Campbell Hausfeld WG3080 Wire Feed Arc Welder Instruction Manual

Campbell Hausfeld WG3080 Wire Feed Arc Welder

Product Information

Specifications

• Models: WG3080, WG3090, and WG4130
• Power Requirements: Dedicated 120 volt or 230 volt circuit (depending on model)
• Circuit Breaker or Fuse Rating for 120 Volt Models:
  • 1-2-3: 15 amp
  • 4-5: 20 amp
• Supply Cable Replacement Instructions: Refer to page 8
• Manufacturer Website: www.campbellhausfeld.com

Components and Controls

Refer to Figure 1 for the components and controls of the welder:

1. Torch with .030 in. tip
2. Heat Selector
3. Circuit Breaker or Slow Blow Fuse for 120V Models

Product Usage Instructions

Circuit Requirements
This equipment requires a dedicated circuit depending on the model. For 120-volt models, refer to the chart below for the correct circuit breaker or fuse rating. It is important not to run other appliances, lights, or tools on this circuit while operating the equipment. Extension cords are not recommended to avoid blown fuses or tripped circuit breakers.

Failure to comply with these recommendations can result in
equipment damage.

Unpacking
When unpacking the product, carefully inspect it for any damage that may have occurred during transit. Tighten any loose fittings and screws before putting the unit into service. If there are any missing or damaged items, contact customer support at 1-800-7465641.

Safety Guidelines
It is important to read and follow all instructions provided in the manual to ensure personal safety and prevent equipment problems. The following symbols are used to indicate important safety information:

• Danger: An imminently hazardous situation which, if not avoided, WILL result in death or serious injury.
• Warning: Potentially hazardous situation which, if not avoided, COULD result in death or serious injury.
• Caution: Potentially hazardous situation which, if not avoided, MAY result in minor or moderate injury.
• Notice: Important information that, if not followed, may cause damage to the equipment.
• Note: Additional information pertaining to the product or its proper usage.

General Safety Information

CALIFORNIA PROPOSITION 65: This product, when used for welding, produces fumes or gases that contain chemicals known to the State of California to cause birth defects, reproductive harm, and, in some cases, cancer. The power cord and other cables on this product also contain chemicals, including lead, known to the State of California to cause cancer and birth defects or other reproductive harm. It is important to wash hands after handling. 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 personal injury.

FAQs

Q: Can I use an extension cord with the welder?
A: No, extension cords are not recommended as they can cause blown fuses or tripped circuit breakers. It is important to use a dedicated circuit for the welder.

Q: Where can I find supply cable replacement instructions?
A: You can find the supply cable replacement instructions on page 8 of the user manual.

Description

These Campbell Hausfeld wire feed welders are designed to be used on standard 120V (WG3080 and WG3090) or 230V (WG4130) outlet. The welder is equipped with infinite wire speed control to accurately select the proper wire feed rate needed for various welding conditions. Internal components are thermostatically protected. This welding system is designed for use with the Flux Cored Arc Welding (FCAW) or the Gas Metal Arc Welding (GMAW) process. As delivered from the factory, this welder can weld with .030 in. (0.8mm) diameter flux core wire. A starter spool of .030 in. (0.8 mm) flux cored wire is included. To use the GMAW process with the WG3090 and WG4130, it is necessary to purchase shielding gas and MIG wire only. With the WG3080, a regulator/hose kit must be purchased in addition to the shielding gas and MIG wire.

CIRCUIT REQUIREMENTS
This equipment requires a dedicated 120 volt or 230 volt circuit (depending on model). Refer to the following chart for correct circuit breaker or fuse rating for 120 volt models. 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.

COMPONENTS AND CONTROLS
(FIGURE 1)

1. Work Clamp – connects to work piece.
2. Torch with .030 in. tip.
3. Power Cord – plug into 120 volt or 230 volt outlet (depending on model).
4. Light – illuminates if thermostat has automatically shut welder off.
5. Infinite Wire Speed Control – turn clockwise to increase wire speed and counterclockwise to decrease wire speed.
6. Off/Heat Selector – Selects welding power and turns welder on.
   Five selections are possible:
   1 – 2 – 3 – 4 – 5.

