POWER FIST 8785008 75A Mini Inverter Stick Welder User Manual

: June 13, 2024
: POWER FIST

8785008 75A Mini Inverter
Stick Welder
User Manual

Please read and understand all instructions before use. Retain this manual for future reference.

SPECIFICATIONS

Rating (Voltage, Current, Frequency)	120VAC, 20A, 60Hz
Phase	Single
Output Current Range	20 to 75A
Duty Cycle	40% at 75A
Welding Capacity	1/8 in.
Electrode Size	3/32 in. Diameter
Insulation Class	H
Protection Class	IP21S
Cooling Type	Fan Cooled
Storage Temperature	10 to 120ºF (-12 to 48ºC)
Dimension (L × W × H)	12-14/16 x 4-4/16 x 6-15/16 in.

(31.5 x 10.2 x 17.6 cm)
Weight| 3 kg

INTRODUCTION

The 75A Mini Inverter Stick Welder is ideal for small DIY and fabrication projects. It welds carbon steel, stainless steel, cast iron, copper and nickel up to 1/8 in. thick.
Inverter technology produces smoother weld characteristics than traditional welders. Suitable for basic, rutile and cellulosic electrodes. Includes ground lead and electrode holder.

SAFETY

WARNING! Read and understand all instructions before using this tool. The operator must follow basic precautions to reduce the risk of personal injury and/or damage to the equipment.
Keep this manual for safety warnings, precautions, operating or inspection and maintenance instructions.

HAZARD DEFINITIONS

Please familiarize yourself with the hazard notices found in this manual. A notice is an alert that there is a possibility of property damage, injury or death if certain instructions are not followed.
DANGER! This notice indicates an immediate and specific hazard that will result in severe personal injury or death if the proper precautions are not taken.
WARNING! This notice indicates a specific hazard or unsafe practice that could result in severe personal injury or death if the proper precautions are not taken.
CAUTION! This notice indicates a potentially hazardous situation that may result in minor or moderate injury if proper practices are not taken.
NOTICE! This notice indicates that a specific hazard or unsafe practice will result in equipment or property damage, but not personal injury.

WORK AREA

Operate in a safe work environment. Keep your work area clean, well-lit and free of distractions.
Remove all unnecessary people from the work area when welding. Anyone remaining in the work area must wear the appropriate welding safety equipment.
Store tools properly in a safe and dry location. Keep tools out of the reach of children.
Do not weld on damp surfaces that can transmit the electric current without taking precautions for the welder and bystanders. The electrode, welding head and nozzle are electrically ‘hot’.
Do not install or use in the presence of flammable gases, dust or liquids.
Welding sparks and ejected molten slag can start a fire. Remove combustible materials within 39 ft (12 metres) of the welding unit. See Fire and Explosion Precautions.
Have a fire extinguisher readily available (see Fire and Explosion Precautions).
Use protective screens or barriers to protect others from flash and glare; warn others in the area to look away from the arc.
Keep the welding unit at least one foot from any wall or structure.
Check that the work area is free from fires, sparks or hot debris before leaving.

PERSONAL SAFETY

WARNING! Wear personal protective equipment approved by the Canadian Standards Association (CSA) or American National Standards Institute (ANSI).
HEAD PROTECTION
DANGER! Never look directly at the welding arc without the proper protection. The light can cause flash burn damage and impair vision. Although treatment is possible, multiple occurrences can result in permanent eye damage.

Protect your eyes from welding light by wearing a welder’s helmet fitted with a filter shade suitable for the type of welding you are doing. The welding process produces intense white light, infrared and ultraviolet light, these arc rays can burn both eyes and skin. a. Consult the Welding Shade Guide in Appendix A for the minimum shade to protect the eyes based on the amperage and type of welding.
An opaque helmet will protect against the ultraviolet or infrared light. A helmet will also protect against ejected hot material and slag. The helmet should protect the face, forehead, ears and neck.
Wear a fire-resistant head covering like a skullcap or balaclava hood to protect your head when the faceplate is down or when using a welding hand-held face shield.
Wear ventilated safety goggles beneath the welding helmet or behind the hand-held face shield. The cooling weld bead may fragment or eject slag that can damage the eyes, when the helmet or hand-held face shield is not in place. a. Eye protection equipment should comply with CSA Z94.3-07 or ANSI Z87.1 standards based on the type of work performed.
Wear fire resistant earplugs when welding overhead to prevent spatter or slag from falling into your ear.

