Ready Welder 10000 User manual

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READY WELDER II
TABLE OF CONTENTS
Warranty Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
Frequently Asked Questions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Important Operating Tips . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Thin Metal Welding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Wire Spool Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Loading the Ready Welder II . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Welding Aluminum . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Connecting Your RW-II to Batteries . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Connecting to DC/CV Power Source & Engine Drives . . . . . . . . . . . . 9
Connecting to DC/CC Engine Drives & Stick Machines . . . . . . . . . . . . 9
Connecting to Premier Power Welder & Other Alternator Systems . . . 10
MIG Machine As The RW-II Power Source . . . . . . . . . . . . . . . . . . . 11
Diagrams For Battery Connections . . . . . . . . . . . . . . . . . . . . . . . 11-12
Diagrams For Connection to CV MIG Machine . . . . . . . . . . . . . . . 13-14
Diagrams For Connection to CC Stick Welder . . . . . . . . . . . . . . . 14
Routine Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Recommended Periodic Mantenance . . . . . . . . . . . . . . . . . . . . . . 15
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Applications Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Assembly Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . Back Cover
FOR ADDITIONAL ASSISTANCE, CONTACT US AT [phone]
FOR ADDITIONAL ASSISTANCE, CONTACT US AT: [phone]

1
WARRANTY INFORMATION
This Limited Warranty supercedes all previous RW-II warranties and is exclusive, with no other guarantees or war-
ranties expressed or implied.
Your RW-II is warranted to be free from defects in material and workmanship for a period of one year from the date
of the original purchase (proof of purchase required). This warranty covers only failures due to defects in material
or workmanship which occurs during normal use, and does not cover damage which occurs in shipment, or failures
which result from accident, misuse, abuse, neglect, mishandling, misapplication, alteration, or modication of the
product, or damage that is attributable to acts of God.
The warrantor shall not be responsible for any incidental or consequential damages resulting from the use of this
product, or arising out of any breach of this warranty. All express and implied warranties, including the warranties or
merchantability and tness for a particular purpose, are limited to the applicable warranty period set forth above.
IMPORTANT NOTICE: Certain states do not allow the exclusion or limitation of incidental or consequential dam-
ages or limitations to the length of an implied warranty, therefore the above exclusions or limitations may not apply
to you. This warranty gives you specic legal rights, and you may also have other rights, which vary from state to
state.
SAFETY
READ THESE WARNINGS - PROTECT YOURSELF AND OTHERS
BE AWARE, SERIOUS INJURY OR DEATH MAY RESULT if welding or cutting equipment is not properly
installed, used, and maintained. Misuse of this equipment and other practices can be both hazardous and dangerous to
the operator and any persons in the general work area. The operator, supervisor, and helper must read and understand
the following safety warnings and instructions before installing or using any welding or cutting equipment.
The welding and/or cutting process is used in many potentially dangerous and hazardous conditions. In environments
such as elevated heights, areas of limited ventilation, close quarters, around water, uncertain power sources, in hostile
environments, etc., it is important that the operators are aware of the dangers and limitations associated with work-
ing in these types of conditions. Only properly trained and experienced operator(s) trained in safe practices for the
environments in which they are expected to work and are under competent supervision should use this welder. It is
essential that the operator, supervisor, and others in the work areas are aware of the dangers of the welding or cutting
process. Training and supervision are both important and necessary for a safe work place. Please keep these instruc-
tions for future use and reference.
BE AWARE, THE FOAM IN THE RW-II CASE IS FLAMMABLE
Make sure the case is a sufcient distance from welding and cutting activity and is closed to avoid sparks, slag, or
any hot material from coming in contact with the foam.
ELECTRIC SHOCK CAN CAUSE INJURY OR DEATH
Install and maintain equipment in accordance with the National Electric Code NFPA 70 and local codes. Do not ser-
vice or repair equipment with power on or batteries connected. Do not operate equipment with protective insulators
or covers removed. Service or repair to equipment must be done by qualied and/or trained personnel only.
