TCEW 160 D - Welding machine EINHELL - Free user manual and instructions

Frequently Asked Questions - TCEW 160 D EINHELL

USER MANUAL TCEW 160 D EINHELL

Danger! - An electric shock from the welding electrode can be fatal Danger! - The inhaling of welding fumes can harm your health Danger! - Welding arc radiation can damage your eyes and injure your skin Danger! - Welding sparks can cause an explosion or fi re Danger! - Electromagnetic fi elds can disturb the operation of pacemakers Danger! Danger from electric shock Danger! - Read the operating instructions to reduce the risk of injury Caution! Wear special welders‘ gloves. Hot glowing particles may fl y about while you are welding. You should therefore wear special welding gloves to protect your hands and arms. Anl_TC_EW_160_D_SPK9.indb 15Anl_TC_EW_160_D_SPK9.indb 15 26.07.2017 09:01:0026.07.2017 09:01:00GB

Danger! When using the equipment, a few safety pre- cautions must be observed to avoid injuries and damage. Please read the complete operating instructions and safety regulations with due care. Keep this manual in a safe place, so that the in- formation is available at all times. If you give the equipment to any other person, hand over these operating instructions and safety regulations as well. We cannot accept any liability for damage or accidents which arise due to a failure to follow these instructions and the safety instructions.

1. Safety regulations

The corresponding safety information can be found in the enclosed booklet. Danger! Read all safety regulations and instructions. Any errors made in following the safety regula- tions and instructions may result in an electric shock, fi re and/or serious injury. Keep all safety regulations and instructions in a safe place for future use. Safety components: a) Danger from electric shock: An electric shock from a welding electrode can be fatal. Never perform any welding in rain or snow. Wear dry insulating gloves. Do not touch the electrode with your bare hands. Do not wear wet or damaged gloves. Protect yourself from an electric shock by insulating yourself from the workpiece. Do not open the equipment housing. b) Danger from welding fumes: The inhaling of welding fumes can harm your health. Keep your head out of the fumes. Use the equip- ment in open areas. Use a ventilation system to remove the fumes. c) Danger from welding sparks: Welding sparks can cause an explosion or fi re. Keep combustible materials away from the welding area. Do not weld combustible materials. Welding sparks can cause fi res. Keep a fi re extinguisher nearby and someone watching who can use it immediately. Do not weld on drums or any closed containers. d) Danger from welding arc radiation: Wel- ding arc radiation can damage your eyes and injure your skin. Wear a hat and safety gog- gles. Wear ear protection and a high, closed shirt collar. Use a welding helmet and fi lters of the correct size. Wear complete body protec- tion. e) Danger from electromagnetic fi elds: Wel- ding current creates electromagnetic fi elds. Do not use together with medical implants. Never wind the welding cables around your body. Guide welding cables together.

2. Layout and items supplied

3. Adjustment wheel for welding current

4. Selector switch 230 V / 400 V

5. Control lamp for overheating

6. Welding current scale

Please check that the article is complete as specifi ed in the scope of delivery. If parts are missing, please contact our service center or the sales outlet where you made your purchase at the latest within 5 working days after purchasing the product and upon presentation of a valid bill of purchase. Also, refer to the warranty table in the service information at the end of the operating instructions.

Open the packaging and take out the equip- ment with care.

Remove the packaging material and any packaging and/or transportation braces (if available).

Check to see if all items are supplied.

Inspect the equipment and accessories for transport damage.

If possible, please keep the packaging until the end of the guarantee period. Danger! The equipment and packaging material are not toys. Do not let children play with plastic bags, foils or small parts. There is a danger of swallowing or suff ocating!

Original operating instructions

The electric welder can be used to weld various metals using the appropriate coated electrodes. The equipment is to be used only for its prescri- bed purpose. Any other use is deemed to be a case of misuse. The user / operator and not the manufacturer will be liable for any damage or inju- ries of any kind caused as a result of this. Please note that our equipment has not been de- signed for use in commercial, trade or industrial applications. Our warranty will be voided if the machine is used in commercial, trade or industrial businesses or for equivalent purposes.

