WP MIG 135i User manual

OWNER'S MANUAL
Arc Welding Machine
WP 135i
WP 165i
EN 60 974-1
EN 60 974-10
Dear customer
We congratulate You for buying our top-
quality welding device. You
are kindly asked to carefully read this manual, to assure faultless
operation. Take special care
in complying with Safety
Instructions.
Dear customer
We congratulate You for buying our quality welding device. You are
kindly asked to carefully read this manual, to assure faultless operation.
Take special care in complying with Safety Instructions.
Weldpartner
Gompenstraat 9
5145 RM Waalwijk
www.weldpartner.nl

Weldpartner Nederland
Gompenstraat 9
5145 RM Waalwijk
DECLARATION OF CONFORMITY
We, Weldpartner a company of elektrolas, Gompenstraat 9, waalwijk, the
netherlands declare that the arc welding machines described in this manual:
- WP 135i
- WP 165i
are designed and produced according to the following EU - Directives:
- Low Voltage Directive, No.: 2006/95/ EEC
- EMC Directive, No.: 2004/108/ EEC with their amendments
and inspected according to following EU - Norms:
- EN 60 974-1
- EN 60 974-10
Every intervention on these machines from an unauthorized person makes this
Declaration invalid.
Waalwijk, 03 July 2015 Weldpartner Nederland
Joost van den Hooven
CONTENTS

1. SAFETY PRECAUTIONS – READ BEFORE USEG ......................................................................... 1
S YMBOL USAGE ................................................................................................................................................... 1
A RC W ELDING H AZARDS ..................................................................................................................................... 1
A DDITIONAL S YMBOLS FOR I NSTALLATION , O PERATION , AND M AINTENANCE ................................................... 4
EMF I NFORMATION ............................................................................................................................................. 5
L IMITATIONS OF WARRANTY DECLARATION REGARDING MACHINE USE .............................................................. 5
2. INFORMATION AND FEATURES ........................................................................................................ 6
R ATING L ABEL .................................................................................................................................................... 6
G ENERAL I NFORMATION ...................................................................................................................................... 6
S PECIFICATIONS ................................................................................................................................................... 7
3. INSTALLATION ....................................................................................................................................... 8
W ORKER AND WORKING AREA PROTECTION ........................................................................................................ 8
T YPICAL MIG PROCESS CONFIGURATION ............................................................................................................. 8
M AINS SUPPLY ..................................................................................................................................................... 8
T ORCH CONNECTION ............................................................................................................................................ 8
G ROUND CONNECTION ......................................................................................................................................... 8
S HIELDING GAS CONNECTION ............................................................................................................................... 9
I NSTALLATION OF WIRE REEL ............................................................................................................................... 9
P OLARITY CHANGE .............................................................................................................................................. 9
4. OPERATION ........................................................................................................................................... 10
D UTY CYCLE AND OVERHEATING ....................................................................................................................... 10
F RONT PANEL DESCRIPTION ............................................................................................................................... 11
S ETTING IN OPERATION ...................................................................................................................................... 12
MIG (GMAW) W ELDING .................................................................................................................................. 12
O VERLOAD CONTROL ......................................................................................................................................... 12
5. MIG (GMAW) WELDING GUIDELINES ............................................................................................. 13
W ORK PIECE PREPARATION ................................................................................................................................ 13
T YPICAL MACHINE SETTINGS ............................................................................................................................. 14
P OSITIONING THE WELDING TORCH .................................................................................................................... 15
G UN MOVEMENT DURING WELDING ................................................................................................................... 16
W ELDING RESULTS AND TROUBLESHOOTING ..................................................................................................... 17
6. MAINTENANCE ..................................................................................................................................... 21
M AINTENANCE OF ELECTRIC PARTS ................................................................................................................... 21
M AINTENANCE OF WIRE FEEDER AND TORCH ..................................................................................................... 21
C IRCUIT DIAGRAM ............................................................................................................................................. 22
S PARE PARTS – WIRE FEEDER ............................................................................................................................. 23

