Silver Beauty 90100 User Manual

Read this manual before operating the Silver Beauty Mig Welder 90100 and related equipment.

Your safety depends on you. Follow all safety rules and directions for efficient operation.

Common sense is essential for safe and efficient operation of the welding equipment.

Read and understand all safety material before using the welder for your protection and others.

Protect yourself and others by familiarizing with safety rules for arc welding and gas cylinders.

A brief safety list acts as a reminder; be aware of all safety rules before welding.

Refer to ANSI Standard Z49.1 for comprehensive safety information on welding and cutting.

Ensure all electrical work is performed by qualified electricians for safety and proper function.

Keep the welding machine clean, dry, and in good working order for optimal performance.

Keep ventilation openings clear and allow 12 inches around the machine for proper airflow.

Ensure correct power source wiring and always unplug before moving the welder.

The power source must be properly grounded to prevent electrical hazards.

Do not exceed the duty cycle of your power source; check the name plate for specifications.

Keep your MIG gun well maintained; worn parts can lead to poor welds and safety issues.

Always have the correct type of fire extinguisher readily available when welding.

Check welding area for flammable material and remove it due to hot metal and sparks.

Do not weld near explosives or explosive materials like gasoline tanks.

Ensure proper ventilation. Never use oxygen for ventilation.

Do not weld or cut when strong fumes are present in the area.

To prevent electrical shock, do not weld in wet areas.

Check the welding area 30 minutes after welding for any signs of fire.

Do not weld around oil, grease, or paint as they are flammable and produce toxic fumes.

Remember to use adequate ventilation when performing welding operations.

The welder is responsible for their own safety and others'. Know and obey all safety rules.

Be aware that electric shock can kill; all electric shocks are potentially fatal.

Always wear dry gloves when performing arc welding to prevent electrical hazards.

Keep yourself well insulated from the floor when arc welding to avoid grounding.

Wear dry, thick-soled shoes to prevent grounding and electrical shock.

Stop welding immediately if you feel electrical shock. Do not use until repaired.

Always unplug the welding machine from the power outlet before moving or working on it.

Only qualified personnel should work on arc welding equipment due to shock risk.

Arc welding produces fumes that can be a potential health hazard.

Always ensure adequate ventilation when welding to manage hazardous fumes.

Some materials like galvanized metals produce toxic fumes; remove coatings before welding.

Arc welding produces hot metal, sparks, and molten metal drips, posing burn risks.

Protect yourself from burns, fires, and explosions. Wear safety glasses under the welding hood.

Use a welding hood with at least a #10 shade lens and proper cover plates conforming to ANSI Z87.1.

Always wear dry, protective, fire-resistant clothing free from oil and grease.

Do not carry matches or lighters in pockets, as they can catch fire or explode.

Arc welding emits rays that can burn skin and eyes.

Never look at the arc without a welding helmet and #10 shade lens.

Cover all exposed skin when welding to prevent burns from arc rays.

Warn people in the vicinity before striking an arc to protect them from hazards.

The arc is dangerous up to 50 feet. Protect fellow workers from arc flash and burns.

Always identify the gas content before operating the welder.

If a gas leak occurs, immediately close the cylinder valve.

If regulator is faulty, close valve and remove from service. Follow fault indicators.

Do not repair regulators yourself. Send faulty ones for repair to designated locations by trained personnel.

Handle cylinders carefully to prevent leaks and damage to walls, valves, or safety devices.

Identify gas content by markings, not color. Notify supplier if unmarked.

Never deface or alter cylinder markings; it is illegal and hazardous.

Always treat gas cylinders as if they are full for safety.

Locate or secure cylinders to prevent them from being knocked over.

Refer to CGA pamphlet P-1 for more information on pressurized cylinder safety and regulations.

Never strike an arc on a gas cylinder, as it is extremely hazardous.

Avoid exposing gas cylinders to high temperatures above 110° F.

Safety in Welding and Cutting standard from American Welding Society.

Safe practice for occupational and educational eye and face protection.

Safe practices for welding and cutting containers with hazardous substances.

Standard for oxygen-fuel gas systems for welding and cutting.

Standard covering cutting and welding processes.

Safe handling of compressed gases in containers.

OSHA standard for welding, cutting, and brazing practices.

MIG welding feeds a power wire electrode continuously into the weld puddle at a controlled rate.

Wire connects to positive supply, workpiece to negative supply for MIG welding.

Arc strikes upon wire contact with workpiece, melting wire onto the workpiece.

Wire feed speed controls welding current; faster speed means higher current.

Shielding gas protects the weld puddle from oxidation and impurities, but should not be wasteful.

Proper gas coverage is crucial for good welding; excessive coverage is costly.

The welder has a 20% duty cycle: 2 minutes welding to 8 minutes rest per 10 minutes.

MIG welding offers 50% faster welding time compared to other methods.

Operator training time is kept to a minimum with MIG welding.

Eliminates post-welding cleaning by removing the need for slag removal.

MIG welding results in minimum waste of welding consumables.

MIG welding is a faster and more efficient way to complete welding tasks.

