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  5. Operator's Manual

KDAR 100WFG Operator's Manual

Manual is about: Wire Feed Welders

Summary of 100WFG

  • Page 1

    Warning: do not assemble, install, or operate this equipment without reading all of this manual and the safety precautions and warnings illustrated in this manual. Kdar company tel: 866-939-9013 15009 manchester road #283 fax: 636-922-4622 ballwin, mo 63011 web site: www.Hotmaxtorches.Com operator’s...

  • Page 2: Warning

    Safety precautions and warnings please read before using equipment warning • keep children away from this equipment • protect your self and others from possible injury • pacemaker wearers should consult with their doctor before operating • read and follow all instructions in this manual before opera...

  • Page 3

    Welding sparks can cause injury, fire, or explosion • remove all flammable materials from the welding area • always have a charged fire extinguisher available in the welding area • when not welding make sure the welding tip is not grounded, this causes a heat build up and possi- ble fire • avoid wel...

  • Page 4

    Noise can damage hearing • prolonged noise exposure from welding equipment can cause damage if levels of noise exceed the osha standards • wear approved hearing protectors • warn other workers nearby of the high noise level and hazard california proposition 65 warnings • welding or cutting equipment...

  • Page 5: Specifications

    Kdar company 4 specifications description uom 100wfg 135wfg 175wfg power source v 115 115 230 frequency hz 60 60 60 phase 1 1 1 rated no-load voltage v 29 32 35 rated input current a 12 17 22 rated input capacity kva 2.8 3.9 5.1 rated duty cycle % 20 20 20 rated output current/voltage a/v 88/18.4 11...

  • Page 6: Installation/setup

    Kdar company 5 installation/setup package contents 1. Wfg welder 2. Ground clamp cable assembly 3. Gun cable assemblies 4. 10# spool adapter 5. 5’ gas hose 6. Gas regulator 7. Gas shield nozzle 8. 5 contact tips 9. Hex wrench 10. Face shield with welding lens safety considerations warning electric s...

  • Page 7: Installation/setup

    Installation/setup 6 kdar company selecting a location the wfg welder should be placed where clean cool air can easily flow through the vents in the front of the unit. Dirt and dust can be drawn into the unit resulting in excessive operating temperatures and shutdowns, therefore, dirt and dust aroun...

  • Page 8: Installation/setup

    Installation/setup kdar company 7 ground clamp & lead connection 1. Ground cable attachment: the hot max mig welders use a convenient 1/4 turn connection for attaching the ground cable to the unit. Insert the male end of the ground cable into the female con- nection port and turn 1/4 turn clockwise....

  • Page 9: Installation/setup

    Installation/setup kdar company 8 gas connection • cylinder can explode if damaged. Keep cylinder chained upright to a secure support. • keep cylinder away from areas where it could be damaged. • never lift or move the welder with the cylinder attached. • do not let the welding electrode touch the c...

  • Page 10: Installation/setup

    Installation/setup kdar company 9 input connections the wfg series welders have power input cables located on the rear of the unit. (figure 4) requirements for rated output the wfg100 and wfg135 has a 15 amp, 125 volt, three prong plug (nema type 5-15p) installed at the fac- tory. This plug must be ...

  • Page 11: Operation

    Operation kdar company 10 electric shock can kill • do not touch live electrical parts of the electrode with skin or wet clothing. • insulate yourself from work and ground. • always wear insulated gloves and keep them dry. Safety considerations warning fumes & gases can be hazardous • plasma cutter ...

  • Page 12: Operation

    Operation kdar company 11 controls 1. Power on/off switch—the fan will run when the power is on and air will be exhausted form the front of the unit. The welding output and wire feeder will remain off until the gun trigger is pressed. 2. Power on indicator—this led is on and re- mains on when the po...

  • Page 13: Operation

    Operation kdar company 12 loading wire note: always turn power off when working inside the welder enclosure. 4” diameter spool 1. Remove wing nut and washer (1) and the plastic tension spacer (2). 2. Place the spool (label out) on the shaft with the wire feeding from under the spool. 3. Replace the ...

  • Page 14: Operation

    Kdar company 13 operation wire feeding 1. Release the spring loaded tension arm (1) by flip- ping it to the right and down. 2. Lift the idle arm (2). 3. Make sure the grove size on the drive roll (3) is in the feeding position that matches the wire size be- ing used. Refer to the suggested settings ...

  • Page 15: Operation

    Kdar company 14 operation welding 1. See suggested settings at the back of this manual or on the inside of the wire feed compartment door for welding wire and shielding gas recommenda- tions. 2 see suggested settings for information on setting the controls on the hot max wfg for specific welding wir...

  • Page 16: Operation

    Kdar company 15 operation changing drive roll the drive roll has two groves; the smaller grove is for .023” - .025” welding wire and the larger grove is for .030” - .035” welding wire. The welder is shipped set up for the larger welding wire sizes. To change the drive roll position: 1. Connect the u...

  • Page 17: Maintenance

    Kdar company 16 maintenance general maintenance power supply compartment the hot max wfg does not have any serviceable parts inside the power supply compartment. Do not attempt to service parts in the power supply compart- ment. Contact kdar company for instructions if you have problems that can not...

  • Page 18: Troubleshooting

    Kdar company 17 troubleshooting warning most components of the wfg series welders are not serviceable by the operator and should only be ser- viced by a qualified repair technician. Unauthorized repairs to these units may result in danger to the operator and will void the factory warranty. For your ...

  • Page 19: Troubleshooting

    Kdar company 18 troubleshooting problem arc is unstable—poor starting possible cause 1. Check to insure proper input voltage to the welder. 2. Check electrode polarity to make sure it is cor- rect for the process being used. 3. Check tip for proper size and damage; replace if necessary. 4. Insure pr...

  • Page 20: Additional Hot Max Products

    Kdar company 19 additional hot max products hot max stick welders 300 amp ac 300/200 amp acdc hot max plasma cutter 25 amp big max propane torch mobil max portable torch kit hot max cutting torch kit little max propane torch kit.

  • Page 21: Suggested Settings

    Suggested settings kdar company 20

  • Page 22: Suggested Settings

    Suggested settings kdar company 21.

  • Page 23: Suggested Settings

    Suggested settings kdar company 22.

  • Page 24

    Kdar company 15009 manchester rd. #283 ballwin, mo 63011-4626 phone: 866-939-9013 fax: 636-922-4622.