Campbell Hausfeld WS2800 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.
IN971400AV 8/04
Operating Instructions & Parts Manual Model WS2800
Shielded Metal
Arc Welder
Description
This Campbell Hausfeld electric arc
welding machine runs on 230 volt,
single phase input power. This welder
is equipped with infinite amperage
control to accurately select the proper
current needed for various welding
conditions. Internal components are
thermostatically protected.
This welding system is designed for use
with the Shielded Metal Arc Welding
(SMAW) process. As delivered from the
factory, this welder can weld with up
to 5/32" diameter electrodes.
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 230 volt circuit. Refer to the
following chart for the correct circuit
breaker or fuse rating. Do not run
other appliances, lights, or tools on
this circuit while operating this
equipment. Extension cords are not
recommended. Blown fuses and tripped
circuit breakers can result from failure
to comply with this recommendation.
Specifications
Rated Input Voltage . . . . . . . . .230v AC
Rated Input Amperage . . . . .See chart
Power Cord Length . . . . . . . . . . . . .6 FT
Electrode Cord Length . . . . . . . . .10 FT
Grounding Cord Length . . . . . . . .10 FT
Cycles . . . . . . . . . . . . . . . . . . . . . . .60 Hz
The electrode
holder is "live"
(has current potential) when machine is
turned on.
Components and Controls
1. Work Clamp – connect to work piece
2. Electrode Holder – holds welding
electrode.
3. Power Cord – plug into 230 volt outlet.
4. On/Off Switch.
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.
7. Overload Indicator Light – lights when
duty cycle exceeded.
8. Power Indicator Light – lights when
unit is energized.
General Safety
Danger means a
hazard that will
Weld Circuit Breaker or
Current Slow Blow Fuse
AC 50 amp
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
For parts, manuals, product & service information
visit www.chpower.com
or call 800-746-5641
© 2004 Campbell Hausfeld/Scott Fetzer
Weld Voltage 31v AC
Weld Amps 180a AC
Duty Cycle 20%
Max. Open
Circuit Voltage 65 Volt AC
1
2
3
4
8
7
5
6
Figure 1 - Welder Components and Controls
REMINDER: Keep your dated proof of purchase for warranty purposes! Attach it to this manual or file it for safekeeping.
40
Notes
Manual de instrucciones y lista de repuestos
BUILT TO LAST
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CAUTION
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WARNING
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DANGER
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WARNING
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CAUTION
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CA o Corriente Alterna - corriente
eléctrica que cambia de dirección
periódicamente. Corriente de 60 ciclos se
desplaza en ambas direcciones 60 veces por
segundo.
Longitud del Arco - la distancia entre el
extremo del electrodo y el punto de
contacto con la superficie de trabajo.
Metal Básico - el material que se va a
soldar.
Unión a tope - la unión de dos miembros
alineados aproximadamente en el mismo
plano.
Cráter - el vacio que se forma cuando el
arco hace contacto con el metal básico.
CD o Corriente Directa - corriente
eléctrica que se deplaza en un sólo sentido.
La polaridad (+ o -) determina el sentido
del desplazamiento.
CD Polaridad Reversa - ocurre cuando el
portaelectrodo está conectado al polo
positivo de la soldadora. Esta tecnica dirije
más calor para derretir el electrodo en vez
de la pieza de trabajo. Generalmente esta
técnica se usa con piezas delgadas.
CD Polaridad Directa - oocurre cuando el
portaelectrodo está conectado al polo
negativo de la soldadora. Con esta tecnica
la mayoría del calor se dirije a la pieza de
trabajo para lograr una mayor penetración
en piezas gruesas.
Electrodo - un alambre de metal con una
capa que tiene aproximadamente la misma
composición del material que se va a soldar.
Soldadura de Filete - soldadura
triangular, para unir dos superficies en
ángulo recto, en T o en las esquinas.
Fundente - un material, que al calentarse,
emite un gas que cubre el área donde va a
soldar. Este gas protege los metales que va
a soldar contra las impurezas presentes en
el aire.
Soldar con Arcos de Fundente - también
se conoce como soldar sin gas, esta técnica
para soldar usa una soldadora con alambre.
El alambre es tubular y lleno de fundente.
Soldar con Arcos de Metal Gaseoso - es
un proceso para soldar usado con una
soldadora con alambre. El alambre es
sólido y se usa un gas inerte.