See page 8 for supply cable replacement instructions.

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.

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. Report any missing or damaged items by calling 1-800-746-5641.

READ & FOLLOW ALL INSTRUCTIONS SAVE THESE INSTRUCTIONS DO NOT DISCARD

Safety Guidelines

This manual contains information that is very important to know and understand. This information is provided for SAFETY and to PREVENT EQUIPMENT PROBLEMS. To help recognize this information, observe the following symbols.

• Danger indicates an imminently hazardous situation which, if not avoided, WILL result in death or serious injury.
• Warning indicates a potentially hazardous situation which, if not avoided, COULD result in death or serious injury.
• Caution indicates a potentially hazardous situation which, if not avoided, MAY result in minor or moderate injury.
• The notice indicates important information, that if not followed, may cause damage to equipment.
• NOTE: Note means any additional information pertaining to the product or its proper usage.

General Safety Information

CALIFORNIA PROPOSITION 65
This product, when used for welding, produces fumes or gases that 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.). The power cord and other cables on this product contain chemicals, including lead, known to the State of California to cause cancer and birth defects or other reproductive harm. Wash hands after handling.

GENERAL SAFETY

warning
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.

• All installation, maintenance, repair and operation of this equipment should be performed by qualified persons only in accordance with national, state, and local codes.
  warning 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 all components of the arc welder are clean and in good condition prior to operating welder. Be sure insulation on all cables, torch and power cord is not damaged. Always repair or replace damaged components before operating the welder. Always keep welder panels, shields, etc. in place when operating welder.

• Always wear dry, protective clothing, welding gloves and insulated footwear when operating unit.

• Always operate welder in a clean, dry, well-ventilated
  area. Do not operate welder in humid, wet, rainy or poorly ventilated areas.

• Be sure work piece is properly supported and grounded prior to beginning any electric arc welding operation.

• Spread out coiled welding cable before use to avoid overheating and damage to insulation.
  Danger Never immerse wire or torch in water. If welder becomes wet for any reason, be absolutely certain it is completely clean and dry before use!

• Always shut equipment off and unplug power cord prior to moving the unit.

• Always attach the work lead first.

• Verify work piece is securely grounded.

• Always shut off electric arc welding equipment when not in use and cut off any excess wire from torch.

• Never allow any part of the body to touch welding wire 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 specified on equipment labels.

• Never use an electric arc welder to thaw frozen pipes.
  warning 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.
  warning 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 lens, flame-resistant clothing, leather welding gloves and full foot protection. Never look at arc welding operations without eye protection as described above.
  warning

  • 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 all persons in 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.
  warning

  • 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 ensure flying sparks and heat do not cause flames in hidden areas, cracks, etc.
  warning

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

• Keep head and face out of welding fumes.

• Extremely toxic fumes are created when galvanized or cadmium plated metals or metals which contain zinc, mercury or beryllium are heated. Complete the following precautions before performing electric arc welding operations on these metals:

  • Remove coating from base metal.
  • Make sure welding area is well ventilated.
  • Use an air-supplied respirator.
    warning
    The electromagnetic field 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 torch and work cables together and secure with tape when possible.

• Never wrap arc welder cables around the body.

• Always position torch and work leads on the same side of the body.

• Exposure to electromagnetic fields during welding may have other health effects which are not known.
  warning
  Always be sure welding area is secure and free of hazards (sparks, flames, glowing metal or slag) prior to leaving. Be sure equipment is turned off and excess wire is cut off. Be sure cables are loosely coiled and out of the way. Be sure all metal and slag has cooled.
  Danger
  Cylinders can explode if damaged. Shielding gas cylinders contain gas under high pressure. If damaged, a cylinder can explode. Since gas cylinders are normally part of the welding process, be sure to treat them carefully.

• Protect compressed gas cylinders from excessive heat, mechanical shocks and arcs.

• Install and secure cylinders in an upright position by chaining them to stationary support or equipment cylinder rack to prevent falling or tipping.

