90 AMP Flux Wire Welder: Owner's Manual & Safety Instructions
90 AMP Flux Wire Welder: Owner's Manual & Safety Instructions
90 AMP Flux Wire Welder: Owner's Manual & Safety Instructions
Save This Manual Keep this manual for the safety warnings and precautions, assembly, operating,
inspection, maintenance and cleaning procedures. Write the product’s serial number in the back of the manual
near the assembly diagram (or month and year of purchase if product has no number). Keep this manual and
the receipt in a safe and dry place for future reference.
90 AMP
FLUX WIRE WELDER
General Safety
PROTECT yourself and others. Read and understand this information.
1. Before use, read and understand 7. Never leave the Welder unattended while
WELDING TIPS
SETUP
an air-supplied respirator.
• Heart disease • Ulcers
• Damage to the reproductive organs 6. Have a recognized specialist in
• Inflammation of the small intestine or Industrial Hygiene or Environmental Services
stomach • Kidney damage check the operation and air quality
• Respiratory diseases such as and make recommendations
emphysema, bronchitis, or pneumonia for the specific welding situation.
Follow OSHA guidelines for
2. Do not use near degreasing or Permissible Exposure Limits (PEL’s) and
painting operations. the American Conference of Governmental
BASIC WELDING
Industrial Hygienists recommendations for
3. Keep head out of fumes. Threshold Limit Values (TLV’s) for fumes and gases.
Do not breathe exhaust fumes.
WELDING TIPS
1. Wear ANSI-approved welding eye protection 4. Wear an approved head covering to protect
featuring at least a number 10 shade lens rating. the head and neck. Use aprons, cape, sleeves,
shoulder covers, and bibs designed and
2. Wear leather leggings, fire resistant shoes approved for welding and cutting procedures.
or boots during use. Do not wear pants with
cuffs, shirts with open pockets, or any clothing 5. When welding/cutting overhead or in confined
that can catch and hold molten metal or sparks. spaces, wear flame resistant ear plugs or
ear muffs to keep sparks out of ears.
3. Keep clothing free of grease, oil,
solvents, or any flammable substances.
Wear dry, insulating gloves and protective clothing.
MAINTENANCE
1. Turn off, disconnect power, and 6. Do not expose welders to rain or wet conditions.
discharge electrode to ground before setting Water entering a welder will increase
SAFETY
down torch/electrode holder and before service. the risk of electric shock.
2. Do not touch energized electrical parts. 7. Do not abuse the cord. Never use the cord
Wear dry, insulating gloves. Do not touch electrode for carrying, pulling or unplugging the welder.
holder, electrode, welding torch, or welding wire with Keep cord away from heat, oil, sharp edges
bare hand. Do not wear wet or damaged gloves. or moving parts. Damaged or entangled
cords increase the risk of electric shock.
3. Connect to grounded, GFCI‑protected
power supply only. 8. Do not use outdoors.
4. Do not use near water or damp objects. 9. Insulate yourself from the workpiece and ground.
Use nonflammable, dry insulating material if possible,
5. People with pacemakers should consult their
SETUP
Fire Safety
ARC AND HOT SLAG can cause fire.
1. Clear away or protect flammable objects. 5. If working on a metal wall, ceiling, etc.,
Remove or make safe all combustible materials for a prevent ignition of combustibles on the
radius of 35 feet (10 meters) around the work area. other side by moving the combustibles to a
Use a fire resistant material to cover or block all open safe location. If relocation of combustibles is
doorways, windows, cracks, and other openings. not possible, designate someone to serve as
a fire watch, equipped with a fire extinguisher,
2. Keep ABC-type fire extinguisher near during the cutting process and for at least one
work area and know how to use it. half hour after the cutting is completed.
WELDING TIPS
SAFETY
1. Do not use the welder if the switch does not turn 4. Store idle welders out of the reach of children and
it on and off. Any welder that cannot be controlled do not allow persons unfamiliar with the welder or
with the switch is dangerous and must be repaired. these instructions to operate the welder. Welders
are dangerous in the hands of untrained users.
2. Disconnect the plug from the power
source before making any adjustments, 5. Use the welder and accessories in accordance
changing accessories, or storing welders. with these instructions, taking into account the
Such preventive safety measures reduce the working conditions and the work to be performed.
risk of starting the welder accidentally. Use of the welder for operations different from those
intended could result in a hazardous situation.
3. Prevent unintentional starting.
Ensure the switch is in the off-position before
SETUP
connecting to power source or moving
the welder. Carrying or energizing welders
that have the switch on invites accidents.
