ATD Tools 3175 User manual

May 01, 2013

2
SPECIFICATIONS
ATD-3175

3
TABLE OF CONTENTS
SafetySummary. .............................................4
Safety Information........................................4
Shock Hazards................................................5
Flash Hazards .................................................5
Fire Hazards.....................................................6
Fume Hazards.................................................7
Compressed Gasses
and Equipment Hazards..........................7
Additional Safety Information..................8
WelderSpecifications. .................................9
Description .....................................................9
Welder Operating Characteristics .........9
Duty Cycle ..................................................9
Internal Thermal Protection .....................9
Know Your Welder......................................10
Welder Installation......................................11
Power Source Connection .......................11
Power Requirements ..............................11
Connect to Power Source ....................11
Extension Cords ......................................11
Assembling the Welder ............................11
Unpacking the Welder ..........................11
Packing List.................................................11
Assemble the Face Shield ....................11
Installing the Handle...............................12
Selecting Shielding Gas..........................12
Install the Shielding Gas ........................13
Check the Gas Flow ...................................13
Align and Set the Drive Roller ................13
Install the Welding Wire ..........................14
Set the Wire Drive Tension ....................16
Installing Aluminium Wire ......................16
Change Polarity............................................16
Operation.........................................................17
Controls and Indicators ...........................17
Power Switch ..........................................17
Voltage Selector .....................................17
Wire Speed Control ..............................17
Tuning in the Wire Speed ............................17
Learning to Weld ...........................................18
Holding the Gun ........................................18
Welding Techniques..................................19
Moving the Gun .....................................19
Types of Weld Beads ..............................20
Welding Positions ..................................20
Multiple Pass Welding ...........................21
Special Welding Methods ...................22
Spot Welding............................................22
Maintenance..................................................23
General .........................................................23
Consumable Maintenance......................23
Maintaining the Contact Tip ................23
Maintaining the Nozzle ...........................24
Testing for a Shorted Nozzle .................24
Replace a Gun Liner ..................................24
Preventive Maintenance...........................26
Troubleshooting..........................................26
Wiring Diagram............................................28
Parts List..........................................................29
Suggested Settings...................................33

4
The warnings, cautions and instructions dis-
cussed in this instruction manual can not cover
all possible conditions or situations that could
occur. It must be understood by the operator
that common sense and caution are factors
which can not be built into this product, but
must be supplied by the operator. Reading this
operator’s manual before using the welder
will enable you to do a better, safer job. Learn
the welder’s applications and limitations as
well as the specic potential hazards peculiar
to welding.
IMPORTANT SAFETY INFORMATION
The following safety information is provided
as guidelines to help you operate your new
welder under the safest possible conditions.
Any equipment that uses electrical power
can be potentially dangerous to use when
safety or safe handling instructions are not
known or not followed. The following safety
information is provided to give the user the
information necessary for safe use and
operation.
A procedure step preceded by a WARNING is
an indication that the next step contains a pro-
cedure that might be injurious to a person if
proper safety precautions are not heeded.
A procedure preceded by a CAUTION is an
indication that the next step contains a pro-
cedure that might damage the equipment
being used.
ANOTE may be used before or after a pro-
cedure step to highlight or explain some-
thing in that step.
READ ALL SAFETY INSTRUCTIONS CARE-
FULLY before attempting to install, operate,
or service this welder. Failure to comply with
these instructions could result in personal
injury and/or property damage.
RETAIN THESE INSTRUCTIONS FOR
FUTURE REFERENCE.
Note:
tThe following safety alert symbols identify
important safety messages in this manual.
tWhen you see one of the symbols shown
here, be alert to the possibility of person-
al injury and carefully read the message
that follows.
This symbol indicates that the pos-
sibility of electric shock hazard
exists during the operation of the
step(s) that follow.
This symbol indicates that the pos-
sibility of re hazard exists during
the operation of the step(s) that
follow.
This symbol indicates that the hel-
met must be worn during the
step(s) that follow to protect
against eye damage and burns
due to ash hazard.