1
1. SAFETY PRECAUTIONS – READ BEFORE USEG
Symbol usage
Means Warning! Watch Out! There
are possible hazards with this
procedure! The possible hazards
are shown in the adjoining
symbols.
▲Marks a special safety message.
This group of symbols means Warning! Watch
Out! Possible ELECTRIC SHOCK, MOVING
PARTS, and HOT PARTS hazards.
Consult symbols and related instructions below
for necessary actions to avoid the hazards.
Arc Welding Hazards
▲The symbols shown below are used
throughout this manual to call attention
to and identify possible hazards. When
you see the symbol, watch out, and
follow the related instructions to avoid
the hazard. The safety information
given below is only a summary of the
more complete safety information
found in the Safety Standards. Read
and follow all Safety Standards.
▲Only qualified persons should install,
operate, maintain, and repair this unit.
▲During operation, keep everybody,
especially children, away.
ELECTRIC SHOCK can kill.
Touching live electrical parts
can cause fatal shocks or
severe burns. The electrode
and work circuit is electrically
live whenever the output is on.
The input power circuit and machine internal
circuits are also live when power is on. In semi-
automatic or automatic wire welding, the wire, wire
reel, drive roll housing, and all metal parts
touching the welding wire are electrically live.
Incorrectly installed or improperly grounded
equipment is a hazard.
•Do not touch live electrical parts.
•Wear dry, hoIe-free insulating gloves and body
protection.
•Insulate yourself from work and ground using
dry insulating mats or covers big enough to
prevent any physical contact with the work or
ground.
•Do not use AC output in damp areas, if
movement is confined, or if there is a danger of
falling.
•Use AC output ONLY if required for the welding
process.
•If AC output is required, use remote output
control if present on unit.
•Disconnect input power or stop engine before
installing or servicing this equipment.
Lockout/tagout input power according to Safety
Standards.
•Properly install and ground this equipment
according to its Owners Manual and national,
state, and local codes.
•Always verify the supply ground — check and
be sure that input power cord ground wire is
properly connected to ground terminal in
disconnect box or that cord plug is connected
to a properly grounded receptacle outlet.
•When making input connections attach proper
grounding conductor first - double-check
connections.
•Frequently inspect input power cord for
damage or bare wiring replace cord
immediately if damaged — bare wiring can kill.
•Turn off all equipment when not in use.
•Do not use worn, damaged, undersized, or
poorly spliced cables.
•Do not drape cables over your body.
•If earth grounding of the work piece is required,
ground it directly with a separate cable.