PROTECTIVE CLOTHING

Wear a leather apron or jacket, leather welding gloves and full foot protection. Choose clothing fabrics that resist sparks, heat, flames and splashes of molten material. Artificial fabrics may burn and melt, resulting in a more severe injury. a. Wear welding capes and sleeves when performing overhead welding.
Do not wear clothes or protective gear that are frayed, oily or greasy as they may ignite from the heat or ejected slag and sparks.
Wear thick clothes that do not expose the skin. Ultraviolet or infrared light can burn skin with sufficient exposure.
Do not wear clothing that can hold hot debris or sparks such as pant cuffs, shirt pockets or boots. Choose clothing that has flaps over pockets or wear clothing to cover the openings such as pant legs over the boots or an apron over the shirt.
Gloves shall should contain an insulating lining to protect against an electric shock.
Rubber soled footwear or electrically insulated work boots are recommended while working with a welding unit. The non- skid sole is will also help maintain footing and balance during work. a. Select boots with steel toe protection to prevent injury from falling objects.

RESPIRATORS

Respiratory protection is needed when ventilation is not sufficient to remove welding fumes or when there is risk of oxygen deficiency. a. Wear a NIOSH approved respirator when working on materials that produce dust or particulate matter.
Work in a confined space only if it is well ventilated or while wearing an airsupplied respirator. Welding fumes and gases can displace air and lower the oxygen level causing injury or death. Be sure the breathing air is safe (See Fumes and Gases).
The user can take the additional precaution of informing another person in the work area of the potential danger, so that person can watch for indications that the user is suffering from oxygen deprivation.

PERSONAL PRECAUTIONS
Control the tool, personal movement and the work environment to avoid personal injury or damage to the tool.

Do not operate any tool when tired or under the influence of drugs, alcohol or medications.
Avoid wearing clothes or jewelry that can become entangled with the moving parts of a tool. Keep long hair covered or bound.
Remove all jewelry or metal items from your person before welding. Metal items may connect to the welding unit’s electrical circuit, causing an injury or death.
Do not overreach when operating the tool. Proper footing and balance enables better control in unexpected situations.
Support the workpiece or clamp it to a stable platform. Holding the workpiece by hand or against your body may lead to personal injury.
Do not wear any personal grooming products that are flammable, such as hair preparations, perfume or cologne with an alcohol base.
Remove any combustibles, such as butane lighters or matches, from your person before doing any welding. Hot welding sparks may light the matches or ignite leaking lighter fuel.

SPECIFIC SAFETY PRECAUTIONS

WARNING! DO NOT let comfort or familiarity with product (gained from repeated use) replace strict adherence to the tool safety rules. If you use this tool unsafely or incorrectly, you can suffer serious personal injury.
Welding produces sparks, molten slag, intense white light, plus infrared and ultraviolet light. A cooling bead can eject chips or fragments of slag. Any of these can cause direct harm to the eyes and skin of the welder or bystanders.