Soldar con Arcos de Tungsteno - es un
proceso para soldar usado con soldadoras
con generadores de alta frecuencia. El arco
se crea con un electrodo no-consumible de
tugnsteno. No necesariamente se usa metal
de relleno.
Unión de superposición - la unión de dos
miembros superpuestos en planos paralelos.
Voltaje de circuito abierto - el voltaje
entre el electrodo y la pinza de conexión a
tierra de la soldadora cuando no hay flujo
de corriente (no se está soldando). Esto
determina la rápidez con que se enciende el
arco.
Sobremonta - ocure si el amperaje es
demasiado bajo. En este caso, el metal
derretido se cae del electrodo sin haberse
unido al metal básico.
Porosidad - cavidad que se forma durante
la solidificación del área soldada. Las
porosidades debilitan la unión.
Penetración - la profundidad que el arco
se penetra dentro de la pieza de trabajo
durante el proceso de soldar. Para soldar
bien se debe lograr 100% de penetración,
es decir todo el grosor de la pieza de
trabajo se debe derretir y solidificar. El área
afectada por el calor se debe ver facilmente
desde el otro lado.
Soldar con arcos protegidos - es un
proceso de soldar que usa un electrodo
consumible para sostener el arco. La
protección se logra al derretir el fundente
del electrodo .
Escoria - una capa de residuo de fundente
que protege la unión de óxidos y otros
contaminantes mientras los metales se
solidifican (enfrian). Esta se debe limpiar
una vez que el metal se haya enfriado.
Salpiqueo - las particulas de metal que
salpican durante el proceso de soldar y que
se solidifican en la superficie de trabajo.
Esto se puede minimizar al rociar un
repelente adecuado antes de comenzar a
soldar.
Soldadura de puntos - una unión hecha
para mantener las piezas alineadas hasta
que se haya completado el proceso de
soldar.
Angulo de desplazamiento - el ángulo
del electrodo con respecto a la línea a
soldar. Este varia entre los 5º y 45º según
sean las condiciones.
Unión en T - es la unión del borde de una
pieza de metal con la superficie de otra en
un ángulo de 90º .
Socavación - el resultado de soldar con un
amperaje demasiado alto. Esto ocasiona
ranuras en ambos lados de la reborde que
reduce la resistencia de la unión.
Sedimento - el volumen de metal
derretido al soldar antes de que se
solidifique como metal soldado.
Reborde - una capa delgada o capas de
metal depositado en el metal básico
cuando el electrodo se derrite.
Generalmente su grosor es el doble del
diámetro del electrodo.
Angulo de trabajo- el ángulo del
electrodo con respecto a la línea horizontal,
medido en ángulos rectos a la línea de
soldar .
Glosario de Terminología usada por soldadores
2
Operating Instructions and Parts Manual
Shielded Metal Arc Welder
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.
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
e
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
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.
www.chpower.com
Current Filter
(Amps) Shade
!
WARNING
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DANGER
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WARNING
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Manual de instrucciones y lista de repuestos
Lista de Repuestos
Modelo WS2800
1 Etiquetas de Advertencia DK683400AV 1
2 Conector Dinse WC000200AV 2
3 Enchufe Dinse WC000300AV 2
4 Cordón de energía – 230V, 50A (NEMA 6-50P),
7 pies (213 cm), 12AWGX3C, Tipo SJT * 1
5 Cable de soldar – 5 AWG (15mm2) x 10 pies (305 cm) WC000800AV 2
6 Pinza de trabajo – 250A WC100100AV 1
7 Liberador de tensión WC102400AV 1
8 Portaelectrodo – 300A WC200200AV 1
9 Mango WC301600AV 1
10 Tapón del tubo – 9,94" (24mm) OD WC301601AV 2
11 Tornillo de la máquina – M4-0.7 X 35 mm (Mango) * 4
12 Manivela, Juego de (incluye manivela, perilla, perno, arandelas y tuerca) WC302300SJ 1
13 Interruptor de energía WC402400AV 1
14 Interruptor térmico WC402500AV 1
15 Luz indicadora – Verde WC402600AV 1
16 Luz indicadora – Amarilla WC402700AV 1
17 Ventilador WC402800AV 1
18 Eje WC704300AV 1
19 Contratuerca WC704301AV 2
20 Rueda WC704400AV 2
21 Rueda giratoria WC704500AV 2
22 Tornillo de la máquina – M4-0,7 X 10 mm (Rueda giratoria) * 8
23 Puerta WC705100AV 1
24 Pasador de la bisagra WC705300AV 2
25 Puntero del medidor WC705500AV 1
26 Rejilla del ventilador WC706200AV 1
27 Pasador de la puerta WC706300AV 1
28 Lentes de soldar – Oscuros 10, 2x4-1/4" (51x108mm) WC801100AV 1
29 Protector manual WC801300AV 1
30 Martillo/cepillo cincelador WC803000AV 1
* Piezas estándar, disponibles en su tienda local de venta de ferretería o suministros de soldar.