Maintenance
BASIC WELDING
1. Maintain welders. Check for misalignment or 3. Maintain labels and nameplates on the Welder.
binding of moving parts, breakage of parts These carry important information.
and any other condition that may affect the If unreadable or missing, contact
welder’s operation. If damaged, have the Harbor Freight Tools for a replacement.
welder repaired before use. Many accidents
are caused by poorly maintained welders. 4. Unplug before maintenance. Unplug the Welder
from its electrical outlet before any inspection,
2. Have your welder serviced by a qualified maintenance, or cleaning procedures.
repair person using only identical
replacement parts. This will ensure that
the safety of the welder is maintained.
WELDING TIPS
SAVE THESE INSTRUCTIONS.
MAINTENANCE
CONNECTION:
Check with a qualified electrician if you are in doubt as to whether the outlet is properly grounded.
Have a plug installed by a certified electrician. Do not use the Welder if the power cord or plug is
damaged. If damaged, have it repaired by a service facility before use. If the plug will not fit the
outlet, have a proper outlet installed by a qualified electrician.
Grounded Welders
1. The grounding prong in the plug is connected 2. The Welder must be plugged into an appropriate
through the green wire inside the cord to the outlet, properly installed and grounded in
grounding system in the Welder. The green wire accordance with all codes and ordinances.
SETUP
Extension Cords
1. If an extension cord is used, it must have 4. When using more than one extension cord to
the following wire size: up to 30 feet, use make up the total length, make sure each cord
10 AWG size wire; 30 to 50 feet, use 8 AWG contains at least the minimum wire size required.
BASIC WELDING
Symbology
Gun Cable
OCV Open Circuit Voltage
MAINTENANCE
Cooling Fan
IPM Inches Per Minute
SAFETY
18 gauge (0.048″) to 3/16″ (0.19″) mild steel only
Capacity
Not for welding aluminum or stainless steel
20% @ 90A
Duty Cycle
(See explanation on page 14)
Open Circuit Voltage 27
KVA 2.38
Welder Tips / Wire Size Installed tip will accept .030″ to .035″ FLUX CORE wire
Wire Spool Capacity 4″ diameter / 2 lb. spool
SETUP
Setup
Read the ENTIRE IMPORTANT SAFETY INFORMATION section at the beginning of this
manual including all text under subheadings therein before set up or use of this product.
BASIC WELDING
Turn the Power Switch off and unplug the welder before assembly.
Cover Assembly
WELDING TIPS
1. Slide the Handle into the slot on
the Cover from the back. notch drops
into slot on Handle Screw
Cover here
2. The notch on the front of the Handle should drop
into the slot in the Cover. Both ends of the Handle
should lay flush against the top of the Cover.
Cover
ON MIN
GROUND
120V~
60Hz
20A
Cover
SETUP
Knob
3. Remove the Knob, Spring and the Top Plate.
If replacing a Spool, remove the old Spool
and all remaining wire from the liners. Spring
Top Plate
4. Place the new flux core Wire Spool
over the Spool Spindle.
To prevent wire feed problems, set the Spool
so that it will unwind counterclockwise . Wire Spool
WELDING TIPS
Spindle
0″
.03
MAINTENANCE
wire must
unwind this
direction
SAFETY
Feed Swing Feed
Arm Tensioner
SETUP
number facing up is the same as the wire diameter
on the Spool.
Replace and secure the Feed Knob.
IMPORTANT:
Securely hold onto the end of the welding wire and
keep tension on it during the following steps.
BASIC WELDING
If this is not done, the welding wire will unravel
and create a tangled “bird’s nest”, wasting wire. Wire HOLD WIRE
Liner SECURELY welding
8. Cut off all bent and crimped wire.
wire
Make sure that the cut end has no burrs
or sharp edges; cut again if needed. 0″
.03
WELDING TIPS
Feed Tensioner clockwise a couple of turns. 0″
.03
0″
.03
Feed Swing
Arm
13. Lay the Gun Cable out in a straight line so that the Nozzle
MAINTENANCE
WARNING
The following steps require applying power to the welder
with the cover open.
To prevent serious injury from fire or electric shock:
1. Do not touch anything, especially not the Ground Clamp,
with the Gun or welding wire or an arc will be ignited.
2. Do not touch internal welder components
SETUP
GUN
OFF MAX
GROUND
120V~
60Hz
20A
15. Point the Gun away from all objects and press the 2″
WELDING TIPS
Trigger until the wire feeds out of the gun two inches. Gun
The Wire Liner may come out with the welding
wire, this is normal, just push the Wire Liner
back into the Gun.
