GOWELDINST JUNE 2007
OPERATING
Broco products are built with
your safety in mind, but it is
INSTRUCTIONS
the responsibility of the
operator to exercise good
work practices and common
MANUAL
sense.
WARNING: You must read
and understand these
operating instructions
thoroughly and follow the
procedures contained herein
before attempting to use the
Broco GOWELD portable
welder. Failure to do so can
result in death, serious injury,
property damage or poor
GOWELD Portable Welder
performance.
DC Only Input: 42 VDC 300A MAX
Made in the U.S.A. by:
IF YOU HAVE ANY QUESTIONS
REGARDING THE SAFE
Broco, Inc.
OPERATION OF PRODUCTS,
10868 Bell Court
STOP! DO NOT ATTEMPT TO
Rancho Cucamonga, CA 91730-4819
OPERATE! Contact Broco, Inc.,
Tel: 909 483 3222 Fax: 909 483 3233
Tel: 800-845-7259 / 909-
Toll Free: 800 845 7259
483-3222, fax: 909-483-
E-mail Sales @Brocoinc.com
3233, for technical
www.brocoinc.com
assistance.
WARNING:
ARC WELDING CAN BE HAZARDOUS. PROTECT YOURSELF
AND OTHERS FROM POSSIBLE SERIOUS INJURY OR
DEATH. KEEP CHILDREN AWAY. PACEMAKER WEARERS
MUST CONSULT THEIR DOCTORS BEFORE OPERATING.
WEAR PROPER FACE AND EYE PROTECTION,
APPROPRIATE PROTECTIVE (FLAME OR SPARK
RESISTANT) CLOTHING, FOOTWEAR AND GLOVES. DO
NOT BREATHE WELDING FUMES AND GASES.
鈥? ELECTRIC & MAGNETIC FIELDS MAY BE
DANGEROUS.
鈥? ELECTRIC SHOCK CAN KILL.
鈥? ARC RAYS CAN BURN EYES & EXPOSED SKIN.
鈥? FUMES & GASES CAN BE DANGEROUS.
鈥? WELDING SPARKS CAN CAUSE FIRE & EXPLOSION.
鈥? GAS CYLINDERS CAN EXPLODE IF DAMAGED.
WARNING:
Welding equipment is potentially dangerous to the
operator and persons in the area and must be used in
strict accordance with the instructions provided. Read the
instruction manual before using GOWELD. Welding
should be performed by trained individuals only and
according to industry accepted safety practices.
漏 2007 by BROCO, INC. all rights reserved. This manual
may not be reproduced in whole or in part without the
express written permission of Broco, Inc.
TABLE OF CONTENTS
INFORMATION
SAFETY
Chapter 1 SAFETY PRECAUTIONS AND
GENERAL INFORMATION
PREPARATION
Section I. INTRODUCTION
1-1. WELDING PROCESS
1-2. WARNINGS
1-3. SAFETY PRECAUTIONS
Section II. EQUIPMENT DESCRIPTION
1-4. GOWELD WELDER FEATURES
OPERATION
Chapter 2 PREPARATION
Section I. SETUP PROCEDURES
2-1. PREPARING THE WORK AREA
2-2. PRE-ASSEMBLY INSPECTION
MAINTENANCE
Section II. GOWELD SETUP
2-3. LOADING THE WIRE
2-3-1. Wire selection.
2-3-2. Contact tip.
2-3-3. Loading electrode / wire drive
2-3-4. Tension roller pressure setting. TROUBLESHOOTING
2-4. CABLE CONNECTIONS
2-4-1. Harness to power source.
2-4-1-1. Batteries.
2-4-2. GOWELD to harness.
2-4-2-1. Choosing polarity.
2-4-2-2. Power & ground leads.
2-5. GAS CONNECTION
2-5-1. Regulator adjustment.
2-5-2. Gas hose connection.
Chapter 3 OPERATING INSTRUCTIONS
Section I. INTRODUCTION
3-1. TORCH OPERATION
Section lI. OPERATING PROCEDURES
3-2. WELDING CAPABILITY
3-3. CONTROLS & SETTINGS
3-3-1. Wire speed control.
3-3-2. Voltage control.
3-3-3. LED indicators.
3-4. SEQUENCE OF OPERATION
3-5. WELDING TECHNIQUES
3-6. AUTOMATIC PROTECTION SHUTDOWN
3-7. SHUTDOWN PROCEDURES
Chapter 4 SCHEDULED MAINTENANCE
Section I. INTRODUCTION
4-1. PREVENTIVE MAINTENANCE
Section II. SCHEDULED MAINTENANCE
4-2. PREVENTIVE MAINTENANCE
PROCEDURES
Chapter 5 TROUBLESHOOTING
5-1. USING THE TROUBLESHOOTING
GUIDE.
5-2. TROUBLESHOOTING GUIDE.
Chapter 6 CORRECTIVE MAINTENANCE
INFORMATION
Chapter 1 GENERAL INFORMATION AND SAFETY
SAFETY
PRECAUTIONS
Section I. INTRODUCTION
1-1. WELDING PROCESS
GOWELD is the lightest most portable, full-function, smart
semi-automatic wire feed welder. GOWELD goes where you
go, in the field, in the shop, in the garage. With GOWELD the
operator can weld with solid wire electrode and shielding gas
(MIG) or self-shielded flux core wire electrode (FCAW). Wire
welding is the most economical welding method, due to the
high deposition rate, high efficiency, and low equipment
cost.
GOWELD uses DC power from 2 (or 3) 12V rechargeable
batteries (automobile or deep cycle type) to weld steel or
aluminum. GOWELD can also be used as a spool gun for
conventional CV welding power sources utilizing an accessory
voltage regulator.
GOWELD accommodates 4鈥? (10cm) diameter 2 lb (0.9 kg)
spools of .023 (0.6mm) to .045 (1.1mm) diameters wire
electrode to weld material in excess of 1/2鈥? (13mm) thick. A
trigger operated valve controls the flow of the shielding gas.
GOWELD features a die cast aluminum chassis, heavy duty
motor with optical encoder and programmed microprocessor
control circuit to monitor feed and weld functions. Together
the optical encoder and microprocessor yield speed control
with the least variance. LED indicators show power, polarity,
low battery warning and motor status.