• Keep cylinders away from any welding or other electrical circuits.

• Never allow a welding electrode to touch any cylinder.

• Use only correct shielding gas cylinders, regulators, hoses and fittings designed for the specific application; maintain all parts properly.

• Turn face away from valve outlet when opening cylinder valve.

• Keep protective cap in place over valve except when cylinder is in use or connected for use.

• Read and follow instructions on compressed gas cylinders, associated equipment, and CGA publication P-1 listed in Safety Standards.
  Danger
  Never use flammable gasses with MIG welders. Only inert or non-flammable gasses such as carbon dioxide, argon, helium or mixtures of one or more of these gasses are suitable for MIG welding.

warning
Never lift cylinders off the ground by their valves or caps or with chains or slings.

ADDITIONAL SAFETY STANDARDS
ANSI Standard Z49.1 from American Welding Society, 550 N.W. Le June 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 Refer to Material Safety Data Sheets and manufacturers instructions for metals, wire, coatings and cleaners.

Code for Safety in Welding and Cutting
CSA Standard W117.2, from Canadian Standards Association, Standards Sales, 178 Rexdale Boulevard, Rexdale, Ontario, Canada M9W 1R3

Cutting And Welding Processes
NFPA Standard 51B, from National Fire Protection Association, Batterymarch Park, Quincy, MA 02269

Safe Practices For Occupational And Educational Eye And Face Protection
ANSI Standard Z87.1, from American National Standards Institute, 1430 Broadway, New York, NY 10018

Installation

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

• For best results locate welder in a clean and dry environment. Dust and dirt in the welder retain moisture and increase wear of moving parts.
• Place welder in an area with at least twelve inches (305 mm) of ventilation space at both the front and rear of unit. Keep all obstructions out of this ventilation space.
• Store welding wire in a clean, dry location with low humidity to prevent oxidation.
• Use a properly grounded receptacle for the welder and ensure welder is the only load on power supply circuit. Refer to chart on page 1 for correct circuit capacity.
• Use of an extension cord is not recommended for electric arc welding machines. Voltage drop in the extension cord may significantly degrade performance of the welder.

Assembly

TORCH INSTALLATION (See Figure 2)

1. Make sure unit is off and unplugged.
2. Feed the connectors for the torch switch through the hole in the control panel. These leads are to be fed up over the polarity studs and through the hanger on the center wall.
3. Insert the brass torch connector through the hole in the control panel and into the drive deck. Make sure the connector is inserted fully into the drive deck. Loosen the torch clamp knob a few turns if the connector will not insert fully. Tighten the torch clamp knob securely after the brass torch connector is fully inserted.
4. Connect the torch switch connectors to the two 1/4-inch terminals in the center wall. Polarity is not important. Make sure these wires do not interfere with the polarity studs or drive deck.

WORK CLAMP INSTALLATION (See Figure 3)

1. Remove one hex nut from work 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.

WIRE INSTALLATION
NOTE : Before installing welding wire, be sure:

1. The diameter of welding wire matches groove in drive roller on wire feed mechanism (See Figure 4).
2. Wire matches contact tip in end of torch (See Figure 5).

A mismatch on any item could cause the wire to slip and/or bind.

NOTE : Always maintain control of loose end of welding wire to prevent unspooling.

1. Verify unit is off and open door panel to expose wire feed mechanism.
2. Remove the spool lock by pushing in and rotating 1/4 turn counterclockwise. Then remove lock, spring and retainer.
3. Flip tensioning knob down and swing arm up on drive mechanism. This allows initial feeding of wire into torch liner by hand.
4. Install wire spool onto spindle so wire can come off bottom of spool. Do not cut the wire loose yet. Install retainer, spring and lock by pushing in and turning lock 1/4 rotation clockwise.
5. Hold wire and cut the wire end from spool. Do not allow wire to unravel. Be sure end of wire is straight and free of burrs.
6. 6. Feed wire through wire guide, over the groove in drive roller and back into wire guide. Flip swing arm down and tension knob up. Adjust tension by rotating tension knob.
7. Unscrew nozzle and contact tip from end of welding torch (See Figure 5). Plug welder into a proper power supply receptacle.
8. Turn on welder and set wire speed Activate torch trigger until wire feeds out past the torch end. Turn welder off.
9. Carefully slip contact tip over wire, screw tip into torch end and reinstall nozzle (See Figure 5). Cut wire off approximately 1/4 inch from nozzle end.

