Power Fist 8785008 Manuel utilisateur

V4.0 8785008

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

future reference.

User Manual

75A Mini Inverter

Stick Welder

8785008 75A Mini Inverter Stick Welder V4.0

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

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.

75A Mini Inverter

Stick Welder

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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

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

free of distractions.

2. Remove all unnecessary people from the work area when welding.

Anyone remaining in the work area must wear the appropriate welding

safety equipment.

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

of children.

4. 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’.

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

6. 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.

8785008 75A Mini Inverter Stick Welder V4.0

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

7. Have a fire extinguisher readily available (see Fire and Explosion Precautions).

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

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

9. Keep the welding unit at least one foot from any wall or structure.

10. 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.

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.

2. 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.

3. 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.

4. 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.

5. Wear fire resistant earplugs when welding overhead to prevent spatter or

slag from falling into your ear.

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PROTECTIVE CLOTHING

1. 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.

2. 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.

3. Wear thick clothes that do not expose the skin. Ultraviolet or infrared light

can burn skin with sufficient exposure.

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. Gloves shall should contain an insulating lining to protect against an

electric shock.

6. 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

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

(See Fumes and Gases).

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.

8785008 75A Mini Inverter Stick Welder V4.0

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

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.

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

hair preparations, perfume or cologne with an alcohol base.

7. 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.

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. Arc welding requires the use a hand-held face shield or helmets with full

face protection per CSA standard Z94.3.1.

3. 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.

V4.0 75A Mini Inverter Stick Welder 8785008

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Remove or cover any reflective surface behind the user such as a glossy

painted surface, aluminum, stainless steel or glass.

4. 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.

5. 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.

6. 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.

7. 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.

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

in a burn injury.

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

danger of falling.

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

11. Insulate the ground clamp when not connected to a workpiece to prevent

contact with any metal object.

12. 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.

13. Never dip the electrode in water for cooling.

14. Remove the electrode from the holder when not in use.

15. Do not point the electrode holder at any body part of yourself or at

anyone else.

16. 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.

8785008 75A Mini Inverter Stick Welder V4.0

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

17. 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.

18. 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.

19. 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.

1. 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.

2. 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.

3. 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.

4. Avoid welding near hydraulic lines or containers containing flammable contents.

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

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toxic and flammable substances and vapours per the American Welding

Standard AWS F4.1.

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.

7. 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.

8. Do not weld a panel that is a sandwich construction of combustible and

metal materials.

9. 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.

10. Ventilation systems should be positioned so sparks or molten slag isn’t

carried to an adjacent area.

11. 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.

8785008 75A Mini Inverter Stick Welder V4.0

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

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.

1. 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.

2. 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.

3. 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.

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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 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.

6. 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

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.

c. The electrode or welding wire;

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

e. The output terminals.

2. 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.

3. 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.

8785008 75A Mini Inverter Stick Welder V4.0

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

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.

4. Only use insulated connectors to join welding cables.

5. Ensure there are no contacts between the workpiece and work area that

would allow it to ground, other than through the ground cable circuit

6. 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.

7. Unplug the welding unit when not in use as the unit as current is still

entering the unit, even when it is turned off.

8. Frequently inspect input power cable for wear and tear, replace the cable

immediately if damaged. Bare wiring is dangerous and can kill.

9. Do not use damaged, under sized or badly joined cables.

10. 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.

11. 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.

1. Do not drape or carry coiled welding cables on your body while the cables

are plugged into the welding unit.

2. Do not start the tool when the electrode is touching the workpiece.

3. 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.

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4. Take work breaks to prevent the tool's motor from overheating and/or

overloading. Refer to the welding unit’s duty cycle in Specifications.

5. Keep hands away from the electrode and the area it is being applied to

when the tool is in operation.

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

not weld on an electrical conduit.

7. Do not touch the electrode or welded surface immediately after use. The

surface will be hot and may cause an injury.

8. Never use a tool with a cracked or worn electrode. Change the electrode

before using and discard the damaged one.

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.

a. When an extension cord is required, use a welding version that

exceeds the welding unit’s maximum power requirement.

2. 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.

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. 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.

5. Make sure to locate the cord so that it is not stepped on, tripped over or

otherwise subject to damage or stress.

8785008 75A Mini Inverter Stick Welder V4.0

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

6. 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.

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. Use the lowest current setting possible during welding.

6. 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.

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

8. Keep the lead cable and ground cables on the same side of your body.

9. Do not weld while carrying the welding power source.

10. 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

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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.

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

1. 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.

8785008 75A Mini Inverter Stick Welder V4.0

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

2. Place the electrode into the electrode holder and clamp tight.

3. Turn the power source on.

4. 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 as filler

material the residue from the flux that forms a

slag covering over the weld

metal must be chipped away after welding.

1. Strike the electrode on the workpiece to create the arc and hold the

electrode steady to maintain the arc.

2. The heat of the arc melts the surface of the base metal to form a molten

pool at the end of the electrode.

3. The melted electrode metal is transferred across the arc into the molten

pool and becomes the deposited weld metal.

4. The deposit is covered and protected by a slag, which comes from the

electrode coating.

5. The arc and immediate area are enveloped by an atmosphere of

protective gas.

6. 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.

Fig. 2

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a. Rock the electrode back and forth if it sticks to the workpiece. Failure

to separate the stuck rod can overload the welding unit.

7. To finish the weld, break the arc by quickly snapping the electrode away

from the workpiece.

8. 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 only

a 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 which

has particular properties to suit specific classes of work. It is recommend to

consult your welding supplier for the correct selection of electrode.

8785008 75A Mini Inverter Stick Welder V4.0

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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).

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 overheating 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.

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

Table 1

V4.0 75A Mini Inverter Stick Welder 8785008

Visit www.princessauto.com for more information 19

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.

8785008 75A Mini Inverter Stick Welder V4.0

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

CARE & MAINTENANCE

1. Maintain the tool with care. A tool in good condition is efficient, easier to

control and will have fewer problems.

2. 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.

3. 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.

4. Follow instructions for lubricating and changing accessories.

5. Only use accessories intended for use with this tool.

6. Keep the tool handles clean, dry and free from oil/grease at all times.

7. 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.

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Power Fist 8785008 Manuel utilisateur

Power Fist 8785008 Manuel utilisateur

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