4. Symbols and technical data

EN 60974-6 European standard for arc welding sets and wel- ding power supplies with limited on time (Part 6).

Symbol for welding power supplies which are sui- table for welding in environments with increased electrical danger. ~ 50 Hz Alternating current and rated frequency value [Hz]

Rated idling voltage [V] 160 A/ 24.4 V Maximum welding current and the corresponding standardized operating voltage [A/V]

Highest welding time rated value in continuous mode tON (max) for highest welding current rated value at an ambient temperature of 20 °C, ex- pressed in minutes and seconds.

Highest welding time rated value in intermittent mode ΣtON for highest welding current rated value at an ambient temperature of 20 °C over an uninterrupted time of 60 min, expressed in minu- tes and seconds.

Average load time [s]

Average reset time [s] 1(3) ~ 50 Hz Line input; number of phases, the alternating cur- rent symbol and the rated frequency value

1max Highest rated value of the line current [A]

1eff Eff ective value of the highest line current [A] IP 21 S Protection type

Symbol for protection class II Welding times depend on the power which is taken from the equipment. At high power the ON period is shorter and the cooling time longer; at low power the ON period is longer and the cooling time shorter. Overheating guard Electrode tongs Earth terminal Anl_TC_EW_160_D_SPK9.indb 17Anl_TC_EW_160_D_SPK9.indb 17 26.07.2017 09:01:0026.07.2017 09:01:00GB

The equipment is interference-suppressed in compliance with EC Directive 2004/108/EC Mains connection: .................. 230/400 V ~ 50 Hz Welding current (A): .................................55-160

5. Assembly Instructions

This welding set can be operated with a rated voltage of 230 V and 400 V. The desired rated voltage can be set by means of the rotary switch illustrated in Figure 2-4. Please follow the opera- ting instructions, as described below: Figure 2: In its initial position the rotary switch is set to 400 Volt. The welding set is operated at a rated voltage of 400 Volt in a closed electric circuit. To prevent accidental selection of the wrong rated voltage, please secure the setting position by in- serting a screw into the respective hole on the left below the rotary switch. Figure 4: To operate the appliance with a rated voltage of 400 V, please slacken and remove the screw lo- cated below the rotary switch on the left and then turn the switch to the desired position, which is labeled 400 V. After this, please tighten the screw in the marked drill hole located below the rotary switch on the right. Please observe the following instructions in order to avoid the risk of fi re, electric shock or personal injuries.

Never use the appliance with a rated voltage of 400 V if the appliance is set to 230 V. Cau- tion: Fire risk!

Please disconnect the appliance from the po- wer supply before setting the rated voltage.

Adjusting the rated voltage during operation of the welding set is strictly prohibited.

Before operating the welding set, please ensure that the rated voltage selected on the appliance complies with that of the power source. Note: The welding set is supplied with 2 power cables and plugs. Please connect the appropriate plug to the appropriate power source (connect a 230 V plug to a 230 V socket-outlet and a 400 V plug to a 400 V socket outlet)

7. Welding preparations

Connect the earth terminal (-) (2) direct to the part to be welded or to the support on which the part is resting. Ensure that the earth terminal (-) is in di- rect contact with the part to be welded. You should therefore avoid coated surfaces and/or insulated materials. The electrode holder cable has a spe- cial clamp at one end, which is used to secure the electrode. The welding safety shield must be used at all times for welding. It protects your eyes from the radiation emitted by the arc and nevertheless enables you to watch the welding process (not included in items supplied). Anl_TC_EW_160_D_SPK9.indb 18Anl_TC_EW_160_D_SPK9.indb 18 26.07.2017 09:01:0126.07.2017 09:01:01GB

