Powerfist 8976052 Le manuel du propriétaire

8976052 V4.0

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

reference.

User Manual

MINIMIG 100E

Flux-Cored Welder

8976052 MINIMIG 100E Flux-Cored Welder V4.0

2 For technical questions call 1-800-665-8685

SPECIFICATIONS

Input Voltage 120V AC

Duty Cycle 20% at 80A

Metal Type Steel

Output Current 60 to 80A (peak 125A)

Max. Amperage Draw 125A

Current Range 60 to 80A (peak 125A)

Mild Steel Weld Thickness Range 18 gauge to 3/16 in.

AC/DC Output AC

Generator Compatible Yes

Electrode Type Flux core wire

Electrode Size 0.030 / 0.035 in.

Dimensions 17.56 x 9.65 x 14.37 in.

INTRODUCTION

Your new MIG (Metal Inert Gas) wire feed welder is designed for maintenance

and sheet metal fabrication. The welding unit consists of a single-phase power

transformer, stabilizer, rectifier and a wire feeder. The welding unit features a

stepless wire feed speed setting and includes thermal protection.

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.

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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

1. Operate in a safe work environment. Keep your work area clean, well lit

and free of distractions.

2. Keep anyone not wearing the appropriate safety equipment away from the

work area.

3. Store tools properly in a safe and dry location. Keep tools out of the reach

of children.

4. Do not install or use in the presence of flammable gases, dust or liquids.

5. 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).

PERSONAL PROTECTIVE EQUIPMENT

1. Non-skid footwear is recommended to maintain footing and balance in the

work environment.

2. Steel toe footwear or steel toe caps to prevent injury from falling objects.

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.

1. 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.

8976052 MINIMIG 100E Flux-Cored Welder V4.0

4 For technical questions call 1-800-665-8685

2. An opaque helmet will protect against the ultraviolet or infrared light. A

helmet will also protect against ejected hot material and slag.

3. Wear a fire-resistant head covering like a skull cap or balaclava hood to

protect your head when the faceplate is down or when using a welding

hand shield.

4. Wear safety goggles beneath the welding helmet or behind the hand

shield. The cooling weld bead may fragment or eject slag that can damage

the eyes, when the helmet or hand shield is not in place.

5. Wear ear plugs when welding overhead to prevent spatter or slag from

falling into ear.

PROTECTIVE CLOTHING

1. Wear protective clothing made from durable, flame resistant materials,

leather welding gloves and full foot protection.

2. Wear a leather apron or jacket, leather welding gloves and fire-resistant

footwear when welding. Wear thick clothes that do not expose the skin.

Ultraviolet or infrared light can burn skin with sufficient exposure.

3. Choose clothing fabrics that resist sparks, heat and flames. Artificial

fabrics may burn and melt, resulting in a more severe injury.

4. 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.

5. Remove all jewelry before proceeding to weld

6. Wear protective clothing made from durable, flame resistant materials,

leather welding gloves and full foot protection.

7. Use protective screens or barriers to protect others from flash and glare;

warn others in the area to look away from the arc.

RESPIRATORS

1. 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.

2. Work in a confined space only if it is well ventilated or while wearing 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.

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3. 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.

1. Do not operate any tool when tired or under the influence of drugs,

alcohol or medications.

2. Avoid wearing clothes or jewelry that can become entangled with the

moving parts of a tool. Keep long hair covered or bound.

3. 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.

4. Do not overreach when operating the tool. Proper footing and balance

enables better control in unexpected situations.

5. Support the workpiece or clamp it to a stable platform. Holding the

workpiece by hand or against your body may lead to personal injury.

General Safety Precautions

6. Do not wear any personal grooming products that are flammable, such as

hair preparations or cologne with an alcohol base.

7. Remove any combustibles, such as butane lighters or matches, from your

person before doing any welding.