2
•Do not touch electrode if you are in contact with
the work, ground, or another electrode from a
different machine.
•Use only weII-maintained equipment. Repair or
replace damaged parts at once. Maintain unit
according to manual.
•Wear a safety harness if working above floor
level.
•Keep all panels and covers securely in place.
•Clamp work cable with good metal-to-metal
contact to work piece or worktable as near the
weld as practical.
•Insulate work clamp when not connected to
work piece to prevent contact with any metal
object.
•Do not connect more than one electrode or
work cable to any single weld output terminal.
▲SIGNIFICANT DC VOLTAGE exists after
removal of input power on inverters.
•Turn off inverter, disconnect input power, and
discharge input capacitors according to
instructions in Maintenance Section before
touching any parts.
FUMES AND GASES can be
hazardous.
Welding produces fumes and
gases. Breathing these fumes
and gases can be hazardous
to your health.
•Keep your head out of the fumes. Do not
breathe the fumes.
•If inside, ventilate the area and/or use exhaust
at the arc to remove welding fumes and gases.
•If ventilation is poor use an approved air-
supplied respirator.
•Read the Material Safety Data Sheets
(MSDSs) and the manufacturers’ instructions
for metals, consumables, coatings, cleaners,
and degreasers.
•Work in a confined space only if it is well
ventilated, or while wearing an air-supplied
respirator. Always have a trained watch-person
nearby. Welding fumes and gases can displace
air and lower the oxygen level causing injury or
death. Be sure the breathing air is safe.
•Do not weld in locations near degreasing,
cleaning, or spraying operations. The heat and
rays of the arc can react with vapours to form
highly toxic and irritating gases.
•Do not weld on coated metals, such as
galvanized, lead, or cadmium plated steel,
unless the coating is removed from the weld
area, the area is well ventilated, and if
necessary, while wearing an air-supplied
respirator. The coatings and any metals
containing these elements can give off toxic
fumes if welded.
ARC RAYS can burn eyes
and skin.
Arc rays from the welding
process produce intense
visible and invisible (ultraviolet
and infrared) rays that can
burn eyes and skin. Sparks fly
off from the weld.
•Wear a welding helmet fitted with a proper
shade of filler to protect your face and eyes
when welding or watching (see Safety
Standards).
•Wear approved safety glasses with side shields
under your helmet.
•Use protective screens or barriers to protect
others from flash and glare; warn others not to
watch the arc.
•Wear protective clothing made from durable,
flame-resistant material (leather and wool) and
foot protection.
WELDING can cause fire or
explosion.
Welding on closed
containers, such as tanks,
drums, or pipes, can cause
them to blow up. Sparks can
fly off from the welding arc.
The flying sparks, hot work piece, and hot
equipment can cause fires and burns. Accidental
contact of electrode to metal objects can cause
sparks, explosion, overheating, or lure. Check and
be sure the area is safe before doing any welding.
•Protect yourself and others from flying sparks
and hot metal.
•Do not weld where flying sparks can strike
flammable material.
•Remove all flammables within 35 ft (10.7 m) of
the welding arc. If this is not possible, tightly
cover them with approved covers.

3
•Be alert that welding sparks and hot materials
from welding can easily go through small
cracks and openings to adjacent areas.
•Watch for fire, and keep a fire extinguisher
nearby.
•Be aware that welding on a ceiling, floor,
bulkhead, or partition can cause fire on the
hidden side.
•Do not weld on closed containers such as
tanks, drums, or pipes, unless they are properly
prepared according to Safety Standards.
•Connect work cable to the work as close to the
welding area as practical to prevent welding
current from travelling long, possibly unknown
paths and causing electric shock and fire
hazards.
•Do not use welder to thaw frozen pipes.
•Remove stick electrode from holder or cut off
welding wire at contact tip when not in use.
•Wear oil-free protective garments such as
leather gloves, heavy shirt, cuffless trousers,
high shoes, and a cap.
•Remove any combustibles, such as butane
lighter or matches, from your person before
doing any welding.
FLYING METAL can injure
eyes.
•Welding, chipping, wire
brushing, and grinding
cause sparks and flying
metal. As welds cool, they
can throw off slag.
•Wear approved safety glasses with side shields
even under your welding helmet.
BUILDUP OF GAS can
injure or kill.
•Shut off shielding gas
supply when not in use.
•Always ventilate confined
spaces or use approved
air-supplied respirator.
HOT PARTS can cause
severe burns.
•Do not touch hot parts
bare handed.
•Allow cooling period before working on gun or
torch.
MAGNETIC FIELDS can
affect pacemakers.
•Pacemaker wearers keep
away.
•Wearers should consult
their doctor before going
near arc welding, gouging, or spot welding
operations.
NOISE can damage
hearing.
Noise from some processes
or equipment can damage
hearing.
•Wear approved ear
protection if noise level is
high.
CYLINDERS can explode if
damaged.
Shielding gas cylinders
contain gas under high
pressure. If damaged, a
cylinder can explode. Since
gas cylinders are normally
part of the welding process, be sure to treat them
carefully.
•Protect compressed gas cylinders from
excessive heat, mechanical shocks, slag, open
flames, sparks, and arcs.
•Install cylinders in an upright position by
securing to a stationary support or cylinder rack
to prevent falling or tipping.
•Keep cylinders away from any welding or other
electrical circuits.
•Never drape a welding torch over a gas
cylinder.
•Never allow a welding electrode to touch any
cylinder.
•Never weld on a pressurized cylinder - explosion
will result.
•Use only correct shielding gas cylinders,
regulators, hoses, and fittings designed for the
specific application: maintain them and
associated parts in good condition.
•Turn face away from valve outlet when opening
cylinder valve.