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 20% duty cycle, actual welding can occur for two minutes, then the welder must cool for eight minutes. Internal components of this welder are protected from overheating with an automatic thermal switch. A red lamp is illuminated on the front panel if the duty cycle is exceeded. Do not switch unit off. This will allow the internal fan to cool the unit quickly. Welding operations may continue when the red lamp is no longer illuminated.

OVERLOAD PROTECTION
The welder is equipped with a circuit breaker which protects the machine if the maximum output is exceeded, such as when the output is short-circuited. The circuit breaker button will extend out when tripped. Manually push the button in to reset.

POLARITY
MIG welding wire requires the electrode to be positive. Flux welding wire requires the electrode to be negative. Always use the polarity recommended by the welding wire manufacturer. The welder is factory set for flux welding wire.

TO CHANGE POLARITY (SEE FIGURE 6)

1. Unplug power cord from socket.
2. Open wire feed compartment door.
3. Remove two nuts from polarity studs.
4. Connect cable from drive deck to positive stud and cable from work clamp to negative stud for electrode positive polarity for MIG welding. Connect cable from drive deck to negative stud and cable from work clamp to positive stud for electrode negative polarity for flux core welding.
5. Reinstall two nuts and tighten securely.

Caution
If the nuts are not tightened properly, excessive heat will be generated by the loose connection and the insulators on the studs will be damaged.

SHIELDING GAS PREPARATION

Danger
Improper handling and maintenance of compressed gas cylinders and regulators can result in serious injury or death! Always secure gas cylinders to a wall or other fixed support to prevent cylinder from falling over. Read, understand and follow all compressed gas and equipment warnings in the safety instructions.

NOTE : Shielding gas is not required if flux-core welding wire is used.

GAS TYPES
There are 3 types of gas generally used for gas metal arc welding; 100% argon, a mixture of 75% argon and 25% carbon dioxide (C25) or 100% carbon dioxide.

Danger
Use ONLY the type of gas recommended for your welder. Use ONLY an inert, non-flammable type of gas. Failure to do so will result in a very hazardous situation.

The 75/25 mixture is recommended for general steel welding. For aluminum welding, use 100% argon. Cylinders of either type gas may be obtained at your local welding supply outlet. Secure cylinder to prevent it from falling over. Obtaining Correct Gas Type. The gas used in any welding application for your welder must be an INERT, NON-FLAMMABLE TYPE. You can get the type of gas needed from a nearby welding gas distributor (often found in the Yellow Pages under “Welders” or “Welding Equipment”).

REGULATOR
An adjustable regulator with two gauges is supplied with the WG3090 and WG4130. The WG3080 is not supplied with a regulator (see parts list for optional regulator/hose kit). The regulator provides a constant shielding gas pressure and flow rate during the welding process. Each regulator is designed to be used with a specific gas or mixture of gases. The argon and argon mixture use the same thread type. The 100% carbon dioxide uses a different thread type. An adapter is available at your local welding gas supplier to change between the two.

HOSE AND REGULATOR HOOKUP PROCEDURE
warning
Cylinder gas is under high pressure. Point cylinder outlet away from yourself and any bystanders before opening.

1. With cylinder securely supported, stand on side of cylinder opposite cylinder outlet then remove cylinder cap and open valve slightly by turning counterclockwise. When gas is emitted from cylinder, close valve by turning clockwise. This will blow out dust or dirt that may have accumulated around valve seat.
2. Install regulator onto cylinder valve. Tighten stem nut securely to gas valve.
3. Install one end of gas hose to fitting on the back of welder and other end of hose to fitting on regulator. Make sure gas hose is not kinked or twisted.
4. While standing opposite cylinder outlet, slowly open cylinder valve. Inspect for leaks in the connections.
5. Turn unit on and pull trigger on torch to allow gas to flow. Adjust gas regulator to between 20 and 40 CFH. Release trigger and turn unit off.
6. Remember to close gas cylinder valve when finished welding.

