IMPORTANT OPERATING TIPS FOR THE RWII
In order to obtain the best possible performance and service life from your new RWII, we recommend that you read and practice the following operating tips:
1.) SAFETY - Never open the RWII if it is connected to a live power source! Opening the case halves while the gun is powered will likely cause severe damage to the circuit board and other parts inside the RWII. This damage will not be covered by the warranty. Also, never leave the power connected to the RWII when you are not actually welding as the tip stays “hot” at all times when the power remains connected. Always disconnect the RWII from the power source when not in use.
2.) Power Connections for the RWII - The RWII comes with battery clamps which can be mounted onto the 3/8” copper lugs (hardware provided). Whenever possible it is preferable to make your power connections using the 3/8” copper lugs mounted directly to the battery terminals. Many deep-cycle batteries come with additional threaded post terminals, with wing-nuts on them, which are ideal for making these connections. The battery clamps are convenient to use but may restrict current flow and should therefore only be used when use of the 3/8” lugs is not feasible. Always securely attach the copper lug(s) to appropriate connection points directly on the welding machine itself if possible. Never connect the RWII to AC Output Terminals on arc welding machines.
3.) Battery Selection - Battery selection is a crucial part of a successful RWII operation. The size and power ratings of the batteries selected will have a great effect on the duration of welding time and the depth of penetration possible. For welding metal 1/8” and thicker, the larger the batteries the better. Deep cycle marine batteries are recommended, with threaded tip terminal posts topped with wing-nuts, in group sizes of 24D to 31D. Gel-Cell batteries from Exide work extremely well but do require a special charger. Keep your batteries fully charged between uses to extend their life-span. Thin metal in general, and thin aluminum in particular, requires much lower amperage levels to be welded successfully than thicker metals. Sometimes the use of a single 12 volt battery with .030”-035” aluminum wire, and the proper gas mixture, will weld thin aluminum sheet. Normally the use of 18 volts, from connecting 12 volt and 6 volt batteries together in series, are necessary to weld thin steel, aluminum or stainless steel. Thinner wire conducts less electricity, so it is helpful to use thinner wire (.023”) on thin metal and thicker wire (up to .045”) when welding thicker metal. When using 12 volts the use of thicker wire may be helpful as it allows more current to flow at the lower voltage.
4.) Clean Metal Surfaces - The metal surfaces to be welded together should be clean and free from any “mill scale” deposits found on most steel products as they come from the foundry. Grinding the surfaces to be welded down to shiny bare metal will greatly improve the strength and penetration of the weld. Because MIG welding is an electrical process, any action taken which improves the conductivity of the metal being welded will improve the final results. This also applies to the surface to which the large “grounding clamp” is connected to as well. Make sure the ground clamp is attached to clean, bare metal on the piece being welded. For safety’s sake remember, the cleaner the surfaces welded, the stronger the weld.
5.) The “RWII Applications Table” - The RWII “Operators Manual” contains the “RWII Applications” Chart. Successful welding with the RWII can be achieved if you follow the guidelines shown in this chart, especially as it directly relates to POLARITY. Flux core wire requires straight polarity (Red light) ground positive, while solid wire (all metals) requires reverse polarity (Green light) ground negative and the use of an appropriate gas mixture, as specified. When using the AC/DC power supply supplied with RWII, the LED’s no longer indicate arc current polarity but simply reveal that the RWII circuit board is being powered. The AC/DC power supply must be connected in the same polarity as the arc current.
6.) Lever Tension Spring Settings - The lever tension spring adjuster selector should normally be left in the “Aluminum” slot for proper wire feed tension for .035” wire. Use of .023” wire may sometimes require that the selector spring be moved to the “Extra Grip” slot setting, while thicker wires may require use of the “Aluminum” slot setting. Select the firmest setting which still allows the wire to feed freely without causing the motor to bog down or the wire feed rate to