Badger Welder B22 User manual

Revision A – January 5, 2023 - Refer to www.badgerwelder.com for latest revision
B22 Extended Power Pack
Operations Manual
TM

Revision A – January 5, 2023 - Refer to www.badgerwelder.com for latest revision
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Table of Contents
1. Product Features
2. Warranty Information
Limited Warranty
Warranty Claims and Repair Services
3. Safety
Be Aware of Your Surroundings
Electric Shock Can Cause Death
Personal Protective Equipment
Avoid Vehicle Damage
4. Initial Setup
Unpacking
5. Operation
Setup Instructions
6. Routine Maintenance
Inspecting For Damaged Parts
Maintenance
Battery Replacement
7. Charging
Overview
120 Volt AC Charging
12 Volt DC Vehicle Charging
USB and USB-C Charging Ports
Revision History
Revision A – January 5, 2023
Initial release

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Section 1.
Product Features
Extended Welding Time and Improved Weld Quality
The B22 Extended Power Pack is intended for use as an accessory for your 24 Volt Badger Welder. It is
designed for portability and quick setup to extend the welding time and even improve the weld quality
of your Badger Welder. Additionally, this Power Pack includes USB and USB-C ports and can provide
over 100,000mAh of charging power to your mobile devices.
Made in USA
Badger Welders and Extended Power Packs are engineered and built in Wisconsin using an IP67 rated
American-made hard case, with internal components manufactured from powder-coated steel for
durability and long life. Our Welders and Power Packs are quality-built and factory-backed.
Section 2.
Warranty Information
Limited Warranty
The M22 Extended Power Pack is warranted to be free from defects in materials and workmanship for a
period of one year from the date of the original retail purchase. This warranty does not cover part
failure or damage due to accidents, shipping, normal wear, abuse, improper use, modification, failure to
properly maintain the product, or damage caused by acts of God. Badger Welder, LLC, and its suppliers
shall not be responsible for any incidental or consequential damages resulting from the use or misuse of
this product or arising out of any breach of this warranty. No other express or implied warranties are
covered, including merchantability or fitness for a particular purpose.
Within the one-year warranty period, Badger Welder, LLC will repair or replace any warranted parts or
components that fail due to defects in materials or workmanship, provided that Badger Welder, LLC is
notified by email within 30 days of such defect or failure. This warranty does not cover consumables,
including the batteries. Any attempt to open or service this product without prior instructions from
Badger Welder, LLC will void this warranty.
Warranty Claims or Repair Services
For warranty claims or any repair services requested, please contact us by email at:
[email protected]
Please include the following information in your email:
Your name
Your phone number
Product serial number
Date and location of purchase
A brief description of any problems or services requested

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Section 3.
Safety
WARNING: READ AND UNDERSTAND THIS ENTIRE MANUAL BEFORE USE! Keep a printed copy with the
Power Pack and routinely verify if there are any revisions by checking at www.badgerwelder.com. This
product is a low-voltage battery pack, however, BE AWARE THAT SERIOUS INJURY OR DEATH MAY
RESULT if welding equipment is not properly installed, used, and maintained.
Be Aware of Your Surroundings
WELDING CAN CAUSE FIRES AND EXPLOSIONS. Sparks and weld spatter produced by welding
can ignite fuels, gasses, leaves, brush, or other flammable materials. Carefully check the work
area for any flammable materials nearby. Always keep a FIRE EXTINGUISHER nearby.
Be aware of OTHER PEOPLE around the work area. Make them aware of the dangers of sparks,
weld spatter, fumes, electricity, or looking at the welding arc.
Mobile working conditions can present other hazards that are not covered in these safety
guidelines. Make yourself aware of the inherent risks of welding and carefully review the work
area to determine if there are any risks of damage, personal injury, or death. You are ultimately
responsible for ensuring a safe work area.
Electric Shock Can Cause Death
Before replacing any consumables, turn the Power Switch OFF. If servicing the welder or
changing polarity, turn the Power Switch off AND disconnect the Main Battery Fuse located
under the Spool Mounting Plate.
Never touch the welding tip or ground clamp with bare hands when the power is ON.
Never perform any service with any external power sources connected to the welder.
Do not operate the welder if the Spool Mounting Plate is not securely in place.
Do not use the welder in wet environments. Never immerse any part of the welder or
workpiece in water.
Personal Protective Equipment
Welding processes produce extreme heat and strong ultraviolet rays. Protect your eyes with a
proper welding helmet. Protect your head and all exposed skin from sparks and UV rays to
prevent burns.
Always wear dry welding gloves in good condition.
Avoid Vehicle Damage
If welding on a vehicle, ALWAYS disconnect that vehicle’s POSITIVE and NEGATIVE battery cables
to avoid damage to the vehicle’s electrical systems.
If using vehicle batteries to power the welder, they MUST BE DISCONNECTED AND REMOVED
from the vehicles.
ALWAYS place the welder ground clamp on the same metal component that you are welding on
to ensure that the welder’s electrical path is not going through your vehicle’s electrical wires,
brake lines, fuel lines, or other components.
DO NOT weld on or near a vehicle that is leaking fuel or oil.
DO NOT attempt to jump start a vehicle with this welder.