SPECIFIC SAFETY PRECAUTIONS

1. Arc Welding requires the use a hand shield or helmets with full face

protection per CSA standard Z94.3.1.

2. 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.

3. 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.

4. 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.

8976052 MINIMIG 100E Flux-Cored Welder V4.0

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5. 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.

6. Do not allow the uninsulated portion of the wire feed torch to touch the

ground clamp or grounded work. An arc flash will result from contact and

can injury the unprepared user and bystanders.

7. Do not handle hot metal or electrode stubs with bare hands. Handling may

result in a burn injury.

8. Do not use the welding unit if personal movement is confined or if there is

a danger of falling.

9. Keep all panels and covers securely in place when operating the welding unit.

10. Insulate the work clamp when not connected to a workpiece to prevent

contact with any metal object.

11. Do not operate the welder if the output cable, MIG gun, wire or wire feed

system is wet. Do not immerse them in water. These components and the

welder must be completely dry before attempting to use them.

12. Do not point the MIG gun at any body part of yourself or at anyone else.

13. Do not use a welder to thaw frozen pipes.

FIRE AND EXPLOSION PRECAUTIONS

Arc welding can produce sparks, hot slag or spatter, molten metal drops and

hot metal parts that can start fires.

1. Clear the floor and walls of an area of all combustible and/or flammable

materials. Hot debris ejected during welding can land at a considerable

distance way. 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.

2. Check that there are no openings or cracks that hot debris can enter.

3. Check both sides of a panel or wall for combustible material. Remove the

combustible material before welding.

4. Have a fire extinguisher available for immediate use. A dry chemical fire

extinguisher with

Types A, B and C is suggested.

a. Welding a combustible metal like zinc, magnesium or titanium

requires a Type D fire extinguisher.

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b. Do not use liquid based fire extinguishing methods near the electric

arc welding unit, as it may cause a shock hazard.

5. 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.

6. 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.

FUMES AND GASES

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.

Stop welding 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.

1. Only work in a confined space if the area is well ventilated or while

wearing an air-supplied respirator. Always have a trained watchperson

nearby.

2. Avoid positions that allow welding fumes to reach your face.

3. Ventilate the work area to remove welding fumes and gases. The fumes

and gases should be drawn away from the user. Welding fumes and gases

can displace air and lower the oxygen level causing injury or death. Be

sure the breathing air is safe.

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.

4. 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.

5. Consult the manufacturer's Material Safety Data Sheets (MSDS) 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

8976052 MINIMIG 100E Flux-Cored Welder V4.0

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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.

ELECTROMAGNETIC FIELDS

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.

1. Twist or tape cables together and prevent coils.

2. Do not drape cables on your body.

3. Keep the welding power source and cables as far away from the user as

practical. A minimum of 24 in. is recommended.

4. Connect the workpiece clamp as close to the weld as possible, but lay the

electrode and workpiece cables away from the user.

5. 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.

6. Do not allow the electrode to touch the metal while welding.

7. Wrap MIG gun and ground cable together whenever possible.

8. Keep MIG gun and ground cables on the same side of your body.

ELECTRICAL SAFETY

WARNING! To reduce risk of electric shock, be certain that the plug is

connected to a properly grounded outlet.

1. 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;

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c. the electrode or welding wire;

d. any metal parts on the electrode holder or wire feed torch.

2. Insulate yourself from the electrical current and ground using dry

insulating mats or covers big enough to prevent physical contact with the

workpiece or ground.

3. Disconnect the tool from the power source before cleaning, servicing,

changing parts/accessories or when not in use.

4. Protect yourself against electric shocks when working on electric

equipment. Avoid body contact with grounded surfaces. There is an

increased chance of electrical shock if your body is grounded.

5. Do not expose the tool to rain or wet conditions. Water entering a power

tool will increase the risk of electric shock.

6. 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.

7. Do not alter any parts of the tool or accessories. All parts and accessories are

designed with built-in safety features that may be compromised if altered.