4
•Keep protective cap in place over valve except
when cylinder is in use or connected for use.
•Read and follow instructions on compressed gas
cylinders, associated equipment, and Safety
Standards.
Additional Symbols for Installation, Operation, and Maintenance
FIRE OR EXPLOSION hazard.
•Do not install or place unit
on, over, or near combustible
surfaces.
•Do not install unit near
flammables.
•Do not overload building wiring — be sure power
supply system is properly sized, rated, and
protected to handle this unit.
FALLING UNIT can cause
injury.
•Use lifting eye to lift unit only,
NOT running gear, gas
cylinders, or any other
accessories.
•Use equipment of adequate
capacity to lift and support
unit.
•If using lift forks to move unit, be sure forks are
long enough to extend beyond opposite side of
unit.
OVERUSE can cause
OVERHEATING
•Allow cooling period; follow
rated duty cycle.
•Reduce current or reduce
duty cycle before starting to
weld again.
•Do not block or filter airflow to unit.
STATIC (ESD) can damage
PC boards.
•Put on grounded wrist strap
BEFORE handling boards or
parts.
•Use proper static-proof bags
and boxes to store, move, or
ship PC boards.
MOVING PARTS can cause
injury.
•Keep away from moving
parts.
•Keep away from pinch points
such as drive rolls.
WELDING WIRE can cause
injury.
•Do not press gun trigger until
instructed to do so.
•Do not point gun toward any
part or the body, other
people, or any metal when
threading welding wire.
MOVING PARTS can cause
injury.
•Keep away from moving
pans such as fans.
•Keep all doors, panels,
covers, and guards closed
and securely in place.
H.F. RADIATION can cause
interference.
•High frequency (HF,) can
interfere with radio,
navigation, safety services,
computers, and
communications equipment.
•Have only qualified persons familiar with
electronic equipment perform this installation.
•The user is responsible for having a qualified
electrician promptly correct any interference
problem resulting from the installation.
•If notified by the FCC about interference, stop
using the equipment at once.
•Have the installation regularly checked and
maintained.

5
• Keep high-frequency source doors and panels
tightly shut. Keep spark gaps at correct setting,
and use grounding and shielding to minimize the
possibility of interference.
ARC WELDING can cause
interference.
•Electromagnetic energy can
interfere with sensitive
electronic equipment such
as computers and
computer-driven equipment
such as robots.
•Be sure all equipment in the welding area is
electromagnetically compatible.
•To reduce possible interference, keep weld
cables as short as possible, close together, and
down low, such as on the floor.
•Locate welding operation 100 meters from any
sensitive electronic equipment.
•Be sure this welding machine is installed and
grounded according to this manual.
•If interference still occurs, the user must take
extra measures such as moving the welding
machine, using shielded cables, using line filters,
or shielding the work area.
EMF Information
Considerations About Welding And The Effects Of Low Frequency Electric And Magnetic Fields
Welding current, as it flows through welding cables, will cause electro-magnetic fields. There has been
and still is some concern about such fields, However, after examining more than 500 studies spanning
17 years of research, a special blue ribbon committee of the National Research Council concluded
that: "The body of evidence, in the committees judgment, has not demonstrated that exposure to
power-frequency electric and magnetic fields is a human-health hazard." However studies are still
going forth and evidence continues to be examined. Until the final conclusions of the research are
reached, you may wish to minimize your exposure to electromagnetic fields when welding or cutting.
To reduce magnetic fields in the workplace, use the following procedures:
•Keep cables close together by twisting or taping them.
•Arrange cables to one side and away from the operator.
•Do not coil or drape cables around your body.
•Keep welding power source and cables as far away from operator as practical.
•Connect work clamp to work piece as close to the weld as possible.
About Pacemakers:
Pacemaker wearers consult your doctor first. If cleared by your doctor, then following the above
procedures is recommended.
Limitations of warranty declaration regarding machine use
▲The welding machine(s) described in this manual are designed exclusively for electrical
arc welding with shielding gases Argon, CO
2
or Ar + CO
2
mixture(s) employing MIG or
MAG technology. Using this machine for other purpouses is not allowed. Using this
machine in opposition with instructions can put the welder in danger. Damage can occur
to the welding machine if not operated according to this manual. Failures and accidents
due to such actions are not covered by warranty, nor can the producer be held
responsible.