1-2. WARNINGS AND SAFETY PRECAUTIONS
WARNING
This statement appears where the information must
be followed exactly to avoid serious personal injury
or loss of life.
CAUTION
This statement appears where the information must
be followed to avoid minor personal injury or
damage to property.
1-2-1. Warnings.
WARNING
To avoid serious injury or death, all personnel shall heed these warnings.
a. All users and their supervisory personnel must read and be thoroughly
familiar with these operating instructions prior to using this
equipment.
b. Never use the equipment unless you are familiar with acceptable
industrial welding and cutting procedures and practices.
c. Always use this equipment following generally accepted industrial
safety procedures and practices.
d. Always apply and adhere to ANSI/ASC Z49.1-1988 Safety in Welding
and Cutting standards, NFPA 51B-1989 Cutting and Welding
Processes, and ANSI Z87.1-1989 the Practice for Occupational and
Educational Eye and Face Protection, or similar locally prevailing
standards when using this equipment.
e. Never remove, cover, or alter the warning labels attached to this
equipment.
f. Never point the welder at anybody.
g. Never open the GOWELD housing, no user serviceable parts are
within. Always return GOWELD to the factory or an authorized repair
facility for major repairs.
h. Never modify this equipment in any manner or use it in any way not
specified in this manual.
i. Never use any equipment that is unsafe or appears to be unsafe.
INFORMATION
SAFETY
1-2-2. Safety Precautions.
WARNING
Failure to heed these safety precautions may result in death, severe bodily
injury, or severe property damage. Protect yourself and others. Fumes and
gases developed may be dangerous to your health. Ultra-violet rays and
splatter can injure eyes and exposed skin. Electric shock can kill. Welding
sparks can cause fire or explosion. Compressed gas cylinders may explode
if damaged.
NOTE
Vibrations produced by GOWELD during a normal operating cycle do not
exceed 2.5m/s2, the minimum reportable standard for hand-held and
hand-guided machinery.
This equipment produces airborne noise emissions in excess of 70 dB(A).
GOWELD sound level has been measured at 74 dB(A) during a normal
operating cycle.
a. Always clear the work area of flammable materials. If this is not
possible, cover them to prevent the welding sparks from starting
a fire. Always have an approved fire extinguisher in good working
condition available.
b. Never weld in an explosive atmosphere.
c. Always use extreme caution when operating the welder in windy
or other adverse conditions.
d. Always clear the work area of unnecessary bystanders.
e. The operator and all bystanders must always wear adequate face
and eye protection, protective (flame and/or spark resistant)
clothing, footwear, and gloves when using this equipment. Wear
oil free protective garments such as leather gloves, heavy shirt,
cuffless pants, high leather steel-toed work shoes, and a cap over
your head.
f. Always use a number 10 or 11 shade welding filter lens when
welding or observing welding to protect your eyes from arc rays.
Always wear safety glasses with side shields when in a welding
area to protect from sparks.
g. Always wear earplugs when welding in a confined space or out of
position. Falling sparks can cause injury.
h. Always wear approved hearing protection.
i. Always remove all personal metal items (i.e., rings, watches, etc.)
when working with the torch as they can trap sparks and slag
causing a severe burn and damage to the item.
j. Always keep your head away from the fume plume. Welding
fumes and gases may be hazardous to your health.
k. Always use adequate ventilation and exhaust at the arc point to
keep fumes and gases from your breathing zone as well as the
general area. Special breathing apparatus may be required when
welding in confined spaces or when welding or cutting
galvanized, cadmium plated (or other heavy metal plated), or
painted parts to avoid inhalation of toxic fumes and gases.
l. Never weld in locations near chlorinated hydrocarbon vapors
coming from degreasing, cleaning or spraying operations.
Phosgene, a highly toxic gas, may form.
m. Always use enough ventilation in confined spaces to prevent
shielding gases from displacing air and causing injury or death.
n. Always read and understand the material safety data sheet
(MSDS) for the electrode being used with this equipment.
o. Always consult a physician before welding if you have a
pacemaker or history of heart problems.
p. Always insulate yourself from the work and the ground using dry
insulation large enough to cover the full area of physical contact
with the work and ground.
q. Never touch live electrical parts. The welder is 鈥渉ot鈥? when
attached to a battery or other power source. The electrode,
electrode reel, welding head, contact tip, nozzle and other
exposed metal parts are also 鈥渉ot.鈥? Never touch these parts with
bare skin or wet clothing. Always wear dry, hole-free gloves to
insulate hands.
r. Never lay the welder on top of the work or place it where it can
accidentally contact the work or ground or other metal that
contacts the work or ground. Electric arc or overheating may
result in shock or fire hazard.
s. Always be sure the ground cable makes a good electrical
connection with the metal being welded. The connection should
be as close as possible to the area being welded.
t. Never coil the electrode lead around your body.
u. Never place your body between the electrode and the ground
cable.
INFORMATION
v. Always use a safety belt to prevent a fall should you get a shock
when working above floor level.
SAFETY
w. Always keep the welder away from compressed gas cylinders,
and batteries. Protect gas cylinders and batteries from falling
sparks or molten metal.
x. Never heat, cut or weld tanks, drums or containers unless purged
with inert gas (such as argon or nitrogen) or other steps have
been taken to insure that flammable or toxic vapors are not
present.
y. Always vent hollow castings or containers before heating, cutting
or welding to prevent explosion.
z. Never allow falling sparks or molten metal to contact any part of
the welder, its cables or hose. Damage may result which could
render the equipment unsafe to operate.
aa. Always use caution when welding overhead to avoid falling
sparks, molten material, and falling objects.
bb. Never use a high pressure gas cylinder that does not comply with
current inspection and testing requirements. Always ensure the
cylinder is marked with a sticker showing a valid inspection
certification.
cc. Always keep high pressure gas cylinders in an upright position,
securely chained to a cart or fixed support.
dd. Never drop a high pressure gas cylinder. Never leave a high
pressure gas cylinder in direct sunlight for prolonged periods.