8. Make certain the power source conforms to requirements of your

equipment (see Specifications).

9. When wiring an electrically driven device, follow all electrical and safety

codes, as well as the most recent Canadian Electrical Code (CE) and

Canadian Centre for Occupational Health and Safety (CCOHS).

WARNING! All wiring should be performed by a qualified electrician.

ELECTRIC 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.

1. Do not use a power tool with a broken or inoperative trigger/power switch

or safety guard.

2. Make sure the power switch is in the OFF position before connecting the

tool to the power supply.

3. Do not drape or carry coiled welding cables on your body when the cables

are plugged into the welding unit.

4. Do not start the tool when the welding wire is touching the workpiece.

8976052 MINIMIG 100E Flux-Cored Welder V4.0

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5. Always use both hands when operating the tool, unless the tool is

designed for single hand use.

6. Hold the tool by the insulated gripping surfaces when performing an

operation where it may contact hidden wiring or its own cord. Contact

with a ‘live’ wire will electrify exposed metal parts and shock the operator.

7. Do not allow the tool's motor to overload and/or overheat by taking work

breaks.

8. When the tool is in operation, keep hands away from the welding wire and

the area it is being applied to.

9. Do not connect the welding unit ground clamp to an electrical conduit. Do

not weld on an electrical conduit.

10. Do not use the tool on any material containing asbestos.

11. Do not touch the welding wire or welded surface immediately after use.

The surface will be hot and may cause an injury.

12. Do not allow persons who are not familiar with the tool or have not read

these instructions to use the tool.

POWER CORD

1. Insert the power cord plug directly to the power supply whenever possible.

Extension cords are not recommended for use with this welding unit.

2. Do not operate this tool if the power cord is frayed, damaged or poorly

spliced, as an electric shock may occur, resulting in personal injury or

property damage.

a. Inspect the tool's power cord for cracks, fraying or other faults in the

insulation or plug before each use.

b. Discontinue use if a power cord feels more than comfortably warm

while operating the tool.

c. Have the power cord replaced by a qualified service technician.

3. Keep all connections dry and off the ground to reduce the risk of electric

shock. Do not touch plug with wet hands.

4. Prevent damage to the power cord by observing the following:

a. Never use the cord to carry the tool.

b. Do not pull on the cord to disconnect the plug from an outlet.

c. Keep the power cord clear of the tool and the tool's work path while

in operation. The cord should always stay behind the tool.

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d. Keep cord away from heat, oil, sharp edges or moving parts.

5. Do not allow people, mobile equipment or vehicles to pass over

unprotected power cords.

a. Position power cords away from traffic areas.

b. Place cords in reinforced conduits.

c. Place planks on either side of the power cord to create a protective

trench.

6 Do not wrap cord around 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.

USE AND CARE OF THE TOOL

1. 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.

2. Do not carry the tool with fingers near or on the trigger/switch.

3. Avoid unintentional starts. Be sure that the ignition switch/trigger is in the

neutral or OFF position when not in use or before connecting it to any

power source.

PARTS IDENTIFICATION

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 parts list are included.

Contents:

• Welding Unit

• MIG Gun with Cable

• Ground Cable with Clamp

• Nozzle

• 0.035 contact tip

• Wire, Flux-cored .030

• Brush/Chipping

Hammer

8976052 MINIMIG 100E Flux-Cored Welder V4.0

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IDENTIFICATION KEY

A. Power Switch -This switch turns

the welding unit ON and OFF.

Make sure the power switch is

in the OFF position before

performing any maintenance on

the welding unit.

B. MIG Gun with Cable - The MIG

gun controls the delivery of

the welding wire to the

material to be welded. the

welding wire is fed through

the MIG gun with cable when

the MIG gun trigger is pulled. you will need to install a contact tip and

welding nozzle to the end of the MIG gun, as described later in this

manual, prior to welding.