Use the correct tool for the job. This tool was designed for a specific function. Do not modify or alter this tool or use it for an unintended purpose.
Arc welding requires the use a hand-held face shield or helmets with full face protection per CSA standard Z94.3.1.
Protect against reflected arc rays. The rays can reflect off a shiny surfaces behind the user, into the helmet and off the filter lens into the eyes.
Remove or cover any reflective surface behind the user such as a glossy painted surface, aluminum, stainless steel or glass.
Welding produces sparks and molten slag. A cooling bead can eject chips or fragments of slag. Any of these can cause direct harm to the eyes or skin of the user or bystanders.
Erect protective screens or barriers to protect bystanders from the flash and glare; warn others in the area not to watch the arc. Do not strike a welding arc until all bystanders and you (the user) have welding shields and/or helmets in place.
Immediately replace a cracked or broken helmet or a scratched or damaged lens filter to avoid damage to the eyes or face from arc flash or ejected molten material.
Do not allow the welding stick to accidentally touch the ground clamp or grounded work. An arc flash will result from contact and can injury the unprepared user and bystanders.
Do not handle hot metal or electrode stubs with bare hands. Handling may result in a burn injury.
Do not use the welding unit if personal movement is confined or if there is a danger of falling.
Keep all panels and covers securely in place when operating the welding unit.
Insulate the ground clamp when not connected to a workpiece to prevent contact with any metal object.
Do not operate the welding unit if the torch, electrode holder, welding cable or ground cable are wet. Do not immerse them in water. These components and the welding unit must be completely dry before attempting to use them.
Never dip the electrode in water for cooling.
Remove the electrode from the holder when not in use.
Do not point the electrode holder at any body part of yourself or at anyone else.
Insulate yourself from the work and the ground using dry insulation. Make certain that the insulation is large enough to cover your full area of physical contact.
When not welding, make certain that no part of the electrode circuit is touching the workpiece or the ground. Accidental contact can cause overheating and create a fire hazard.
Maintain good ventilation of the louvers on this equipment. Good ventilation is of critical importance for the normal performance and service life of this equipment.
When working above floor level, use a safety belt to protect yourself from a fall should you get a shock.

FIRE AND EXPLOSION PRECAUTIONS

Arc welding can produce sparks, hot slag or spatter, molten metal drops and hot metal parts that can start fires.

Clear the floor and walls of an area of all combustible and/or flammable materials up to 39 ft (12 metres) away from the welding unit. Hot debris ejected during welding can land at a considerable distance away. Solid floors of concrete or masonry is the preferred working surface.
a. Cover any combustible material with fire resistant covers or shields, if it cannot be removed. The covering must be tight and should not leave openings for sparks or ejected slag to enter.
b. Check both sides of a panel or wall for combustible material. Remove the combustible material before welding.
A combustible floor should be protected with a fire resistant covering. Alternatives are to spray the floor with water to keep it wet for the duration of the welding or cover with damp sand. Care must also be taken to avoid an electric shock when this is done. A combustible floor directly laid onto concrete does not need to be sprayed with water.
Seal cracks and openings to adjacent areas that a spark or slag can enter. Seal any openings found with a fire-resistant cover. Shut doors and windows that do not provide ventilation or erect protective screens in front of them when possible.
Avoid welding near hydraulic lines or containers containing flammable contents.
Do not perform any welding work on containers that held flammable or toxic substance, until they are cleaned by a person trained in removing toxic and flammable substances and vapours per the American Welding Standard AWS F4.1.
Open a container before performing any welding work on it. The heat generated by the welding process will cause the air and gases to expand. The internal pressure may cause a sealed or closed container to rupture, possibly causing an injury or death.
Do not weld pipes or metal that are covered in combustible material or in contact with combustible structure such as a wall. Only weld if the covering can be safely removed.
a. Follow all safety precautions and legal requirements before welding a workpiece that contains Asbestos or attempting to remove the Asbestos covering. This requires expert knowledge and equipment.
b. Molten slag can run down the inside and outside of a pipe and start a fire. Be aware where the pipe terminates and take precautions.
Do not weld a panel that is a sandwich construction of combustible and metal materials.
Have a fire extinguisher available for immediate use. A dry chemical fire extinguisher for Types A, B and C is suggested.
a. Welding a combustible metal like zinc, magnesium or titanium requires a Type D fire extinguisher.
b. Do not use liquid based fire extinguishing methods near the electric arc welding unit, as it may cause a shock hazard.
Ventilation systems should be positioned so sparks or molten slag isn’t carried to an adjacent area.
Have a Fire Watcher observing areas outside of the welder’s view, such as the opposite side of a wall or behind the welder. A fire may also start on the other side of a structure that could not be removed. The Fire Watcher will extinguish a fire or raise the alarm to evacuate if the fire cannot be contained by the extinguishing equipment. a. A fire watch extends at least 30 minutes after the welding is complete to ensure there are no fires caused by smoldering sparks or ejected material.