Never expose a high pressure gas cylinder to fire or extreme
heat. High pressure gas cylinders can be dangerous. Use with
caution.
ee. Always ensure the correct over pressure safety relief device is
installed in the high pressure cylinder valve. Never use a safety
relief device whose burst pressure is higher than that
recommended by the cylinder manufacturer.
ff. Always keep valve protection caps in place and hand tight except
when the cylinder is in use or connected for use.
gg. Always keep your head and face away from the cylinder valve
outlet and regulator when opening the cylinder valve.
hh. Always use DC power. Never connect AC electric power to this
welder.
ii. Always know the composition of the target material.
jj. Always know what is behind the target material.
kk. Always ensure that all parts of the welder are in good working
order prior to use to avoid potential malfunction.
See: American National Standard Z49.1-88 Safety in Welding and Cutting
published by the American Welding Society, 550 N.W. LeJeune Road;
Miami, FL 33126.
鈥淩ecommended Safe Practices for the Preparation for Welding and
Cutting of Containers and Piping That Have Held Hazardous Substances鈥?,
AWS F4.1 from the American Welding Society.
鈥淧recautions for Safe Handling of Compressed Gases in Cylinders,鈥? CGA
publication P-1, available from the Compressed Gas Association, 1235
Jefferson Davis Highway, Arlington, VA 22202.
OSHA Safety and Health Standards 29 CFR 1910 available from the U.S.
Department of Labor; Washington, D.C. 20210.
Section 2. EQUIPMENT DESCRIPTION
INFORMATION
1-4. GOWELD WELDER FEATURES
SAFETY
1. Dual mode operation- GOWELD can be used as a stand-alone welder
with battery power source or as a MIG spool gun with a MIG
compatible welder (GMAW or FCAW mode) when used with the
accessory power conditioning unit, 鈥淧CU鈥?.
2. GOWELD is designed for 42 volts DC max welding power input,
allowing the use of three batteries in series for longer duration or
welding steel to 1鈥? (25cm) thick..
3. Die cast aluminum chassis- all hardware is mounted to this internal
chassis (frame). It supports the motor, drive assembly, trigger, micro
switch, gas valve, circuit board and wire spool.
4. The plastic housing shrouds the working portions of the welder,
protecting from exposure and adding visual style.
5. Wire speed control is at the welder鈥檚 fingertips. Large knob has easy
to read numbers. Each graduation represents 100 inches (250cm) per
minute (ipm). Operating range of 50 - 1,000 ipm (125 鈥? 2,500
cm/minute).
6. Spring loaded, hinged top cover for easy electrode loading. Over sized
knob is easy to grasp while wearing gloves.
7. Heavy duty drive mechanism includes high torque 12 volt industrial
motor containing oversized windings and ball bearings to ensure
maximum life.
8. Knurled gearing is steel. Tension wheel has ball bearings.
9. Locking cam tension release lever means easy electrode loading.
GOWELD does not require application of constant pressure to offset
spring loaded tension wheel.
10. Optical encoder fitted to the back of the motor gives true speed
readings. More accurate and responsive than back EMF type systems.
11. Programmed microprocessor controls and monitors feed and weld
functions. Together the optical encoder and microprocessor yield
speed control with the least variance. More consistent speed means
more consistent welds. Battery levels are also monitored.
12. Diagnostic capabilities through the control circuit interface cable. No
disassembly is required for testing the board, processor or motor.
13. Handle mounted micro switch is more durable than board mounted
switches. Micro switch and gas valve are both operated directly off the
trigger.
14. LED indicators for power on, polarity, low battery and motor overheat
condition.
Wire Speed Control Knob Top Cover Knob
Nozzle
Top Cover
Contact Tip
Green Power LED
Yellow Volt + LED
Yellow Volt - LED
Red Low Battery LED
Trigger
Fig. 1.1 GOWELD Side View
INFORMATION
SAFETY
Spool Hub Chassis
Tension Release Lever
Tension Roller Adjusting Knob
Wire Electrode
Drive Rollers
Front Block Assembly
Rear Guide Tube
Front Guide Tube
Wire Electrode Guide
Spool Locking Screw
Fig. 1.2 GOWELD Top View
Chapter 2 PREPARATION
Section I. SETUP PROCEDURES
2-1. PREPARING THE WORK AREA
WARNING
Never operate the welder in explosive or flammable environments.
PREPARATION
Never operate the welder with other personnel or bystanders in front of the
welder or in the immediate work area.
Always use extreme caution when operating the welder in windy or other
adverse conditions.
Some plastics, paints, and plated parts give off toxic fumes. Organic
materials may be combustible. Exotic metals may ignite. Glass and thin
porcelain may shatter. Rock and minerals may spall.
a. Clear the work area of bystanders/non-essential personnel.
b. Clear the work area of flammable materials. If this is not possible,
cover them to prevent the welding sparks from starting a fire. Always
have an approved fire extinguisher in good working condition
available.
c. The operator and all bystanders must always wear adequate face and
eye protection, protective (flame and/or spark resistant) clothing,
footwear, and gloves when using this equipment. Wear oil free
protective garments such as leather gloves, heavy shirt, cuff-less
pants, high leather steel-toed work shoes, and a cap over your head.
d. Place the batteries and gas cylinder in a location away from the
immediate work area.
e. When the target material is a container or pipe, know the material
previously contained therein. Always thoroughly purge pipelines and
containers with an inert gas (such as nitrogen or argon) prior to
welding.
f. Ensure that falling material (molten metal, sparks, pieces of target
material) will not cause injury to operator or bystanders or cause
damage to property.
2-2. PRE-SETUP INSPECTION.
WARNING
Never use any equipment which is unsafe or appears to be unsafe.
a. Always inspect the power cables, gas hose, control circuit cable and
electrical connectors for damage or wear prior to and immediately
following each use of the welder.
b. Always inspect the welder for damage or wear prior to and
immediately following each use.
c. Check the battery for leaks. Never use a leaking battery as gases may
be toxic and/or combustible. Seepage may be caustic, harming skin
and eyes.
Section II. GOWELD SETUP
2-3. LOADING THE WIRE
WARNING
Never load electrode wire or remove or replace the contact tip, gas
diffuser, or other parts while the power cables are connected to the
batteries or to any other power source.
Always remove the battery cable harness clamps from the batteries before
loading electrode wire or removing or replacing the contact tip, gas
diffuser or other parts.
NOTE
Tools required are pliers, 1/2鈥? (13mm) open end wrench, 9/16鈥? (14mm)
open end wrench and wire cutters (dikes).
2-3-1. Wire selection.