C. Thermal Indicator - The thermal indicator light will glow and the welding

until will shut down when the unit overheats. Once the unit cools to the

operating temperature the light will shut off. Wait another 15 minutes

before resuming welding with this unit.

D. 1/2 Switch – The switch is for the two main voltage choices. Refer to the

"set up" chart inside the wire feed compartment for the correct voltage

based on the welding operation.

E. Wire Speed Dial - Use this dial to adjust the speed that the welding unit

feeds wire to the torch. The number 1 is the slowest wire feed speed, 10 is

the highest. You will need to adjust or ‘tune in’ your wire speed for

different welding conditions (thickness of metals, metal type, wire size,

etc.). When the wire speed is properly ‘tuned-in’ the welding wire will melt

into the material you are welding as quickly as it is fed through the

welding torch.

IMPORTANT! The wire will feed faster without an arc. When an arc is being

drawn, the wire speed will slow.

F. Power Cord

G. Ground Clamp - Attaching the ground clamp to your workpiece ‘completes’

the welding current circuit. You must attach the ground clamp to the

metal you are welding. If the ground clamp is not connected to the metal

workpiece you intend to weld, the welding unit will not have a completed

circuit and you will be unable to weld. A poor connection at the ground

Fig. 1

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clamp will waste power and heat. Scrape away dirt, rust, scale, oil or paint

from the clamping surface before attaching the ground clamp.

ASSEMBLY

ASSEMBLE THE HANDLE

1. Line up the holes in the handles with the holes on the top of the welding

unit.

2. Place a lock washer then a washer onto the welding unit handle screws.

3. Insert the screws with the washers through the holes on the welding unit

handle and into the top of the welding unit and tighten.

INSTALLATION

Power Requirements

This welding unit is designed to operate on a properly grounded 120 volt, 60

Hz, single-phase alternating current (AC) power source that has a 20 amp time

delayed fuse or circuit breaker. The use of the proper circuit size can eliminate

nuisance circuit breaker tripping when welding.

NOTICE! Do not operate this welding unit if the actual power source voltage

is less than 105 volts AC or greater than 132 volts AC. Improper

performance and/or damage to the welding unit will result if operated on

inadequate or excessive power.

A qualified electrician should verify the actual voltage of the power outlet,

confirm the outlet is grounded and that the fuse is properly installed.

The use of an extension cord is strongly discouraged because of the voltage

drop it will cause. This voltage drop can affect the welding unit’s performance.

If an extension cord is necessary, #12 wire gauge is the thinnest allowed. The

maximum length of the extension cord should not exceed 25 ft in length.

ALIGN AND SET THE DRIVE ROLLER

The correct drive roller grove must be set on the wire drive mechanism before

the welding wire is installed in the unit.

1. Open the door to the welding unit’s drive compartment.

2. Remove the drive tension by loosening the drive tension adjusting knob

(Fig. 2-1) and lifting the drive tension adjustor away from the drive tension

arm (Fig. 2-2). Pull the drive tension arm away from the drive roller.

8976052 MINIMIG 100E Flux-Cored Welder V4.0

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3. If there is a wire already installed in the welding unit, roll it back onto the

wire spool by hand-turning the spool counterclockwise. Be careful not to

allow the wire to come out of the rear end of the inlet guide tube (Fig. 2-3)

without holding onto it or it will unspool itself. Put the end of the wire

into the hole on the outside edge of the wire spool and bend it over to

hold the wire in place. Remove the spool of wire from the drive

compartment of the welding unit.

4. Rotate the drive roller Cap (Fig. 2-4) counterclockwise and remove it from

the drive roller.

5. Pull the drive roller off the drive roller shaft.

DRIVE ROLLER ADJUSTMENTS

The drive roller has two grooves

built into it for different wire

sizes. The correct wire size

number is stamped on each side

of the drive roller. The number

facing you when installing the drive roller must match the wire size. Use only

the proper size drive roller when using your welding unit.

