Wire Feed Arc Welder

Welding Guidelines (Continued)

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 Teflon® wire liner, smooth-groove drive roller and aluminum contact tips are recommended when welding aluminum. Campbell Hausfeld offers these parts in Kit WT2532. Call 1-800- 746-5641 to order.

PUSH VS PULL TECHNIQUE

The type and thickness of the work piece 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 backhand or pull technique (See Figure 12).

Figure 12

PULL

PUSH

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

Troubleshooting Chart - Welder

 

Symptom

Possible Cause(s)

Corrective Action

 

No output

1. Duty cycle exceeded

1. Allow welder to cool until lamp goes out

 

 

2. Poor work clamp connection

2. Be sure all connections are secure, and attaching surface

 

 

3. Tripped circuit breaker

is clean

 

 

3. Reset by pushing button on back of unit

 

 

4. Blown breaker or fuse

4. Reduce circuit load, reset breaker or replace fuse

 

 

 

 

 

Wire tangles at drive roller

1. Wrong size contact tip

1. Use proper size contact tip

 

 

2. Torch liner clogged or

2. Clean or replace wire liner

 

 

damaged

 

 

 

3. Contact tip clogged or

3. Clean or replace contact tip

 

 

damaged

 

 

 

4. Drive roller worn

4. Replace

 

 

5. Not enough tension

5. Tighten tension knob

 

 

 

 

 

Gun nozzle arcs to work

1. Slag inside gun nozzle

1. Clean slag from gun nozzle

 

surface

2. Insulation ring melted/expired

2. Replace nozzle

 

 

 

 

 

Work clamp and/or cable

1. Poor contact

1. Be sure all connections are secure, and attaching surface

 

gets hot

2. Using an extension cord with

is clean

 

 

2. Never use an extension cord longer than 20 ft

 

 

excessive length

 

 

Wire does not feed

1. Wire jammed

1. Reload wire

 

 

2. Out of wire

2. Replace wire spool

 

 

3. Not enough tension

3. Tighten tension knob if wire is slipping

 

 

4. Wire liner worn

4. Replace liner

 

 

5. Wire disconnected internally

5. Call 1-800-746-5641 for assistance

 

 

6. Contact tip clogged

6. Replace contact tip

 

 

 

 

 

(Aluminum) Wire burns back

1. Wire speed too slow

1. Run speed in 7 - 10 range

 

into tip or (Aluminum) Metal

2. Travel speed too slow or heat

2. Increase the travel speed or reduce heat settings

 

bubbles or burns through

is too high

 

 

 

 

 

 

Weld pops and sputters

1. Wire speed setting

1. Tune in correct setting (1-5 mild steel; 5-10 aluminum)

 

 

2. Contact tip size too large

2. Replace contact tip

 

 

3. Polarity set incorrectly

3. Reverse polarity

 

 

4. Drive roller slipping

4. Increase tension

 

 

5. Gas bottle empty

5. Replace gas bottle

 

 

 

 

 

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