GOWELD can be used with solid steel or aluminum wire or flux-
cored steel wire depending upon the job requirements and
availability of shielding gas. Solid steel wire (ER70S, AWS
SFA5.18) requires the use of 鈥淪teel Mix鈥? shielding gas (argon/
CO2 mix); aluminum wire (AWS SFA5.10) requires argon
shielding gas; and flux-cored steel wire (E71T, AWS SFA5.20) is
gasless.
GOWELD accepts wire sizes from .023鈥? (0.6mm) - .045鈥? (1.1mm)
diameter. Choose a size appropriate for the material being
welded. As a general rule, GOWELD works best over a wide range
of material thicknesses using .030鈥? (0.8mm) or .035鈥? (0.9mm)
wire.
2-3-2. Contact tip.
Welding current is transmitted to the electrode through the
contact tip. It is important that the orifice in the contact tip is
sized to correspond to the diameter of the wire electrode (i.e. use
.030鈥? [0.8mm] contact tip with .030鈥? [0.8mm] wire).
PREPARATION
Remove the contact tip and the gas diffuser prior to loading the
electrode wire.
a. Remove the nozzle by gripping it firmly in a gloved hand and
pulling it straight off the GOWELD.
b. Remove the nozzle insulator by gripping it firmly with a
gloved hand (or pliers if on too tight) and turning it
counterclockwise until the threads are clear of the gas
diffuser.
c. Use a 1/2鈥? (13mm) wrench to hold the gas diffuser in place,
grip the contact tip with the pliers and turn counterclockwise
until disengaged from the gas diffuser. Remove the contact
tip.
d. Use a 9/16鈥? (14mm) wrench to hold the front block
extension, while using the 1/2鈥? (13mm) wrench to turn the
gas diffuser counterclockwise until the threads are
disengaged from the front block extension. Remove the gas
diffuser.
2-3-3. Loading electrode / wire drive
a. Ensure the gas diffuser and contact tip have been removed
as per the previous step.
b. Open the GOWELD top cover by turning the top knob
counterclockwise until the threads are disengaged from the
spindle. Lift lid carefully until it is fully extended. Do not
allow the retention spring to slam the lid open. The retention
spring will support the lid, keeping it from falling.
c. Turn the spool locking screw counterclockwise to reduce the
diameter of the spool hub shaft. This will allow the electrode
spool to slide over the shaft and rest on the spool hub.
d. Lift up on the tension release lever to open the gap between
the drive roller and tension roller.
e. While tightly holding the electrode to prevent it from
unspooling, cut off the bent end and straighten the first 6
inches (15cm). Cut off the first inch (2.5cm).
f. Insert the wire end into the front guide tube, pushing it
through the gap in the drive rollers and into the rear guide
tube until the end of the wire protrudes approximately 2鈥?
(5cm) from the front block extension.
g. Lower the tension release lever to engage the electrode wire
with the drive rollers.
h. Place the roll of electrode wire onto the spool hub with the
tailing end coming off the right side to point towards the
front of the welder. Make sure the index pin on the spool hub
engages a slot on the bottom of the spool. Tear away paper
label on spool to expose slot if necessary.
i. Finger tighten the spool locking screw by turning it clockwise
until increased resistance is felt.
j. Slide the gas diffuser over the wire and thread onto the front
block extension. Tighten using the 1/2鈥? (13mm) and 9/16鈥?
(14mm) wrenches.
k. Slide the correct size contact tip over the wire and thread
onto the gas diffuser. Use the pliers and 1/2鈥? (13mm)
wrench to tighten.
l. Replace the insulator, finger tighten.
m. Replace the gas nozzle by pressing it on to the front of the
welder. Adjust nozzle setback to allow for appropriate wire
stick out for electrode type and size.
Spool Locking Screw
Rear Guide Tube Front Guide Tube
Nozzle Gas Diffuser
Insulator
Contact Tip Front Block Assembly
Drive Rollers Tension Release Lever
Spool Hub
Fig. 2.1 Wire Electrode Path
PREPARATION
2-3-4. Tension roller pressure setting.
NOTE
The tension roller pressure is set at the factory to accommodate .035鈥?
(0.9mm) flux cored wire.
a. Set the tension roller pressure as light as possible to maintain a
continuous feed while minimizing wire distortion.
b. The knurled adjusting knob rotates counterclockwise to reduce
pressure and clockwise to increase pressure.
c. With the wire loaded and the power cables attached point the
welder at a non-conductive hard object (a concrete floor or wall
for example) with the contact tip approximately two inches from
the surface.
d. Depress the trigger causing wire to beginning spooling out at low
speed, approximately 100 inches (250cm) per minute. As the
wire hits the surface it should be turned aside, coiling the wire.
e. Slowly turn the adjusting knob counterclockwise until the wire
begins to slip in the rollers. Remove pressure from the trigger to
shut down the drive system.
f. Turn the adjusting knob 陆 turn clockwise.
g. Test to ensure there is no longer any slippage by again
depressing the trigger and observing the wire and spool.
2-4. CABLE CONNECTIONS
2-4-1. Harness to power source.
WARNING
Never allow the GOWELD to unintentionally contact any part of the
workpiece or other surface that may be grounded into the welder circuit as
electric shock may occur. Once the GOWELD has been attached to the
power source the electrode is always 鈥渉ot.鈥? The trigger controls the drive
motor and gas flow only, GOWELD does not have an internal contactor.
NOTE
If the clamps are not on the proper terminal, the gun will not operate.
When the cables are correctly attached to the batteries and the green LED
power indicator will light and the motor will operate when the trigger is
PREPARATION
depressed. If the clamps are attached to the wrong terminals on the
batteries the LED indicator will not light and the motor will not operate.
2-4-1-1. Batteries.
WARNING
Never position (place) the batteries where sparks from welding may strike
them. Batteries may generate ignitable gases (hydrogen) creating an
explosion risk. Serious injury may occur.
Batteries are capable of generating high instantaneous currents and such
large currents can cause personal injury. Care should be taken not to
accidentally short circuit the batteries!
Always disconnect batteries from vehicle before attaching the GOWELD
harness to prevent damage to vehicle components.
Never use GOWELD with batteries that are connected to a battery charger.
Always remove all charging cables before connecting GOWELD to the
batteries. Personal injury or damage to the battery may result.
