AWELCO STANLEY 58902, User Manual, Page: 6 / 32

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to use ARGON (100%), to weld steel it is enough a
compound of ARGON 80% and CO2 20%.
You can only use pure CO2 in case you want to weld
iron.
4. WELDING GUIDE
GENERAL RULE
When welding on the lowest output settings, it is necessary to
keep the arc as short as possible. This should be achieved
by holding the welding torch as close as possible and at an
angle of approximately 60 degrees to the work piece. The arc
length can be increased when welding on the highest
settings, an arc length up to 20mm (0,8in). can be enough
when welding on maximum settings.
GENERAL WELDING TIPS
From time to time, some faults may be observed in the weld
owing to external influences rather then due to welding
machinè faults.Here are some that you may come across :
· Porosity
Small holes in the weld, caused by break-down in gas
coverage of the weld or sometimes by foreign bodies
inclusion. Remedy is, usually, to grind out the weld.
Remember, check before the gas flux (about 8
liters/minutes), clean well the working place and finally incline
the torch while welding.
· Spatter
Small balls of molten metal which come out of the arc. A little
quantity is unavoidable, but it should be kept down to a
minimum by selecting correct settings and having a correct
gas flow and by keeping the welding torch clean.
· Narrow heap welding
Can be caused by moving the torch too fast or by an
incorrect gas flow.
· Very thick or wide welding
Can be caused by moving the torch too slowly.
· Wire burns back
It can be caused by wire feed slipping, loose or damaged
welding tip, poor wire, nozzle held too close to work or
voltage too high.
· Poor penetration
It can be caused by moving torch too fast, too low voltage
setting or incorrect feed setting, reversed polarity, insufficient
blunting and distance between strips. Take care of
operational parameters adjustment and improve the
preparation of the workpieces.
· Workpiecès piercing
It may be caused by moving the welding torch too slow, too
high welding power or by an invalid wire feeding.
· Heavy spatter and porosity
Can be caused by nozzle too far from work, dirt on work or by
low gas flow. You have the two parameters, remeber that gas
must not be lower than 7-8 liters/min. and that the current of
welding is appropriate to the wire you are using. It is
advisable to have a pressure reducer of input and output. On
the manometer you can read the range expressed in liter.
· Welding arc instability
It may be caused by an insufficient welding voltage, irregular
wire feed, insufficient protective welding gas
5. FAULT FINDING
FAULT REASON REMEDY
Wire isn’t
conveyed when
feed rolli s
turning
1. Dirt in liner
and/or contact tip
2. The friction
brake in the hub is
too tightened
3. Faulty welding
torch Blow with
compressed air,
Replace contact tip
Loosen
Check sheating of
torches wire guide
Wire feeding in
jerk or erratic
way
1. Contact tip
defect
2. Burns in contact
tip
3. Dirt in feed rool
groove
4. Feed roll’s
groove worn
Replace
Replace
Clean
Replace
No arc
1. Bad contact
between earth clamp
and workpiece
2. Short-circuit
between contact tip
and gas shroud Tighten earth
clamp and check
connections
Clean, replace tip
and/or shroud as
necessary
Porous welding
seams
1. Failure of gas
shield owing to
spatters in gas shro
2. Wrong welding
torch distance and/or
inclination from
workpiece
3. Too small gas
flux
4. Humid
workpieces
5. Heavily rusted
workpieces
Clean gas shroud
from spatters
The length of stick
out wire from tip
must be 5-10 mm
(0.2-0.4in).
Inclination not less
than 60° degrees in
relation to
workpiece
Increase flux of
welding gas
Dry with heat
producer
Clean workpieces
from rust
The machine
suddenly stops
welding
operations after
an extended
and heavy duty
use
1.
welding machine
overheated due to
an excessive use in
stated duty cycle
Don’t switch off the
machine, let it cool
down for about
20/30 minutes
The machine is
switch off even
it is 1. Fuse blowed on
the service
transformer
Replace