Welding
If the wire does not feed properly and the
Wire
Spool is stationary, turn the welder to OFF,
unplug it, and slightly tighten the Feed
Tensioner clockwise before retrying.
MAINTENANCE
2-3
wire bends.
SETUP
GUN
ON MIN
BASIC WELDING
OFF MAX
GROUND
120V~
60Hz
20A
WELDING TIPS
welding wire used. The included Tip (.035″) will work
with both .030″ and .035″ wire. Slide the Contact
Tip over the wire and thread it clockwise into the
Gun. Tighten the Contact Tip using a wrench.
Nozzle
19. Replace the Nozzle and cut the wire
off at 1/2″ from tip (1/2″ stickout).
Contact
20. Swing the Cover closed until the
Tip
Cover Latch locks in place.
MAINTENANCE
GUN
=
ON MIN
FIRE AND BURNS:
Keep welding tip clear of grounded
objects whenever unit is plugged in. OFF MAX
GROUND
120V~
60Hz
20A
WELDING TIPS
SAFETY
GUN
Gun
Cable
ON MIN
Wire
SETUP
Speed Current
Dial Switch
OFF MAX
BASIC WELDING
GROUND
WELDING TIPS
the Power Switch is on. as a concrete slab, well clear of the ground clamp while
allowing the welder to cool with the Power Switch on, so
Wire Speed Dial:
the Fan can help cool the welder. Once the welder cools
This controls the speed that the welding wire feeds out of
enough to be used again, use shorter welding periods
the welding Gun.
and longer rest periods to prevent needless wear.
Adjust this according to the weld settings chart
to achieve a good weld. (See next page.) Current Switch:
This controls the output amperage of the welder.
Ground Cable:
Adjust this according to the weld settings
This connects to the base metal to provide a good
chart to achieve a good weld.
connection for the current to travel back to the welder.
Power Switch:
This turns on power to the Welding Gun
and internal cooling fan.
MAINTENANCE
Power Cord:
Plug the Power Cord into a properly grounded
120 V~ outlet, on at least a 20 amp dedicated circuit
with delayed action type circuit breaker or fuses.
thicknesses of material. The settings should only be used at the beginning of a weld and must be
adjusted after stopping and carefully inspecting the weld. Proper welding takes experience.
This welder has an internal thermal protection 90 AMP FLUX WIRE WELDER
ITEM 68887
20A
SAFETY
Clean the weld surfaces thoroughly with
a wire brush or angle grinder; there must clamps
be no rust, paint, oil, or other materials on
the weld surfaces, only bare metal.
workpieces
2. Use clamps (not included) to hold the workpieces
in position so that you can concentrate on
proper welding technique. The distance Clean
(if any) between the two workpieces must be surfaces to
controlled properly to allow the weld to hold bare metal.
both sides securely while allowing the weld
to penetrate fully into the joint. The edges of
SETUP
thicker workpieces may need to be chamfered Chamfer thick workpieces.
(or beveled) to allow proper weld penetration.
GUN
OFF MAX
Clean
WIRE FEED SPEED Wire .030″-.035″ Flux-core
Capacity XX Ga. – X/X″ Steel Plate
surface to
Ground bare metal.
Electrode – X′
Cables
Ground Clamp – X′
GROUND
BASIC WELDING
Clamp
120V~
60Hz
GUN
20A GUN
+
the Current Switch to the desired settings. ON MIN
ON MIN
Refer to the chart on the welder
or the chart on the facing page.
WARNING! DO NOT SWITCH THE OFF MAX OFF MAX
CURRENT WHILE WELDING. Wire .030″-.035″ Flux-core WIRE FEED SPEED Wire .030″-.035″ Flux-core
WIRE FEED SPEED Capacity XX Ga. – X/X″ Steel Plate
Capacity XX Ga. – X/X″ Steel Plate
Electrode – X′ Electrode – X′
Cables Cables
Ground Clamp – X′ Ground Clamp – X′
GUN
GROUND GROUND
120V~ 120V~
60Hz 60Hz
20A
WELDING TIPS
20A
OFF MAX
GROUND
120V~ GUN
20 Amp minimum circuit
60Hz
20A
MAINTENANCE
HOLD
GUN
6. Hold the Gun, without touching the Trigger, with the ON MIN
CLEAR
wire and tip clearly away from any grounded objects.