NOTE
Care and Maintenance of Batteries:
Important: Fully charge a battery when new and always store the battery in
a fully charged condition; keep it fully charged throughout its useful life.
Recharge after each use.
A simple way to check a battery鈥檚 condition is a voltmeter. A typical 12v
battery should read 12.6 volts or higher when fully charged.
Do not fully discharge a battery. If a lead acid battery is fully discharged
and left in either an open or closed circuit for a long period of time,
damage can occur and in an extreme case, the battery may not accept a
charge. Maximum final discharge voltage should be no lower than 1.20
volts/cell in very high discharge applications. (Eg. For a 12v battery: 1.20
volt per cell x 6 cells = 7.2 volts).
For extended storage of a battery or if it is used infrequently, top charge
the battery every six weeks if stored above 60掳F, every six months if
stored below 60掳F. Remember 鈥渉eat kills batteries.鈥?
It is recommended that batteries be charged at a rate equal to
approximately 1/10th of their rated capacity. (Eg. A 55 amp hour battery
should be charged at a rate not to exceed 6 amps. Do not overcharge or
the battery will be damaged.
Unless an urgent requirement, do not use a quick charger as it only
surface charges the plates and can lead to overheating damage. A lower
current charges the battery more deeply and uniformly and that means
better performance.
NOTE
GOWELD鈥檚 control circuit input must be kept to only 24 volts DC. Welding
power can be from a combination of two (or three) 12v batteries.
Using 2 batteries. (24 volt welding power)
a. Join the batteries in series using the jumper
cable provided. Attach one end of the cable to
the positive terminal of the first battery and
the other end of the cable to the negative
terminal of the second battery.
b. Attach the black (negative-) clamp to the open
negative (-) terminal on the first battery.
Red
Battery
Clamp Black
Battery
Clamp
Red
Micro
Clamp
12 Volt
12 Volt
Fig. 2.3 GOWELD Harness To Two Batteries
c. Attach the red (positive+) clamp to the open
positive (+) terminal on the second battery.
d. Attach the red micro clamp to the positive (+)
terminal of the second battery.
Using 3 batteries. (36 volt welding power)
NOTE
While welding power can be 36 volts, input power to the welder control
circuit must be 24 volts. The red micro clamp is for control circuit power
input only.
a. Join the batteries in series using the jumper
cable provided and a second cable (one
element of an automotive jumper cable set
may be used). Attach one end of the cable to
the positive terminal of the first battery and
the other end of the cable to the negative
terminal of the second battery. Attach one end
of the second cable to the positive terminal of
the second battery and the other end of that
cable to the negative terminal of the third
battery.
b. Attach the black (negative-) harness clamp to
the open negative (-) terminal on the first
battery.
c. A
t
t
a
Red
c
Battery
h
Clamp Black
Battery
t
Clamp
h
e
Red
Micro
r
Clamp
12 Volt 12 Volt 12 Volt
Fig. 2.4 GOWELD Harness To Three Batteries
ed
c. Attach the red micro clamp to the positive (+)
terminal of the second battery.
d. Attach the red (positive+) harness clamp to
the open positive (+) terminal on the third
battery.
2-4-2. GOWELD to harness.
PREPARATION
Connect the GOWELD to the power harness by plugging the 5-pin
control cable connectors together and mating the appropriate
welder power and ground cable connectors with the harness
cable connectors.
2-4-2-1. Choosing polarity.
鈥? Solid steel electrode- weld with Reverse polarity, electrode
(welder) positive, ground cable negative.
鈥? Stainless steel electrode- weld with Reverse polarity,
electrode (welder) positive, ground cable negative.
鈥? Flux-core self shielding steel electrode- weld with Straight
polarity, electrode (welder) negative, ground cable positive.
鈥? Aluminum- weld with Reverse polarity, electrode (welder)
positive, ground cable negative.
鈥? Flux-core hardfacing wire- weld with Reverse polarity,
electrode (welder) positive, ground cable negative.
2-4-2-2. Power & ground leads.
a. Straight polarity- mate the welder power cable connector
with the connector attached to the black (negative) battery
clamp. Mate the ground cable connector with the connector
attached to the red (positive) battery clamp.
b. Reverse polarity- mate the welder power cable connector
with the connector attached to the red (positive) battery
clamp. Mate the ground cable connector with the connector
attached to the black (negative) battery clamp.
Regulator Or Flowmeter GOWELD
Gas Supply
Ground Clamp
Power Harness
12 Volt Batteries
12 Volt
12 Volt
Fig. 2.5 GOWELD System Setup
(Two battery reverse polarity illustrated.)
2-4-3. Ground cable to work.
WARNING
Never position the ground cable where the operator鈥檚 body can come
between the work and the ground. Always position the ground cable away
from the welder.
PREPARATION
Attach the ground cable clamp to the item being welded. Be sure that the
clamp is secure and that it is positioned away from the operator.
2-5. GAS CONNECTIONS
2-5-1. Gas hose connection.
GOWELD has a 鈥淏鈥? size inert gas fitting on the gas hose. Attach
the GOWELD hose to the regulator or flow meter outlet fitting by
threading the nut into the fitting. If the regulator fitting has a
male thread, a FEM 鈥淏鈥?-FEM 鈥淏鈥? adaptor will be required.
2-5-2. Regulator adjustment.
WARNING
Never stand directly in front of or directly behind the gas regulator while
opening the gas cylinder valve to reduce the risk of injury in the unlikely
event of regulator failure.
a. Shielding gas flow rate should be set to approximately
20cfh.
b. Open the gas cylinder valve slowly.
c. Slightly depress the GOWELD trigger to begin the flow of
gas. Do not press so far that the wire feed motor is
activated.
d. With the gas flowing, adjust the regulator delivery pressure
to 20 psig (1.5 bar) or the flow meter indicator to 20 cfh.
e. Release the trigger to stop the flow of gas.
Chapter 3 OPERATING INSTRUCTIONS
Section I. INTRODUCTION
3-1. GOWELD OPERATION
WARNING
Never operate the welder in explosive or flammable environments.
Never operate the welder with other personnel or bystanders in front of the
welder or in the immediate work area.
Always use extreme caution when operating the welder in windy or other
adverse conditions. Nearby organic materials may be combustible.