No se muestra
No. de
Ref. Descripción Número Ctd.
Figura 16 - Repuestos
Para mayor información
sobre este producto
llame al 1-800-746-5641
(desde los E.E.U.U.)
1
13
15
17, 26
16
3
12
14 (dentro
de la caja)
4
9
10
11
7
18
19
20
21
22
23
27
24
25
2
5
8
6
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
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.
The use of an extension cord is not
recommended for electric arc
welding machines. The voltage drop
in the extension cord may
significantly degrade the
performance of the welder.
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
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
Model WS2800
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.
• 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.).
• To request Material Safety Data Sheet
(MSDS), visit the Internet at
www.chpower.com or call
1-800-746-5641.
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
www.chpower.com
3
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WARNING
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Garantía Limitada 5-3-1
1.Duración: El fabricante garantiza que reparará, sin costo alguno por repuestos o mano de obra la soldadora o la pistola o los cables que
estén dañados bien en material o mano de obra, durante los siguientes periodos después de la compra original:
Por 5 años: El transformador y rectificador de la soldadora
Por 3 años: Toda la soldadora (se excluyen: pinzas, pistola,portaelectrodos, cables, o accesorios que vienen con la soldadora)
Por 1 año: Pinzas, Pistola, Portaelectrodo, Acessorios y Cable para Soldar (de haberlos)
2. QUIEN OTORGA ESTA GARANTIA (EL GARANTE):
Campbell Hausfeld
The Scott Fetzer Company
100 Production Drive
Harrison, OH 45030
Teléfono: (513)-367-4811
3. BENEFICIARIO DE ESTA GARANTIA (EL COMPRADOR): El comprador original del producto Campbell Hausfeld.
4. Cobertura de la garantía: Defectos en material y fabricación que ocurran dentro del periodo de validez de la garantía. La garantía
cubre la soldadora, el transformador y rectificador, la pistola o el portaelectrodo y los cables sólamente.
5. Lo que no está cubierto por esta garantía:
A. Las garantías implicitas, incluyendo las garantías de comercialidad y conveniencia para un fin particular SON LIMITADAS A LA DURACION
EXPRESA DE ESTA GARANTIA. Después de este periodo, todos los riegos de pérdida, por cualquier razón, serán la responsabilidad del
propietario del producto. En algunos estados no se permiten limitaciones a la duración de las garantías implicitas, por lo tanto, en tal caso
esta limitación o exclusión no es aplicable.
B. CUALQUIER PERDIDA, DAÑO INCIDENTAL, INDIRECTO O CONSECUENTE O GASTO QUE PUEDA PUEDA RESULTAR DE UN DEFECTO, FALLA
O MAL FUNCIONAMIENTO DEL PRODUCTO CAMPBELL HAUSFELD. En algunos estados no se permite la exclusión o limitación de daños
incidentales o consecuentes, por lo tanto, en tal caso esta limitación o exclusión no es aplicable.
C. Esta garantía no cubre aquellos accesorios que se desgastarán con el uso normal del producto; la reparación o reemplazo de los mismos
será la responsabilidad del propietario. Ejemplos de los productos de desgaste por el uso son (lista parcial): Bqouillas de contacto, boquillas,
forros internos de la pistola, bobinas, felpa para limpiar el alambre. Además, esta garantía no cubre daños que ocurran al reemplazar o darle
servicio a las piezas arriba enumeradas.
D. Cualquier falla que resulte de un accidente, abuso, negligencia o incumplimiento de las instrucciones de funcionamiento y uso indicadas
en el(los) manual(es) que se adjuntan al producto.
E. Servicio antes de entrega, por ejemplo ensamblaje y ajustes.
7. Responsibilidades del Garante bajo esta Garantía: Reparar o reemplazar, como lo decida el garante, los productos o componentes
defectuosos durante el periodo de validez de la garantía.
8. Responsibilidades del Comprador bajo esta Garantía:
A. Entregar o enviar el producto o componente a Campbell Hausfeld. Los gastos de flete, si los hubiere, deben ser pagados por el comprador.