This symbol indicates that the pos-
sibility of toxic gas hazard exists
during operation of the step(s)
that follow.
This symbol indicates that the pos-
sibility of being burned by hot slag
exists during operation of the
step(s) that follow.
This symbol indicates that the eye
protection should be worn to pro-
tect against ying debris in the fol-
lowing step(s).
This symbol indicates that the pos-
sibility of injury or death exists due
to improper handling and mainte-
nance of compresses gas cylinders
or regulators.
tPublished standards on safety are avail-
able. They are listed in ADDITIONAL
SAFETY INFORMATION at the end of this
SAFETY SUMMARY.
The National Electrical Code, Occupation
Safety and Health Act regulations, local
industrial codes and local inspection
requirements also provide a basis for equip-
ment installation, use, and service.
SAFETY SUMMARY

5
SHOCK HAZARD
WARNING
ELECTRIC SHOCK CAN KILL! To reduce the
risk of death or serious injury from shock,
read, understand, and follow the following
safety instructions. In addition, make certain
that anyone else who uses this welding
equipment, or who is a bystander in the
welding area understands and follows these
safety instructions as well.
tIMPORTANT! TO REDUCE THE RISK OF
DEATH, INJURY, OR PROPERTY DAM-
AGE, DO NOT ATTEMPT OPERATION of
this welding equipment until you have
read and understand the following safe-
ty summary.
tDo not, in any manner, come into physi-
cal contact with any part of the welding
current circuit. The welding current cir-
cuit includes:
a) the work piece or any conductive
material in contact with it,
b) the ground clamp,
c) the electrode or welding wire,
d) any metal parts on the electrode
holder, or wire feed gun.
tDo not weld in a damp area or come in
contact with a moist or wet surface.
tDo not attempt to weld if any part of
clothing or body is wet.
tDo not allow the welding equipment to
come in contact with water or moisture.
tDo not drag welding cables, wire feed
gun, or welder power cord through or
allow them to come into contact with
water or moisture.
tDo not touch welder, attempt to turn
welder on or o if any part of the body
or clothing is moist or if you are in phys-
ical contact with water or moisture.
tDo not attempt to plug the welder into
the power source if any part of body or
clothing is moist, or if you are in physical
contact with water or moisture.
tDo not connect welder work piece clamp
to or weld on electrical conduit.
tDo not alter power cord or power cord
plug in any way.
tDo not attempt to plug the welder
into the power source if the ground
prong on power cord plug is bent over,
broken o, or missing.
tDo not allow the welder to be connected
to the power source or attempt to weld if
the welder, welding cables, welding site,
or welder power cord are exposed to any
form of atmospheric precipitation, or salt
water spray.
tDo not carry coiled welding cables
around shoulders, or any other part of
the body, when they are plugged into the
welder.
tDo not modify any wiring, ground
connections, switches, or fuses in this
welding equipment.
tWear welding gloves to help insulate
hands from welding circuit.
tKeep all liquid containers far enough
away from the welder and work area so
that if spilled, the liquid can not possibly
come in contact with any part of the
welder or electrical welding circuit.
tReplace any cracked or damaged parts
that are insulated or act as insulators
such as welding cables, power cord, or
electrode holder IMMEDIATELY.
FLASH HAZARDS
WARNING
ARC RAYS CAN INJURE EYES AND BURN
SKIN! To reduce the risk of injury from arc
rays, read, understand, and follow the fol-
lowing safety instructions. In addition, make
certain that anyone else that uses this weld-
ing equipment, or is a bystander in the
welding area understands and follows these
safety instructions as well. Headshields and
lter should conform to ANSI Z87.1 stan-
dards.
tDo not look at an electric arc without
proper protection. A welding arc is
extremely bright and intense and, with
inadequate or no eye protection, the
retina can be burned, leaving a perma-
nent dark spot in the eld of vision. A
shield or helmet with a number 10 shade
lter lens (minimum) must be used.
tDo not strike a welding arc until all
bystanders and you (the welder) have

6
welding shields and/or helmets in place.