Never breathe welding fumes. Some plastics, paints, and plated parts give
off toxic fumes.
The welder operates on the following principle. GOWELD conducts
electrical energy from a set of batteries through an alloy wire welding
electrode to a grounded workpiece, causing the tip of that electrode to go
molten in the arc and transfer to the work where it fuses with the base
material creating a buildup of alloy filler material (the 鈥渨eld鈥?). A control
knob allows the operator to set the electrode wire feed speed (range 0鈥? 鈥?
1000鈥? [2,500cm] per minute). The trigger opens the gas valve so that gas
will flow out the tip of the unit to surround the welding wire and shield the
weld puddle. The trigger also operates the micro switch which enables the
wire feed motor.
3-2. WELDING CAPABILITY
Welding duration is dependent upon the batteries being used as the power
source. Larger capacity deep cycle 12v batteries will provide the most
welding 鈥渁rc time鈥? between charges. On average 10-20 minutes of welding
arc time can be performed with GOWELD on one set of batteries.
GOWELD operates at 50% duty cycle, which means GOWELD can be used
for 5 minutes of arc-time in a 10 minute period to stay within the
operating temperature parameters.
GOWELD will accommodate welding wire of .023鈥? (0.6mm) -.045鈥?
(0.9mm) diameter. GOWELD can be used to weld material ranging from
1/8鈥? (3mm) thickness to 1鈥? (25mm).
GOWELD can be used to weld with:
鈥? Steel- Solid wire
鈥? Steel- Self shielding wire
鈥? Aluminum- Solid wire
鈥? Stainless- Solid wire
鈥? Hardfacing- Cored wire
3-3. CONTROLS & SETTINGS
3-3-1. Wire speed control.
The wire speed control is indexed to the value on the control
knob X100. Example: The 鈥?4鈥? mark on the knob correlates to
approximately 400 inches per minute (ipm).
Turning the knob clockwise increases the wire speed while
turning the knob counter-clockwise decreases wire speed.
There is a direct relationship between welding wire speed and the
OPERATION
welding current (in amps). As the wire speed changes up or down
the welding current changes in the same direction (up or down).
Optimum speed will result in a stable arc, smooth transfer of
weld material to the work, good bead profile, good penetration
and constant stick-out.
3-3-2 Voltage Control.
The accessory voltage control unit is not available at this time.
Call the factory for tips on voltage reduction.
3-3-3 LED INDICATORS
There are 4 LED indicators on the GOWELD unit and their
operation is as follows:
鈥? Green 鈥淧OWER鈥? LED will illuminate when control circuit
power is supplied to the GOWELD through the control
cable. The voltage supplied must be 24vDC for proper
operation. The green LED will flash slowly to indicate
motor overheat condition. When the motor has cooled
sufficiently the green LED will return to a steady light.
The green LED will flash rapidly in the case of wire jam
to indicate the motor is not turning. (See 3-6-1 & 3-6-2.)
鈥? Yellow 鈥淰olt+鈥? and 鈥淰olt-鈥? LEDs are welding polarity
indicators. When the welding power to the GOWELD is
connected to either the + or 鈥? terminal of the supply
battery, one of these LEDs will come on to indicate the
polarity of that connection. (See 2-4-2-1.)
鈥? Red 鈥淟ow Battery鈥? LED is normally off. As the battery
voltage drops during use, this LED will begin to flash.
The rate of flashing will increase as the voltage drops
closer to the preset low battery limit (14 volts for two
batteries and 21 volts for 3 batteries) . The flashing will
stop with the LED on continuously when the voltage
drops below the low battery limit. If the trigger was on
when the low battery limit is reached, the motor will
stop automatically in order to prevent damage to the
batteries from discharging them too far. When this
condition is active, the LED will stay on until the trigger
is released at which time the LED will begin to flash
again as the batteries recover. The low battery limit is
established at 19 volts for a 2 battery system and 29
volts for a 3 battery system. (See 3-6-3.)
3-4 SEQUENCE OF OPERATION
WARNING
Never use the equipment unless you are familiar with acceptable
industrial welding and cutting procedures and practices.
Always use this equipment following generally accepted industrial safety
procedures and practices.
The operator and all bystanders must always wear adequate face and eye
protection, protective (flame and/or spark resistant) clothing, footwear,
and gloves when using this equipment. Wear oil free protective garments
such as leather gloves, heavy shirt, cuffless pants, high leather steel toed
work shoes, and a cap over your head.
Always use a number 10 or 11 shade welding filter lens when welding or
observing welding to protect your eyes from arc rays. Always wear safety
glasses with side shields when in a welding area to protect from sparks.
Always keep your head away from the fume plume. Welding fumes and
gases may be hazardous to your health.
Always use adequate ventilation and exhaust at the arc point to keep
fumes and gases from your breathing zone as well as the general area.
Special breathing apparatus may be required when welding in confined
spaces or when welding or cutting galvanized, cadmium plated (or other
heavy metal plated), or painted parts to avoid inhalation of toxic fumes
and gases.
Always use enough ventilation in confined spaces to prevent shielding
gases from displacing air and causing injury or death.
Never lay the welder on top of the work or place it where it can
accidentally contact the work or ground or other metal that contacts the
work or ground. Electric arc or overheating may result in shock or fire
hazard.
OPERATION
Always insulate yourself from the work and the ground using dry insulation
large enough to cover the full area of physical contact with the work and
ground.
1. Check/prepare the work area.
2. If a shielding gas is to be used, attach the regulator to the gas
cylinder then connect the gas line to the regulator. Set the
regulator to the appropriate gas delivery pressure.
3. Attach the jumper cable to the batteries.
4. Attach the harness to the batteries.
5. Attach the ground clamp to the work.
6. Load the wire electrode.
7. Check to see that the selected contact tip is the appropriate size
for the electrode being used. Install the diffuser, contact tip and
nozzle.
8. Connect the GOWELD control circuit cable.
9. Set the wire feed speed as per section 3-3-2.
10. Connect the GOWELD welding power cable and ground cable to
the harness making sure the polarity is appropriate for the
electrode being used.
11. Bring the welder into position near the work piece.
12. Ensure eye protection is in place. Make sure auto darkening
lenses are turned 鈥渙n鈥?.