• After you have made all the electrical connections for the power supply and for the welding circuit, you can proceed as follows: Insert the unsheathed end of the electrode into the electrode holder (1) and connect the earth ter- minal (-) (2) to the part you wish to weld. Ensure that a good electric contact is made. Switch on the welding set at the switch (4) and set the welding current using the hand wheel (3) to suit the electrode you wish to use. Hold the safety shield in front of your face and rub the tip of the electrode on the part you wish to weld as if you were striking a match. This is the best method of igniting the arc. Check that you have the correct electrode and current strength on a test part. Electrode (Ø mm):
• Welding current (A) 2 p. 55
• - 80 A 2,5 p. 60
• - 110 A 3,2 p. 80
• - 160 A 4 - 160 A Important! Do not dab the workpiece with the electrode since it could be damaged, making it more diffi cult to ignite the arc. As soon as the arc has ignited, attempt to keep it a distance from the workpiece equivalent to the diameter of the electrode. This distance should be kept as constant as pos- sible during the welding process. The angle of the electrode in the direction in which you are working should be 20/30°. Always use tongs to remove spent electrodes and to move parts that you have just welded. Please note that the electrode holder (1) must always be put down so that it is insulated after you have completed the welding work. Do not remove the slag until the weld has cooled. If you want to continue a weld after an interrupti- on, the slag from your initial attempt must fi rst be removed. p. 120

9. Overheating guard

The welding set is fi tted with an overheating guard that protects the welding transformer from overheating. If the overheating guard trips, the control lamp (5) on your set will be lit. Allow the welding set to cool for a time.

10. Replacing the power cable

Danger! If the power cable for this equipment is damaged, it must be replaced by the manufacturer or its after-sales service or similarly trained personnel to avoid danger.

11. Cleaning, maintenance and

ordering of spare parts Danger! Always pull out the mains power plug before star- ting any cleaning work.

Keep all safety devices, air vents and the motor housing free of dirt and dust as far as possible. Wipe the equipment with a clean cloth or blow it with compressed air at low pressure.

We recommend that you clean the device immediately each time you have finished using it.

Clean the equipment regularly with a moist cloth and some soft soap. Do not use cleaning agents or solvents; these could at- tack the plastic parts of the equipment. Ensu- re that no water can seep into the device. The ingress of water into an electric tool increases the risk of an electric shock.

There are no parts inside the equipment which require additional maintenance.

11.3 Ordering replacement parts:

Please quote the following data when ordering replacement parts:

Article number of the machine

Identification number of the machine

For our latest prices and information please go to www.isc-gmbh.info

12. Disposal and recycling

The equipment is supplied in packaging to pre- vent it from being damaged in transit. The raw materials in this packaging can be reused or recycled. The equipment and its accessories are made of various types of material, such as metal and plastic. Never place defective equipment in your household refuse. The equipment should be taken to a suitable collection center for proper disposal. If you do not know the whereabouts of such a collection point, you should ask in your local council offi ces.

Store the equipment and accessories in a dark and dry place at above freezing temperature. The ideal storage temperature is between 5 and 30 °C. Store the electric tool in its original packaging. Anl_TC_EW_160_D_SPK9.indb 20Anl_TC_EW_160_D_SPK9.indb 20 26.07.2017 09:01:0126.07.2017 09:01:01GB

For EU countries only Never place any electric power tools in your household refuse. To comply with European Directive 2012/19/EC concerning old electric and electronic equipment and its implementation in national laws, old electric power tools have to be separated from other waste and disposed of in an environment-friendly fashion, e.g. by taking to a recycling depot. Recycling alternative to the return request: As an alternative to returning the equipment to the manufacturer, the owner of the electrical equipment must make sure that the equipment is properly disposed of if he no longer wants to keep the equipment. The old equipment can be returned to a suitable collection point that will dispose of the equipment in accordance with the national recycling and waste disposal regulations. This does not apply to any ac- cessories or aids without electrical components supplied with the old equipment. The reprinting or reproduction by any other means, in whole or in part, of documentation and papers accompanying products is permitted only with the express consent of the iSC GmbH. Subject to technical changes Anl_TC_EW_160_D_SPK9.indb 21Anl_TC_EW_160_D_SPK9.indb 21 26.07.2017 09:01:0126.07.2017 09:01:01GB