FUMES AND GASES

WARNING! Stop welding and move to a location with ventilation if your eyes, nose or throat become irritated. This indicates the ventilation is not adequate to remove the fumes. Do not resume welding until the ventilation is improved and the discomfort ceases. Seek medical attention if the symptoms do not diminish or if the welder experiences nausea, dizziness or malaise. Welding may produce hazardous fumes and gas during the welding process. A well ventilated work area can normally remove the fumes and gases, but sometimes the welding produces fumes and gases that are hazardous to your health.

Only work in a confined space if the area is well ventilated or while wearing a respirator or an air-supplied respirator. Welding fumes and gases can displace air and lower the oxygen level causing injury or death. Be sure the breathing air is safe. Always have a trained watchperson nearby.
a. If ventilation in the work area is poor, use an approved air-supplied respirator. All the people in the work area must also have air-supplied respirators.
b. Oxygen displacement can occur in confined areas when the shielding gas fills the area and pushes out air.
Avoid positions that allow welding fumes to reach your face. Always attempt to weld ‘upwind’ of the workpiece with the airflow across the face of the welder. Airflow from behind may create a low pressure area in front of the welder and draw the fumes to the person.
Ventilate the work area to remove welding fumes and gases. The fumes and gases should be drawn away from the user.
a. Ventilation should be enough to disperse fumes, but not enough to disturb the shielding gas or flame during welding.
b. Ventilation exhaust shall be directed to a non-work area to avoid exposing other people to potential toxic or dangerous fumes.
c. Air removed from the work area by the ventilation system must be replenished with fresh air to avoid oxygen starvation or a build-up of fumes or gases. Only use air to provide ventilation. Any other combination of gases may be explosive or toxic to people in the work area.
d. Ventilation methods that remove gas and fumes from the welding point before they reach the welder’s face should be given preference.
Avoid welding in a work area that has vapours from cleaning, degreasing or any spraying operations. The heat and light from welding can react with the vapour and form irritating or potentially toxic gases. Wait for the vapours to disperse.
Consult the manufacturer’s Safety Data Sheets (SDS) for instructions and precautions about metals, consumables, coatings, cleaners and degreasers.
a. Do not weld on coated metals such as galvanized, lead or cadmium plated steel, unless the coating is removed from the weld area. The coatings and any metals containing these elements can give off toxic fumes during the welding process.
b. Do not weld, cut or heat lead, zinc, cadmium, mercury, beryllium or similar metals without seeking professional advice and inspection of the welding area’s ventilation. These metals produce extreme toxic fumes, which can cause discomfort, illness and death.
c. Do not weld or cut near chlorinated solvents or in areas that chlorinates solvents can enter. The heat or ultraviolet light of the arc can separate chlorinated hydrocarbons into a toxic gas (phosgene) that can poison or suffocate the user or bystanders.
Check the Safety Data Sheet for the proper handling and safety precautions for consumable welding rods as the coating can have multiple chemicals.

