut off electric arc welding

equipment when not in use 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.

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Figure 2 - Front Panel Controls

Electrode Polarity Chart

Rod Type DCEP DCEN

6011 Deep Penetrating x 6013 General Purpose x x 7014 Fast Fill x x 7018 High Strength x Auto Strike x x Aluminum x Stainless x Hardface x

Figure 3 - Back Panel Controls

x = recommended

DANGER

WARNING

CAUTION

WARNING

DANGER

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 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

ground 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

● 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 proper shade as specified in the following chart, flame resistant clothing, leather welding gloves, and full foot protection.

Current Filter

Up To 160 Amps 10

160 To 250 Amps 12

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

Model WS2100

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.

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 airsupplied respirator.

● Keep the head and face out of the

welding fumes.

● Do not perform electric arc welding

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Current Filter (Amps) Shade

WARNING

WT2240 Electrode Container, to preserve the flux coating.

● The welder control panel contains

information regarding proper input voltage and amperage. Follow the specifications on the welder front panel.

● 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 under Specifications for correct circuit capacity.

HAND SHIELD ASSEMBLY (See Figure 4)

1. Cut retainer stiffeners and detachable handle away from shield. Trim the excess plastic to remove sharp edges.

2. Insert the filter lens.

3. Attach the stiffeners over the pins on the lens retainers.

Operating Instructions and Parts Manual

Inverter Technology Arc Welder

Protection Association, Batterymarch Park, Quincy, MA 02269

Safe Handling of Compressed Gases in Cylinders

CGA Pamphlet P-1, from Compressed Gas Association, 1235 Jefferson Davis Highway, Suite 501, Arlington, VA 22202

Code for Safety in Welding and Cutting

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

Cutting And Welding Processes

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

Safe Practices For Occupational And Educational Eye And Face Protection

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

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

Installation

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. Avoid locations exposed to high temperature, high humidity, dust and corrosive fumes. High humidity causes moisture condensation on electrical components. Moisture can contribute to corrosion and short electrical components. Dust and dirt in the welder retain moisture and increase wear of moving parts.

● Place the welder in an area that

provides at least twelve inches (305 mm.) of ventilation space at both the front and rear of the unit. Keep all obstructions away from this ventilation space.

● Store electrodes in a clean, dry

location with low humidity, such as

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MODEL WT1000 (See Figure 5)

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

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

3. Position one of the holes in the adjustment arm over the pins which are located in the ear area of the face shield. These adjustment arms control

Figure 5 – Helmet Assembly

Headgear

Face Shield

Shaded Lens

Clear Lens Cover (2)

Post

Lens Retainer

Adjustment Arm (2)

Tension Nut (2)

Stud Screw (2)

WELDING HELMET ASSEMBLY

(Promotional Models Only)

Lens

Lens Retainer

Retainer Stiffener

Figure 4 – Hand Shield

the closeness of fit and can be easily repositioned if necessary.

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

5. Trial fit the welding helmet. Adjust headgear ratchet band to a comfortable position and lower the face shield. If the shield is too far or too close to the face, use a different hole in the adjustment arm. Adjust the tension nuts so that helmet can be easily lowered over the face by nodding the head.

Operation

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-20 amp

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 protective welding gear including: eye

WARNING

actual weld time that can occur in a ten minute interval. For example, at a 10% duty cycle, actual welding can occur for one minute, then the welder must cool for nine minutes.

Internal components of this welder are protected from overheating with an automatic thermal switch. A yellow lamp is illuminated on the control panel if the duty cycle is exceeded. Welding operations may continue when the yellow lamp is no longer illuminated.

Maintenance

Disconnect power

supply and turn machine off before inspecting or servicing any components.

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. Check condition of electrode holder

insulating pieces and immediately replace cracked or missing insulators. Verify that all fasteners are tight and insulated.

Do not operate this

welding machine with cracked or missing insulation on welding cables, electrode holder, or power cord.

Every 3 months: Replace any unreadable labels on the

welder. Use compressed air to blow all dust and lint from the ventilation openings.

Model WS2100

protection with proper shade, 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 ground clamp to the

work piece or workbench (if metal). Make sure the contact is secure, and not obstructed by paint, varnish, corrosion, or non-metallic materials.

5. Insert the exposed part of the

electrode (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 diameter. Refer to the following chart for proper electrode current settings.

The electrode

holder and rod are electrically "hot"(have 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 and holder away

from the grounded work piece or workbench. Turn on the welder. A green light is illuminated when the welder power is on.