Service information We have competent service partners in all countries named on the guarantee certifi cate whose contact details can also be found on the guarantee certifi cate. These partners will help you with all service re- quests such as repairs, spare and wearing part orders or the purchase of consumables. Please note that the following parts of this product are subject to normal or natural wear and that the following parts are therefore also required for use as consumables. Category Example Wear parts* Electrode holder, mass tongs Consumables* Missing parts

• Not necessarily included in the scope of delivery! In the eff ect of defects or faults, please register the problem on the internet at www.isc-gmbh.info. Ple- ase ensure that you provide a precise description of the problem and answer the following questions in all cases:

Did the equipment work at all or was it defective from the beginning?

Did you notice anything (symptom or defect) prior to the failure?

Warranty certifi cate Dear Customer, All of our products undergo strict quality checks to ensure that they reach you in perfect condition. In the unlikely event that your device develops a fault, please contact our service department at the address shown on this guarantee card. You can also contact us by telephone using the service number shown. Please note the following terms under which guarantee claims can be made:

1. These guarantee terms apply to consumers only, i.e. natural persons intending to use this product

neither for their commercial activities nor for any other self-employed activities. These warranty terms regulate additional warranty services, which the manufacturer mentioned below promises to buyers of its new products in addition to their statutory rights of guarantee. Your statutory guarantee claims are not aff ected by this guarantee. Our guarantee is free of charge to you.

2. The warranty services cover only defects due to material or manufacturing faults on a product which

you have bought from the manufacturer mentioned below and are limited to either the rectifi cation of said defects on the product or the replacement of the product, whichever we prefer. Please note that our devices are not designed for use in commercial, trade or professional applica- tions. A guarantee contract will not be created if the device has been used by commercial, trade or industrial business or has been exposed to similar stresses during the guarantee period.

3. The following are not covered by our guarantee:

- Damage to the device caused by a failure to follow the assembly instructions or due to incorrect installation, a failure to follow the operating instructions (for example connecting it to an incorrect mains voltage or current type) or a failure to follow the maintenance and safety instructions or by ex- posing the device to abnormal environmental conditions or by lack of care and maintenance. - Damage to the device caused by abuse or incorrect use (for example overloading the device or the use or unapproved tools or accessories), ingress of foreign bodies into the device (such as sand, stones or dust, transport damage), the use of force or damage caused by external forces (for ex- ample by dropping it). - Damage to the device or parts of the device caused by normal or natural wear or tear or by normal use of the device.

4. The guarantee is valid for a period of 24 months starting from the purchase date of the device. Gu-

arantee claims should be submitted before the end of the guarantee period within two weeks of the defect being noticed. No guarantee claims will be accepted after the end of the guarantee period. The original guarantee period remains applicable to the device even if repairs are carried out or parts are replaced. In such cases, the work performed or parts fi tted will not result in an extension of the guarantee period, and no new guarantee will become active for the work performed or parts fi tted. This also applies if an on-site service is used.

5. To make a claim under the guarantee, please register the defective device at: www.isc-gmbh.info.

Please keep your bill of purchase or other proof of purchase for the new device. Devices that are returned without proof of purchase or without a rating plate shall not be covered by the guarantee, because appropriate identifi cation will not be possible. If the defect is covered by our guarantee, then the item in question will either be repaired immediately and returned to you or we will send you a new replacement. Of course, we are also happy off er a chargeable repair service for any defects which are not covered by the scope of this guarantee or for units which are no longer covered. To take advantage of this service, please send the device to our service address. Also refer to the restrictions of this warranty concerning wear parts, consumables and missing parts as set out in the service information in these operating instructions. Anl_TC_EW_160_D_SPK9.indb 23Anl_TC_EW_160_D_SPK9.indb 23 26.07.2017 09:01:0126.07.2017 09:01:01F

5. Assembly Instructions

= dB (A); guaranteed L