Operation

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

2. Turn welder off.

3. Verify 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.
   warning
   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 galvanized, zinc plated, lead, or cadmium plated materials, refer to the General Safety Information Section for instructions. Extremely toxic fumes are created when these metals are heated.

4. Connect work clamp to work piece or workbench (if metal). Make sure contact is secure. Avoid surfaces with paint, varnish, corrosion or non-metallic materials.

5. Rotate Wire Speed Control to setting per decal inside wire feed compartment, then adjust as needed after test.

6. Plug power cord into a proper voltage receptacle with proper circuit capacity (see circuit requirements on Page 1).

7. Switch welder on to desired heat setting per decal inside wire feed compartment, then adjust as needed after test.
   NOTE : These settings are general guidelines only. Heat setting may vary according to welding conditions and materials.

8. Verify wire is extended 1/4 in. from contact tip. If not,squeeze trigger to feed additional wire, release trigger, turn welder off, and cut wire to proper length. Then, switch back on to desired heat setting.
   NOTE : The welder transformer is off and will not energize until the trigger is pulled. This is a “cold torch” welding machine and it will not weld until the trigger is pulled.

9. Position torch near work piece, lower welding helmet by nodding head or positioning the hand shield, and squeeze torch trigger. Adjust heat setting and wire speed as needed.

10. When finished welding, turn welder off and store properly.

Maintenance

warning
Disconnect power supply and turn machine off before inspecting or servicing any components. Keep wire compartment cover closed at all times unless wire needs to be changed.

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. Inspect the condition of the torch contact tip and nozzle. Remove any weld slag. Replace torch contact tip or nozzle if damaged.

Warning
Do not operate this welding machine with cracked or missing insulation on welding cables, torch or power cord.

EVERY 3 MONTHS:

1. Replace any unreadable safety labels on the welder.
2. Use compressed air to blow all dust and lint from ventilation openings.
3. Clean wire groove on drive roller. Remove drive roller and use a small wire brush to clean. Replace if worn or damaged.

CONSUMABLE AND WEAR PARTS
The following parts require replacement:

• Wire feed drive roller
• Wire guide
• Torch liner
• Nozzle/contact tips
• Wire – This welder will accept either 4 in. or 8 in. diameter spools. Flux-Cored welding wire is susceptible to moisture and oxidizes over time, so it is important to select a spool size that will be used within approximately 6 months. For mild steel welding, AWS ER70S6 solid wire or AWS E71T-GS Flux-Cored wire is recommended.

CHANGING WIRE SIZES
This welder is setup for .030 in. (0.8 mm) wire. If a different wire size is used, the wire feed drive roller and contact tip may need changing. There are two grooves in the drive roller. The small groove is for .024 in. (0.6 mm) MIG wire and the large groove is for .030 – .035 in. (0.8 – 0.9 mm) flux core and MIG wire. Rotate the tension knob down and swing arm up and flip the drive roller to choose the correct groove. Optional drive rollers for other wire sizes are available (See parts breakdown). The contact tip should also match the wire diameter used. The tip diameter is marked on the contact tip in inches and/or millimeters.

SUPPLY CABLE REPLACEMENT

1. Verify that welder is OFF and power cord disconnected.
2. Remove welder side panel to expose switches.
3. Disconnect the power cord leads per the diagram inside the unit.
4. Disconnect the ground wire connected to welder base.
5. Loosen the cord strain relief screws and pull cord out of strain relief.
6. Install new cord in reverse order per the diagram inside the unit.