13. Squeeze the trigger to commence welding.
14. To stop welding release the trigger and pull GOWELD away from
the work.
3-5 WELDING TECHNIQUES
鈥? Position the tip of the electrode over the place on the work where the
weld is to start.
鈥? Hold GOWELD so the angle of the welder relative to the length of the
weld is approximately 10掳-25掳 from vertical. The angle of the welder
relative to the plate is approximately 45掳 for filet welding or 5掳from
vertical for a beveled butt joint.
鈥? Use the backhand method (where the wire feeds opposite the
direction of travel, filler metal is deposited into the previous weld-
drag) for flat, horizontal, overhead and vertical down welding
positions.
鈥? Use the forehand method (where the wire feeds in the direction of
travel, filler metal is deposited directly on the workpiece- push) for
the vertical up welding position.
鈥? Travel speed should be between 10鈥? (25cm) per minute and 13鈥?
(33cm) per minute. Vary the travel speed while welding a test
coupon to determine the rate that yields the best penetration for that
application and the operator鈥檚 technique.
鈥? Wire stickout (the distance from the contact tip to the work) should
be maintained at between 3/8鈥? (9mm) and 戮鈥? (19cm) depending
upon the electrode type and size, wire feed speed and material
thickness. Generally a longer stickout and high wire feed speed are
preferable for welding thin materials, while less stickout will increase
penetration.
鈥? Torch manipulation (鈥渨eaving鈥?) allows the operator to obtain the
desired fill with a minimum number of passes. As a general rule a
small circular motion is recommended for fillet welds. A back-and-
forth weave with a slight pause at the sides is typically used for butt
weld root passes and fill passes. Adjust the weave for the desired
width of the resultant weld.
Direction of Travel Torch angle 10掳- 25掳
From Vertical
OPERATION
Fig. 3.1 Backhand Technique
Torch angle 10掳- 25掳
Direction of Travel
From Vertical
Fig. 3.2 Forehand Technique
Torch angle 45掳
From Vertical
Fig. 3.3 Transverse Angle Filet Weld
Torch angle 5掳 From
Vertical
Fig. 3.4 Transverse Angle Butt Weld
Position variations:
Vertical up- Butt weld root passes are made with a slight
o
鈥淯鈥? pattern. Fill passes are made using a side to side weave
with a very slight backstep at the sides. Fillet welds are
made using an inverted angle, up to the center then down
to the opposite side, pause, up to the center and so on.
Vertical down- An inverted 鈥渦鈥? is used for butt weld root and
o
fill passes and filet welds. Keep the arc on the leading edge
of the puddle for best penetration.
Overhead- Butt weld root, fill and cover passes and filet
o
welds are all made using a back and forth weave with a
slight pause at the sides.
OPERATION
Direction Direction
of Travel of Travel
Fig. 3.5 Vertical Down & Vertical Up Filet Welds
3-6 AUTOMATIC PROTECTION SHUTDOWN
NOTE
GOWELD has been designed to automatically shut down to prevent
damage to GOWELD鈥檚 motor, circuits or the batteries. In the event
GOWELD appears to cease operation while welding look first to one of the
following conditions.
3-6-1 OVERHEAT PROTECTION
GOWELD鈥檚 motor is equipped with an external thermister which
continuously sends temperature data to the microprocessor.
When the motor temperature reaches 100掳C the overheat
protection program will shut the motor off.
Overheat protection is indicated by the slowly flashing green
鈥減ower鈥? LED.
Allow GOWELD to cool a few minutes then continue welding.
3-6-2 WIRE JAM CONDITION
In the unlikely event of a wire jam preventing the welder鈥檚 motor
from turning while the trigger is being pulled, the microprocessor
will cease sending current to the motor to prevent damage to the
motor or other components.
Wire jam condition is indicated by the rapidly flashing green
鈥減ower鈥? LED.
Disconnect the welder from the batteries, open the GOWELD top
cover, remove the jammed wire, check the wire path and reload
the wire.
3-6-3 LOW BATTERY CONDITION
Rechargeable batteries can often be damaged by depleting them
too far before charging, shortening battery life. GOWELD鈥檚
microprocessor monitors battery voltage level and causes a
shutdown before the voltage drops to potentially damaging
levels.
When the combined voltage of the two batteries falls below 19
volts while welding (29 volts for three batteries), the red 鈥渓ow
battery鈥? LED will begin to flash. The rate of flashing will increase
as the voltage drops closer to the preset low battery limit.
When the combined voltage of the two batteries falls to 14 volts
(21 volts for three batteries), GOWELD鈥檚 battery protection
program will shut the motor off. The red 鈥渓ow battery鈥? LED will
remain constantly 鈥渙n鈥? while the trigger is depressed.
Recharge the batteries or exchange for a fresh set to resume
welding.
3-7 SHUTDOWN PROCEDURES
1. Remove the cable harness from the batteries.
2. Disconnect the GOWELD power cable and ground cable from the
harness.
OPERATION
3. Disconnect the control circuit cable from the harness. Grasp the
connector firmly in both hands. Depress the locking tab while
pulling straight apart. Do not pull on the wires.
4. Close the gas cylinder valve. Depress the trigger to relieve the
pressure from the gas hose. Disconnect the gas hose from the
regulator and remove the regulator from the cylinder. (Replace
the cylinder valve protector cap.)
5. Cut off the melted end of the electrode wire.
6. Open the GOWELD top cover by turning the top knob
counterclockwise until the threads are disengaged from the
spindle. Lift lid carefully until it is fully extended. Do not allow the
retention spring to slam the lid open. The retention spring will
support the lid, keeping it from falling.
7. Twist the spool locking screw counterclockwise to reduce the
diameter of the spool hub shaft.
8. Remove the electrode spool from the spool hub while keeping
tension on the wire to prevent 鈥渂ird nesting.鈥?
9. While keeping pressure on the wire with a finger, raise the on the
tension release lever to open the gap between the drive roller
and tension roller.
10. Pull back on the wire to remove it from the GOWELD front end.
Secure the free end of the electrode through a hole in the spool
for storage.
11. Lower the tension release lever.
12. Wipe the inside of the GOWELD with a clean dry cloth to remove
any dust or debris. Close and secure the lid.
13. Remove the nozzle and clean the nozzle, tip and torch front end.
14. Remove the jumper cable from the batteries.
15. Wipe the GOWELD, cables and accessories with a clean cloth and
replace in the carrying case.