List of standard accessory parts included with the Silver Beauty MIG Welder Model 90100.

List of optional and replacement accessories available for the welder.

Details primary input power data: volts, amps, and frequency.

Details secondary output power data: volts, amps, and duty cycle.

Specifies the usable wire sizes for MIG welding, including recommended types.

Lists usable gases for MIG welding and their applications for different metals.

Steps for preparing the welder unit, including unpacking and securing components.

Steps for preparing the welding torch, including tip and nozzle removal.

Place the wire spool on the spindle so the wire feeds over the top.

Relieve wire feed motor tension and unscrew hand nut to select the correct drive roller size.

Remove drive roller to select the correct size based on its grooves for the wire size.

Replace the drive roller correctly oriented and tighten the hand nut.

Insert torch connector, tighten set screw carefully, and connect gas hose and wires.

Manually feed the wire from spool through guide tube, over drive roller, into torch.

Set tension adjustment spring to the lowest setting initially; adjust as rollers wear.

Plug in welder, pull trigger to feed wire through torch until about 6 inches extends from tip.

Screw contact tip onto torch, matching its size to the wire size.

Replace the gas nozzle by turning it clockwise and pushing it onto the torch.

Lists gases for MIG welding: 75% Argon/25% CO2 for Steel, 100% CO2 for Steel, 100% Argon for Alum.

Small gas cylinders (≤ 5.5 inches diameter) can be chained to the back of the welder.

Large gas cylinders (> 5.5 inches diameter) should be chained to a nearby wall.

After securing the cylinder, remove the protective cap from the bottle.

Install a CO2 cylinder adapter if needed for your setup.

Thread the gas regulator onto the cylinder bottle and tighten securely.

Connect the gas hose fitting to the installed regulator.

Slide the gas hose onto the fitting and secure it with the hose clamp.

Open the gas cylinder valve completely to allow gas flow.

Set the regulator to a gas flow of 20-35 CFH (9-16 LPM).

Place the spool of aluminum wire on the small spindle.

Change the drive roller to one specifically for aluminum wire.

Feed aluminum wire through the torch using the same procedure as for steel.

Change the shielding gas to 100% argon for welding aluminum.

Describes the controls located on the front view of the welder.

Chart specifying welding wire size and corresponding wire feed speed settings for steel.

Chart specifying welding wire size and corresponding wire feed speed settings for aluminum.

Read safety instructions, remove flammable materials before welding.

Set heat using proper stick out (3/8" to 1/2") for optimum welding conditions.

Turn heat (voltage) setting to desired number, lower for light metal, higher for thick.

Adjust wire feed speed until a high-pitched buzz is heard, indicating proper setting.

Retune wire speed when heat setting changes. Start high to reduce tip wear.

Hold gun at 45 degrees, keeping nozzle 1/4" to 1/2" from work for optimal weld.

A welding technique directing the torch towards the progress of welding.

A welding technique directing the torch opposite to the progress of welding.

Illustrates various common welding joint types used in fabrication.

Details on feather edge and shoulder edge preparation for welding.

Techniques for spot welding, effective for auto body repair and thin metal fabrication.

Lap spot welding involves lapping steel pieces; weld puddle penetrates bottom piece.

Plug welds fill holes in top piece, penetrating bottom, for auto body repair.

Burn through welding involves the puddle burning through the top piece, requiring a tight fit.

Stitch welding is used for continuous welds on thin or rusty metal to prevent warpage.

Technique for filling holes with welds, involving multiple tack and overlap welds.

Hold gun at 45 degrees with nozzle 1/4" from surface; closer gun yields deeper weld.

Move the welding gun smoothly and steadily during the welding process.

Avoid welding in drafty areas, as air movement can cause pitted welds by blowing gas away.

Maintain cleanliness of the welding wire and the wire liner for consistent performance.

Apply antispatter spray to hot nozzle and tip to prevent slag build-up and ensure gas flow.

Avoid creating sharp bends or kinks on the welding torch cable.

Clean the gun liner when changing wire spools, using solvents or compressed air.

Periodically blow dust from welder internals with low-pressure air to maintain cooler operation.

Troubleshooting for power source stopping due to overload or overheating.

Troubleshooting for no weld current when the lamp is on.

Troubleshooting for wire not feeding or pulsating, checking roller, liner, and tip.

Troubleshooting for an unstable arc, checking wire feed and base metal.

Troubleshooting for wire stubbing into workpiece (popping sound), checking speed and tension.

Troubleshooting for wire nesting, checking wire tension and torch seating.

Troubleshooting for electrode welding to the tip, checking wire speed and torch angle.

Troubleshooting for porous welds, checking gas, nozzle, and base metal cleanliness.

Troubleshooting for a weld bead that is too narrow and raised, adjusting current and speed.

Troubleshooting for a weld bead that is too wide, adjusting current, speed, and arc length.

Troubleshooting for fuses blowing, checking wire tension and contact tip.

List of individual welder components available as repair parts, with item numbers and prices.

List of individual torch components available as repair parts, with item numbers and prices.