Do not wear a cracked or broken
helmet and replace any cracked or bro-
Do not allow the uninsulated portion
of the wire feed gun to touch the ground
clamp or grounded work to prevent an
Provide bystanders with shields or hel-
Wear protective clothing. The intense light
of the welding arc can burn the skin in
much the same way as the sun, even
through light-weight clothing. Wear dark
clothing of heavy material. The shirt worn
should be long sleeved and the collar kept
buttoned to protect chest and neck.
Protect against REFLECTED ARC RAYS. Arc
such as a glossy painted surface, alu-
minum, stainless steel, and glass. It is
possible for your eyes to be injured by
protective helmet or shield. If welding
with
tive background exists in your welding
area, either remove it or cover it with
cause skin burn in addition to eye injury.
FIRE HAZARDS
WARNING
FIRE OR EXPLOSION CAN CAUSE DEATH,
INJURY, AND PROPERTY DAMAGE! To
reduce the risk of death, injury, or property
stand, and follow the following safety
instructions. In addition, make certain that
anyone else that uses this welding equip-
ment, or is a bystander in the welding area,
understands and follows these safety
instructions as well. REMEMBER! Arc welding
by nature produces sparks, hot spatter,
molten metal drops, hot slag, and hot metal
damage eyes.
Do not wear gloves or other clothing that
contains oil,
substances.
tions.
Do not weld in an area until it is checked
mable materials. BE AWARE that sparks
through small cracks and openings. If
work and combustibles cannot be sepa-
rated by a minimum of 35 feet, protect
Do not weld on walls until checking for
and removing combustibles touching the
other side of the walls.
Do not weld, cut, or perform other such
work on used barrels, drums, tanks, or
other containers that had contained a
stance and vapors, to make a used con-
tainer safe for welding or cutting, are
quite complex and require special edu-
cation and training.
Do not strike an arc on a compressed
gas or air cylinder or other pressure ves-
sel. Doing so will create a brittle area
that can result in a violent rupture imme-
diately or at a later time as a result of
rough handling.
Do not weld or cut in an area where the
(such as
grain dust), gas, or liquid vapors (such as
gasoline).
Do not handle hot metal, such as the
work piece or electrode stubs, with bare
hands.
Wear leather gloves, heavy long sleeve
shoes, helmet, and cap. As necessary,
use additional protective clothing such as
leggings, or apron. Hot sparks or metal
can lodge in rolled up sleeves, trouser
should be kept buttoned and pockets
eliminated from the shirt front.
for immediate use! A portable chemical
mended.
Wear ear plugs when welding overhead to

7
prevent spatter or slag from falling into ear.
tMake sure welding area has a good,
solid, safe oor, preferably concrete or
masonry, not tiled, carpeted, or made of
any other ammable material.
tProtect ammable walls, ceilings, and
oors with heat resistant covers or
shields.
tCheck welding area to make sure it is free
of sparks, glowing metal or slag, and
ames before leaving the welding area.
FUME HAZARDS
WARNING
FUMES, GASSES, AND VAPORS CAN
CAUSE DISCOMFORT, ILLNESS, AND
DEATH! To reduce the risk of discomfort, ill-
ness, or death, read, understand, and follow
the following safety instructions. In addition,
make certain that anyone else that uses this
welding equipment or is a bystander in the
welding area, understands and follows
these safety instructions as well.
tDo not weld in an area until it is checked
for adequate ventilation as described in
ANSI standard #Z49.1. If ventilation is
not adequate to exchange all fumes and
gasses generated during the welding
process with fresh air, do not weld unless
you (the welder) and all bystanders are
wearing air-supplied respirators.
tDo not heat metals coated with, or that
contain, materials that produce toxic
fumes (such as galvanized steel), unless
the coating is removed. Make certain the
area is well ventilated, and the operator
and all bystanders are wearing air-sup-
plied respirators.
tDo not weld, cut, or heat lead, zinc, cad-
mium, mercury, beryllium, or similar
metals without seeking professional
advice and inspection of the ventilation
of the welding area. These metals pro-
duce EXTREMELY TOXIC fumes which can
cause discomfort, illness, and death.
tDo not weld or cut in areas that are near
chlorinated solvents. Vapors from chlori-
nated hydrocarbons, such as
trichloroethylene and perchloroethylene,
can be decomposed by the heat of an
electric arc or its ultraviolet radiation.