B. Ser cuidadoso con el funcionamiento del producto, como se indica en el(los) manual(es) del propietario.
9. Cuando efectuará el garante la reparación o reemplazo cubierto bajo esta garantía: La reparación o reemplazo dependerá del
flujo normal de trabajo del centro de servicio y de la disponibilidad de repuestos.
Esta garantía limitada le otorga derechos legales especificos y usted también puede tener derechos que varian de un estado a otro.
Encendido/Apagado
Tierra
Negro
Blanco
Verde
S2
NC
T1
S2
M
G
Y
S1
Figura 15 - Esquema del cableado
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.
ELECTRODE HOLDER ASSEMBLY
(See Figure 5)
1. Loosen the handle setscrew in the
electrode holder a few turns. Do not
remove this setscrew completely.
Remove the insulated handle and slide
it over the end of the welding cable
with the crimped sleeve.
2. Loosen the cable setscrew in the
bottom of the brass body of the
electrode holder.
3. Slide the welding cable/crimped
sleeve into the back of the brass body,
aligning the flat side of the crimped
connector with the face of the cable
setscrew.
4. Tighten the cable setscrew to
securely hold the welding
cable/crimped sleeve.
5. Slide the insulated handle onto the
electrode holder and tighten the
handle setscrew. Do not overtighten
this setscrew. Overtightening will
damage the insulated handle.
HAND SHIELD ASSEMBLY (See
Figures 6 & 7)
1. Cut retainer stiffeners and
detachable handle away from shield.
Trim the excess plastic to remove sharp
edges.
2. Insert the filter lens.
4
Operating Instructions and Parts Manual
Shielded Metal Arc Welder
HANDLE ASSEMBLY (See Figure 2)
1. Fasten end caps onto handle.
2. Handle may be attached in two
positions (high or low). Using the four
screws and washers provided, attach
the handle to the back of the case
WHEEL ASSEMBLY (See Figure 2)
1. Slide the axle through the holes in
the sides of the case.
2. Slide the wheels onto the axle and
lightly tap the pal-nuts into place on
the axle grooves.
CASTER ASSEMBLY (See Figure 2)
1. Using the eight screws and washers
provided, attach the casters to the
bottom of the case.
DINSE PLUG ASSEMBLY (See Figure
3)
1. Strip 1/2” of insulation from the end
of the welding cable opposite the
crimped connectors.
2. Insert this end of the welding cable
through the dinse plug boot and slide
the bare wire into the copper sleeve.
3. Insert the welding cable/copper
sleeve assembly into the back of the
dinse plug.
4. Tighten the setscrew, securing the
cable in place.
5. Slide the boot over the hex portion
of the dinse plug.
6. Repeat for the other lead.
WORK CLAMP ASSEMBLY (See
Figure 4)
1. Remove one hex nut from work
3. Attach the stiffeners over the pins on
the lens retainers.
4. To attach the handle, place shield on
a flat surface and press handle into
place.
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MODEL WT1000 (See Figure 8)
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
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
WELDING HELMET ASSEMBLY
(Promotional Models Only)
Welding
Cable
Ring Connector
Work
Clamp
Hex
Nut
Figure 2 – Handle, Wheel and Caster
Assembly
Figure 3 - Dinse Plug Assembly
Set Screw
Boot
Welding
Cable
Wire
Sleeve
Dinse Plug
Electrode
Holder
Handle
Setscrew
Cable
Setscrew
Crimped
Sleeve
Handle
Welding
Cable
Figure 4 – Work Clamp Assembly
Figure 5 – Electrode Holder
Lens
Lens
Retainer
Retainer
Stiffener
Figure 6 – Hand Shield
Figure 7 – Hand Shield
~
~
36
Manual de instrucciones y lista de repuestos
DIAGNOSTICO DE AVERIAS
Problema Posibles Causas Acción a tomar
La soldadora no hace ruido al
encenderla (La luz verde no está åΩ
La soldadora hace ruido pero no
suelda
La soldadora le da corrientasos
La soldadora se sobrecalienta - se
queman los fusibles o el
cortacircuito se activa
Se le dificulta encender el arco
Reborde es muy delgado en
algunos sitios
Reborde es muy grueso en algunos
sitios
Los bordes de la soldadura están
disparejos
El reborde no penetra el metal
básico
El electrodo se pega a la pieza de
trabajo
El electrodo salpica y se pega
1. No hay corriente en el
tomacorrientes
2. El cordón eléctrico está
roto o dañado
1. La electricidad en el
electrodo no es la
adecuada
2. Hay conexiones mal
hechas en la soldadora
1. Contacto accidental con
la pieza de trabajo
2. Hay transmisión de
corriente debido a la
humedad en la ropa o el
área de trabajo
1. Uso de un cordón de
extensión
2. El diámetro del electrodo es muy grande
3. El circuito está sobrecargado
1. El diámetro del
electrodo es muy grande
2. La pieza de trabajo no
está conectada a tierra
adecuadamente.