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Section 4.
Initial Setup
Unpacking
The B22 Extended Power Pack is shipped with the batteries fully charged and is ready to use with no
additional setup required. If this Extended Power Pack was shipped to you, we recommend saving the
box and shipping materials in the event that any warranty service or other repairs are required.
Section 5.
Operation
Setup Instructions
*NOTE: This Power Pack is always on and does not require operation of a power switch.
STEP 1: Start with the Welder Power Switch in the OFF/EXTERNAL BATTERY position.
STEP 2: Connect the included Bridge Cable to the Welder and the Power Pack.
STEP 3: Follow startup instructions for the Welder.
*NOTE: With the Welder Power Switch in the OFF/EXTERNAL BATTERY position, the welder will be
powered from the Extended Power Pack ONLY. If all batteries are fully charged, with the Welder Power
Switch in the INTERNAL BATTERY WELD position, the welder will be powered from the Welder AND
Extended Power Pack together which can double the weld time and improve weld quality.
Section 6.
Routine Maintenance
Inspecting for Damage or Wear
Before each use, inspect the Power Pack for damage or excessive wear. DO NOT turn on or use the
Power Pack if there are any exposed or broken wires or any missing components or parts. DO NOT turn
on or use the Power Pack if it is wet or there are any signs of moisture inside of the case.
Maintenance
To extend the life of the Power Pack, vacuum out any dirt or dust and wipe down surfaces with a dry
cloth. Recharge the batteries after any use and keep the batteries fully charged as much as possible.
Battery Replacement
With proper use and charging, the batteries should last several years. Batteries can be replaced by the
user, by Badger Welder, LLC, or by one of our service centers. Please contact Badger Welder LLC for
battery replacement instructions or a list of service centers. To avoid damage to Power Pack and
possible personal injury, do not attempt to open the case without instructions. Opening the case
without instructions from Badger Welder, LLC will void the warranty.

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Section 7.
Charging
Overview
The B22 Extended Power Pack uses AGM batteries that are rated at 24 Volts DC. A full charge may show
over 26 volts, and the normal operating range for welding is between 24 and 27 volts. For optimal
welding, you may need to recharge the batteries when they reach 24 volts or connect the welder to
external batteries for additional welding time.
120 Volt AC Charger
The B22 Extended Power Pack does not include its own charger, but instead uses the 120 Volt AC
charger that was included with your Badger Welder. If you would like an additional charger, or your
charger is lost or damaged, a replacement can be found at www.badgerwelder.com or at most battery
supply stores or even pharmacies and retailers that sell electric wheelchairs and scooters. Make sure
the charger is a Fully Automatic Smart Charger designed for 24 Volt AGM batteries and utilizes a 3-pin
XLR connector.
The XLR Charging Port is located on the outside front of the case, to the right of handle. To charge,
simply plug in the 24 Volt DC Smart Charger and follow the Charger manufacturer’s instructions included
with the Charger. When charging is complete, unplug the Charger from the Power Pack. Charging time
will vary based on battery level, but typically takes between 3 and 4 hours. The charging circuit is
protected by a pop-up circuit breaker located on the control panel.
12 Volt DC In-Vehicle Charging
The B22 Extended Power Pack can also be recharged from a 12 Volt DC vehicle. To do this, plug the
supplied 120 Volt AC Smart Charger into the vehicle’s 400w 120 Volt AC outlet if available, or simply use
a portable 400w DC to AC inverter available at www.badgerwelder.com or at most auto supply stores, or
other stores that sell vehicle accessories.
Be sure that the vehicle is running to prevent draining of the vehicle battery. Plug the 400w inverter
into the vehicle’s cigarette plug, then plug the supplied AC charger into the inverter and follow the
instructions above for the 120 Volt AC charger. In-vehicle charging times will be similar to using the 120
AC charger alone.
USB and USB-C Charging Ports
The B22 Extended Power Pack includes a dual Charging Port with one USB and one USB-C port. A fully
charged Power Pack can deliver over 100,000mAh of charge to your portable devices. To use these
ports, press the Power Button located on the USB Port. The USB ports will light up to indicate they are
on. When you are done charging your devices, press the power button to shut off the USB ports to
avoid a very slow drain of the batteries. Be aware that use of the USB ports can drain the batteries
below the voltage needed for welding and could extend the recharging time.