These actions can cause PHOSGENE, a
HIGHLY TOXIC gas to form, along with
other lung and eye-irritating gasses. Do
not weld or cut where these solvent
vapors can be drawn into the work area
or where the ultraviolet radiation can
penetrate to areas containing even very
small amounts of these vapors.
tDo not weld in a conned area unless it
is being ventilated or the operator (and
anyone else in the area) is wearing an
air-supplied respirator.
tStop welding if you develop momentary
eye, nose, or throat irritation as this indi-
cates inadequate ventilation. Stop work
and take necessary steps to improve ven-
tilation in the welding area. Do not
resume welding if physical discomfort
persists.
COMPRESSED GASSES AND
EQUIPMENT HAZARDS
WARNING
IMPROPER HANDLING AND
MAINTENANCE OF COMPRESSED GAS
CYLINDERS AND REGULATORS CAN
RESULT IN SERIOUS INJURY OR DEATH!
To reduce the risk of injury or death from
compressed gasses and equipment hazards,
read, understand, and follow the following
safety instructions. In addition, make certain
that anyone else who uses this welding
equipment or a bystander in the welding
area understands and follows these safety
instructions as well.
tDo not use ammable gasses with MIG
welders. Only inert or nonammable
gasses are suitable for MIG welding.
Examples are Carbon Dioxide, Argon,
Helium, etc. or mixtures of more than
one of these gasses.
tDo not attempt to mix gasses or rell a
cylinder yourself. Do not expose cylin-
ders to excessive heat, sparks, slag and
ame, etc. Cylinders exposed to temper-
atures above 130°F will require water
spray cooling.

8
tDo not expose cylinders to electricity of
any kind.
tDo not use a cylinder or its contents for
anything other than its intended use. Do
not use as a support or roller.
tDo not locate cylinders in passageways
or work area where they may be struck.
tDo not use a wrench or hammer to open
a cylinder valve that cannot be opened
by hand. Notify your supplier.
tDo not modify or exchange gas cylinder
ttings.
tDo not deface or alter name, number or
other markings on a cylinder. Do not rely
on cylinder color to identify the contents.
tDo not connect a regulator to a cylinder
containing gas other than that for which
the regulator was designed.
tDo not attempt to make regulator repairs.
Send faulty regulators to manufacturer’s
designated repair center for repair.
tDo not attempt to lubricate a regulator.
tAlways change cylinders carefully to pre-
vent leaks and damage to their walls,
valves, or safety devices.
tAlways secure cylinders with a steel chain
so that they cannot be knocked over.
tAlways protect a cylinder, especially the
valve, from bumps, falls, falling objects
and weather. Remember that gasses in
the cylinders are under pressure and
damage to a regulator can cause the
regulator or portion of the regulator to
be explosively ejected from the cylinder.
tAlways make certain the cylinder cap is
securely in place on the cylinder, when-
ever the cylinder is moved.
tAlways close the cylinder valve and
immediately remove a faulty regulator
from service, for repair, if any of the fol-
lowing conditions exist.
tGas leaks externally.
tDelivery pressure continues to rise with
down stream valve closed.
tThe gauge pointer does not move o the
stop pin when pressurized or fails to
return to the stop pin after pressure is
released.
WARNING
This product contains chemicals, including
lead, or otherwise produces chemicals
known to the State of California to cause
cancer, birth defects and other reproductive
harm. Wash hands after Handling.
(California Health & Safety Code Sec.
25249.5 et seq.)