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.

Duty Cycle / Thermostatic Protection

Welder duty cycle is the percentage of

Welding Guidelines General

This line of welding machines utilizes a process known as Shielded Metal-Arc Welding (SMAW). This process is used to bond metals by heating them with an electric arc created between the electrode and the work piece.

Electrodes used for shielded metal arc welding have two parts. The inner core is a metal rod or wire that should be similar in composition to the base metal. The outer coating is called flux. Various types of flux exist. Each coating is used for a particular welding situation.

While the metal is molten, it can be contaminated by elements in the air. This contamination could weaken the weld. The flux coating creates a protective barrier called slag that protects the molten metal from contaminants.

When current (amperage) flows through the circuit to the electrode, an arc is formed between the end of the electrode and the work piece. The arc melts the electrode and the work piece. The melted metal of the electrode flows into the molten crater and forms a bond with the work piece as shown. Note: Discontinue using and discard electrodes that burn down to 1 to 2 inches from the electrode holder.

Striking an Arc

Place the bare end of the electrode in the holder. Grip the holder lightly to

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Amperage Output Guide

Electrode Diameter Current Setting

1/16” 30-60 Amps 5/64” 40-70 Amps 3/32” 60-100 Amps 1/8” 90-110 Amps

Slag

Weld

Wire

Flux

Work piece

Crater

Figure 6 - Weld Components

Same as

electrode

diameter

Same as

electrode

diameter

Figure 7 - Striking An Arc

WARNING

Operating Instructions and Parts Manual

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Inverter Technology Arc Welder

reduce tiring of the hand and arm. Note: Always keep the jaws of the

holder clean to insure good electrical contact with the electrode.

Be careful not to

touch the work piece or welding bench with the electrode as this causes arc flashes.

There are two methods which can be used to start or strike the arc; the tapping method and the scratching method. In the tapping method, the electrode is brought straight down and tapped on the work piece.

With the scratching method, drag the electrode at an angle along the surface much like striking a match. Regardless of method, upon contact with the plate, immediately raise the electrode a distance equal to the diameter of the electrode or it will stick to the surface. Always hold the electrode pointed into the weld.

Note: Should the electrode stick to the work piece, break it loose by quickly twisting or bending at the holder while pulling upward. If the electrode does not break loose, disengage the electrode by releasing it from the holder.

Arc Welding Basics

Five basic techniques affect weld quality. These are: electrode selection, current setting, weld angle, arc length, and travel speed. Proper implementation of these techniques is necessary for good weld quality.

Electrode Type and Size

The correct choice of electrode 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 electrode.

All electrodes are classified into five main groups: mild steel, high-carbon steel, special alloy steel, cast iron, and nonferrous such as aluminum. The majority of arc welding is done with the electrodes in the mild steel group.

The electrode material should correspond with the work piece material.

Flux coatings are made for use with either AC (alternating current), DC (direct current) reverse polarity, or DC straight polarity, although some function well on both AC and DC current.

Commonly Used Electrodes

1. E-6011 Deep Penetrating

• The strong arc force and rapid solidification of the metal makes vertical and overhead welding easier with this rod.

• Where time does not permit rust, scale or paint removal, this rod penetrates rapidly and easily.

• Acceptable for AC or DC welding current (reverse polarity).

2. E-6013 General Purpose

• All position, smooth deposit rod with low spatter.

• For all mild steel and general purpose work.

• Acceptable for AC or DC welding current (straight or reverse polarity).

3. E-7014 Iron Powder

•A general purpose "drag" rod for all positions.

• Ideal for situations where fit between metal pieces is poor.

• The iron powder in the flux coating combines with the filler rod to make a smooth deposit with very little spatter.

• Ideal for ornamental work.

• Acceptable for AC or DC welding current (straight or reverse polarity).

4. E-7018 Low Hydrogen

• An all position high strength electrode designed to produce low hydrogen content combined with excellent mechanical properties.

• Acceptable for AC or DC welding current (reverse polarity).

Current

The correct current involves the adjustment of the welding machine to the required amperage setting. Current represents the actual flow of electricity and is regulated by a knob on the welder. The current used depends on the size (diameter) and type of electrode used, position of the weld, and the thickness of the work piece.

Consult specifications listed on the electrode package or generalized chart in the Operation section. Excessive current burns through light metals, and the weld bead is flat and porous or the bead undercuts the work piece (See Fig. 11). The bead appears high and irregular if the current is too low.