Operator should not and must not contact electrically live parts. Do Not touch electrode with bare skin and elec-
trical ground at the same time. Always wear dry welding gloves in good condition. Be aware aluminized protective
clothing can become part of the electrical path. Keep oxygen cylinders, chains, wire ropes, cranes, hoists, and eleva-
tors away from any part of the electrical path. All ground connections must be checked periodically to determine that
they are mechanically strong and electrically adequate for the required current. When welding is to be suspended for
any sustained period of time, such as during lunch or overnight, the READY WELDER II should be disconnected
from its arc current power source when not in use. Never immerse MIG guns, electrode holders, TIG torches,
plasma torches, or electrodes in water.

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2
SAFETY (continued)
BE AWARE, ARC RAYS, HOT SLAG AND SPARKS CAN AND DO CAUSE INJURIES TO EYES
AND SKIN
The welding and/or cutting processes produce extreme localized heat and strong ultraviolet rays. Never attempt to
weld and/or cut without proper welding equipment, including, but not limited to, a welding helmet with the proper
lens, which complies with federal guide lines. A number 12 to 14 shade lter lens on the helmet provides the best
protection against arc radiation . Please note that in a conned area prevent the reected arc rays from entering around
the helmet. It is important to make sure others are protected from arc rays and sparks. Approved shielding curtains
and/or appropriate goggles should be used by all persons working in the close vicinity of the welding area to provide
protection to others in the surrounding area and operators of nearby equipment. Skin should and must also be pro-
tected from arc rays, heat and molten metal. The operator must always wear protective gloves and clothing which
will not allow skin to become exposed. All clothing pockets should be closed and cuffs sewn shut. Leather aprons,
sleeves, leggings, etc. should and must be worn for out-of-position welding and/o r cutting. High top work shoes
provide adequate protection from foot burns; for added protection, use leather spats. Flammable hair products should
not be used when welding and/or cutting. Where the work permits, the operator should be enclosed in an individual
booth painted with a nish of low reectivity such as zinc oxide, an important factor for absorbing ultraviolet radia-
tion, and lamp black, or shall be enclosed with non-combustible screens similarly painted.
BE AWARE, WELDING SPARKS CAN AND DO CAUSE FIRES AND EXPLOSIONS
Causes of re and explosions are: combustibles reached by the arc, ame, ying sparks, hot slag or heated materi-
als. Remove combustible materials and items from the work area and/or provide a re watch. Avoid oily or greasy
clothing as a spark may ignite them. It is necessary and required that the operator have a re extinguisher nearby and
have knowledge and training in it’s use. Be aware and alert to the danger of conduction or radiation. For example , if
welding and/or cutting is to be done on a metal wall, partition, ceiling or roof, precautions must be taken to prevent
ignition of combustibles on the other side. Do not weld and/or cut containers that have held combustibles. All hollow
spaces, cavities and containers should be and must be vented prior to welding and/or cutting to permit the escape of
air or gases. Purging with inert gas is recommended. Use only inert gases or inert gas mixes as required by the pro-
cess. Use of combustible compressed gases can cause explosions resulting in personal injury or death. Arcing against
any compressed gases can cause explosions resulting in personal injury or death.
1. Code of Federal Regulations, (OSHA) Section 29 Part 1910.95, 132-134, 251-254 and 1000. U.S. Government
Printing Ofce, Washington, D.C. 20402
2. ANSI Z49.1 “Safety in Welding and Cutting”
3. ANSI Z87.1 “Practice of Occupational and Educational Eye and Face Protection”
4. ANSI Z88.2 “Standard Practice for Respiratory Protection”, American National Standard Institute, 1430 Broad
way, New York, NY 10018
5. AWS F4. 1 “Recommended Safe Practices for Welding and Cutting Containers”, The American Welding Soci-
ety, 550 NW Lejeune Road, P.O. Box 351040, Miami, FL 33135
6. NFPA 51B “Fire Prevention in Cutting and Welding Processes”
7. NFPA-7 “National Electrical Code “National Fire Protection Association, Battery Park, Quincy, MA 02269
8. CSA Standard W117.2 “Safety in Welding, Cutting and Allied Processes” Canadian Standards Association, 178
Rexdale, Ontario, Canada M9W 1R3
SAFETY AND OPERATION REFERENCES

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FREQUENTLY ASKED QUESTIONS
Below you will nd answers to the most “frequently asked questions” regarding RW-II, the DC Powered MIG Welder
/ Spool Gun. If you have any additional questions, call us at [phone] between 8 AM and 5 PM PST on week-
days.We hope this information will help you to obtain the highest level of satisfaction from your RW-II.