ELECTRICAL SAFETY

Do not come into physical contact with the welding current circuit. The welding current circuit includes:
a. The workpiece or any conductive material in contact with it.
b. The ground clamp.
c. The electrode or welding wire;
d. Any metal parts on the electrode holder or wire feed torch.
e. The output terminals.
Insulate yourself from the electrical current and ground using electrical insulating mats or covers big enough to prevent physical contact with the workpiece or ground.
Connect the ground clamp as close to the welding area on the workpiece as practical to prevent welding current from traveling along an unexpected path and causing an electric shock or fire hazard.
a. An option is to attach the ground clamp to a bare metal spot on a metal workbench. The circuit will complete as long as the workpiece is also in full contact with the bare metal workbench.
Only use insulated connectors to join welding cables.
Ensure there are no contacts between the workpiece and work area that would allow it to ground, other than through the ground cable circuit
Do not exceed the duty cycle or amperage required for the type of welding. Excessive amperage can cause the deterioration of protective insulation and create a shock hazard.
Unplug the welding unit when not in use as the unit as current is still entering the unit, even when it is turned off.
Frequently inspect input power cable for wear and tear, replace the cable immediately if damaged. Bare wiring is dangerous and can kill.
Do not use damaged, under sized or badly joined cables.
Do not disconnect the power cord in place of using the ON/OFF switch on the tool. This will prevent an accidental startup when the power cord is plugged into the power supply.
a. In the event of a power failure, turn off the machine as soon as the power is interrupted. The possibility of accidental injury could occur, if the power returns and the unit is not switched off.
Make certain the power source conforms to requirements of your equipment (see Specifications).

POWER TOOL PRECAUTIONS
This equipment requires a dedicated 120 volt, 20 amp single-phase alternating current circuit equipped with a similarly rated circuit breaker or slow blow fuse. Do not run other appliances, lights, tools or equipment on the circuit while operating this welding unit.

Do not drape or carry coiled welding cables on your body while the cables are plugged into the welding unit.
Do not start the tool when the electrode is touching the workpiece.
Hold the tool by the insulated gripping surfaces when performing an operation where it may contact hidden wiring or its own cord and cables. Contact with a ‘live’ wire will electrify exposed metal parts and shock the operator.
Take work breaks to prevent the tool’s motor from overheating and/or overloading. Refer to the welding unit’s duty cycle in Specifications.
Keep hands away from the electrode and the area it is being applied to when the tool is in operation.
Do not connect the welding unit ground clamp to an electrical conduit. Do not weld on an electrical conduit.
Do not touch the electrode or welded surface immediately after use. The surface will be hot and may cause an injury.
Never use a tool with a cracked or worn electrode. Change the electrode before using and discard the damaged one.

POWER CORD

Insert the power cord plug directly to the power supply whenever possible. Extension cords are not recommended for use with this welding unit.
a. When an extension cord is required, use a welding version that exceeds the welding unit’s maximum power requirement.
Do not operate this tool if the power cord is frayed or damaged, as an electric shock or surge may occur, resulting in personal injury or property damage.
b. Inspect the tool’s power cord for cracks, fraying or other faults in the insulation or plug before each use.
c. Discontinue use if a power cord feels more than comfortably warm while operating the tool.
Keep all connections dry and off the ground to reduce the risk of electric shock. Do not touch plug with wet hands.
Prevent damage to the power cord by observing the following:
a. Do not pull on the cord to disconnect the plug from an outlet.
b. Keep cord away from heat, oil, sharp edges or moving parts.
c. Place the electrical cord in a position that prevents it from contacting the tool or workpiece. The cord should always stay behind the tool.
Make sure to locate the cord so that it is not stepped on, tripped over or otherwise subject to damage or stress.
Do not wrap the cord around the tool, as sharp edges may cut insulation or cause cracks if wound too tight. Gently coil cord and either hang on a hook or fasten with a device to keep cord together during storage.

ELECTROMAGNETIC FIELDS

WARNING! Stop welding immediately and move away from the welding unit if you feel faint, dizzy, nausea or shocks. Seek medical attention.
Electromagnetic Fields (EMF) can interfere with electronic devices such as pacemakers. Anyone with a pacemaker should consult with their doctor before working with or near an arc welding unit. The following steps can minimize the effects of electromagnetic fields.