Table 1 indicates which drive roller groove should be used with each wire

diameter size.

1. Find the side of the drive roller (Fig. 3-1) that

is stamped with the same wire diameter (Fig.

3-2) as that of the wire being installed. Push

the drive roller onto the drive roller motor

shaft (Fig. 3-3), with the side stamped with

the desired wire diameter facing you.

2. Reinstall the drive roller cap (Fig. 2-4) and

lock in place by turning it clockwise.

Wire Diameter

Drive Roller Groove

0.030 in. 0.030 in.

0.035 in. 0.035 in.

Fig. 2

Fig. 3

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3. Close the door to the welding unit drive compartment.

SELECTING THE WELDING WIRE

The welding unit can handle different dimensions and types of welding wire.

Self-Shielding Flux-Core Wire - Four and eight-inch spools of 0.030 in.

(0.8 mm) or 0.035 in. (0.9 mm).

INSTALL THE WELDING WIRE

WARNING! Electric shock can kill! Always turn the power switch OFF and unplug

the power cord from the power source before installing the welding wire.

Remove old wire from the torch assembly before installing new welding wire. This

will help to prevent the possibility of the wire jamming inside the torch liner.

1. Remove the nozzle and contact tip from the end of the torch assembly.

a. Check that the power is OFF and

the power cord unplugged before

removing the welding nozzle. The

contact tip on this welding unit is

electrically hot whenever the

torch trigger is pulled.

2. Make sure the proper groove on the

drive roller is in place for the installed

wire. Change the drive roller if the

proper grove is not in place (see Align

and Set the Drive Roller).

3. Unwrap the spool of wire and find the leading end of the wire. Do not

unhook it. The leading end goes through a hole in the outer edge of the

spool and is bent over the spool edge to

prevent the wire from unspooling.

4. Place the spool on the spindle so the wire is

straight, not at an angle, when it enters the

welding unit mechanism (Fig. 4).

5. The purpose of the drive brake is to halt the

spool of wire at nearly the same moment that

wire feeding stops.

a. Four Inch Wire Spool - Install the drive

brake hardware on the top of the spool

of wire, as shown in Fig. 5-A.

A

B

Fig. 5

Fig. 4

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b. Eight Inch Wire Spool - Install the spindle adapter and drive brake

hardware, as shown in Fig. 5-B.

6. Set the spool tension. Too much tension and the wire will slide on the

drive roller or the wire won’t feed into the mechanism. Tool little tension

and the wire may unspool itself. Readjust the drive brake tension to

correct for either problem.

a. Turn the wire spool with one hand and while adjusting the tension

with the other hand.

b. Tighten (turn clockwise) the drive tension adjustment knob with your

free hand.

c. Stop tightening when drag is felt on the wire spool that you are

turning.

d. The wire spool is ready for use.

7. Free the leading end of the wire from the spool and use wire cutters to

remove the bent portion, leaving a straight 90° cut. Do not let go of the

welding wire while doing this, as the wire may unspool itself.

8. Loosen the tension adjusting knob holding the drive tension arm in place

and lift the tension arm away from the driver roller.

9. Insert the leading end of the wire into the inlet guide tube. Then push the

wire across the drive roller and insert six inches into the torch assembly.

a. Make certain that the welding wire is actually going into the torch

liner and not alongside it. A misaligned wire may be deflected in

another direction and could damage the internal mechanisms.

10. Line the wire in the drive roller groove, then place the drive tension arm

on the drive roller.

11. Flip the quick release drive tensioner back up into position on the drive

tensioner arm.

12. Tighten (turn clockwise) the drive tension adjusting knob until the tension

roller is applying enough force on the wire to prevent it from slipping out

of the drive assembly.

13. Let go of the wire.

14. Connect the welding unit power cord to the power source.

15. Turn the welding unit ON.

16. Set the voltage switch to the voltage (heat) setting recommended for the

gauge metal that is to be welded. Refer to the label mounted on the cover,

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inside the drive compartment, for recommended voltage (heat) settings

for your welding job.