6
2. INFORMATION AND FEATURES
Rating Label
General Information
▲Do not operate or install this equipment
without thoroughly reading this manual
and the safety precautions contained
throughout.
•Save this manual and keep it handy for
reference.
•Disconnect mains of the semi-automatic
welding machine after finishing work or
before a long break.
▲DO NOT make any modifications to the
machine. It may cause changes in the
features and deterioration of technical
data.
▲Any adaptations to this machine are
prohibited and may void the warranty.
▲Warranty is void if any damage to the
machine is caused by misuse.
•Acceptable range of ambient temperature
is from 10—40°C.
•Acceptable range of humidity is 20°C at
95% humidity.
•Specifications may change without
previous notice.

7
Specifications
MIG 135i MIG 165i
Supply voltage 230 / 240 V 230 / 240 V
Supply frequency 50 / 60 Hz 50 / 60 Hz
Fuses, slow 16 A 16 A
Welding range 20 – 135 A 20 – 165 A
No load voltage 17 – 23 V 17 – 25 V
Duty cycle:
100% - 50 A
60% - 70 A
35% - 90 A
100% - 80 A
60% - 100 A
35% - 130 A
Welding wire diameter 0,6 mm – 0,8 mm (steel) 0,6 mm – 0,9 mm (steel)
Protection IP 23 IP 23
Insulation class H H
Cooling AF AF
Dimensions 400 x 290 x 310 mm 400 x 290 x 310 mm
Weight 12 kg 14 kg

8
3. INSTALLATION
Worker and working area protection
Fumes and gases produced by welding are dangerous for your health. Ventilation in workplace must
be adequate to remove all harmful fumes and gases but not too strong since it could remove the
shielding gas flowing over work piece. Arc welding rays are dangerous for your eyes. The welder must
always use helmet with protective glass no. 11 for MIG/MAG. All personal protectives including
working clothes, leather apron, gloves, etc. must always be worn when welding or handling the work
piece.
Typical MIG process configuration
1……... Main transformer
2……... Wire feeder
3……... Gas tank and supply
4……... Ground cable and wire,
current and gas conduit
EU connector)
5……... Welding torch
Mains supply
INPUT primary cable is supplied with machine. Connect the machine to mains
according to legislation of the country where machine is being used. Connection
can be effected through plug or directly. Supply system should be protected at all
times by the fuse stated in technical data section. Connection to mains can be
done by authorized, educated person only.
Torch connection
Contact tip must correspond to welding wire diameter. Turn on the machine. Inch the wire through
torch outlet by activating the switch located on torch handle.
Ground connection
Earth lead with clamp for connection to work piece is in the accessory kit. Connect the plug to the
machine and clamp to work piece.