Twist or tape cables together and prevent coils.
Do not drape cables on your body.
Keep the welding power source and cables as far away from the user as practical. A minimum of 24 in. is recommended.
Connect the workpiece clamp as close to the weld as possible, but lay the electrode and workpiece cables away from the user.
Use the lowest current setting possible during welding.
Avoid long and regular bursts of energy while welding. Apply the electrode in short strokes and intermittently. This will prevent the pacemaker from interpreting the signal as a rapid heartbeat.
Do not allow the electrode to touch the metal while welding.
Keep the lead cable and ground cables on the same side of your body.
Do not weld while carrying the welding power source.
Do not work next to, sit or lean on the welding power source.

UNPACKING

WARNING! Do not operate the tool if any part is missing. Replace the missing part before operating. Failure to do so could result in a malfunction and personal injury.
Remove the parts and accessories from the packaging and inspect for damage.
Make sure that all items in the contents are included.
Contents: Welding Unit
Ground Lead and ARC Lead Set

IDENTIFICATION KEY

A Power Indicator – This lights up when the welding machine has power.
B Overload Indicator – This lights up when the thermal overload protector opens and shuts the welder down. POWER FIST 8785008 75A Mini Inverter Stick
Welder - KEY C Shoulder strap
D Current Adjusting Knob – The welding current knob on the front panel has an infinite output adjustment between 20 and 75A. The panel has a number guide for the amount of output amps.
E Arc Lead – The arc lead is attached to the negative output socket.
F Ground Lead – The ground lead is attached to the positive output socket. The welding clamp connects to the workpiece, completing the electrical circuit.
G Power Switch – Located on the rear panel.
H Power Cord – Attached to rear panel

ASSEMBLY & INSTALLATION

Letter references in parenthesis (A) refer to the included Identification Key.
INSTALLATION SET UP FOR ARC (STICK) WELDING
Please install the machine strictly according to the following steps.
POWER REQUIREMENTS
The power cord supplied with this welding unit is designed to handle the maximum power required (see Specifications). Refer to the welding unit’s data plate and ensure the power supply can meet those requirements.
CONNECTING THE POWER LEADS

Connection of Output Cables – An electrode may require either a positive or a negative charge for optimum results. Connect the electrode holder to the Positive Outlet Socket (F) or Negative Outlet Socket (E) based on the electrode manufacturer’s information for the correct polarity set up.
Place the electrode into the electrode holder and clamp tight.
Turn the power source on.
Set the welding current (D) relevant to the electrode type and size, as recommended by the electrode manufacturer.

OPERATION

ARC (MANUAL METAL ARC) WELDING
One of the most common types of arc welding is manual metal arc welding (MMA) or stick welding. An electric current is used to strike an arc between the base material and a consumable electrode rod or ‘stick’. The electrode rod is made of a material that is compatible with the base material being welded and is covered with a flux that gives off gaseous vapours that serve as a shielding gas and providing a layer of slag, both of which protect the weld area from atmospheric contamination. The electrode core itself acts s filler material the residue from the flux that forms a slag covering over the weld metal must be chipped away after welding. POWER FIST 8785008 75A Mini
Inverter Stick Welder - WELDING

Strike the electrode on the workpiece to create the arc and hold the electrode steady to maintain the arc.
The heat of the arc melts the surface of the base metal to form a molten pool at the end of the electrode.
The melted electrode metal is transferred across the arc into the molten pool and becomes the deposited weld metal.
The deposit is covered and protected by a slag, which comes from the electrode coating.
The arc and immediate area are enveloped by an atmosphere of protective gas.
Hold the electrode slightly above the workpiece (1/8 in.) to maintain the arc while travelling at an even speed to create an even weld deposition.
a. Rock the electrode back and forth if it sticks to the workpiece. Failure to separate the stuck rod can overload the welding unit.
To finish the weld, break the arc by quickly snapping the electrode away from the workpiece.
Wait for the weld to cool and carefully chip away the slag to reveal the weld metal underneath.