ADDITIONAL SAFETY INFORMATION
For additional information concerning weld-
ing safety, refer to the following standards
and comply with them as applicable.
tANSI Standard Z49.1 – SAFETY IN
WELDING AND CUTTING – obtainable
from the American Welding Society, 550
NW Le Jeune Road, Miami, FL 33126
Telephone [phone], Fax (305)
443-7559 – www.amweld.org or
www.aws.org
tANSI Standard Z87.1 – SAFE PRACTICE
FOR OCCUPATION AND EDUCATION-
AL EYE AND FACE PROTECTION –
obtainable from the American National
Standards Institute, 11 West 42nd St.,
New York, NY 10036 Telephone (212)
642-4900,
Fax [phone] – www.ansi.org
tNFPA Standard 51B – CUTTING AND
WELDING PROCESS – obtainable from
the National Fire Protection Association,
1 Batterymarch Park, P.O. Box 9101,
Quincy, MA 02269-9101 Telephone
[phone]
Fax [phone] – www.nfpa.org
tOSHA Standard 29 CFR, Part 1910,
Subpart Q., WELDING, CUTTING AND
BRAZING – obtainable from your state
OSHA oce or U.S. Dept. of Labor
OSHA, Oce of Public Aairs, Room
N3647, 200 Constitution Ave.,
Washington, DC 20210 –
www.osha.gov
tCSA Standard W117.2 – Code for
SAFETY IN WELDING AND CUTTING. –
obtainable from Canadian Standards
Association, 178 Rexdale Blvd.,
Etobicoke, Ontario M9W 1R3 –
www.csa.ca
tAmerican Welding Society Standard
A6.0. WELDING AND CUTTING CON-
TAINERS WHICH HAVE HELD COM-
BUSTIBLES. – obtainable from the
American Welding Society, 550 NW Le
Jeune Road, Miami, FL 33126
Telephone [phone], Fax (305)
443-7559 – www.amweld.org or
www.aws.org

9
WELDER SPECIFICATIONS
DESCRIPTION
Your new MIG (GMAW) core (FCAW)
wire feed welder is designed for mainte-
nance and sheet metal fabrication. The
welder consists of a single-phase power
transformer, stabilizer, ,anda
unique built-in control/feeder.
Now you can weld sheet metal from 24
gauge up to 1/4 inch thick with a single
pass. You can weld thicker steel with bevel-
ing and multiple pass techniques. Table 1
lists your MIG welder
Table 1. Welder
Primary (input) Volts 230V AC
Primary (input) Amps 22.5
elgniSesahP
Frequency 60 Hz
Secondary (output) volts 20
CSA rated output amps 120
Open Circuit Volts (Max.) 30V DC
Duty Cycle Rating 25%
WELDER OPERATING
CHARACTERISTICS
DUTY CYCLE
The duty cycle rating of a welder show
long the operator can weld and how long the
welder must be rested and cooled. Duty cycle is
expressed as a percentage of 10 minutes and
represents the maximum welding time allowed.
The balance of the 10-minute cycle is required
for cooling. Your new welder has a duty cycle
rating of 25% at the rated output. This means
that you can weld for two-and-a-half (2.5) min-
utes out of 10 with the remaining seven-and-a-
half (7.5) minutes required for cooling. (See
Table 2).
Table 2. Duty Cycle Ratings
Duty Maximum Required
Cycle Welding Resting
Rating Time Time
20% 2 minutes 8 minutes
25% 2.5 minutes 7.5 minutes
40% 4 minutes 6 minutes
60% 6 minutes 4 minutes
80% 8 minutes 2 minutes
100% 10 minutes 0 minutes
INTERNAL THERMAL PROTECTION
CAUTION
Do not constantly exceed the duty cycle or
damage to the welder can result. If you
exceed the duty cycle of the welder, an inter-
nal thermal protector will open, shutting
all welder functions except the cooling fan. If
this happens, DO NOT SHUT OFF THE
WELDER. Leave the welder turned on with
the fan running. After cooling, the thermal
protector will automatically reset and the
welder will function normally again.