3. El voltaje se ha reducido
debido a carga excesiva
1. La velocidad de
desplazamiento varia
2. El nivel del amperaje es
muy bajo
1. La velocidad de
desplazamiento varia o
es muy lenta
2. El nivel del amperaje es
muy alto
1. La velocidad de
desplazamiento es muy
rápida
2. El arco es muy corto
3. El nivel del amperaje es
muy alto
1. ILa velocidad de
desplazamiento varia
2. l nivel del amperaje es
muy bajo
El electrodo está en
contacto con la pieza de
trabajo cuando el arco está
encendido
Los electrodos están
húmedos
1. Chequée el fusible o el cortacircuito
2. Debe darle servicio
1. Chequee la pinza de conexión a tierra, el cable y la conexión a la
pieza. Chequee el cable del electrodo y la pinza.
2. Chequee todas las conexiones externas de la soldadora
1. Evite hacer contacto con la pieza de trabajo
2. Cerciórese de que la ropa y el área de trabajo estén secas
1. Si es posible, reubique la soldadora para evitar el uso de cordones de
extensión. Si no la puede reubicar, use un cordón de extensión más
grueso (de un número más bajo)
2. Use un electrodo de un diámetro más pequeño
3. La soldadora requiere una línea exclusiva
1. Use un electrodo de un diámetro más pequeño
2. Cerciórese de que la conexión a tierra es adecuada ( no hay pintura,
barniz u óxido)
3. Conecte la soldadora a una línea exclusiva
1. Disminuya y mantenga la velocidad de desplazamiento
2. Debe aumentarlo o usar un electrodo de un diámetro más pequeño
1. Debe aumentarla y mantenerla constante
2. Debe bajarlo
1. Debe reducirla
2. Debe aumentarlo
3. Debe bajarlo
1. Debe reducirla y mantenerla constante
2. Debe aumentarlo
Mantenga el electrodo a la distancia adecuada tan pronto haya
encendido el arco
Use electrodos secos y siempre almacene los electrodos en un sitio seco
Para mayor información sobre este producto llame al
1-800-746-5641 (desde los E.E.U.U.)
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
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
Model WS2800
5
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: 230v-50 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
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.
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.
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.
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Figure 8 – Helmet Assembly
Headgear
Face Shield
Shaded Lens
Clear Lens Cover (2)
Post
Lens Retainer
Adjustment
Arm (2)
Tension Nut (2)
Stud Screw (2)
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.
Electrode Current
Diameter Setting (Amps)
3/32" (2.5 mm) 60-110
1/8" (3.2 mm) 110-160
5/32" (4.0 mm) 150-230
!
WARNING
!
WARNING
!
WARNING
!
WARNING
!
WARNING
Modelo WS2800
35
Longitud del arco muy corta
Corriente muy alta
Longitud del arco muy larga
Corriente muy baja
Velocidad muy lenta
Velocidad muy rápida
Corriente, longitud del arco y
velocidad normales
Metal Básico
Figura 14 - Apariencia de la soldadura
Nota: El ancho (A) del reborde debe ser
aproximadamente el doble del diámetro de
la varilla de electrodo que se use.
paso para soldar. Primero deberá hacer
un paso primordial, éste será seguido
por pasos adicionales de relleno (vea la
Fig. 8 y 9). Si las piezas son gruesas, tal
vez sea necesario biselar los bordes
que están unidos en un ángulo de 60º .
Recuerde que deberá limpiar las
escorias antes de cada paso.
6
Operating Instructions and Parts Manual
www.chpower.com
Shielded Metal Arc Welder
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
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 (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).
Slag
Weld
Wire
Flux
Work piece
Crater
Same as
electrode
diameter
Same as
electrode
diameter
Figure 10 - Striking An Arc
Figure 9 - Weld Components
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
!
WARNING
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