Welding Guidelines

General
This welding machine can utilize the Flux Cored Arc Welding (FCAW) process or the Gas Metal Arc Welding (GMAW) process. The weld must be protected (shielded) from contaminants in the air while it is molten. The FCAW process uses a tubular wire with a flux material inside. The flux creates a shielding gas when melted. The GMAW process uses inert gas to shield the weld while molten. When current is produced by a transformer (welding machine) and flows through the circuit to the weld wire, an arc is formed between the end of the weld wire and the work piece. This arc melts the wire and the work piece. The melted metal of the weld wire flows into the molten crater and forms a bond with the work piece as shown (Figure 7).

Arc Welding Basics
Six basic techniques affect weld quality. These are: wire selection, heat setting, weld angle, wire speed, travel speed, and electrode extension. An understanding of these techniques is necessary for effective welds.

HEAT SETTING
The correct heat involves the adjustment of the welding machine to the required setting. Heat or voltage is regulated by a switch on the welder. The heat setting used depends on the size (diameter) and type of wire, position of the weld, and the thickness of the work piece. Consult specifications listed on the welder. It is suggested that the welder practice with scrap metal to adjust settings, and compare welds with Figure 8.

WIRE TYPE AND SIZE
The correct choice of wire 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 wire.

FLUX-CORED WIRE

WELD ANGLE
Weld angle is the angle at which the nozzle is held during the welding process. Using the correct angle ensures proper penetration and bead formation. As different welding positions and weld joints become necessary, nozzle angle becomes an increasingly important factor in obtaining a satisfactory weld. Weld angle involves two positions – travel angle and work angle. 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.

WIRE SPEED
The wire speed is controlled by the knob on the front panel. The speed needs to be “tuned” to the rate at which the wire is being melted in the arc. Tuning is one of the most critical functions of wire feed welding. Tuning should be performed on a scrap piece of metal the same type and thickness as that to be welded. Begin welding with one hand “dragging” the torch nozzle across the scrap piece while adjusting the wire speed with the other hand. Too slow of speed will cause sputtering and the wire will burn up into the contact tip. Too fast a speed will also cause a sputtering sound and the wire will push into the plate before melting. A smooth buzzing sound indicates the wire speed is properly tuned. Repeat the tuning procedure each time there is a change in heat setting, wire diameter or type, or work piece material type or thickness. For Aluminum, wire speed is typically set higher (7-9 speed range).

TRAVEL SPEED
The travel speed is the rate at which the torch is moved across the weld area. Factors such as diameter and type of weld wire, amperage, position, and work piece material thickness all affect the speed of travel necessary for completing a good weld (See Figure 8). 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. For Aluminum, travel speed is typically faster.

ELECTRODE EXTENSION
Electrode extension (or electrode stick-out) is the distance between the end of the contact tip and and the end of the welding wire. The recommended electrode extension is from 1/4 in to 1/2 in (6 mm to 13 mm). If the electrode extension is too long, welding current will be reduced and the bead will be high and narrow with less penetration.

SLAG REMOVAL (FLUX-CORED WIRE ONLY)

Warning
Wear ANSI approved safety glasses (ANSI Standard Z87.1) and protective clothing when removing slag. Hot, flying debris can cause personal injury to anyone in the area.

After completing the weld, wait for the welded sections to cool. A protective coating called slag now covers the weld bead which prevents contaminants in the air from reacting with the molten metal. Once the weld cools to the point that it is no longer glowing red, the slag can be removed. Removal is done with a chipping hammer. Lightly tap the slag with the hammer and break it loose from the weld bead. The final clean-up is done with a wire brush. When making multiple weld passes, remove the slag before each pass.

WELDING POSITIONS
Four basic welding positions can be used; flat, horizontal, vertical, and overhead. Welding in the flat position is easier than any of the others because welding speed can be increased, the molten metal has less tendency to run, better penetration can be achieved, and the work is less fatiguing. Welding is performed with the wire at a 45º travel angle and 45º work angle. Other positions require different techniques such as a weaving pass, circular pass, and jogging. A higher skill level is required to complete these welds. Overhead welding is the least desirable position as it is the most difficult and dangerous. Heat setting and wire selection will vary depending upon the position. All work should be performed in the flat position if possible. For specific applications, consult an arc welding technical manual.