17. Set the wire speed control to the middle of the wire speed range.

18. Straighten the torch cable and pull the trigger on the welding torch to

feed the wire through the torch assembly.

19. When at least an inch of wire sticks out past the end of the torch, release

the trigger.

20. Turn the power switch to the OFF position.

21. Select a contact tip stamped with the same diameter as the wire being

used. If stamped in metric, use Table 1.

a. A contact tip one size larger may be required if the wire jams due to

inherent variances in

flux-cored welding wire.

22. Slide the contact tip over the wire protruding from the end of the torch.

Thread the contact tip into the end of the torch and hand-tighten securely.

23. Install the nozzle on the torch assembly. For best results, coat the inside

of the nozzle with anti-stick spray or gel.

24 Cut off the excess wire that extends past the end of the nozzle, but leave

a short stub.

25. The wire feed is ready for use.

SET THE WIRE DRIVE TENSION

Prevent an arc flash from occurring during the process of setting the drive

tension, by not allowing the wire coming out of the torch to contact with the

workpiece, ground clamp or any grounded material.

1. Pull the trigger on the torch.

2. Turn the drive tension adjustment knob clockwise, increasing the drive

tension until the wire seems to feed smoothly without slipping.

The wire should not slip between the wire and the drive roller under normal

conditions. An obstruction in the wire feed path will cause the wire to slide on

the drive roller.

Once the tension is properly adjusted, the quick release drive tensioner may be

unlocked and relocked without readjusting the drive tension adjustment knob.

The wire drive tension will require a reset if the diameter or type of welding

wire is changed.

8976052 MINIMIG 100E Flux-Cored Welder V4.0

18 For technical questions call 1-800-665-8685

OPERATION

IMPORTANT! Metal thinner than 18 gauge cannot be welded with this

machine. Attempting to do so will cause burn through (blowing holes) in

the metal you are intending to weld. The maximum steel thickness that

shoudl be attempted is 1/4 in.

CHOOSE A WELDING LOCATION

Selecting the proper location to use the welding unit can significantly increase

the welding unit’s performance, reliability and lifespan.

Locate the welding unit in an environment that is clean and dry. Place the

welding unit to ensure free circulation of air around all sides of the welding

unit. Dust and dirt can accumulate on the moving parts of the welding unit.

Debris can retain moisture and that can increase wear for moving parts.

The power outlet used for the welding unit must be properly grounded and the

welding unit must be the only load on the electrical circuit. See Power

Requirements in the Installation section.

Turn the welding unit OFF before plugging into appropriate 120 volt 20 amp

power outlet.

The use of an extension cord is discouraged for arc welding machines. Extension

cord use will significantly degrade the performance of the welding unit.

PREPARING THE MIG GUN/TORCH

The MIG gun or torch will require cleaning and preparation before each use.

Any previous welding will leave carbon deposits and molten bits on the nozzle

and welding tip. The metal beads and carbon deposits will disrupt the shielding

gas flow from the nozzle, resulting in uneven protection of the weld puddle.

The debris may also cause the nozzle to overheat and melt or distort the

welding wire before it reaches the weld point.

1. Remove the nozzle and inspect for molten beads inside the nozzle and on

the end.

2. Insert closed welding pliers into the rear end of the nozzle and rotate the

pliers to scrape off the metal beads.

3. Clean the carbon deposits on both the nozzle and welding tip with a cloth.

The metal should shine. Discard and replace the nozzle or welding tip if

the deposits or beads cannot be removed.

4. Treat the nozzle by dipping it in MIG Nozzle Dip. Twist the nozzle as it is

inserted up to the bevel into the grease. Continue twisting as the nozzle is

removed, leaving a coating of grease inside and out.