9
Shielding gas connection
Gas hose can be found in the accessory kit. Fasten your gas regulator onto gas bottle then connect it
with the machine using supplied gas hose.
Installation of wire reel
Open the side cover and unscrew reel brake cover. Mount the reel in such way that
one end of wire hangs downwards. Mount brake cover back in position.
Cut off the bent end of the wire. Lead the end of the wire trough inlet guide and unclip
pressure handle of feed rollers in order to make the work easier. Ensure both wire
inlet guide and the feeding rollers groove are aligned. Push the welding wire to the
inlet of the torch connection. Replace the pressure handle to reestablish pressure on
the wire. If handle pressure is too strong the wire could be transformed - flattened. If
the pressure is too low the wire could slip in the feeding groove. Use tension knob to
adjust this.
1…….. Feeding rolls
2…….. Pressure roll
3…….. Pressure adjustment
4…….. Wire inlet
Polarity change
Open the wire compartment side cover and set change the wires according
as indicated on the picture below. Change polarity only for certain types of
flux-cored welding wire. Read the welding wire manufacturer’s instructions.

10
4. OPERATION
Duty cycle and overheating
Duty Cycle is percentage of 10 minutes that unit can weld at rated load without
overheating. If unit overheats, thermostat(s) opens, output stops, and cooling fan
runs. Wait fifteen minutes for unit to cool. Reduce amperage or duty cycle before
welding.
60% Duty Cycle at 100 A.
Overheating
▲Welding machine must be used according to technical data from this manual. If the
machine is overloaded, failures may occur that are not be covered by warranty.

11
Front panel description
1 …........ ON/OFF switch
2 …........ Welding voltage adjustment
3 …........ Wire speed adjustment
4 …........ LED – ON indication
5 …........ LED – Overload indication
6 …........ Central connector EU)
7 …........ Return cable connection

12
Setting in operation
Set the main switch (1) in ''ON'' position. Turn the wire speed knob (3) counterclockwise,
press the torch button and adjust the gas flow with regulator. Regulate gas flow during
operation in position »Gas test«. In this position there is no welding current on the tip and
the wire feeder is switched off. Lower gas flow would affect the welding quality and cause
a porous weld while high gas flow results in bigger consumption of gas.
MIG (GMAW) Welding
After selecting the apropriate voltage (2) and setting the wire speed (3), welding process starts by
pressing the the torch button. Use steps from 1 to 4 for welding and position »Gas test« for checking
the gas flow. For normal welding torch must be held at a certain distance from the welding spot. When
placed too far welding area cannot be protected with gas which causes a porous weld. When placed
too close welding material and torch components (such as welding tip) can burn out. Before starting
the welding it is recommended to make tests and trial runs on scarp material.
Overload control
Thermal protection is built in the machine's main transformer. If the machine
overheats, thermal fuse will prevent further use and control lamp (5) on the front
side will light up. In this case the welder must wait until the maxchine's
temperature drops to normal. Note the machine must be left switched on for the
fan to keep running.

13
5. MIG (GMAW) welding guidelines
Work piece preparation
Welding joint describes the welding spot and exact position of work pieces to be welded together.
Work piece preparation, groove form and width, material type and thickness, together with certain
welding technique all determine joint type.
Around the groove work pieces should be dry and clean, free of rust, metallic coating, dirt, colour or
grease.
Joint type Groove shape Weld shape Metal thickness
[mm]
Work piece
spacing [mm]
Square butt
joint
single sided
up to 1,5
from 1,5 0 to 2
Square butt
joint
double sided
2 to 4 up to 2
3 to 6 up to 1
V – butt joint
3 to 6 up to 1
Square T - joint
single sided
from 0,6 -
Square T - joint
double sided
from 0,6 -
Lap joint
0,6 to 1,5 -
Edge joint from 1 -