WELD PASSES
Sometimes more than one pass is necessary to fill the joint. The root pass is first, followed by filler passes and the cover pass. If the pieces are thick, it may be necessary to bevel the edges that are joined at a 60º angle. Remember to remove the slag before each pass for the FCAW process.

ALUMINUM WELDING
Any aluminum surface to be welded, must be cleaned thoroughly with a stainless steel brush to eliminate any oxidation on the weld and grounding surface. 100% Argon shielding gas must be used when welding aluminum. If 100% Argon is not used, metal penetration is unlikely. A PTFE wire liner, smooth-groove drive roller and aluminum contact tips are recommended when welding aluminum. Campbell Hausfeld offers these parts in Kit WT2531. Call 1-800-746-5641 to order.

PUSH VS PULL TECHNIQUE
The type and thickness of the workpiece dictates which way to point the torch nozzle. For thin materials (18 gauge and smaller) and all aluminum, the nozzle should point out in front of the weld puddle and push the puddle across the workpiece. For thicker steel, the nozzle should point into the puddle to increase weld penetration. This is called the backhand or pull technique (See Figure 12).

For Information About This Product Call 1-800-746-5641

Glossary of Welding Terms

• AC or Alternating Current – electric current that reverses direction periodically. Sixty cycle current travels in both directions sixty times per second.
• Arc Length – the distance from the end of the electrode to the point where the arc makes contact with the work surface.
• Base Metal – the material to be welded.
• Butt Joint – a joint between two members aligned approximately in the same plane.
• Crater – a pool, or pocket, that is formed as the arc comes in contact with the base metal.
• DC or Direct Current – electric current which flows only in one direction. The polarity (+ or -) determines which direction the current is flowing.
• DC Reverse Polarity – occurs when the electrode holder is connected to the positive pole of the welding machine. Reverse Polarity directs more heat into melting the electrode rather than the work piece. It is used on thinner material.
• DC Straight Polarity – occurs when the electrode holder is connected to the negative pole of the welding machine. With straight polarity more heat is directed to the work piece for better penetration on thicker material.
• Electrode – a coated metal wire having approximately the same composition as the material being welded.
• Fillet Weld – approximately a triangle in cross-section, joining two surfaces at right angles to each other in a lap, T or corner joint.
• Flux – a coating, when heated, that produces a shielding gas around the welding area. This gas protects the parent and filler metals from impurities in the air.
• Flux Cored Arc Welding (FCAW) – also called Gasless, is a welding process used with a wire-feed welding machine. The weld wire is tubular with flux material contained inside for shielding.
• Gas Metal Arc Welding (GMAW) – also called MIG, is a welding process used with a wire feed welding machine. The wire is solid and an inert gas is used for shielding.
• Gas Tungsten Arc Welding (GTAW) – also called TIG, is a welding process used with welding equipment with a high frequency generator. The arc is created between a non-consumable tungsten electrode and the work piece. Filler metal may or may not be used.
• Open Circuit Voltage (OCV) – the voltage between the electrode and the work clamp of the welding machine when no current is flowing (not welding). The OCV determines how quickly the arc is struck.
• Overlap – occurs when the amperage is set too low. In this instance, the molten metal falls from the electrode without actually fusing into the base metal.
• Porosity – gas pockets, or cavities, formed during weld solidification. They weaken the weld.
• Penetration – the depth into the work piece that has been heat effected by the arc during the welding process. A good weld achieves 100% penetration meaning that the entire thickness of the work piece has been heated and resolidified. The heat effected area  should be easily seen on the opposite side of the weld.
• Shielded Metal Arc Welding (SMAW) – also called Stick, is a welding process with uses a consumable electrode to support the arc. Shielding is achieved by the melting of the flux coating on the electrode.
• Slag – a layer of flux soot that protects the weld from oxides and other contaminants while the weld is solidifying (cooling). Slag should be removed after weld has cooled.
• Spatter – metal particles thrown from the weld which cool and harden on the work surface. Spatter can be minimized by using a spatter-resistant spray on the work piece before welding.
• Tack Weld – weld made to hold parts in proper alignment until final welds are made.
• Travel Angle – the angle of the electrode in the line of welding. It varies from 5º to 45º depending on welding conditions.
• T Joint – made by placing the edge of one piece of metal on the surface of the other piece at approximately a 90º angle.
• Undercut – a condition that results when welding amperage is too high. The excessive amperage leaves a groove in the base metal along both sides of the bead which reduces the strength of the weld.
• Weld Pool or Puddle – a volume of molten metal in a weld prior to its solidification as weld metal.
• Weld Bead – a narrow layer or layers of metal deposited on the base metal as the electrode melts. Weld bead width is typically twice the diameter of the electrode.
• Work Angle – the angle of the electrode from horizontal, measured at right angles to the line of welding.
• Lap Joint – a joint between two overlapping members in parallel planes.