Then, turn the Power Switch to ON.
OFF MAX
GROUND
120V~
60Hz
20A
2. For a narrow weld, you can usually draw the wire in stringer bead weave bead
a steady straight line,
this is called a stringer bead.
Note: If Welder is used too long, the amber Overload 90 AMP FLUX WIRE WELDER
ITEM 68887
Indicator will light and the Welder Gun will shut off Gun
until the welder cools. If this happens, rest the Gun on
SAFETY
ON MIN
an electrically non-conductive, heat-resistant surface,
such as a concrete slab, well clear of the ground
clamp. Wait about 8-10 minutes with the Power
Switch to ON for the welder to cool. When the welder OFF MAX concrete slab
can be used again, use shorter welding periods and (or other heat-proof,
Wire
WIRE FEED SPEED .030″-.035″ Flux-core
longer rest periods to help prevent needless wear. Capacity XX Ga. – X/X″ Steel Plate
Electrode – X′
non-conductive
Cables
Ground Clamp – X′ surface)
GROUND
120V~
60Hz
20A
SETUP
7. After welding the test weld on a piece of scrap for a seconds, STOP and examine
few seconds, stop, and check your progress. Clean, your weld using the guidelines
then compare your weld’s appearance with the diagrams
and descriptions in the Welding Tips section starting on
starting on the next page.
the next page. After making any necessary adjustments,
continue to weld while carefully following the FOLLOW DUTY CYCLE!
DUTY CYCLE guidelines as explained on page 14.
BASIC WELDING
up to 2 minutes welding
at rated output
GUN
HOLD
GUN ON MIN
8. When the weld is complete, CLEAR
lift the Gun and welding wire clearly away from any
grounded object, and turn the Power Switch off.
WELDING TIPS
OFF MAX
GROUND
120V~
60Hz
20A
concrete slab
(or other heat-proof,
non-conductive
surface)
examine a weld’s appearance after it has A typical Flux-core Wire (FCAW) Weld
cooled and the slag has been removed. before cleaning.
Then, better welding can be learned by adjusting your weld bead
slag
weld technique to remedy any problems found. spatter
base metal
as shown on top. workpiece
A POOR WELD will be brittle and snap
at the weld, as shown on bottom.
POOR WELD
snaps or cracks
SAFETY
EXCESS PENETRATION OR
INADEQUATE PENETRATION PROPER PENETRATION
BURN-THROUGH
SETUP
and increase penetration: and limit penetration:
(to weld THICKER workpieces properly) (to weld THINNER workpieces properly)
a. Use MAX setting c. Use faster wire feed a. Use MIN setting c. Use slower wire feed
b. Weld more slowly d. Use shorter stickout b. Weld more quickly d. Use longer stickout
BASIC WELDING
Example Weld Diagrams
WELDING TIPS
Good Current Current Weld Speed Weld Speed Stickout
Weld Too Low Too High or Too Fast Too Slow Too Long
Wire Feed
GUN
Too Fast
GUN 90 AMP FLUX WIRE WELDER
TO CORRECT: TO CORRECT: TO CORRECT: TO CORRECT: TO CORRECT:
ITEM 68887
MAINTENANCE
maintain
ON MIN OFF MAX
GROUND
OFF MAX
120V~
60Hz
WIRE FEED SPEED Wire .030″-.035″ Flux-core
20A Capacity XX Ga. – X/X″ Steel Plate
Electrode – X′
Cables
Ground Clamp – X′
PROFILE VIEWS
SETUP
Pause briefly at sides during weave bead. Reduce wire feed speed.
Keep arc on leading edge of weld puddle.
Hold gun at proper angles.
2. Insufficient weld heat:
Increase current and/or wire feed speed.
3. Dirty workpiece:
Clean workpiece down to bare metal.
4. Insufficient weld material:
Increase wire feed speed.
SAFETY
TOP
PARTIALLY CHIPPED AWAY TO SHOW WELD VIEW
Slag is a necessary part of a flux-
core wire weld. It shields the weld from
POSSIBLE CAUSES AND SOLUTIONS
impurities. Clean off the slag with the Chipping
Hammer and Wire Brush after welding. 1. Dirty workpiece or welding wire:
Clean workpiece down to bare metal.
Make certain that wire is clean and free
from oil, coatings, and other residues.
2. Wire feeding too fast:
Reduce wire feed speed.
SETUP
3. Stickout too long:
Reduce stickout.
Porosity
Small cavities or holes in the bead.