16. Charge the batteries according to the instructions for the
batteries in use and the appropriate battery charger.
Chapter 4 SCHEDULED MAINTENANCE
Section I. INTRODUCTION
4-1. PREVENTIVE MAINTENANCE
Preventive maintenance is the responsibility of the
equipment operator.
Preventive maintenance should be conducted in accordance with this
manual and consist of inspecting, servicing, and cleaning. Inspections will
also reveal the need for repairs. Periodic inspections will ensure the welder
is safe and serviceable. Regulator repairs should only be performed by
qualified technicians.
Section II. SCHEDULED MAINTENANCE
4-2. PREVENTIVE MAINTENANCE PROCEDURES
WARNING
Prior to conducting any maintenance, ensure proper shut down procedures
are followed.
Never touch electrically hot parts.
Never operate GOWELD with the covers removed.
MAINTENANCE
Always disconnect the welder power and ground cables from the battery
when GOWELD is not in use.
1. After each use wipe the welder, cables, cable harness, gas hose
regulator, battery jumper cable, and batteries with a clean dry
cloth.
2. Remove the nozzle and contact tip, inspect for damage and
wear. Clean, replace if necessary, and reassemble.
3. Before and after each use, conduct a close inspection of the
cables and hoses. Check for cuts, burns, or any other sign of
damage or wear. After every use, wipe down all cables and hoses
with a clean, oil-free cloth.
4. Wipe the interior of the GOWELD with a clean dry cloth.
5. Every six months, or following a period of heavy use:
a. Remove the plastic lid and handle halves and inspect the
circuit board, motor and drive assembly. Gently blow
accumulated dirt from all components using compressed
air.
b. Lubricate the gear teeth with a small amount of high
temperature resistant grease. Use caution to avoid getting
grease on the drive roller surface.
c. Do not use any solvents to clean the tension roller because it
may wash the lubricant out of the bearings.
d. Do not lubricate the spool hub or friction pad.
Chapter 5 TROUBLESHOOTING
5-1. USING THE TROUBLESHOOTING GUIDE.
This guide is intended to assist in determining the probable causes of
torch malfunctions and their associated repairs. For each potential
problem identified, a probable cause and recommended repair procedure
is listed.
5-2. TROUBLESHOOTING GUIDE.
TYPE OF PROBABLE RECOMMENDED
PROBLEM / CAUSE REPAIR
MALFUNCTION PROCEDURES
a. The cable harness Double check the
1. 鈥淧OWER鈥? LED
clamps are not harness clamp
DOES NOT LIGHT.
connected to the correct connections with
NOTHING
the batteries, the
HAPPENS WHEN battery terminals.
OR battery jumper
THE TRIGGER IS
DEPRESSED. b. The control circuit power cable connection,
cable red micro clamp is and the control
not connected to the cable circuit plug
positive (+) battery connection.
terminal.
OR
c. The battery jumper cable
may be damaged or
missing.
OR
d. The control circuit cable
connector is not plugged
in to the cable harness or
damaged.
Check the
2. 鈥淧OWER鈥? LED
LIGHTS BUT a. Batteries may not have batteries鈥?
TROUBLESHOOTING
condition of
MOTOR DOES sufficient charge.
NOT RUN WHEN (Accompanied by charge. Replace if
necessary.
THE TRIGGER IS blinking red 鈥淟ow Power鈥?
PULLED. LED.)
OR Allow GOWELD to
b. Overheat protection may cool a few minutes
be shutting motor off. until green LED
(Accompanied by slowly stops blinking.
flashing green 鈥淧ower鈥?
LED.)
Clear the wire jam,
OR
inspect the wire
c. Wire jam protection may
path and reload
be shutting motor off
the electrode.
(accompanied by rapidly
flashing green 鈥淧ower鈥?
LED.)
3. POLARITY
Double check the
INDICATOR LED
welder power
a. The welder power cable
DOES NOT COME
cable connection
is not correctly connected
ON.
to the harness.
to the cable harness or
Make sure all
damaged.
battery
OR
connections are
b. The large red clamp is
correct.
not connected to the
positive (+) battery
terminal.
4. THERE IS NO ARC
BETWEEN THE
Double check the
ELECTRODE AND
ground cable
a. The ground is not
THE WORK.
connection to the
correctly attached to the
harness. Make
work or damaged.
sure the ground
OR
clamp is securely
b. The ground cable
attached to the
connector is not correctly
work, with good
connected to the cable
metal-to-metal
harness.
contact.
5. THE MOTOR
RUNS BUT THE
Check drive roller
WIRE DOES NOT
tension
a. The drive roller tension
FEED SMOOTHLY.
adjustment as per
adjustment may be too
section 2-3-4
loose.
above.
OR
b. The wire may be tangled
Inspect the wire
on the spool.
spool for tangles,
OR
replace if
c. The contact tip may be
necessary.
clogged.
OR
Clean or replace
d. The drive rollers may be
the contact tip.
contaminated with
excess dirt, residue or
Clean drive rollers.
grease.
6. THE WELDING
ARC IS
UNSTEADY,
INTERMITENT. Check the
a. Batteries may not have batteries鈥?
sufficient charge. condition of
(Accompanied by charge. Replace if
blinking red 鈥淟ow Power鈥? necessary.
LED.)
OR Clean or replace
b. The contact tip is dirty, the contact tip.
worn or the wrong size.
OR Increase the wire
c. The wire speed is set too speed/amperage.
low.
OR Make sure the
d. The ground connection is ground clamp is
not making sufficient securely attached
contact with the work. to the work, with
OR good metal-to-
e. The metal to be welded metal contact.
has not been sufficiently
cleaned of oil, paint or Ensure the metal
rust. to be welded is
clean, with all
paint, rust and oils
removed.
TROUBLESHOOTING
Chapter 6 CORRECTIVE MAINTENANCE
Major repairs to the GOWELD including but not limited to
circuit board testing and replacement, motor replacement
and drive assembly replacement should only be done by the
factory or its authorized repair center. Contact Broco, Inc. at
(800) 845-7259, (909) 483-3222, Fax (909) 483-3233, e-
mail sales@brocoinc.com or return authorization or other
repair information.
--NOTES--
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