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5/64 in. (2 mm) H i g h 7 . Position the electrode to begin weld, lower the welding helmet or position the hand shield, and strike an arc. Adjust output setting as n e e d e d . 8 . When finished welding, turn welder off and store properly. Do not operate thiswelding machine with cracked or missing insulation on welding cables, electrode holder, or power cord. Every 3 months: Replace any unreadable labels on the welder. Use compressed air to blow all dust and lint from the ventilation o p e n i n g s . w w w . c h p o w e r . c o m 4 Flux Work Piece Flux Work Piece M o d e l WS0970 and WS0990 Welding Guidelines G e n e r a l This welding machine utilizes a process known as Shielded Metal-Arc Welding (SMAW). This process is used to bond metals by heating them with an electric arc created between the electrode and the work piece. Electrodes used for shielded metal arc welding have two parts. The inner core is a metal rod or wire that should be similar in composition to the base metal. The outer coating is called flux. Various types of flux exist. Each coating is used for a particular welding situation. While the metal is molten, it can be contaminated by elements in the air. This contamination could weaken the weld. The flux coating creates a protective barrier called slag that protects the molten metal from contaminants. When current (amperage) flows through the circuit to the electrode, an arc is formed between the end of the electrode and the work piece. The arc melts the electrode and the work piece. The melted metal of the electrode flows into the molten crater and forms a bond with the work piece as shown in Figure 6. Wire Slag Weld NOTE: Discontinue using and discard electrodes that burn down to 1 to 2 inches from the electrode holder. STRIKING AN ARC Attach work clamp to work piece. The jaws of the work clamp must make good contact with clean bare metal of the work piece for good welding results. Place the bare end of the electrode in the holder. Grip the holder lightly to reduce tiring of the hand and arm. Crater Figure 6 - Weld Components NOTE: Always keep the jaws of the holder clean to ensure good electrical contact with the electrode. Be careful not to touch the work piece or welding bench with the electrode as this causes arc flashes. The best method of striking an arc is the scratching method. Drag the electrode at an angle along the surface much like striking a match. Upon contact with the plate, lift the electrode approximately 1/16 in. off the surface or it will stick (See Figure 7). Same as Electrode Diameter Figure 7 - Scratching Method NOTE: Should the electrode stick to the work piece, break it loose by quickly twisting or bending at the holder while pulling upward. If the electrode does not break loose, disengage the electrode by releasing it from the holder. ELECTRODE TYPE AND SIZE Two types of electrodes are recommended for this welder. The electrodes are commonly known by the AWS (American Welding Society) designation as follows: 1 . E-6013 GENERAL PURPOSE • All position, smooth deposit rod with low spatter. • For all mild steel and general purpose w o r k . 2 . E-7014 FAST FILL • Smooth bead and fast deposition • Ideal for joints with poor fitup and general repair work NOTE: E-6011 and E-7018 are not recommended for use with these welders. Recommended electrode diameter is 1/16 in. or 5/64 in.. Call (800) 746-5641 for availability. A rc Welding Basics Four basic techniques affect weld quality. These are: amperage setting, weld angle, arc length, and travel speed. Proper use of these techniques is necessary for good weld quality. AMPERAGE SETTING The correct amperage involves the adjustment of the welding machine to the required amp setting. This is regulated by selecting the appropriate high or low setting. The amperage required depends on the size (diameter) of electrode used and the thickness of the work piece. Excessive currents burn through light metals and the weld bead is flat and porous (See Figure 9). The bead appears high and irregular if the current is too low. WELD ANGLE Weld angle is the angle at which the electrode is held during the welding process. Using the correct angle ensures proper penetration and bead formation. Electrode angle involves two positions travel angle and work angle (See Figure 8). 5o - 45o Travel Angle Work Angle Figure 8 - Weld Angle Travel angle is the angle in the line of welding and may vary from 5. to 45. from the vertical, depending on welding conditions. Work angle is the angle from horizontal, measured at right angles to the line of welding. w w w . c h p o w e r . c o m 5 Shielded Metal Arc Welder Welding Guidelines ( C o n t i n u e d ) Normal Amps, Arc Length, Speed Amperage Too Low Amperage Too High Arc Length Too Long Speed Too Slow Speed Too Fast Workpiece NOTE: Weld bead width (W) should be approximately twice the diameter fo the electrode rod used. W Figure 9 - Weld Appearance Arc Length Too Short For most applications, a 45. travel ...

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