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manual abstract
2. Remove the protective film covering from both sides of each lens cover. Put one clear lens cover on each side of the shaded lens. Place these three lenses together into the face shield and secure with the lens retainer. The lens retainer should snap into the second notch in the face shield. 3. Position one of the holes in the adjustment arm over the pins which are located in the ear area of the face shield. These adjustment arms control the closeness of fit and can be easily repositioned if necessary. 4. Position the headgear inside the face shield. Assemble the helmet by inserting the stud screw through the headgear and shield into the tension nut as shown. Do not tighten tension nut completely. 5. Trial fit the welding helmet. Adjust headgear ratchet band to a comfortable position and lower the face shield. If the shield is too far or too close to the face, use a different hole in the adjustment arm. Adjust the tension nuts so that helmet can be easily lowered over the face by nodding the head. Figure 5 – Helmet Assembly Headgear Face Shield Shaded Lens Clear Lens Cover (2) Post Lens Retainer Adjustment Arm (2) Tension Nut (2) Stud Screw (2) Operation 1. Be sure to read, understand, and comply with all precautions in the General Safety Information section. Be sure to read the entire section entitled Welding Guidelines prior to using this equipment. 2. Turn welder off and plug into appropriate receptacle: 115v-20 amp 3. Verify that the 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. All persons ! WARNING operating this equipment or in the area while equipment is in use must wear protective welding gear including: eye 4 Model WS2100 protection with proper shade, flame resistant clothing, leather welding gloves, and full foot protection. If heating, ! WARNING welding, or cutting materials that are galvanized, zinc plated, lead, or cadmium plated refer to the General Safety Information Section for instructions. Extremely toxic fumes are created when these metals are heated. 4. Connect the ground clamp to the work piece or workbench (if metal). Make sure the contact is secure, and not obstructed by paint, varnish, corrosion, or non-metallic materials. 5. Insert the exposed part of the electrode (the end with no flux) into the jaws of the electrode holder. 6. Set the amperage adjustment knob to the proper amperage for the electrode diameter. Refer to the following chart for proper electrode current settings. Amperage Output Guide Electrode Diameter Current Setting 1/16” 30-60 Amps 5/64” 40-70 Amps 3/32” 60-100 Amps 1/8” 90-110 Amps The electrode ! WARNING holder and rod are electrically "hot"(have current potential) when the welder is on. Grounding against any metallic surface may produce an arc which could cause sparks and damage eyesight. 7. Hold the electrode and holder away from the grounded work piece or workbench. Turn on the welder. A green light is illuminated when the welder power is on. 8. Position the electrode to begin weld, lower the welding helmet or position the hand shield, and strike an arc. Adjust weld amperage as needed. 9. When finished welding, turn welder off and store properly. 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 10% duty cycle, actual welding can occur for one minute, then the welder must cool for nine minutes. Internal components of this welder are protected from overheating with an automatic thermal switch. A yellow lamp is illuminated on the control panel if the duty cycle is exceeded. Welding operations may continue when the yellow lamp is no longer illuminated. Maintenance Disconnect power ! WARNING supply and turn machine off before inspecting or servicing any components. 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. Check condition of electrode holder insulating pieces and immediately replace cracked or missing insulators. Verify that all fasteners are tight and insulated. Slag Weld Wire Flux Work piece CraterFigure 6 - Weld Components Do not operate this ! WARNING welding 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 openings. Welding Guidelines General This line of welding machines 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 composit...