However you should wait at least ten min-
utes after the thermal protector opens
before resuming welding. You must do this
even if the thermal protector resets itself
before the ten minutes is up or you may
experience less than duty cycle
performance.
If you that the welder will not weld for
two minutes without stopping, reduce the
wire speed slightly and tune in the welder at
the lowest wire speed setting that still pro-
duces a smooth arc. Welding with the wire
speed set too high causes excessive current
draw and shortens the duty cycle.
This MIG welder, equipped with gas, is capable
of welding with .023” (0.6mm) and .030” (0.8mm)
solid steel wire using DC reverse polarity, and with
.030” (0.8mm) and .035” (0.9mm) self shielded
diameter solid steel wire .035”(0.9mm) using DC
reverse polarity may also be used. Welding with
larger than .035” (0.9mm) is not recommended.

10
KNOW YOUR WELDER
Handle – Rugged, top mounted handle
allows for easy transport of your welder.
Wire Speed Control – Use this dial to adjust
the speed at which the welder feeds wire to the
gun. 1 is the slowest wire feed speed, 10 is the
highest. You will need to adjust or “tune-in”
your wire speed for dierent welding conditions
(thickness of metals, gas -vs- gasless welding,
metal type, wire size, etc.). When the wire speed
is properly “tuned-in” the welding wire will melt
into the material you are welding as quickly as
it is fed through the welding gun.
Voltage Selector – The voltage selectors
control the weld heat. There are six voltage
heat selections available on this welder. Lower
voltage (less heat) is achieved by setting the
Voltage Selector Switch to the MIN position
and/or the Voltage Selector Dial to a lower
number. Higher voltage (more heat) is
achieved by setting the Voltage Selector
Switch to the MAX position and/or the
Voltage Selector Dial to a higher number.
Dierent materials and material thickness will
require dierent voltage settings. You will
need to adjust your voltage accordingly for
dierent welding conditions. By properly
adjusting your voltage settings and wire feed
speed, you will enable clean, precision welds.
(Refer to the Suggested Settings Chart on p.33
of this manual OR on the inside of the door of
the welder.)
Power Switch – This switch turns the welder
ON and OFF. (Make sure the power switch is
in the OFF position before performing any
maintenance on the welder.)
Power Cord – This is a standard, 230 volt
power cord with a NEMA 6-50P 50 amp
plug. (Make sure you are using a properly
grounded 230 VAC, 60Hz, single phase, 50
amp power source.)
Ground Clamp – Attaching the ground
clamp to your work piece “completes” the
welding current circuit. You must attach the
ground clamp to the metal you are welding.
If the ground clamp is not connected to the
metal work piece you intend to weld, the
welder will not have a completed circuit and
you will be unable to weld. A poor connec-
tion at the ground clamp will waste power
and heat. Scrape away dirt, rust, scale, oil or
paint before attaching the ground clamp.
Ground Cable – The ground cable connects
the ground clamp to the internal workings of
the welder.
Welding Gun and Cable – The welding gun
controls the delivery of the welding wire to the
material to be welded. The welding wire is fed
through the welding cable and welding gun
when the welding gun trigger is pulled. You will
need to install a contact tip and welding nozzle
to the end of the welding gun, as described
later in this manual, prior to welding.
Welding Terms
Now that you are familiar with the main
parts of the welder, make note of the follow-
ing terms. You will see them used through-
out this manual.
Weld puddle:The localized volume of molten
metal in a weld prior to its solidication.
Weld angle:The angle of the welding wire,
as it extends from the welding gun, in rela-
tion to the item being welded.
Slag:The protective coating that forms on
the surface of molten metal.
Arc:A sustained luminous discharge of elec-
tricity across a gap in a circuit.
Weldingbead:The extended build up of a weld,
made by pushing or pulling the weld puddle.
Figure 1. Model Cat. 3175
Welding Gun
Ground
Clamp
Power
Cable
Ground
Cable
Voltage
Selector
Dial
Power
Switch
Wire
Speed
Gun
Cable
Handle
Voltage Selector Switch