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Model WG3020
Welder components listed below
are in the wire feed compartment.
Open and remove.
HANDLE ASSEMBLY
1. Align handle holes to the inside of
deck lid holes (as shown in Figure 2).
2. Fasten screws through top cover and
into handle using the four small
screws.
WHEEL AND AXLE ASSEMBLY
1. Slide axle through holes in bottle
deck.
2. Push wheels on until snug.
BOTTLE DECK / GAS CYLINDER
BRACKET ASSEMBLY
1. With flat side facing the welder,
align holes in bottle deck with
fastening holes on the bottom back
of the welder.
2. Attach bottle deck with fastening
screws.
3. Bend strap tab upward and fasten
using screw (See Figure 2).
4. Align bottle bracket with holes
directly above vent holes on the back
of the welder and fasten with screws.
5. Slide bottle straps through strap holes
above bottle bracket and through
strap tab (See Figure 2).
FOOT ASSEMBLY
1. Place foot on welder and align holes
in the welder housing.
2. Fasten screws through foot into
cabinet.
Wire Installation
NOTE: Before installing welding wire,
be sure that the diameter of the
welding wire matches the groove in the
drive roller on the wire feed
mechanism and the wire matches the
contact tip in the end of the gun. A
mismatch on any item could cause the
wire to slip or bind.
1. Verify the unit is off and open the
panel on the welder to expose the
wire feed mechanism.
2. Remove the spool quick lock, by
pushing in and rotating 1/4 turn
counterclockwise. The knob, spring,
and spool spacer can now be removed.
NOTE: Spool spacer and spindle spacer
act as an 8” spool spindle adapter.
Purchase of an adapter is not necessary.
* See Figure 3 for assembly.
3. Loosen the wire feed tensioning
screw on the drive mechanism. This
allows initial feeding of the wire into
the gun liner by hand.
4. Install the wire spool onto the
spindle so that the wire can come off
the spool on the end closest to the
wire feed guide tube. Do not cut
the wire loose yet. Install the spool
spacer, spring, and quick lock knob
by pushing in and turning the knob
1/4 rotation clockwise.
5. Hold the wire and cut the wire end
from the spool. Do not allow the wire
to unravel. Be sure that the end of the
wire is straight and free of burrs.
6. Feed the wire through the wire feed
guide tube, over the groove in the
drive roller and into the gun liner.
Tighten the wire feed tensioning screw
so that it is snug. Do not over tighten.
7. Remove the nozzle by turning
counterclockwise. Then unscrew
the contact tip from the end of the
welding torch (See Figure 4). Plug the
welder into the proper power supply
receptacle.
4
Wire Feed Arc Welder
HINT: Keep torch cable straight when
feeding wire.
8. Turn on the welder and set the wire
speed rate to 5. Activate the gun
switch until the wire feeds out past
the torch end. Turn welder off.
9. Carefully slip the contact tip over the
wire and screw it into the torch neck.
Install the nozzle by turning clock-
wise (See Figure 4). Cut the wire off
approximately 1/4” from the end of
the nozzle.
POLARITY
For gas shielded welding, connect the
cable coming out of the torch to the (+)
socket and the work clamp cable to the
(-) socket on the front panel. For flux-
core (no-gas) welding, connect torch to
(-) and work clamp to (+).
DUTY CYCLE / THERMOSTATIC
PROTECTION
Welder duty cycle is the percentage of
actual weld time that can occur in a ten
minute interval at rated output current.
For example, at a 10% duty cycle,
actual welding can occur for one
minute, then the welder must cool for
nine minutes.
Internal components of this welder are
protected from overheating with an
automatic thermal switch. A yellow
lamp is illuminated in the ON/OFF
Switch if the duty cycle is exceeded
.
Welding operations may continue
when the yellow lamp is no longer
illuminated.
Assembly
Torch Neck
Contact Tip
Nozzle
Figure 4 - Torch Nozzle and Contact Tip
www.chpower.com
Figure 2 - WG3020 Assembly
Strap tab
Contact Tip Markings
Wire Size mm
.024” or .6
.030” or .8
.035” or .9
.040” or 1.0
Figure 3 - Weld Wire Routing
Spool Lock
Spool Spring
Spacer
Guide Tube
Tension Screw
Drive
Roller