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Section 2
Tapping Method
1.
Make sure the unit is turned on and the startup cycle has finished.
2.
Select the Stick icon on the Process Selector.
3.
Make sure the electrode holder is in the Positive connector and the work clamp is in the negative connector.
4.
Select the Amp level desired. Use the guide on page 16 to determine approximate amps suitable for the rod size selected. You
should consult the welding electrode manufacturer's recommendation for proper amperage as the ultimate authority. No voltage
adjustment is available. Select Hot Start Time and Hot Start Amps % (Intensity) to improve starting reliability.
5.
Use the arc force control to select the desired arc characteristics, creating the desired arc characteristic and amp response need-
ed to maintain the arc. Cellulose electrodes may not have the same arc force behavior as other welding electrodes, but each
brand and size will weld a little differently. Typically rods such as the E6011 will require a setting over 50% for best resu lts. The
arc force control setting will vary from person to person as well, with different rod angles, positions, and arc lengths all factoring
into the arc force control performance. If you are new to using a transformer welder, there are some aspects that will seem dif-
ferent. One of the main ones is that the arc is better controlled in most situations by "pushing in" when the arc seems to get
weak or unstable and the arc force will kick in as the voltage drops. Holding too long of an arc will signal the inverter to shut
down and to terminate welding output. This threshold is shorter than most transformers, and an extremely long arc cannot be
maintained. However, with a little practice, the arc will be easy to manage.
6.
Strike the arc with either the tapping method or the match strike method. Beginners usually find that the match strike metho d
typically yields the best results.
Stick Welding. Pay particular attention to the Arc Force setting
as it affects the aggressiveness of the arc and the amp re-
sponse. Set the Arc force to approximately 30-50% and readjust
it from that point to find the optimum setting. Adjust in incre-
ments of 5% up or down from there to obtain the best results
Usually, an increase in the arc force for cellulose based flux
welding rods is helpful. Lowering the Arc force setting is gener-
ally desirable for rods iron powder/Titania based flux. Too much
arc force will create overheating of the welding rod, and even
cause them to flame up. Too little can lead to sticking and arc
snuffing. Use the Hot Start features to improve arc starting and
cut down on failed arc strikes. Hot Start Amps refers to the %
over the set amps that the amps will be boosted during arc
striking until the arc is established. Hot Start Intensity controls
the amount of time that the Hot Start stays engaged after the arc
is struck. Start by setting Hot Start to somewhere between 30%
and 50% and set hot start time to .2-.3 seconds. Adjust in in-
crements of 5% up or down to obtain best starting results.
Keep in mind that when stick welding, allow the metal to fill the
puddle as the rod travels forward. Be sure to try to separate the
difference between the slag and the molten pool of metal. The
slag will coalesce behind the puddle if travel and rod angle is
METAL THICKNESS
< 1 mm/.040"
2 mm/.080"
3 mm/ 1/8"
4-10 mm/ 3/16"-3/8"
STICK OPERATION
STARTING METHODS
Striking the Arc
correct. Do not let the slag travel in front of the puddle. Keep the
top of the rod inclined to the direction of travel around 10-20 de-
grees while welding in the flat position (Electrode holder should be
in front and inline of the puddle). To begin, simply start the arc, and
then drag the rod slowly and carefully along the metal, allowing the
rod flux to provide a standoff between the metal filler and the pud-
dle. Be sure to keep feeding the rod steadily downward into the
puddle as the rod melts. In the case of E6010, a slight stepping
motion in front of the puddle about 1/8"-1/4" in front of the puddle
can be used as a key hole opens up in the weld joint, ahead of the
puddle. This is also called "whipping" the rod. Do not flip the end of
the rod too far away from the puddle in a arc motion or the arc may
terminate while using E6010 or similar cellulosic rods. When expe-
rience is gained, numerous manipulation methods may be used with
rods such as E7018, 7014, 6013, and 7024. Weave the rod no
more than 2.5 times the width of the welding rod. To begin weav-
ing, weave small, tight patterns similar to C's, cursive E's, V's, or
even figure 8's. Your bead should looks similar to the beads below.
V shaped beads are a result of running Amps too high. Flattened U
or C shapes are examples of moving too slow.
DC STICK (SMAW) OPERATION GUIDE
ELECTRODE SIZE
1.5 mm/ 1/16"
2 mm/3/32"
3.2 mm/1/8"
3.2-4 mm/ 1/8"-5/32"
21
General Setup and Operation
Scratch/Match Method
WELDING AMPS
20-40
40-90
70-150
85-160
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