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Section 3
SET UP
Base Metal Preparation
As with most welding, clean weld studs and clean base metal will provide the best results. Typical weld penetration is .002
to .004 inches (.05 to .1 mm). Mill scale may easily be this thick. When welding to steel with mill scale, the scale must be
removed first to achieve quality weld results.
A common CD welding mistake is to use a centerpunch mark for location. The ignition tip locates nicely in the centerpunch
mark, but it effectively shortens the tip length. Since the tip is sitting in a depression, the distance from the workpiece to the
face of the weld stud is shorter. Usually, this results in bad welds.
Aluminum can quickly form a layer of oxide. Oxide is non-conductive (not good for welding) and is tough. If welding onto
aluminum is causing problems, it is often best to remove the oxide layer. This can be accomplished via abrasives. A stainless
steel brush works well.
LOCATION
If the power supply is stationary it should be located:
• On a flat, level surfaces with adequate air circulation.
• Near the work area to limit welding cable length (shorter lengths are preferred). Avoid looping the weld
cables.
• In a dry area away from moisture.
• To protect it from grinding dust and other contaminates.
• To provide min. 6" clearance on all sides for cooling.
If the power supply is worn it should be located:
• On your shoulder with strap provided. Note: Remove if heat should become excessive.
• In a dry area away from moisture. Do not use in the rain or while standing in a puddle.
• Near the work area to limit welding cable length (shorter lengths are preferred). Avoid looping the weld cables.
• Care should be taken to avoid a falling hazard as the ground cable and weld tool cables can catch on other objects.
When working off the ground a safety harness should always be used.
• To protect it from grinding dust and other contaminates.
Installation
& Set Up
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