1. How long of welding duration time will I get out of a pair of batteries before I
will need to recharge them? Many factors will determine the length of acceptable quality welding
duration time, with the primary factors being the the type and size of batteries used and the type of welding be-
ing performed. The thicker the metal being welded the greater the amperage draw needs to be in order to obtain
satisfactory results,which will drain the batteries faster. The size and amp hour ratings of the batteries used will
determine the total amount of power available and thus the welding time available, We recommend a deep cycle gel
cell battery, like Optima Batteries offers, or at least a group 31 marine deep cycle battery as a power source for the
Ready Welder II. A fully charged pair of these batteries will normally yield a minimum duration of about 45 min-
utes when welding 1/2” steel or 3/4” aluminum @ approximately 175 amps, while lighter duty welding operations
on thinner metal can offer a duration time of 4 hours or more. Please see the operating tips in your Owner’s Manual
for more battery discussion.
2. What type of batteries and charger should I buy, and what type of maintenence
do I need to perform on the batteries? We highly suggest the purchase and investment of good
quality 12DCV deep-cycle marine or RV batteries, ranging from group 24 to group 31, which is our preference. Our
recommendation is Optima Batteries, they have a few deep cycle options to choose from. Their gel cell batteries will
give you reliable power and a longer life. If you get one with vertical posts capped with wing-nuts, you will have easy
power connections to the RW-II. Regular auto batteries and other batteries not designed for deep cycle discharging
and recharging will have a shorter life span if drawn too low too many times, for occasional or recreational welding
this shouldn’t be a problem. For home use, a 10 amp overnight charging will work well. Maintenance of batteries
should be according to manufacturer’s instructions.
3. Does the trigger control power to the tip? Depends on which model you are speaking of. If it is
a model with a “-CS” at the end of the model number, then the answer is YES, IT DOES. The cold switch upgrade
includes a solenoid system integrated into the cable of the gun near the quick disconnects. This solenoid system is
designed as a safety switch only, and does not affect any other function of the RW-II. On the non-CS models, the trig-
ger only controls wire feed (on-off) and gas ow. The tip is live whenever the RW-II is connected to power source.
The red plastic connectors in the RW-II power cable are designed to be easily disconnected to de-power the welder
between uses without having to disconnect the cables at the power source.
4. Does the wire feed speed control knob adjust the amperage level fed to the
electrode? The wire feed speed control knob indirectly affects amperage based upon the speed and physical
volume of wire being fed to the bead. The amount of wire fed to the bead is directly proportional to the ultimate am-
perage level delivered to the weld . The diameter of the feed wire will also affect the total amperage level delivered
to the welding bead. The larger the wire the hotter it will burn as with the faster the feed rate the hotter the weld.
5. I’ve got two 12 volt batteries under the hood of my vehicle. Can I hook up the
RW-II to these with the motor running and battery cables still connected? No, it is
not recommended as batteries are normally wired in 12V parallel for these applications (except 24V equipment) and
the RW-II prefers a minimum of 18V for welding metal thicker than thin sheet metal, which means the two batteries
must be wired in series to yield 24V. Leaving the batteries connected to the vehicle’s electrical system while you’re
operating a RW-II may cause severe damage to the vehicle’s electrical components. Many auto parts stores sell
“quick disconnect” battery terminals which come in handy for these types of situations. Please isolate the batteries
electrically from the vehicle when welding, and especially when welding on the vehicle itself using ux-cored wire,
as this operation uses positive ground.
6. Can I connect the RW-II to my Arc or MIG Welder to use a “spool gun” attach-
ment? Some RW-II models include an AC/DC power supply to power the circuitry of the gun. It is only required
when connected to CC/stick welders and was specically designed for these types of applications. However, it is rec-
ommended for use when connecting to CV MIG machines as well. While using the AC/DC power supply provided,
the RW-II can safely be used with any DC output welding machine. Do not connect the RW-Il directly to constant
current welding machines without the use of the AC/DC power supply. The power supply must be connected in the
same polarity as the arc current. The use of the power supply is not mandatory when connecting to CV machines
with output ranging from 18V to 40V DC, or batteries.