V4.0 MINIMIG 100E Flux-Cored Welder 8976052

Visit www.princessauto.com for more information 19

5. Wipe off the excess grease on the outside of the nozzle with a finger or

towel and cover the welding tip with the grease.

6. Snip off the welding wire, leaving only a 1/4 in. at most.

7. Screw the nozzle back into place and the MIG gun/torch is ready for use.

ATTACHING THE GROUND CLAMP

1. Clean off dirt, oil, rust, scale, oxidation and paint from the workpiece

where the ground clamp will be attached.

2. Attach the ground clamp to the workpiece. Connect the ground clamp

directly to the workpiece and as close to the weld as possible to prevent

the welding current from traveling along an unexpected path, creating an

electric shock or fire hazard.

If this is not possible, connect the ground clamp to metal attached to the

workpiece, but is not electrically insulated from it. The metal must be of

equal or greater thickness than the workpiece when using this alternate

attachment point.

TURN THE POWER ON

1. Plug the welding unit power cord into an outlet that meets the specified

power requirements (see Specifications).

2. Press the power switch to turn the welding unit ON.

WARNING! The welding unit is ‘live’ once turned on and can cause serious

electrical and burn injuries if mishandled. Take all precautions listed in this

manual when handling the welding unit.

SELECT THE WELDING AMPERAGE

The voltage selector controls the welding heat. Refer to the label inside the

welder side door for recommended settings for your welding job.

TUNING IN THE WIRE SPEED

WARNING! Exposure to a welding arc is extremely harmful to the eyes and

skin. Prolonged exposure to the welding arc can cause blindness and burns.

Never strike and arc or begin welding until you are adequately protected.

Wear flameproof welding gloves, a heavy long sleeved shirt, cuffless

trousers, high topped shoes and a welding helmet.

This is one of the most important parts of a MIG welding operation and must be

done before starting each welding job or whenever any of the following

variable are changes: heat setting, wire diameter or wire type.

8976052 MINIMIG 100E Flux-Cored Welder V4.0

20 For technical questions call 1-800-665-8685

1. Connect the ground clamp to a scrap piece of metal that matches the

material that you are welding. It should be equal to or greater than the

thickness of the actual workpiece and free of oil, paint, rust, etc.

2. Select a heat setting.

3. Hold the torch in one hand, allowing the nozzle to rest on the edge of the

workpiece farthest away from you and at an angle similar to one that will

be used when welding.

4. With your free hand, turn the Wire Speed Dial to maximum and continue

to hold onto the knob.

5. Lower your welding helmet and pull the trigger on the torch to start an

arc, then begin to drag the torch toward you while simultaneously turning

the Wire Speed dial counterclockwise.

6. Listen for a high–pitch buzzing sound. This indicates the setting is correct.

When decreasing the speed, the arc’s sound will change from a sputtering

noise to a high-pitched buzzing sound. It will begin sputtering again if you

decrease the wire speed too much.

You can use the wire speed control to slightly increase or decrease the heat

and penetration for a given heat setting by selecting higher or lower wire

speed settings. Repeat this tune-in procedure if you select a new heat setting, a

different diameter wire or a different type of welding wire.

DUTY CYCLE

The welding unit’s duty cycle rating defines how long the operator can weld

before allowing the welding unit to cool. The duty cycle is a percentage of a 10-

minute period. The welding unit must cool for the remainder of the cycle. This

welding unit has a duty cycle rating of 20% at the rated output (see

Specifications). This means that the user can weld for 2 minutes and then rest

the welding unit for 8 minutes before using it again.

The welding unit may stop before the 2-minute duty cycle time limit. Reduce

the wire speed slightly and tune in the welding unit at the lowest wire speed

setting that still produces a smooth arc. Welding with the wire speed set too

high causes excessive current draw and shortens the duty cycle.

INTERNAL THERMAL 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

welding unit 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.

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Powerfist 8976052 Le manuel du propriétaire

Powerfist 8976052 Le manuel du propriétaire

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