Weld Angle

Weld angle is the angle at which the electrode is held during the welding process. Using the correct angle ensures proper penetration and bead formation. As different welding

Travel Angle

Work Angle

5º - 45º

E - 6 0 1 3

E= Electrode 60= Mild steel 70= High strength Steel 1= Electrode can be used

in all positions

2= Electrode is restricted

for use in flat or horizontal position only

Flux type

AWS Electrode Classification

Figure 8 - Weld Angle

WARNING

positions and weld joints become necessary, electrode angle becomes an increasingly important factor in obtaining a satisfactory weld. Electrode angle involves two positions travel angle and work angle. (See Figure 8.)

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.

Note: Right handed welders should weld from left to right. Left handed welders should weld from right to left. The electrode should always point into the weld puddle as shown.

Arc Length

Arc length is the distance from the work piece to the tip of the electrode, the distance which the arc must travel. A proper arc length is essential to generate the heat needed for welding (See Fig. 11). An arc that is too long produces an unstable arc, reduces penetration, increases spatter, and

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Model WS2100

causes flat and wide beads. Too short an arc does not create enough heat to melt the work piece, the electrode has a tendency to stick, penetration will be poor, and uneven beads with irregular ripples result. A proper arc should be no longer then the diameter of the rod. The sound of a proper arc is a steady, crisp sizzle, similar to bacon frying.

Travel Speed

The travel speed is the rate at which the electrode is moved across the weld area. Factors such as diameter and type of electrode, amperage, position, and work piece material thickness all effect the speed of travel necessary for completing a good weld (See Fig. 11). When the speed is too fast, the bead is narrow and bead ripples are pointed as shown. When the speed is to slow, the weld metal piles up and the bead is high and wide.

Slag Removal

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 electrode 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 electrode 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 handbook.

WELD PASSES

Sometimes more then one pass is necessary to fill the joint. The root pass is first, followed by filler passes and the cover pass (See Figures 9 and 10). 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.

Figure 9 - Multiple Weld Passes

Figure 10 Fillet Welds

WARNING

Operating Instructions and Parts Manual

Inverter Technology Arc Welder

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Arc length too short

Current too high

Arc length too long

Current too low

Speed too low

Speed too fast

Normal

current, arc

length, speed

Base metal

Figure 11 - Weld Appearance

Note: Weld bead width (W) should

be approximately twice the diameter of the electrode rod used.

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Troubleshooting Chart

Symptom Possible Cause(s) Corrective Action

Welder does not hum when turned on (Green lamp not illuminated)

Welder hums but does not weld

Welder gives trickle shocks

Welder overheats - blows fuses, trips circuit breaker

Arc difficult to strike

Bead is intermittently too thin

Bead is intermittently too thick

Ragged depressions at edge of weld

Weld bead does not penetrate base metal

Electrode sticks to work piece

Electrodes sputter and stick

1. No power at receptacle

2. Broken or damaged power cable

1. Inadequate current at electrode

2. Poor connections at welder

1. Accidental contact with work piece

2. Current leakage caused by moist clothing or work area

1. Use of inadequate extension cord

2. Electrode diameter too large

3. Overloaded circuit

1. Electrode diameter too large

2. Work piece not properly grounded

3. Heavy loads making power line voltage low

1. Inconsistent travel speed

2. Output amp setting too low

1. Slow and/or inconsistent travel speed

2. Output amp setting too high

1. Travel speed too fast

2. Arc length too short

3. Output amp setting too high

1. Inconsistent travel speed

2. Output amp setting too low

Electrode is held in contact with work piece while arc is struck

Damp electrodes

1. Check circuit fuse or circuit breaker

2. Power cable requires service

1. Check ground clamp, cable and connection to work piece. Check electrode cable and clamp.

2. Check all welder external connections

1. Avoid contact with work piece

2. Make sure clothing and work area are dry

1. If possible, relocate welder to avoid use of extension cord. If relocation of welder is not possible, use thicker (lower gauge number) extension cord – See chart on page 1.

2. Use smaller diameter electrode

3. Welder requires a dedicated 20 amp circuit

1. Use smaller diameter electrode

2. Verify proper grounding. (No paint, varnish or corrosion)

3. Run welder on dedicated 20 amp circuit

1. Decrease and maintain travel speed

2. Increase output amp setting or change to smaller diameter electrode

1. Increase and maintain travel speed

2. Reduce output amp setting

1. Decrease travel speed

2. Increase arc length

3. Reduce output amp setting

1. Decrease and maintain constant travel speed

2. Increase output amp setting

Lift electrode to correct arc length as soon as arc is struck

Use dry electrodes and store in dry location

For Information About This Product

Call 1-800-746-5641

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1. Duration: The manufacturer warrants that it will repair, at no charge for parts or labor, the Welder, Welding Gun, or Cables, proven

defective in material or workmanship, during the following time period(s) after date of original retail purchase: One (1) Year.