Manual metal arc (stick) electrodes have a solid metal wire core and a flux coating. These electrodes are identified by the wire diameter and by a series of letters and numbers. The letters and numbers identify the metal alloy and the intended use of the electrode.
The metal wire core works as a conductor of the current that maintains the arc. The core wire melts and is deposited into the welding pool.
The covering on a shielded metal arc welding electrode is called flux. The flux on the electrode performs many different functions:

producing a protective gas around the weld area.
providing fluxing elements and deoxidizers.
creating a protective slag coating over the weld as it cools.
establishing arc characteristics.
adding alloying elements.

Covered electrodes serve many purposes in addition to adding filler metal to the molten pool. These additional functions are provided mainly by the covering on the electrode.

ARC (STICK) WELDING FUNDAMENTALS

ELECTRODE SELECTION
As a general rule, the selection of an electrode is straight forward, in that it is ona matter of selecting an electrode of similar composition to the parent metal.
However, for some metals there is a choice of several electrodes, each of whichhas particular properties to suit specific classes of work. It is recommend to consult your welding supplier for the correct selection of electrode.
ELECTRODE SIZE
The size of the electrode generally depends on the thickness of the section being welded and the thicker the section the larger the electrode required. The table gives the maximum size of electrodes that may be used for various thicknesses of section based on using a general-purpose type 6013 electrode (See Table 1).

Average Thickness of Material| Maximum Recommended Electrode Diameter| Current Range (AMPS)
---|---|---
1/32 to 5/64 in. (0.8 to 1.8 mm)| 3/32 in. (2.3 mm)| 60 to 100A
5/64 to 13/64 in. (1.8 to 4.9 mm)| 1/8 in. (3.1 mm)| 100 to 130A
13/64 to 5/16 in. (4.9 to 7.9 mm)| 5/32 in. (3.9 mm)| 130 to 165A
5/16 in. or greater (7.9 mm or greater)| 13/64 in. (4.9 mm)| 165 to 260A

WELDING CURRENT (AMPERAGE)
Correct current selection for a particular job is an important factor in arc welding.
With the current set too low, difficulty is experienced in striking and maintaining a stable arc. The electrode tends to stick to the work, penetration is poor and beads with a distinct rounded profile will be deposited. Too high current is accompanied by verheating of the electrode resulting undercut and burning through of the base metal and producing excessive spatter. Normal current for a particular job may be considered as the maximum, which can be used without burning through the work, over-heating the electrode or producing a rough spattered surface. The table shows current ranges generally recommended for a general-purpose type 6013 electrode (see Table 1).
ARC LENGTH
To strike the arc, the electrode should be gently scraped on the work until the arc is established. There is a simple rule for the proper arc length; it should be the shortest arc that gives a good surface to the weld. An arc too long reduces penetration, produces spatter and gives a rough surface finish to the weld. An excessively short arc will cause sticking of the electrode and result in poor quality welds. General rule of thumb for down hand welding is to have an arc length no greater than the diameter of the core wire.
ELECTRODE ANGLE
The angle that the electrode makes with the work is important to ensure a smooth, even transfer of metal. When welding in down hand, fillet, horizontal or overhead the angle of the electrode is generally between 5 and 15 degrees towards the direction of travel. When vertical up welding the angle of the electrode should be between 80 and 90 degrees to the workpiece.
TRAVEL SPEED
The electrode should be moved along in the direction of the joint being welded at a speed that will give the size of run required. At the same time, the electrode is fed downwards to keep the correct arc length at all times. Excessive travel speeds lead to poor fusion, lack of penetration etc., while too slow a rate of travel will frequently lead to arc instability, slag inclusions and poor mechanical properties.
MATERIAL AND JOINT PREPARATION
The material to be welded should be clean and free of any moisture, paint, oil, grease, mill scale, rust or any other material that will hinder the arc and contaminate the weld material. Joint preparation will depend on the method used include sawing, punching, shearing, machining, flame cutting and others. In all cases, edges should be clean and free of any contaminates. The type of joint will be determined by the chosen application
THERMAL OVERLOAD PROTECTION
Constantly exceeding the duty cycle can damage the welding unit. An internal thermal protector will open when the duty cycle is exceeded, shutting OFF all functions except the cooling fan. Leave the welding unit turned ON with the fan running. The thermal protector will automatically reset and the welding unit will function normally again once it has cooled. Wait at least another 10 minutes after the thermal protector opens before resuming welding. Starting before this additional time may result in a shortened duty cycle.

