MasterCraft WS0973, 58-8023-2 Operating Instructions
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Protect yourself and others by observing all safety information. Failure to comply with instructions could result in personal injury and/or
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Operating Instructions and Parts Manual WS0973, 58-8023-2
Arc Welder
Description
This Mastercraft Arc Welder is designed to
be used on standard 115 V household
current. It is equipped with an output
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 A circuits, up to
5/64” diameter for 20 A circuits. For
replacement electrodes, call 1-866-2202097 for the nearest authorized service
centre.
Unpacking
When unpacking, inspect carefully for any
damage that may have occurred during
transit. Report any damaged or missing
items by calling 1-866-220-2097.
Circuit Requirements
This equipment
requires a
dedicated 115 V 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.
Components and Controls
1. Work Clamp- connect to workpiece
2. Electrode Holder - holds electrode
welding rod
3. Power Cord - plug into 115 V outlet.
4. Power Switch - High/Off/Low.
5. Indicator Light - light activates if
thermostat has automatically shut unit
off.
6. Hand-shield hook - for hanging the
hand-shield for storage and transport.
7. Cable Keepers - for wrapping the
cables during storage and transport.
8. Storage Pocket - for storing the
chipping hammer/brush. Also can be
used for storing a tube of welding
rods.
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.
Figure 1 - Welder Components and Controls
IN972300AV 7/04
Low 15 A
High 20 A
Heat Circuit Breaker or
Setting Slow Blow Fuse
1
2
3
4
5
6
7
REMINDER: Keep your dated proof of purchase for warranty purposes! Attach it to this manual or file it for safekeeping.
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Arc Welder
General Safety
(Continued)
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, provincial, 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 workpiece 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 workpiece 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 workpiece 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 workpieces 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 metres) 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 vapours 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
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2. Insert filter lens.
3. To attach the handle, place shield on
a flat surface and press handle into
place (See Figure 5).
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.
General Safety
(Continued)
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
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
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WS0973, 58-8023-2
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
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
ANSI Standard Z49.1 from American
Welding Society, 550 N.W. LeJune Rd.
Miami, FL 33126
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. 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 Amperage 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.
Assembly
HANDSHIELD
1. Cut detachable handle away from
shield. Trim the excess plastic to
remove sharp edges.
Figure 2
Figure 3
Figure 4
Figure 5
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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.
6. Hold the electrode away from the
grounded workpiece or workbench.
Turn on the welder to either High
or Low. Refer to the following chart
for proper output setting.
7. Position the electrode to begin
weld, lower the welding helmet or
position the hand shield, and strike
an arc. Adjust output setting as
needed.
8. 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 front panel
if the duty-cycle is exceeded. Welding
operations may continue when the
yellow lamp is no longer illuminated.
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Arc Welder
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:
115 V 15 A - Low
115 V 20 A - High
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 minimum shade 10
lens, 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
workpiece. 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.
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.
Electrode Output
Diameter Setting
1/16" (1.6 mm) Low
5/64" (2 mm) High
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MANUAL
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Welding Guidelines
General
This welding machine 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 workpiece.
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 workpiece. The arc melts the
electrode and the workpiece. The melted
metal of the electrode flows into the
molten crater and forms a bond with the
workpiece as shown in Figure 6.
NOTE: Discontinue using and discard
electrodes that burn down to 1 to 2
inches from the electrode holder.
STRIKING AN ARC
Attach work clamp to workpiece. The
jaws of the work clamp must make good
contact with clean bare metal of the
workpiece for good welding results.
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 ensure good electrical
contact with the electrode.
Be careful not to
touch the workpiece
or welding bench with the electrode as
this causes arc flashes.
The best method of striking an arc is the
scratching method. Drag the electrode at
an angle along the surface much like
striking a match. Upon contact with the
plate, lift the electrode approximately
1/16” off the surface or it will stick (See
Figure 7).
NOTE: Should the electrode stick to the
workpiece, 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.
ELECTRODE TYPE AND SIZE
Two types of electrodes are
recommended for this welder. The
electrodes are designated as follows:
1. E-6013 GENERAL PURPOSE
• All position, smooth deposit rod with
low spatter.
• For all mild steel and general purpose
work.
2. E-7014 FAST FILL
• Smooth bead and fast deposition
• Ideal for joints with poor fitup and
general repair work
NOTE: E-6011 and E-7018 are not
recommended for use with these
welders. Recommended electrode
diameter is 1/16” or 5/64”. Call
1-866-220-2097 for availability.
