4.5.1 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
burn-through method are 0.035 inch self-shielding 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.
4.5.2 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.
4.5.3 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.
5. SPOT WELDING INSTRUCTIONS
5.1 Select the wire diameter and heat setting recommended above for the method of spot
welding you intend to use.
5.2 Tune in the wire speed as if you were going to make a continuous weld.
5.3 Hold the nozzle piece completely perpendicular to and about 1/4 inch off the work
piece.
5.4 Pull the trigger on the torch and release it when it appears that the desired
penetration has been achieved.
5.5 Make practice spot welds on scrap metal, varying the length of time you hold the
trigger, until a desired spot weld is made.
5.6 Make spot welds on the actual work piece at desired locations.
DC STICK OPERATION
• 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. Use only the supplied
adapter between the plasma cutter's power cord and the power source receptacle. Make
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