TOP
VIEW
BASIC WELDING
POSSIBLE CAUSES AND SOLUTIONS
1. Dirty workpiece or welding wire:
Clean workpiece down to bare metal. Burn-Through
Make certain that wire is clean and free
from oil, coatings, and other residues. Base material melts away,
leaving a hole in the weld.
2. Inconsistent welding speed:
Maintain steady weld speed.
3. Stickout too long:
Reduce stickout. TOP
VIEW
WELDING TIPS
POSSIBLE CAUSES AND SOLUTIONS
1. Workpiece overheating:
Reduce current and/or wire feed speed.
2. Welding speed too slow:
Crooked/Wavy Bead Increase welding speed and ensure
that welding speed is kept steady.
3. Excessive material at weld:
Reduce wire feed speed.
TOP
VIEW
MAINTENANCE
Gun
SAFETY
+
FIRE AND BURNS:
Unplug the Welder,
rest the Gun on a heat-proof,
electrically non-conductive surface, concrete slab
and allow all parts of the Welder to cool thoroughly (or other heat-proof,
non-conductive
before service.
surface)
1. Periodically remove the Right and Left
side panels, and using compressed air,
blow out all dust from the interior.
SETUP
SAFETY
from the electrical outlet before proceeding.
3. Scrub the exterior of the Tip clean with a wire brush. Nozzle
Clean out the inside of the tip with a tip cleaner (sold
separately). Check that the Tip is the proper type for
the wire size used (.035″ tip for .030–.035″ wire).
Contact
Tip
SETUP
4. Examine the shape of the hole at the end of
the Contact Tip. It should be an even circle; it
should not be oblong or have any bulges in it.
BASIC WELDING
reinstall the Nozzle as well.
WELDING TIPS
MAINTENANCE
IMPORTANT!
Be CERTAIN to shut off the Welder, disconnect it from power, and discharge the Gun to ground
SAFETY
Wire Feed Motor Runs But Wire Does Not Feed Properly
POSSIBLE CAUSES AND SOLUTIONS
1. Insufficient wire feed tension:
Increase wire feed tension properly - follow number 16 on page 11.
2. Incorrect wire feed roll size:
Replace with the proper wire feed roll - follow the Wire Spool Installation instructions, starting on page 8.
SETUP
Verify that Contact Tip is the proper size for the wire. Check that the hole in the tip
is not deformed or enlarged. Also, check that the tip is not dirty; this would prevent a
good connection. If needed, replace Contact Tip with proper size and type.
SAFETY
Power Switch Lights,
But Welder Does Not Function When Switched On
POSSIBLE CAUSES AND SOLUTIONS
1. Tripped thermal protection device:
Shut the welder’s switch to off and allow it to cool for at least 20 minutes.
Reduce duration or frequency of welding periods to help reduce wear on the welder.
Refer to Duty Cycle section on page 14.
SETUP
2. Faulty or improperly connected Trigger:
Qualified technician must check and secure/replace Trigger.
BASIC WELDING
Unit is not connected to outlet properly or outlet is unpowered:
Verify the voltage at the outlet and the connection to the outlet.
If voltage is not present at outlet, check circuit breaker/GFCI devices; if any are tripped,
determine and remedy cause before resetting. Verify that the circuit is designed to
supply the required input amperage as detailed on the Specifications table.
WELDING TIPS
2. Improper gauge or length of extension cord:
Extension cords are not recommended. If possible, eliminate the use of an extension cord.
If an extension cord is needed, refer to the guidelines on page 6.
Wiring Schematic
SAFETY
1 2 3
1 2 3 4
J
G
1234
SETUP
24V
T1
S1
BASIC WELDING
S2 MAX B
WELDING TIPS
b
MIN C
Parts List
1 Grounding Cable 1 15 Heat Relay 1
2 MIG Torch 1 16 Fan 1
3 Potentiometer Knob 1 17 Fan Motor 1
4 Indicator 1 18 Bottom 1
5 MIG Torch Holder 1 19 Right Panel 1
6 Font Panel 1 20 Spool Holder 1
MAINTENANCE
REV 12a
SAFETY
SETUP
BASIC WELDING
Part 9 Detail
9f (hidden by part 9e) 9e 9d
WELDING TIPS
0″
.03
MAINTENANCE
9c 9b 9a
Note: Some parts are listed and shown for illustration purposes only, and
are not available individually as replacement parts.
REV 12a
3491 Mission Oaks Blvd. • PO Box 6009 • Camarillo, CA 93011 • (800) 444-3353