Please provide following information:

• – Model number
• – Serial number (if any)
• – Part description and number as shown in parts list

Address any correspondence to:

• Campbell Hausfeld
• Attn: Customer Service 100 Production Drive Harrison, OH 45030 U.S.A.

Replacement Parts List – Models WG3080, WG3090 and WG4130

REGISTER YOUR PRODUCT ONLINE NOW!www.campbellhausfeld.com

Limited Warranty

1. Duration: The manufacturer warrants that it will repair, at no charge for parts or labor, the Welder, Welding Gun, or Cables, proven defective in material or workmanship, during the following time period(s) after date of original retail purchase:
   For 5 Years: The Welder Transformer and Rectifier
   For 3 Years: The Entire Welder (excluding clamps, welding gun, electrode holder, cables, or accessories packed with welder) For 90 Days: The Welding Clamps, MIG Gun, Electrode Holder, Accessories, and Welding Cables (as applicable)

2. Who Gives This Warranty (Warrantor):
   Campbell Hausfeld, a Scott Fetzer Company
   100 Production Drive
   Harrison, OH 45030 U.S.A.
   Telephone: 1-800-746-5641

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

4. What is covered under this warranty: Defects in material and workmanship which occur within the duration of the warranty period. This warranty extends to the Welder, the Welders Transformer and Rectifier, Welding Gun or Electrode Holder, and cables only.

5. What is not covered under this warranty:

6. Implied warranties, including those of merchantability and FITNESS FOR A PARTICULAR PURPOSE ARE LIMITED IN DURATION TO THIS EXPRESS WARRANTY. After this period, all risks of loss, from whatever reason, shall be on the purchaser. Some states do not allow limitations on how long an implied warranty lasts, so above limitations may not apply to you.

7. ANY INCIDENTAL, INDIRECT, OR CONSEQUENTIAL LOSS, DAMAGE, OR EXPENSE THAT MAY RESULT FROM ANY DEFECT FAILURE OR MALFUNCTION OF THE CAMPBELL HAUSFELD PRODUCT. Some states do not allow limitations on how long an implied warranty lasts, so above limitations may not apply to you.

8. This warranty does not apply to any accessory items included with the product which are subject to wear from usage; the repair or replacement of these items shall be at the expense of the owner. These MIG items include but are not limited to; Contact Tips, Nozzles, Gun Liners, Drive Rollers, Felt Wire Cleaner. In addition, this warranty does not extend to any damage caused by the untimely replacement or maintenance of any of the previously listed CONSUMABLE parts.

9. Any failure that results from accident, purchaser’s abuse, neglect or failure to operate products in accordance with instructions provided in the owner’s manual(s) supplied with the product.

10. Pre-delivery service, i.e. assembly and adjustment.

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

12. Responsibilities of purchaser under this warranty:

13. Please call 1-800-746-5641 for warranty assistance.

14. Provide dated proof of purchase and maintenance records.

15. All welders must be delivered or shipped to the nearest Campbell Hausfeld Authorized Service Center. Freight costs, if any, must be borne by the purchaser.

16. Use reasonable care in the operation and maintenance of the products as described in the owner’s manual(s).

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

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

REMINDER : Keep your dated proof of purchase for warranty purposes! Attach it to this manual or file it for safekeeping.

References

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