14
Typical machine settings
Settings found in tables below are recommended values. Parameters listed are for short-circuit
welding at different joint shape. Both tables refer to mild steel welding with ArCO
2
or pure CO
2
gas.
Thickness
(mm)
Gap
(mm)
Wire
diameter
(mm)
Welding
current
(A)
Welding
voltage
(V)
Welding
speed
(cm/min)
Gas flow
(L/min)
0.8 0 0.8 60~70 16~16.5 50~60 10
1.0 0 0.8 75~85 17~17.5 50~60 10~15
1.2 0 0.8 80~90 17~18 50~60 10~15
2.0 0~0.5 1.0, 1.2 110~120 19~19.5 45~50 10~15
3.2 0~1.5 1.2 130~150 20~23 30~40 10~20
4.5 0~1.5 1.2 150~180 21~23 30~35 10~20
0 1.2 270~300 27~30 60~70 10~20
6
1.2~1.5 1.2 230~260 24~26 40~50 15~20
0~1.2 1.2 300~350 30~35 30~40 15~20
8 0~0.8 1.6 380~420 37~38 40~50 15~20
Butt joint
12 0~1.2 1.6 420~480 38~41 50~60 15~20
Thickness
(mm)
Wire
diameter
(mm)
Welding
current
(A)
Welding
voltage
(V)
Welding
speed
(cm/min)
Gas flow
(L/min)
Joint
shape
1.0 0.8 70~80 17~18 50~60 10~15 L=1~2
1.2 1.0 85~90 18~19 50~60 10~15 L=1~2
1.0,1.2 100~110 18~19.5 50~60 10~15 L=1~2
1.6 1.2 120~130 19~20 40~50 10~20 L=1~2
2.0 1.0,1.2 115~125 19.5~20 50~60 10~15 L= 2~3
1.0,1.2 150~170 21~22 45~50 15~20 L= 2~3
3.2 1.2 200~250 24~26 45~60 10~20 L= 2~3
1.0,1.2 180~200 23~24 40~45 15~20 L= 3~4
4.5 1.2 200~250 24~26 40~50 15~20 L= 3~4
1.2 220~250 25~27 35~45 15~20 L= 3~4
6 1.2 270~300 28~31 60~70 15~20 L= 3~4
1.2 270~300 28~31 55~60 15~20 L= 4~6
1.2 260~300 26~32 25~35 15~20 L= 4~6
8
1.6 300~330 30~34 30~35 15~20 L= 4~6
1.2 260~300 26~32 25~35 15~20 L= 4~6
T-joint
12 1.6 300~330 30~34 30~35 15~20 L= 4~6

15
Positioning the welding torch
Welding wire is energised when the torch button is pressed. Lower your helmet first and then press the
trigger. Wire should be around ½ in past end of nozzle, and tip of wire positioned correctly on seam.
1…….. Hold torch and control trigger with one
hand
2…….. Work piece
3…….. Earth clamp
4…….. Electrode extension (Stickout) ¼ to ½
in
5…….. Cradle torch with the other hand and
rest it on work piece
Heat distribution and weld
material flow are specific for
groove welds and fillet welds.
Optimal torch position differs
from one to another.
Weld bead shape differs
depending on electrode
extension when welding fillet
welds.

16
Gun movement during welding
Weld bead shape as well as penetration and overall joint quality are affected by torch angle, direction
of travel, electrode extension, travel speed, thickness of base material, wire feed speed, and voltage.
Using constant parameters
welding material deposit and
penetration varies with torch
travel speed. For adequate
penetration to be achieved
welding source must provide
more power at higher speeds.
Dragging the torch results in
deeper penetration and
narrower weld. Arc strength
prevents slag to enter the
molten material.
When pushing the torch
penetration will be shallower
and the weld wider. This
movement is suitable for thin
plates because of smaller heat
input.
1…….. Stringer bead – steady
movement along seam
2…….. Wave bead – side to
side movement along
seam
3…….. Wave patterns
Use weave patterns to cover a
wide area in one pass of
electrode.
Normally a single stringer
bead is satisfactory for most
narrow groove weld joints.
However for wide groove weld
joints or bridging across gaps,
a weave bead or multiple
stringer beads work better.