2. Who Gives This Warranty (Warrantor):

Campbell Hausfeld The Scott Fetzer Company 100 Production Drive Harrison, OH 45030 Telephone: (513)-367-4811

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

4. What is covered under this warranty: Defects in material and workmanship which occur within the duration of the warranty period.

This warranty extends to the Welder, the Welders Transformer and Rectifier, Welding Gun or Electrode Holder, and cables only.

5. What is not covered under this warranty:

A. Implied warranties, including those of merchantability and FITNESS FOR A PARTICULAR PURPOSE ARE LIMITED IN DURATION TO THIS EXPRESS WARRANTY. After this period, all risks of loss, from whatever reason, shall be on the purchaser. Some states do not allow limitations on how long an implied warranty lasts, so above limitations may not apply to you. B. ANY INCIDENTAL, INDIRECT, OR CONSEQUENTIAL LOSS, DAMAGE, OR EXPENSE THAT MAY RESULT FROM ANY DEFECT FAILURE OR MALFUNCTION OF THE CAMPBELL HAUSFELD PRODUCT. Some states do not allow limitations on how long an implied warranty lasts, so above limitations may not apply to you. C. This warranty does not apply to any accessory items included with the product which are subject to wear from usage; the repair or replacement of these items shall be at the expense of the owner. These MIG items include but are not limited to; Contact Tips, Nozzles, Gun Liners, Drive Rollers, Felt Wire Cleaner. In addition, this warranty does not extend to any damage caused by the untimely replacement or maintenance of any of the previously listed CONSUMABLE parts. D. Any failure that results from accident, purchaser’s abuse, neglect or failure to operate products in accordance with instructions provided in the owner’s manual(s) supplied with the product. E. Pre-delivery service, i.e. assembly and adjustment.

7. Responsibilities of Warrantor under this warranty: Repair or replace, at Warrantor’s option, products or components which have failed within duration of the warranty period.

8. Responsibilities of purchaser under this warranty:

A. Deliver or ship the Campbell Hausfeld product or component to Campbell Hausfeld. Freight costs, if any, must be borne by the purchaser. B. Use reasonable care in the operation and maintenance of the products as described in the owner’s manual(s).

9. When Warrantor will perform repair or replacement under this warranty: Repair or replacement will be scheduled and serviced according to the normal work flow at the servicing location, and depending on the availability of replacement parts.

This Limited Warranty gives you specific legal rights and you may also have other rights which vary from state to state.

Limited Warranty

Operating Instructions and Parts Manual

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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 then the work piece. It is used on thinner material. DC Straight Polarity - occurs when the electrode holder is connected to the negative pole of the welding machine. With straight polarity more heat is directed to the work piece for better penetration on thicker material. Electrode - a coated metal wire having approximately the same composition as the material being welded. Fillet Weld - approximately a triangle in cross-section, joining two surfaces at right angles to each other in a lap, T or corner joint. Flux - a coating, when heated, that produces a shielding gas around the welding area. This gas protects the parent and filler metals from impurities in the air. Flux Cored Arc Welding (FCAW) also called Gasless, is a welding process

used with a wire-feed welding machine. The weld wire is tubular with flux material contained inside for shielding. Gas Metal Arc Welding (GMAW) also called MIG, is a welding process used with a wire feed welding machine. The wire is solid and an inert gas is used for shielding.

Gas Tungsten Arc Welding (GTAW)

- also called TIG, is a welding process used with welding equipment with a high frequency generator. The arc is created between a non-consumable tungsten electrode and the work piece. Filler metal may or may not be used. Inverter - Technology that converts high voltage AC input power into high amperage DC welding output power through the use of transistor-bridge and constant current rectifier instead of a heavy traditional transformer. Lap Joint - a joint between two overlapping members in parallel planes.

MIG - See “Gas Metal Arc Welding.” Open Circuit Voltage (OCV) - the

voltage between the electrode and the ground 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. Stick - See “Shielded Metal Arc Welding.” Tack Weld - weld made to hold parts in proper alignment until final welds are made.

TIG - See “Gas Tungsten Arc Welding.” 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

Welding Terms

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Campbell Hausfeld WS2100 User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual