Northern Industrial Tools 628575 User manual

Flux Core 125
Item# 628575
OPERATOR’S MANUAL
Read carefully and understand RULES FOR SAFE OPERATION and instructions before
operating. Failure to follow the safety rules and other basic safety precautions may
result in serious personal injury.
Flux Core 125
Item# 628575
Operation Instructions
For technical questions and replacement parts, please call 1-800-222-5381.
Thank you very much for choosing a NORTHERN TOOL + EQUIPMENT CO., product. For
future reference, please complete the owner’s record below:
Model:________________ Purchase Date:___________________
Save the receipt, warranty information and this owner’s manual. It is important that you read
the entire manual to become familiar with this product before using it.
This machine is designed for certain applications only. Northern Tool + Equipment strongly
TGEQOOGPFUVJCVVJKUOCEJKPGPQVDGOQFKſGFCPFQTWUGFfor any application other than
that for which it was designed. If you have questions relative to a particular application, DO
NOT use the machine before you contact Northern Tool + Equipment to determine if it can be
performed on the product.
Before using this welding unit, please read the following instructions carefully.
SAVE THIS MANUAL
You will need this manual for the safety warnings and precautions, assembly (if any), operating, inspection, maintenance and cleaning procedures, parts list and assembly diagram. Keep
your receipt and this manual in a safe and dry place for future reference.
Northern Industrial Welder
Operating Instructions and Parts Manual
Flux Core 125
Please read and save these instructions. Read through this owner’s manual carefully before
using product. Protect yourself and others by observing all safety information, warnings, and
cautions. Failure to comply with instructions could result in personal injury and/or damage to
product or property. Please retain instructions for future reference.
Wire Feed, Gasless Welder
Description
Flux Core 125 portable Gasless Wire
Feed Welder. Uses AC single phase
115v (110-120V), 60Hz/20amp with
time delayed fuse or circuit breaker.
Features two heat settings, infinite wire
speed control, over load and thermal
protection.
Ideal for use welding mild steel 18
gauge to 3/16” for light industrial
applications (for use with Flux Core
wire only).
Specifications and Dimension
DESCRIPTION
Power supply
No-load voltage
Output Range
Duty cycle
Suggested wire
Wire Diameter
Dimension (L x W x H)
Weight
SPECIFICATION
1ph-115V-60HZ
27V
60-80A (Peak 125A)
20%
Flux Core wire
.030”, .035”
17.7”x9.3”x14.3”
38 lbs
Removing from carton
1.1 Remove cartons, bags or Styrofoam containing the welder and accessories.
1.2 Check the contents with the packing list below.
ITEM
QTY.
Portable Wire Feed Welder
Contact tip, .030”
Sample spool Flux Core wire, .030”
Large spool adapter
Chipping hammer/ wire brush
Operator’s Manual
1
1 unit
2pc
1 spool
1pc
1pc
1set
Northern Industrial Welder
Operating Instructions and Parts Manual
Flux Core 125
Wire Feed, Gasless Welder
1.3 After unpacking unit, inspect for any damage that may have occurred during
transit. Check for loose, missing, or damaged parts. Shipping damage claim
must be filed with carrier.
Know your Welder
Wire Compartment
1-2 voltage
Setting
On/off switch
Wire speed
setting
Thermal
Overload
indicator
MIG Gun
Ground cable
and clamp
ON/OFF Switch
In the “OFF” position no power is being supplied to the MIG gun/torch. In the
“ON” position power is supplied to the main transformer and control circuit
Wire compartment
Inside the wire compartment are the wire feeder, spool hub, and set up chart.
1-2 Voltage Setting
1 (low), 2 (high) voltage switch is on the front panel of the machine, Refer to the
“set up” chart inside the wire feed compartment for initial adjustment settings.
Wire speed setting
Adjustment of the wire feed speed (amperage).
Ground cable and clamp
The ground cable and clamp are attached to the work piece to complete the
circuit allowing the flow of current needed to weld.
Welding Cable and MIG gun/torch
The welding wire is driven through the welding cable and MIG gun/torch to the
work piece. It is attached to the drive system, the gun trigger activates the drive
motor.
Thermal Indicator
If the duty cycle of the welder is exceeded the internal temperature will exceed
safe temperatures the machine will shut down and the thermal overload light will
come on.Allow 15 minutes for cool down before the light will go off and the
temperature to fall into an allowable operating range.
Power Cord
2
Flux Core 125
Northern Industrial Welder
Operating Instructions and Parts Manual
Wire Feed, Gasless Welder
The power cord connects the welder to the 115 volt power supply. Plug the 15
amp plug into a 115 volt/20 amp receptacle to supply power to the welder.
General Safety Information
1.1 Your Welding Environment
-Keep the environment you will be
welding in free from flammable
materials.
-Always keep a fire extinguisher
accessible to your welding
environment.
-Always have a qualified person
install and operate this equipment.
-Make sure the area is clean, dry and
ventilated. Do not operate the welder
in humid, wet or poorly ventilated
areas.
-Always have your welder maintained
by a qualified technician in
accordance with local, state and
national codes.
-Always be aware of your work
environment. Be sure to keep other
people, especially children, away
from you while welding.
-Keep harmful arc rays shielded from
the view of others.
-Mount the welder on a secure bench
or cart that will keep the welder
secure and prevent it from tipping
over or falling.
1.2 Your Welder’s Condition
-Check ground cable, power cord and
welding cable to be sure the
insulation is not damaged. Always
replace or repair damaged
components before using the welder.
-Check all components to ensure they
are clean and in good operating
condition before use.
1.3 Use of Your Welder
wire or wire feed system is wet. Do
not immerse them in water. These
components and the welder must be
completely dry before attempting to
use the welder.
-Follow the instructions in this manual.
-Keep welder in the off position when
not in use.
-Connect ground lead as close to the
area being welded as possible to
ensure a good ground.
-Do not allow any body part to come
in contact with the welding wire if you
are in contact with the material being
welded, ground or electrode from
another welder.
-Do not weld if you are in an awkward
position. Always have a secure
stance while welding to prevent
accidents. Wear a safety harness if
working above ground.
-Do not drape cables over or around
your body.
-Wear a full coverage helmet with
appropriate shade lens (see ANSI
Z87.1 safety standard) and safety
glasses while welding.
-Wear proper gloves and protective
clothing to prevent your skin from
being exposed to hot metals, UV and
IR rays.
-Do not overuse or overheat your
welder. Allow proper cooling time
between duty cycles.
-Keep hands and fingers away from
moving parts and stay away from the
drive rolls.
-Do not point MIG gun at any body
part of yourself or anyone else.
Do not operate the welder if the
output cable, electrode, MIG gun,
3
Flux Core 125
Northern Industrial Welder
Operating Instructions and Parts Manual
Wire Feed, Gasless Welder
-Do not breathe in fumes emitted by
the welding process. Make sure your
breathing air is clean and safe.
-Work only in a well-ventilated area or
use a ventilation device to remove
welding fumes from the environment
where you will be working.
-Do not weld on coated materials
(galvanized, cadmium plated or
containing zinc, mercury or barium).
They will emit harmful fumes that are
dangerous to breathe. If necessary
use a ventilator, respirator with air
supply or remove the coating from the
material in the weld area.
-The fumes emitted from some
metals when heated are extremely
toxic. Refer to the material safety
data sheet for the manufacturer’s
instructions.
-Do not weld near materials that will
emit toxic fumes when heated.
Vapors from cleaners, sprays and
degreasers can be highly toxic when
heated.
UV and IR Arc Rays
-Always use this welder in the rated
duty cycle to prevent excessive heat
and failure.
1.4 Specific Areas of Danger,
Caution or Warning
Electrical Shock
Electric arc welders can
produce a shock that
can cause injury or
death. Touching electrically live parts
can cause fatal shocks and severe
burns. While welding, all metal
components connected to the wire
are electrically hot. Poor ground
connections are a hazard, so secure
the ground lead before welding.
-Wear dry protective apparel: coat,
shirt, gloves and insulated footwear.
-Insulate yourself from the work piece.
Avoid contacting the work piece or
ground.
- Do not attempt to repair or maintain
the welder while the power is on.
-Inspect all cables and cords for any
exposed wire and replace damaged
or wore cables immediately.
-Use recommended replacement
cables and cords.
-Always attach ground clamp to the
work piece or work table as close to
the weld area as possible.
-Do not touch the welding wire and
the ground or grounded work piece at
the same time.
-Do not use a welder to thaw frozen
pipes.
Fumes and Gases
The welding arc
produces ultraviolet (UV)
and infrared (IR) rays
that can cause injury to your eyes
and skin. Do not look at the welding
arc without proper eye protection.
-Always use a helmet that covers
your full face from the neck to top of
head and to the back of each ear.
-Use a lens that meets ANSI
standards and safety glasses. For
welders under 160 Amps output, use
a shade 10 lens; for above 160 Amps,
use a shade 12. Refer to the ANSI
standard Z87.1 for more information.
-Cover all bare skin areas exposed to
the arc with protective clothing and
-Fumes emitted from the
welding process displace
clean air and can result in
injury or death.
4
Flux Core 125
Northern Industrial Welder
Operating Instructions and Parts Manual
Wire Feed, Gasless Welder
-To prevent any unintended arcs, cut
wire back to ¼" stick out after welding.
Hot Materials
shoes. Flame-retardant cloth or
leather shirts, coats, pants or
coveralls are available for protection.
-Use screens or other barriers to
protect other people from the arc rays
emitted from your welding.
-Warn people in your welding area
when you are going to strike an arc
so they can protect themselves.
Fire Hazards
Welded materials are hot
and can cause severe
burns if handled
improperly.
-Do not touch welded materials with
bare hands.
-Do not touch MIG gun nozzle after
welding until it has had time to cool
down.
Sparks/Flying Debris
Do not weld on containers
or pipes that contain or
have had flammable,
gaseous or liquid combustibles in
them. Welding creates sparks and
heat that can ignite flammable and
explosive materials.
-Do not operate any electric arc
welder in areas where flammable or
explosive materials are present.
-Remove all flammable materials
within 35 feet of the welding arc. If
removal is not possible, tightly cover
them with fireproof covers.
-Take precautions to ensure that
flying sparks do not cause fires or
explosions in hidden areas, cracks or
areas you cannot see.
-Keep a fire extinguisher close in the
case of fire.
-Wear garments that are oil-free with
no pockets or cuffs that will collect
sparks.
-Do not have on your person any
items that are combustible, such as
lighters or matches.
-Keep work lead connected as close
to the weld area as possible to
prevent any unknown, unintended
paths of electrical current from
causing electrical shock and fire
hazards.
Welding creates hot
sparks that can cause
injury. Chipping slag off
welds creates flying debris.
-Wear protective apparel at all times:
ANSI-approved safety glasses or
shield, welder’s hat and ear plugs to
keep sparks out of ears and hair.
Electromagnetic Field
-Electromagnetic fields
can interfere with various
electrical and electronic
devices such as pacemakers.
-Consult your doctor before using any
electric arc welder or cutting device
-Keep people with pacemakers away
from your welding area when welding.
-Do not wrap cable around your body
while welding.
-Wrap MIG gun and ground cable
together whenever possible.
-Keep MIG gun and ground cables on
the same side of your body.
Shielding Gas Cylinder
can explore
5
Flux Core 125
Northern Industrial Welder
Operating Instructions and Parts Manual
Wire Feed, Gasless Welder
delayed fuse or circuit breaker is
required. DO NOT OPERATE THIS
UNIT if the ACTUAL power source
voltage is less than 105 volts ac or
greater than 132 volts ac.
High pressure cylinders can explode
if damaged, so treat them carefully.
-Never expose cylinders to high heat,
sparks, open flames, mechanical
shocks or arcs
-Do not touch cylinder with MIG gun.
-Do not weld on the cylinder.
-Always secure cylinder upright to a
cart or stationary object cart or
stationary object
-Do not touch cylinder with MIG gun.
-Do not weld on the cylinder.
-Always secure cylinder upright to a
cart or stationary object.
-Keep cylinders away from welding or
electrical circuits.
-Use the proper regulators, gas hose
and fittings for the specific application
• High voltage danger from power
source! Consult a qualified
electrician for proper installation of
receptacle. This welder must be
grounded while in use to protect
the operator from electrical shock.
• Do not remove grounding prong
or alter the plug in any way. Do
not use any adapters between the
welder’s power cord and the power
source receptacle. Make sure the
POWER switch is OFF when
connecting your welder’s power
cord to a properly grounded 115
VAC, 60Hz, 1 phase, 20 amp input
power supply.
2. Extension cord
We do not recommend an extension
cord because of the voltage drop they
produce. This drop in voltage can
affect the performance of the welder.
If you need to use an extension cord
it must be a size #12 gauge or larger.
Do not use an extension cord over 25
ft. in length.
3. Install the wire roller
Open the wire feed compartment.
Before installing any welding wire into
the unit, the proper sized groove must
be placed into position on the wire
drive mechanism. Adjust the drive
roller according to the following steps,
see following picture about the wire
feeder structure:
Assembly
INSTALLING THE HANDLE
1. Line up the holes in the handles
with the holes on the top of the
welder.
2 Place a lock washer then a washer
onto the welder handle screws.
3 Insert the screws with the washers
through the holes on the welder
handle and into the top of the welder
and tighten.
MIG gun/torch assembled,
some assembly required for
ground cable.
Installation
1. Power requirement
AC single phase 115v (110-120V),
60HZ fused with a 20amp time
6
Flux Core 125
Northern Industrial Welder
Operating Instructions and Parts Manual
Wire Feed, Gasless Welder
Inlet Guide
Tube
Drive
Tension
Adjustment
Drive
tension
arm
outside edge of the wire spool and
bend it over to hold the wire in place.
Remove the spool of wire from the
drive compartment of the welder.
3.4. Rotate the Drive Roller Cap
counterclockwise and remove it from
the Drive Roller.
Gun
liner
Drive
Roller
3.1. Open the door to the welder drive
compartment.
3.2. Remove the drive tension (see 1)
by loosening the tension adjusting
knob and lifting the Drive Tension
Adjustor away from the Drive Tension
Arm (see 2). Lift the drive tension arm
away from the drive roller (see 3).
See following images for reference
3.5. Pull the Drive Roller off of the
Drive Roller Shaft.
3.6 Based on the wire diameter,
select the correct groove using the
following table.
Wire Diameter
Roller Groove
.030 inch
0.9
.035 inch
0.9
The drive roller has two wire size
grooves built into it. When installing
the drive roller, the number stamped
on the drive roller for the wire size
you are using should be facing you.
Push the drive roller onto the drive
roller shaft.
3.3. If there is wire already installed in
the welder, roll it back onto the wire
spool by hand-turning the spool
clockwise. Be careful not to allow the
wire to come out of the rear end of
the inlet guide tube without holding
onto it or it will unspool itself. Put the
end of the wire into the hole on the
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Flux Core 125
Northern Industrial Welder
Operating Instructions and Parts Manual
Wire Feed, Gasless Welder
unspool itself when the trigger is
released. Readjust the spool tension
using the wing nut as necessary to
correct for either problem.
4.2.7. With the welder disconnected
from the power source, remove the
leading end of the wire from the spool.
Hold on to it securely, so as not to
allow unspooling or tangling of the
wire as it will result in tangled wire
and lost time.
4.2.8. Cut off any bent portion of the
wire using a wire cutter.
4.2.9. Loosen the tension adjusting
knob holding the drive tension arm in
place and lift the tension arm up off
the drive roller.
4.2.10. Insert the wire into the inlet
guide tube, feed it across the drive
roller and into the torch assembly
about six inches.
4.2.5 The welder can use either 4” or
8” spools, see the following figure for
additional reference. 8” spool requires
an adaptor. The wing nut controls the
tension on the spool.
Wing
nut
8” wire
spool
4” wire
spool
8” spool
Adaptor
• Make certain that the welding
wire is actually going into the torch
liner. If not, the wire will jam up in
the mechanism.
4.2.11 Line the wire up with the
correct groove in the drive roller.
Place the drive tension arm back
above the drive roller.
4.2.12 Place the drive tension
adjustment arm back in place.
4.2.13 Tighten (turn clockwise) the
drive tension adjusting knob until the
tension roller is applying enough
force on the wire to prevent it from
slipping in the drive rollers.
4.2.14. NOW YOU CAN LET GO OF
THE WIRE.
4.2.15. Plug in and turn the welder
ON. Set the VOLTAGE switch to the
voltage (heat) setting recommended
for the gauge metal that is to be
4.2.6. Setting the wire spool tension:
a) Turn the spool of wire with one
hand.
b) Increase the spool tension by
tightening (turn clockwise) the wing
nut while turning the spool. Turn the
spool while tightening the wing nut
until the spool slows down and
operator feels a slight drag.
Stop tightening the wing nut, operator
may need to repeat these steps until
proper spool tension is achieved.
NOTE:
If TOO MUCH tension is applied to
the wire spool, the wire will slip on the
drive roller or will not be able to feed
at all. If TOO LITTLE tension is
applied, the spool of wire will want to
9
Flux Core 125
Northern Industrial Welder
Operating Instructions and Parts Manual
Wire Feed, Gasless Welder
certain that the wire coming out of
the end of the torch does not come
in contact with work piece, ground
clamp or any grounded material
during the drive tension setting
process or arcing will occur.
5.1. Press the trigger on the gun.
5.2. Turn the drive tension adjustment
knob clockwise, increasing the drive
tension until the wire seems to feed
smoothly without slipping.
welded. Refer to the set up chart on
the back side of the drive
compartment door.
CAUTION:
The welding wire is electrically hot
when the power is on and the MIG
gun trigger is activated.
.
4.2.16. Set the WIRE SPEED control
to the middle of the wire speed range.
4.2.17. Straighten the MIG gun cable
and pull the trigger in the gun handle
to feed the wire through the torch
assembly. When at least one inch of
the wire sticks out past the end of the
torch, release the trigger.
4.2.18 Turn the Power Switch to the
OFF position.
4.2.19 Select a contact tip stamped
with the same diameter as the wire
being used.
NOTE:
Due to inherent variances in FluxCored welding wire, it may be
necessary to use a contact tip one
size larger than your Flux Core wire if
wire jams occur.
4.2.20. Slide the contact tip over the
wire (protruding from the end of the
MIG gun). Thread the contact tip into
the end of the gun and hand-tighten
securely.
4.2.21. Install the nozzle on the gun
assembly. To keep spatter from
sticking to inside of the nozzle use
anti-spatter spray or gel.
4.2.22 Cut off excess wire that
extends past the end of the nozzle
more than ¼”.
4.2.23. Turn the welder ON
5. Setting the wire tension
Operation
High voltage danger from power
source! Consult a qualified
electrician for proper installation of
receptacle at the power source.
This welder must be grounded
while in use to protect the operator
from electrical shock. If you are
not sure if your outlet is properly
grounded, have it checked by a
qualified electrician. Do not cut off
the grounding prong or alter the
plug in any way and do not use
any adapters between the welder’s
power cord and the power source
receptacle. Make sure the POWER
switch is OFF then connect your
welder’s power cord to a properly
grounded 115 Vac (110v-120v),
60Hz, single phase, 20 amp power
source.
1. Main control component
Power switch - The power switch
supplies electrical current to the
welder. Whenever the power switch is
in the ON position, the welding circuit
is activated. ALWAYS turn the power
switch to the OFF position and unplug
the welder before performing any
maintenance.
Arc flash can injure eyes! To
reduce the risk of arc flash, make
10
Flux Core 125
Northern Industrial Welder
Operating Instructions and Parts Manual
Wire Feed, Gasless Welder
Voltage selector - The voltage
selector controls the welding heat.
This unit has two step voltage control.
Refer to the label inside the welder
side door for recommended voltage
selector settings for your welding job.
Wire speed control - The wire speed
control adjusts the speed at which the
wire is fed out of the welding torch.
The wire speed needs to be closely
matched (tuned-in) to the rate at
which it is being melted off. Some
things that affect wire speed selection
are the type and diameter of the wire
being used, the heat setting selected,
and the welding position to be used.
Note: The wire will feed faster without
an arc. When an arc is being drawn,
the wire speed will slow down.
2. Hold the torch (MIG gun)
The best way to hold the welding
torch is the way that feels most
comfortable to you. While practicing
to use your new welder, experiment
holding the torch in different positions
until you find the one that seems to
work best for you.
3. Position the torch to the work
piece
There are two angles of the torch
nozzle in relation to the work piece
that must be considered when
welding.
3.1. Angle A can be varied, but in
most cases the optimum angle will be
60 degrees, the point at which the
torch handle is parallel to the work
piece. If angle A is increased,
penetration will increase. If angle A is
decreased, penetration will decrease
also.
3.2. Angle B can be varied for two
reasons: to improve the ability to see
the arc in relation to the weld puddle
and to direct the force of the arc.
4. Distance from the work piece
If the nozzle is held off the work
piece, the distance between the
nozzle and the work piece should be
kept constant and should not exceed
1/4 inch or the arc may begin
sputtering, signaling a loss in welding
performance.
5. Tuning in the wire speed
This is one of the most important
parts of MIG welder operation and
must be done before starting each
welding job or whenever any of the
following variables are changed: heat
setting, wire diameter, or wire type.
EXPOSURE TO A WELDING ARC
IS EXTREMELY HARMFUL TO THE
EYES AND SKIN!
Prolonged exposure to the welding
arc can cause blindness and burns.
Never strike an arc or begin
welding until you are adequately
11
Flux Core 125
Northern Industrial Welder
Operating Instructions and Parts Manual
Wire Feed, Gasless Welder
diameter wire, or a different type of
welding wire.
protected. Wear flameproof
welding gloves, a heavy long
sleeved shirt, trousers with out
cuffs, high topped shoes, and an
ANSI approved welding helmet.
5.1. Connect the Ground Clamp to a
scrap piece of the same type of
material which you will be welding. It
should be equal to or greater than the
thickness of the actual work piece,
and free of oil, paint, rust, etc.
5.2. Select a heat setting.
5.3. Hold the torch in one hand,
allowing the nozzle to rest on the
edge of the work piece farthest away
from you, and at an angle similar to
that which will be used when welding.
(See HOLDING THE TORCH if you
are uncertain of the angle at which
you will be welding).
5.4. With your free hand, turn the
Wire Speed Dial to maximum and
continue to hold onto the knob.
5.5. Lower your welding helmet and
pull the trigger on the torch to start an
arc, then begin to drag the torch
toward you while simultaneously
turning the Wire Speed Dial counterclockwise.
5.6. LISTEN! As you decrease the
wire speed, the sound that the arc
makes will change from a sputtering
to a high-pitched buzzing sound and
then will begin sputtering again if you
decrease the wire speed too much.
The point on the wire speed
adjustment where the high-pitched
buzzing sound is achieved is the
correct setting. You can use the wire
speed control to slightly increase or
decrease the heat and penetration for
a given heat setting by selecting
higher or lower wire speed settings.
Repeat this tune-in procedure if you
select a new heat setting, a different
6. Welding Techniques
EXPOSURE TO A WELDING ARC
IS EXTREMELY HARMFUL TO THE
EYES AND SKIN! Prolonged
exposure to the welding arc can
cause blindness and burns. Never
strike an arc or begin welding until
you are adequately protected.
Wear flameproof welding gloves, a
heavy long sleeved shirt, trousers
with out cuffs, high topped shoes
and an ANSI approved welding
helmet.
ELECTRIC SHOCK CAN KILL! To
prevent ELECTRIC SHOCK, do not
perform any welding while
standing, kneeling, or lying directly
on the grounded work.
6.1 Moving the torch
Torch travel refers to the movement
of the torch along the weld joint and is
broken into two elements: Direction
and Speed. A solid weld bead
requires that the welding torch be
moved steadily and at the right speed
along the weld joint. Moving the torch
too fast, too slow, or erratically will
prevent proper fusion or create a
lumpy, uneven bead.
Travel direction is the direction the
torch is moved along the weld joint in
relation to the weld puddle. The torch
is either PUSHED into the weld
puddle or PULLED away from the
weld puddle.
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Flux Core 125
Northern Industrial Welder
Operating Instructions and Parts Manual
Wire Feed, Gasless Welder
For most welding jobs you will pull the
torch along the weld joint to take
advantage of the greater weld puddle
visibility.
Travel speed is the rate at which the
torch is being pushed or pulled along
the weld joint. For a fixed heat setting,
the faster the travel speed, the lower
the penetration and the lower and
narrower the finished weld bead.
Likewise, the slower the travel speed,
the deeper the penetration and the
higher and wider the finished weld
bead.
6.2 Types of welding beads
As you become more familiar with
your new welder and better at laying
some simple weld beads, you can
begin to try some different weld bead
types.
The STRINGER BEAD is formed by
traveling with the torch in a straight
line while keeping the wire and nozzle
centered over the weld joint. See
following figure.
6.3 Welding position
FLAT POSITION is easiest of the
welding positions and is most
commonly used. It is best if you can
weld in the flat position if at all
possible as good results are easier to
achieve.
HORIZONTAL POSITION Is
performed very much the same as
the flat weld except that angle B (see
HOLDING THE TORCH) is such that
the wire, directed more toward the
metal above the weld joint is to help
prevent the weld puddle from running
downward while still allowing slow
enough travel speed. A good starting
point for angle B is about 30 degrees
DOWN from being perpendicular to
the work piece.
The WEAVE BEAD Used when you
want to deposit metal over a wider
space than would be possible with a
stringer bead. It is made by weaving
from side to side while moving with
the torch. It is best to hesitate
momentarily at each side before
weaving back the other way.
VERTICAL POSITION It is easier for
many people to Pull the torch from
top to bottom. It can be difficult to
prevent the puddle from running
downward. Pushing the torch from
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Flux Core 125
Northern Industrial Welder
Operating Instructions and Parts Manual
Wire Feed, Gasless Welder
The illustrations in following figure
show the sequence for laying multiple
pass beads into a single “V” butt joint.
bottom to top may provide better
puddle control and allow slower rates
of travel speed to achieve deeper
penetration. When vertical welding,
angle B (see HOLDING THE TORCH)
is usually always kept at zero, but
angle A will generally range from 45
to 60 degrees to provide better
puddle control.
OVERHEAD POSITION Is the most
difficult welding position. Angle A (see
HOLDING THE TORCH) should be
maintained at 60 degrees.
Maintaining this angle will reduce the
chances of molten metal falling into
the nozzle. Angle B should be held at
zero degrees so that the wire is
aiming directly into the weld joint. If
you experience excessive dripping of
the weld puddle, select a lower heat
setting. Also, the weave bead tends
to work better than the stringer.
NOTE:
WHEN USING SELF-SHIELDING
FLUX-CORE WIRE it is very
important to thoroughly chip and
brush the slag off each completed
weld bead before making another
pass or the next pass will be of poor
quality.
Fillet Weld Joints. Most fillet weld
joints, on metals of moderate to
heavy thickness, will require multiple
pass welds to produce strong joint.
The illustrations in Figure 19 show
the sequence of laying multiple pass
beads into a T fillet joint and a lap
fillet joint.
6.4 Multiple pass welding
Butt Weld Joints When butt welding
thicker materials, you will need to
prepare the edges of the material to
be joined by grinding a bevel on the
edge of one or both pieces of the
metal being joined. When this is done,
a “V” is created between the two
pieces of metal, that will have to be
welded closed. In most cases more
than one pass or bead will need to be
laid into the joint to close the “V”.
Laying more than one bead into the
same weld joint is known as a
multiple-pass weld.
6.5 Spot welding
There are three methods of spot
welding: Burn-Through, Punch and
Fill, and Lap. Each has advantages
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Flux Core 125
Northern Industrial Welder
Operating Instructions and Parts Manual
Wire Feed, Gasless Welder
3. The LAP SPOT METHOD directs
the welding arc to penetrate the
bottom and top pieces, at the same
time, right along each side of the lap
joint seam. Select the wire diameter,
heat setting, and tune in the wire
speed as if you were welding the
same thickness material with a
continuous bead.
6.6 SPOT WELDING
INSTRUCTIONS
1. Select the wire diameter and heat
setting recommended above for the
method of spot welding you intend to
use.
2. Tune in the wire speed as if you
were going to make a continuous
weld.
3. Hold the nozzle piece completely
perpendicular to and about 1/4 inch
off the work piece.
4. Pull the trigger on the torch and
release it when it appears that the
desired penetration has been
achieved.
5. Make practice spot welds on scrap
metal, varying the length of time you
hold the trigger, until a desired spot
weld is made.
6. Make spot welds on the actual
work piece at desired locations.
and disadvantages depending on the
specific application as well as
personal preference.
1. The BURN-THROUGH METHOD
welds two overlapped pieces of metal
together by burning through the top
piece and into the bottom piece. With
the burn-through method, larger wire
diameters tend to work better than
smaller diameters. Wire diameters
that tend to work best, with the burnthrough method are 0.035 inch selfshielding Flux-Core wire. Do not use
0.030 inch self-shielding Flux Core
wires when using the burn-through
method unless the metal is VERY thin
or excessive filler metal build-up and
minimal penetration is acceptable.
Always select the HIGH heat setting
with the burn-through method and
tune in the wire speed prior to making
a spot weld.
2. The PUNCH AND FILL METHOD
produces a weld with the most
finished appearance of the three spot
weld methods. In this method, a hole
is punched or drilled into the top
piece of metal and the arc is directed
through the hole to penetrate into the
bottom piece. The puddle is allowed
to fill up the hole leaving a spot weld
that is smooth and flush with the
surface of the top piece. Select the
wire diameter, heat setting, and tune
in the wire speed as if you were
welding the same thickness material
with a continuous bead.
Maintenance
The welder needs the regular
maintenance as following:
Periodically clean dust, dirt, grease,
etc. from your welder. Every six
months, or as necessary, remove the
cover panel from the welder and airblow any dust and dirt that may have
accumulated inside the welder.
Replace power cord, ground cable,
ground clamp, or electrode assembly
when damaged or worn.
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Flux Core 125
Northern Industrial Welder
Operating Instructions and Parts Manual
Wire Feed, Gasless Welder
When transporting or storing the
welder after use, it is recommended
to repack the product as it was
received for protection. (Cleaning is
required before storage and you must
seal the plastic bag in the box for
storage
MINOR AND ROUTINE
MAINTENANCE
Store in a clean, dry location away
from corrosive gas, excess dust and
high humidity. In temperatures from
10eF̢120°F and a relative humidity
less than 90%.
Trouble shooting Chart
Symptom (s)
Welder does not
work when the
main switch is
turned on
Possible Causes(s)
1.No power input
2. Power cord or power plug
is broken
3.Main switch is broken
4.Transformer is broken
1.Incorrect power input
2.Inadequate current at
output
3.Poor connection of output
cable
4. Dirty surfaces
5. Wrong welding wire
Corrective Action(s)
1.Check circuit or fuse of
power source
2.Replace power cord
3.Replace switch
4.Replace transformer
1.Check the power source
2.Check for proper
grounding to the work
piece.
3.Check output connection
4. Clean surfaces
5. Use correct wire
Blown fuse or
tripped circuit
breaker
Inadequate fuse or circuit
breaker
Check the fuse in power
source should be 20amp
Arc is hard to start
1. Wrong welding wire
2. Base metal not grounded
reliable
1. Not enough drive roller
pressure
2. Spool hub tension too tight
or loose
3. Contact tip worn or wrong
size
4. Rusty or corroded wire
1.Use correct one
2.Make sure the
connection is good
1. Tighten the drive
tension adjustor on wire
feeder
2. Adjust the wing nut on
the spool holder
3. Replace contact tip
4. Replace wire.
Northern 800#
Will not weld
Inconsistent arc or
wire feed
Misc
Please provide the following:
- Model Number
- Serial Number (if any)
- Part description and number as shown on parts list
16
Flux Core 125
Northern Industrial Welder
Operating Instructions and Parts Manual
Wire Feed, Gasless Welder
Repair Parts List
Reference
number
Description
Part number
Qty
1
Left panel
1.1.01.02.0280
1
2
Wire feeder
2.07.40.370
1
2A
Drive roller
2.20.09.014
1
2B
Roller cover
2.20.09.601
1
3
Fuse holder
2.07.52.005
1
4
Fuse
2.07.52.014
1
5
Control Transformer
1.2.07.02.0036
1
6
Circuit breaker
2.07.80.301
1
7
Spool holder
1.2.01.01.0756
1
7A
Rear bushing
2.06.29.301
1
7B
Spool baffle
1.1.02.01.0762
1
17
Flux Core 125
Northern Industrial Welder
Operating Instructions and Parts Manual
Wire Feed, Gasless Welder
7C
8” spool adaptor
2.05.17.008
1
7D
4” spool holder
1.1.03.01.0050
1
1
7E
Washer
1.1.02.01.0799
7F
Front Bushing
2.05.17.010
1
7G
Mat washer
2.06.17.005
1
7H
Wing nut
2.06.05.002
1
Plastic hinge
2.05.05.064
2
8
9
Fan bracket
1.1.02.01.0609
1
10
Fan motor
1.2.07.02.0027
1
11
Fan blade
2.07.89.707
1
12
Back panel
1.1.01.03.0704
1
13
Cable holder
2.05.05.201
1
14
Power cord
1.2.07.01.0050
1
15
Vertical Middle panel
1.1.01.03.0703
1
16
Right panel
1.1.01.02.0281
1
17
Bottom
1.1.01.03.0705
1
18
Feet
2.05.05.016
4
19
Thermal relay
2.07.36.527
1
20
Main Transformer
1.1.04.01.0482
1
21
Handle
2.05.05.042
1
22
PCB Board
1.1.05.02.0168
1
23
PCB support
2.05.05.106
1
24
Front panel
2.05.05.073
1
25
Cable holder
2.05.05.202
1
26
Ground Cable clamp
1.2.08.02.0079
1
27
Torch
1.2.07.02.0935
1
28
Potentiometer Knob
2.07.11.009
1
18
Flux Core 125
Northern Industrial Welder
Operating Instructions and Parts Manual
Wire Feed, Gasless Welder
29
Indicator
1.2.07.02.0057
1
30
Main Switch
2.07.80.211
1
31
Setting Switch
2.07.80.031
1
32
Cable holder
2.04.31.107
1
33
Door Bolt
2.08.07.803
1
Schematic diagram
TR1
24V
~110V
Black wire
White wire
Green wire
Other Safety and Standards Information
This manual is designed to inform the operator of safety and general use of this
model only. For further information about welding safety refer to the following
standards and comply with them where applicable.
• ANSI Standard Z49.1 — SAFETY IN
WELDING AND CUTTING obtainable
from: American Welding Society 550 NW
Le Jeune Road, Miami, FL 33126
Tel. (800) 443-9353
Fax (305) 443-7559
www.amweld.org or www.aws.org
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Northern Industrial Welder
Operating Instructions and Parts Manual
Wire Feed, Gasless Welder
• ANSI Standard Z87.1 — SAFE PRACTICE
FOR OCCUPATION AND EDUCATIONAL
EYE AND FACE PROTECTION
Obtainable from: American National
Standards Institute (ANSI) 11 West 42nd
St. New York, NY 10036
Tel. (212) 642-4900
Fax (212) 398-0023 www.ansi.org
• NFPA Standard 51B — CUTTING AND
WELDING PROCESS obtainable from:
National Fire Protection Association,
1 Batterymarch Park, P.O. Box 9101
Quincy, MA 02269-9101
Tel. (617) 770-3000
Fax (617) 770-0700 www.nfpa.org
• OSHA Standard 29 CFR, Part 1910,
Subpart Q. —WELDING, CUTTING AND
BRAZING obtainable from your state
OSHA office or from: U. S. Dept. of Labor
OSHA, Office of Public Affairs Room
N3647, 200 Constitution Ave. NW
Washington, DC 20210 www.osha.gov
• CSA Standard W117.2 — Code for
SAFETY IN WELDING AND CUTTING
Obtainable from: Canadian Standards
Association, 178 Rexdale Blvd.,
Etobicoke, Ontario M9W 1R3
www.csa.ca
• American Welding Society Standard A6.0
—WELDING AND CUTTING CONTAINERS
WHICH HAVE HELD COMBUSTIBLES
Obtainable from: American
Welding Society, 550 NW Le Jeune Road
Miami, FL 33126
Tel. (800) 443-9353
Fax (305) 443-7559
www.amweld.org or www.aws.org
20
Flux Core 125
Warranty
Northern Tool + Equipment
Effective Jan 1, 2009
Limited Warranty
This warranty applies to the original purchaser and is subject to the terms and conditions listed below.
This Limited Warranty is for new equipment sold after the above date, providing coverage for defects
in material and workmanship at the time it is shipped from the factory.
Limited to the warranty periods listed below, Northern Tool + Equipment will repair or replace the item
under warranty that fails due to defects in material and workmanship. Northern Tool + Equipment
must be notified within 30 days of the failure, so as to provide instructions on how to proceed with the
repair of your welder and warranty claim processing. Warranty period begins at the time the welder is
purchased from Northern Tool + Equipment.
Warranty Periods
Limited Warranty is divided into four categories: No warranty, 6 months, 1 year, 2 year.
No Warranty
Normal wear items, MIG gun parts (contact tips, nozzle, adapter, MIG gun liner), drive roll, electrode
holder, are not covered under warranty.
6 Months
Parts and labor performed by authorized repair center with original equipment repair parts
1 Year
MIG gun parts (except those listed under normal wear items), cables, regulator.
2 Year
Includes: transformer, reactor, rectifier, solenoid valve, PC board, switches, controls, gas valve, drive
motor, drive system.
Northern Tool + Equipment Co.
2800 Southcross Drive West
PO Box 1219
Burnsville MN 55337