Arc Welding Basics
Four basic techniques affect weld
quality. These are: amperage setting,
weld angle, arc length, and travel
speed. Proper use of these techniques is
necessary for good weld quality.
AMPERAGE SETTING
The correct amperage involves the
adjustment of the welding machine to
the required amperage setting. This is
regulated by selecting the appropriate
high or low setting. The amperage
required depends on the size
(diameter) of electrode used and the
thickness of the workpiece.
Excessive currents burn through light
metals and the weld bead is flat and
porous (See Figure 9). 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.
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.
Slag
Weld
Wire
Flux
Workpiece
Crater
Figure 6 - Weld Components
Same as Electrode Diameter
Figure 7 - Scratching Method
WS0973, 58-8023-2
Figure 8 - Weld Angle
5o - 45
o
Travel Angle
Work Angle
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WARNING
1/16"
6
Arc Welder
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
workpiece 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 Figure 9). An arc that is too long
produces an unstable arc, reduces
penetration, increases spatter, and
causes flat and wide beads. Too short
an arc does not create enough heat to
melt the workpiece, 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 than 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 (See Figure 9). When the speed is
too fast, the bead is narrow and bead
ripples are pointed as shown. When the
speed is too slow, the weld metal piles
up and the bead is high and wide. To
control travel speed, watch the width
of the weld bead (not the arc) when
welding. The weld bead is the orange,
molten metal behind the arc. The width
should be approximately twice the
diameter of the welding rod. Control
travel speed to obtain a consistent
bead width.
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 between 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.
Other positions require different
techniques such as a weaving pass,
circular pass, and jogging. A higher skill
level is required to complete these welds.
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
Welding Guidelines (Continued)
Normal Amperage,
Arc Length, Speed
Amperage Too Low
Amperage Too High
Arc Length Too Short
Arc Length Too Long
Speed Too Slow
Speed Too Fast
Workpiece
NOTE: Weld bead width (W)
should be approximately
twice the diameter fo the
electrode rod used.
W
Figure 9 - Weld Appearance
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WARNING
7
Welding Guidelines (Continued)
cover pass (See Figure 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
between each pass.
Figure 10 - Weld Passes
Cover
Filler
Root
Figure 11 - Multiple Weld Passes
WS0973, 58-8023-2
8
Troubleshooting Chart - Welder
Symptom Possible Cause(s) Corrective Action
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
workpiece
2. Current leakage caused by
moist clothing or work area
1. Use of extension cord
2. Electrode diameter too large
3. Overloaded circuit
1. Wrong type of electrode
2. Electrode diameter too large
3. Workpiece not properly
grounded
4. Heavy loads making power line
voltage low
For Information About This Product, Call 1-866-220-2097
1. Check circuit fuse or circuit breaker
2. Power cable requires service
1. Check work clamp, cable and connection to workpiece.
Check electrode cable and clamp
2. Check all welder external connections
1. Avoid contact with workpiece
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
2. Use smaller diameter electrode
3. Welder requires a dedicated 115 V circuit
1. Verify that electrode is for alternating current (AC) use
2. Use smaller diameter electrode
3. Verify proper grounding. (No paint, varnish or corrosion)
4. Run welder on dedicated 115 V circuit
Welder does not hum when
turned on
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 or too thick
Ragged depressions at edge
of weld
Weld bead does not
penetrate workpiece
Electrode sticks to
workpiece
Electrodes sputter and stick
1. Inconsistent travel speed
2. Output amperage setting
incorrect
1. Travel speed too fast
2. Arc length too short
3. Output amperage setting too
high
1. Inconsistent travel speed
2. Output amperage setting too
low
3. Electrode diameter too large
1. Arc length short
2. Amperage setting low
Damp electrodes
Troubleshooting Chart - Welds
Symptom Possible Cause(s) Corrective Action
1. Carefully watch and control the width of the molten weld
bead
2. Adjust output amperage setting or change to smaller
diameter electrode
1. Watch orange molten weld puddle and control bead width
2. Practice running electrode across workpiece with welder
OFF
3. Reduce output amperage setting
1. Decrease and maintain constant travel speed
2. Increase output amperage setting or change to smaller
diameter electrode
3. Recommend either 1/16” or 5/64” diameter electrodes
1. Lift electrode to correct arc length as soon as arc is struck
2. Increase amperage setting or change to smaller diameter
electrode
Use dry electrodes and store in dry location
Arc Welder
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