FLUX CORE 125 OWNER’S MANUAL WARNING: Read carefully and understand all ASSEMBLY AND OPERATION INSTRUCTIONS before operating. Failure to follow the safety rules and other basic safety precautions may result in serious personal injury.
Thank you very much for choosing a IRONTON product! For future reference, please complete the owner’s record below: Model: _______________ Purchase Date: _______________ Save the receipt, warranty and these instructions. It is important that you read the entire manual to become familiar with this product before you begin using it. This machine is designed for certain applications only. The distributor cannot be responsible for issues arising from modification.
GENERAL SAFETY RULES WARNING: Read and understand all instructions. Failure to follow all instructions listed below may result in serious injury. CAUTION: Do not allow persons to operate or assemble this Flux Core 125 until they have read this manual and have developed a thorough understanding of how the Flux Core 125 works. WARNING: The warnings, cautions, and instructions discussed in this instruction manual cannot cover all possible conditions or situations that could occur.
Do not operate the welder if the output cable, electrode, torch, 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 them. -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.
-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 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.
-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.
TECHNICAL SPECIFICATIONS Item Power Supply No-Load Voltage Output Range Duty Cycle Suggested Wire Wire Diameter Dimensions Weight Description 115V, 20A, 60 HZ, Single Phase 27 Volts AC 60 - 80 Amp AC, Peak 125 Amp AC 20% @ 80A Flux Core Wire .030 - .035 17.7" x 9.3" x 14.3" 38 lbs. KNOW YOUR WELDER Description The IRONTON Flux Core 125 is a portable Gasless Wire Feed Welder. It uses AC single phase 115V (110-120V), 60HZ/20amp with time delayed fuse or circuit breaker.
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 Torch The welding wire is driven through the welding cable and 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 and the machine will shut down.
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 or larger. Check with a qualified electrician and your local electrical codes for your specific area. Do not use an extension cord over 25 ft. in length. 3. INSTALL THE WIRE ROLLER - The wire roller has been factory installed.
4. INSTALL THE WIRE - We recommend the usage of .030 Flux Core Wire on this unit. However, .035 Flux Core wire may also be used. Only Flux Core Welding Wire should be used with this unit. 4.1 Select welding wire - Both four-inch or eight-inch wire spools of .030 or .035 shelf sheilding Flux-Core wire can be used on this welder. Only steel, from 18 gauge up to 3/16 inch thick can be welded with this unit. NOTE: - Metal thinner than 18 gauge cannot be welded with this machine.
4.2.5 The welder can use either 4 inch or 8 inch spools. See the following figure for additional reference. The wing nut controls the tension on the spool. 8 Inch 4 Inch 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 you feel a slight drag.
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. DO NOT OVER TIGHTEN. 4.2.14 NOW YOU CAN LET GO OF THE WIRE. 4.2.15 Plug in the welder power cord and turn the welder ON.
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 adapter between the welder's power cord and the power source receptacle.
6. 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. 7. TUNING IN THE WIRE SPEED - This is one of the most important parts of wire welder operation and must be done before starting each welding job or whenever the voltage setting or wire diameter is changed.
ELECTRIC SHOCK CAN KILL! To prevent ELECTRIC SHOCK, do not perform any welding while standing, kneeling, or lying directly on the grounded workpiece. 8.1 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.
8.3 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.
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. 8.4 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.
8.5 Spot welding There are three methods of spot welding: Burn-Through, Punch and Fill, and Lap. Each has advantages 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 burn-through method are 0.
8.6 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.
DIAGRAM & PARTS LIST Reference # Part# 1 1.1.01.02.8605 2 2.07.40.370 2A 2.07.40.696-R 2B 2.20.09.601 2.07.40.696-I Description Qty. LEFT PANEL, DOOR 1 WIRE FEEDER ASSEMBLY 1 DRIVE ROLLER 1 DRIVE ROLLER COVER 1 INLET GUIDE 1 3 2.07.52.005 FUSE HOLDER 1 4 2.07.52.014 FUSE 1 5 2.07.25.956 CONTROL TRANSFORMER 1 6 2.07.80.317 CIRCUIT BREAKER 1 7 1.2.01.01.0538 SPOOL HOLDER 1 7A 2.05.05.307 ADJUSTING NUT 1 7B 2.06.29.
7C 2.05.05.306 HOLDER END, LOOSE 1 7D 2.05.05.308 BOLT 1 7E 2.05.05.305 HOLDER END, FIXED 1 7F 2.06.14.102 HEX NUT 1 8 2.05.05.064 DOOR HINGE 2 9 1.1.03.01.1513 FAN BRACKET 1 10 1.2.07.02.0027 FAN MOTOR 1 11 2.07.89.707 FAN BLADE 1 12 1.1.01.03.0704 BACK PANEL 1 13 2.05.05.201 CABLE HOLDER 1 14 1.2.07.01.0050 POWER CORD 1 15 1.1.01.03.0703 VERTICAL MIDDLE PANEL 1 16 1.1.01.02.0280 RIGHT PANEL 1 17 1.1.01.03.0705 BOTTOM 1 18 2.05.05.
WARRANTY EFFECTIVE JULY 1, 2014 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 below, Northern Tool + Equipment will repair or replace the item under warranty that fails due to defects in material and workmanship.