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MIG WELDING GUN OPERATION MANUAL

1.0 INTRODUCTION

1.1 WARRANTY

1.2  PRODUCT REGISTRATION

Congratulations on your purchase of the PowerBall® High Performance MIG Welding Gun! Each PowerBall® Welding 

Gun is proudly manufactured and inspected at our facility in Jackson, Michigan. Please check box contents upon 

receipt for any damage that may have occurred during transit and to ensure all torch components are accounted for.

This guide is designed to assist the user whose primary responsibility is to operate and maintain the PowerBall® MIG 

welding gun. This manual provides specific information on installation, safety, basic operation, and maintenance. 

Please read, understand and follow all safety precautions noted in this manual.

For customer service and support, contact ELCo Enterprises at 517-782-8040 or toll free 1-866-584-7281. A digital 

version of this manual and additional product information is available on our website at 

www.wire-wizard.com

LIMITED ONE (1) YEAR WARRANTY

ELCo Enterprises, Inc. (hereinafter “ELCo”) shall warrant this product to be free of defects in material and/or 

workmanship for a period of one (1) year from the date of shipment to the buyer. The warranty shall cover 100% of 

all parts and labor with the exception of misuse, abuse, neglect and typical consumables as determined by ELCo. 

Failure to follow proper installation and/or maintenance procedures specified in the operating instructions will void 

this warranty. ELCo will at its option, repair, replace or issue a credit for the value of the defective product within the 

warranty period.

Buyer accepts all responsibility for compliance with any/all Local, State and Federal Laws or Regulations including 

Regulations of Foreign Governments.

No equipment shall be returned to ELCo without a Return Authorization Number. Upon evaluation and validation of 

warranty, replacements or repairs will be sent to the Buyer. If a replacement is needed immediately, a purchase order 

is required to cover the cost of the product until the warranty is determined.

ELCo’s warranty is limited to replacing any goods that are proved to be defective and ELCo in no event shall have 

any liability for paying incidental or consequential damages including and without limitation, damages resulting in 

personal or bodily injury or death, or damages to, or loss of use of any property. Notwithstanding any of these terms 

and conditions, the warranties set forth shall apply in connection with any sales of goods, services or design by ELCo 

and are in lieu of all other warranties, express or implied, including warranties of merchantability and fitness for a 

particular purpose.

Please register this product online or by phone within 14 days after purchase

Register this product online by going to www.wire-wizard.com/register or scanning the QR code on 

the right, or you may call 517-782-8040 to register by phone. Registering this product will allow us 

to provide expedited service should there be any problems potentially covered by this warranty in 

the future. 

Please record the following information for this product and retain for your records:

Model #:_________________________ Lot #:______________________ Shipment Date:____________________

Online Registration

Summary of Contents for Powerball

Page 1: ...HIGH PERFORMANCE MIG WELDING GUNS OPERATION MANUAL For 300 and 400 Amp Semi automatic MIG Guns ELCo Enterprises Inc Jackson Michigan USA Service Support 517 782 8040 www wire wizard com ...

Page 2: ...CTION 3 1 1 Warranty 3 1 2 Product Registration 3 2 0 SAFETY PRECAUTIONS 4 5 2 1 Welding and Safety Operating References 5 3 0 DUTY CYCLE SPECIFICATIONS 6 5 0 OPERATION 6 5 1 Trigger Pull Adjustment 6 6 0 CONSUMABLES REPLACEMENT 7 6 1 Torch Liner Replacement 7 6 2 Gooseneck Replacement Instructions 8 7 0 TROUBLESHOOTING 8 8 0 REPLACEMENT PARTS LIST 9 9 0 TORCH CONSUMABLES ACCESSORIES 10 TABLE OF C...

Page 3: ...e value of the defective product within the warranty period Buyer accepts all responsibility for compliance with any all Local State and Federal Laws or Regulations including Regulations of Foreign Governments No equipment shall be returned to ELCo without a Return Authorization Number Upon evaluation and validation of warranty replacements or repairs will be sent to the Buyer If a replacement is ...

Page 4: ... and protective clothing Protective clothing should cover all exposed skin to prevent burns and exposure to ultraviolet rays An approved welding curtain or solid wall must be used in areas where other personnel may be exposed to arc rays Other personnel in the work area exposed to arc rays and sparks must also wear a welding helmet and protective clothing to prevent eye injury and burns Ear plugs ...

Page 5: ...nd of welding gun in case of accidental activation of the trigger Weld wire can puncture skin and cause injury Never point the gun toward the body or or others when feeding wire Refer to these safety standards and regulations for additional information on best practices for welding safety ANSI Z49 1 Safety in Welding and Cutting ANSI Z87 1 Practice for Occupational and Educational Eye and Face Pro...

Page 6: ... Ar CO2 shielding gas 100 400 amps with 75 25 mixed Ar CO2 shielding gas 300 amp Air Cooled MIG Gun Maximum wire size 5 64 2 0mm 100 300 amps with pure CO2 shielding gas 100 300 amps with 90 10 mixed Ar CO2 shielding gas 100 300 amps with 75 25 mixed Ar CO2 shielding gas Spring Set Screw Light Medium Heavy Trigger Springs Feeder Adapter design will vary Control Plug Power Cable PowerBall MIG Guns ...

Page 7: ...e no sharp edges This will prevent wire hang up and other feeding problems from occurring 7 Replace and tighten the diffuser contact tip and nozzle Re attach the gun to the wire feeder and feed wire back up through the gun TIP NOZZLE DIFFUSER REPLACEMENT 1 Turn off power supply and remove threaded nozzle by turning counterclockwise 2 Trim wire to a clean end and remove the the tip and or diffuser ...

Page 8: ... has occurred If feeder is set up properly and wire path is clear the microswitch on the gun trigger may need replacing Burn back at contact tip Improper wire feed speed Improper voltage for application Poor wire feed Improper wire stick out Bad ground Check welding parameters and ensure feed speed and voltage are set properly for your welding application Adjust wire stick out if necessary Inspect...

Page 9: ...er Cable replacing cable requires repair kits H I 300 A Guns 300 TORCH CABLE 400 A Guns 400 TORCH CABLE Available in 8 10 12 15 20 25 Add suffix on part number to specify length 8 for 8 10 for 10 etc G Power Jumper Cable WTP ST CABLE H Handle Repair Kit required when attaching or replacing torch cable at handle 300 A Guns WTP 300 HRK 400 A Guns WTP 400 HRK I Feeder Adapter Repair Kit required when...

Page 10: ...US WIRE WTP HTL 45116 10 10 FT 3m TORCH LINER FOR 045 1 16 1 2 1 6mm NON FERROUS WIRE WTP HTL 45116 15 15 FT 4 6m TORCH LINER FOR 045 1 16 1 2 1 6mm NON FERROUS WIRE POWERBALL TORCH LINERS E POWER STEEL LINERS FOR FERROUS WIRES E POWER HI TEMP POLYMER LINERS FOR ALUMINUM NON FERROUS WIRES POWERBALL CONTACT TIPS PB 1 STYLE TIPS STANDARD PB 3 STYLE TIPS FOR HEAVY DUTY APPLICATIONS PB 5 STYLE TAPERED...

Page 11: ..._________________________________ __________________________________________________________ __________________________________________________________ __________________________________________________________ __________________________________________________________ __________________________________________________________ __________________________________________________________ ____________...

Page 12: ...ELCo Enterprises Inc Jackson Michigan USA Service Support 517 782 8040 www wire wizard com SAVE THESE INSTRUCTIONS FOR FUTURE REFERENCE ...

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