CARE & MAINTENANCE

Maintain the tool with care. A tool in good condition is efficient, easier to control and will have fewer problems.
Inspect the tool fittings, alignment, hoses and power supply cord periodically. Have damaged or worn components repaired or replaced by an authorized technician. Only use identical replacement parts when servicing.
Exposure to extremely dusty, damp, or corrosive air is damaging to the welding unit. In order to prevent possible failure or fault of this welding equipment, clean the dust at regular intervals with clean and dry compressed air.
Follow instructions for lubricating and changing accessories.
Only use accessories intended for use with this tool.
Keep the tool handles clean, dry and free from oil/grease at all times.
Maintain the tool’s labels and name plates. These carry important information. If unreadable or missing, contact Princess Auto Ltd. for replacements.
WARNING! Only qualified service personnel should repair the tool. An improperly repaired tool may present a hazard to the user and/or others.

DISPOSAL

Recycle a tool damaged beyond repair at the appropriate facility.
Contact your local municipality for a list of disposal facilities or by-laws for electronic devices, batteries, oil or other toxic liquids.

TROUBLESHOOTING

Visit a Princess Auto Ltd. location for a solution if the tool does not function properly or parts are missing. If unable to do so, have a qualified technician service the tool.

Problem(s)	Possible Cause(s)	Suggested Solution(s)
No arc.	1.Incomplete welding circuit
2.No power supply	1.Check earth lead is connected. Check all cable

connections.
2.Check that the machine is switched on and has a power supply.
Porosity — small cavities or holes resulting from gas pockets in weld metal.| 1.Arc length too long
2.Workpiece dirty, contaminated or moisture
3.Damp electrodes| 1.Shorten the arc length.
2.Remove moisture and materials like paint, grease, oil and dirt, including mill scale from base metal.
3.Use only dry electrodes.
Excessive Spatter.| 1.Amperage too high
2.Arc length too long| 1.Decrease the amperage or choose a larger electrode.
2.Shorten the arc length.
Weld sits on top, lack of fusion.| 1.Insufficient heat input.
2.Workpiece dirty, contaminated or moisture.
3.Poor welding technique.| 1.Increase the amperage or choose a larger electrode.
2.Remove moisture and materials like paint, grease, oil and dirt, including mill scale from base metal.
3.Use the correct welding technique or seek assistance for the correct technique.
Lack of penetration.| 1.Insufficient heat input.
2.Poor welding technique.
3.Poor joint preparation.| 1.Increase the amperage or choose a larger electrode.
2.Use the correct welding technique or seek assistance for the correct technique.
3.Check the joint design and fit up, make sure the material is not too thick. Seek assistance for the correct joint design and fit up.
Excessive penetration – burn through.| 1.Excessive heat input.
2.Incorrect travel speed.| 1.Reduce the amperage or use a smaller electrode.
2.Try increasing the weld travel speed.
Uneven weld appearance.| Unsteady hand, wavering hand.| Use two hands where possible to steady up, practice your technique.
Electrode welds with different or unusual arc
characteristic.| Incorrect polarity.| Change the polarity; check the electrode manufacturer for correct polarity.
Distortion — movement of base metal
during welding.| 1.Excessive heat input.
2.Poor welding technique.
3.Poor joint preparation and or joint design.| 1.Reduce the amperage or use a smaller electrode.
2.Use the correct welding technique or seek assistance for the correct technique.
3.Check the joint design and fit up, make sure the material is not too thick. Seek assistance for the
correct joint design and fit up.