PSGS 120 A1 - Welding machine PARKSIDE - Free user manual and instructions

USER MANUAL PSGS 120 A1 PARKSIDE

4-IN-1-COMPACT LASAPPARAAT

must be rotated in a clockwise direction during assembly and disassembly and not, as described in the user instructions, in an anti-clockwise direction. z “Welding with flux-cored wire” chapter under the section “Fit the gas cylinder” and under the section Adaptation of device to flux-cored wire welding with inert gas” Before you connect the gas cylinder

to the pressure regulator

make sure that the regulator of the pressure regulator is set to the “OFF” position. To do this rotate the regulator of the pressure regulator in a clockwise direction and not, as described in the user instructions, in an anti-clockwise direction. To increase the gas flow, rotate the regulator of the pressure regulator in an anti-clockwise direction towards the “ON” position and not, as described in the user instructions, in a clockwise direction. The “ON” and “OFF” positions are shown correctly on the regulator of the pressure regulator.

Before reading, unfold the page containing the illustrations and familiarise yourself with all functions of the device.

Suitable for welding under increased electrical hazard Welding sparks can cause an explosion or fire. Single-phase static frequency converter- transformer-commutator Arc beams can damage your eyes and injure your skin.

Insulation class Electromagnetic fields can disrupt the function of cardiac pacemakers.

Standardised operating voltage

Warning: Potential hazards!

1max Greatest rated value of the mains current X % Duty cycle

Rated value of the welding current Earth terminal Metal inert and active gas welding including the use of flux-cored wire Manual arc welding with encased rod electrodes Tungsten inert gas welding35GB/IE List of pictograms used / Introduction 4-IN-1 COMPACT WELDER PSGS 120 A1 z Introduction Congratulations! You have purchased one of our high-quality devices. Please familiarise yourself with the product before using it for the first time. To do so, please read through the following operating and safety instructions care- fully. This tool must be set up or used only by people who have been trained to do so.

KEEP OUT OF THE REACH OF

CHILDREN! z Intended use The device is designed for flux-cored welding, MMA welding (welding with rod electrodes) and TIG welding (tung- sten inert gas welding). When using flux-cored wires which do not contain inert gas in solid form, then you must use inert gas in addition. When using the 0.95l argon gas cylinder delivered with the product, you can weld with inert gas for a short period of time even without external inert gas supply (depending on the gas flow which is set, approx. 6 to 10 minutes). When using an external inert gas source, you will need a separate pressure regulator and adapter (neither of which are included with the delivery). When using self-shielding flux-cored wire, you do not need to use any additional gas. In this case, the protective gas is contained in powder form in the wire itself, thus it is fed directly into the arc. This means the device is not susceptible to wind and can be used outside. Only suitable wire electrodes may be used for the device. This welding device is designed for manual arc welding (MMA welding) of steel, stainless steel, steel sheet, galvanised metal and cast materials, using the appropriate coated electrodes. Refer to the information from the electrode manufacturer and the MMA torch stand manufacturer. Only suitable electrodes may be used for the device. For tungsten inert gas welding (TIG welding) it is essential that you observe the operating and safety instructions for the TIG torch you are using, in addition to the instructions and safety instructions in these operating instructions. If it is not handled properly the product can be dangerous for individuals, animals and property. The welding mask must only be used with protective welding glasses as well as prescription glasses which are marked appropriately, used properly and as a general rule, are only used for welding. The welding mask is not designed for laser welding! Use the product only as described and only for the specific applications as stated. Keep these instructions in a safe place. Ensure you hand over all documentation when passing the product on to anyone Compressed argon Gas under pressure Direct current

Rated value of the open circuit voltage

Rated value of the mains voltage36 GB/IE else. Any use that differs to the intended use as stated above is prohibited and potentially dangerous. Damage or injury caused by misuse or disregarding the above warning is not covered by the warranty or any liability on the part of the manufacturer. The device has been designed for household use only and must not be used in commercial or industrial applications. Commercial use will void the guarantee. Observing the safety instructions and assembly instruc- tions and operating information in the instructions for use is also a component of the intended use. It is imperative to adhere to the applica- ble accident prevention regulations. The device must not be used: in insufficiently ventilated rooms, in explosive environments, to defrost pipes, in the vicinity of people with cardiac pacemakers and in close proximity to easily flammable materials. Residual risk Even if you operate the device as intended, there will be residual risks. The following dangers may occur in connection with the build and design of this 4-in-1 compact welder: Eye injuries due to glare, Touching hot parts of the device or workpiece (burn injury), In case of improper protection risk of accident and fire through sparks and slag particles, Harmful emissions from smoke and gases if there is a lack of air or if closed rooms are insufficiently extracted. Reduce the residual risk by carefully using the device as intended and observing all instruction. z Package contents 1 4-in-1 Compact welder 120 A1 2 Welding nozzles for steel wire (1x 0.8 mm; 1x 0.6 mm) 1 Chipping hammer with wire brush 1 Welding mask 1 Operating instructions 1 Earth terminal with cable 1 MIG torch with welding cable

Flux-cored welding wire spool 450 g for inert gas welding 1 Argon gas cylinder 0.95 l

Cover wire feed unit

Control dial for wire feed

Control dial for setting the welding current

Earth cable with earth terminal

Welding nozzle (0.6 mm)

Chipping hammer with wire brush

Welding mask after fitting

Protective glass catch

Bracket for the pressure regulator

Quick-connect pressure regulator

Bracket screws for the pressure regulator

Release knob z Technical specifications Input power: 4.1 kW Mains connection: 230 V~ 50 Hz Weight: 7.8 kg Fuse: 16 A Welding with flux-cored wire: Welding current: I

= 46 – 120 A Duty cycle X: 15% at 120 A welding current 60% at 60 A welding current Open circuit voltage: U

= 60 V Greatest rated value of the mains current:

Effective value of the greatest rated current:

Welding wire reel max.: approx. 1000 g Welding wire diameter max.: 0.8mm Characteristic value Flat MMA welding: Welding current: I

= 27 – 70 A Duty cycle X: 15% at 70 A welding current 60% at 35 A welding current Open circuit voltage: U

= 60 V Greatest rated value of the mains current:

Effective value of the greatest rated current:

Characteristic value Falling TIG welding Welding current: I

= 27 – 70 A Duty cycle X: 15% at 70 A welding current 60% at 35 A welding current Open circuit voltage: U

= 60 V Greatest rated value of the mains current:

Effective value of the greatest rated current:

Characteristic value Falling Changes to technical and visual aspects of the product may be made as part of future developments without notice. Accordingly, no warranty is offered for the physical dimensions, information and specifications in these operating instructions. The operating instructions cannot therefore be used as the basis for asserting a legal claim.38 GB/IE Safety instructions Please read the operating instruc- tions with care and observe the notes described. Familiarise your- self with the device, its proper use and the safety instructions based on these operating instruc- tions. The rating plate contains all technical data of this welding device; please learn about the technical features of this device. Keep the packaging material away from small children. There is a risk of suffocation! This device may be used by children aged 16 years and older, and by persons with reduced physical, sensory or mental capacities, or a lack of experience and knowledge, if they are supervised or have been instructed in how to use the device safely and under- stand the dangers that may arise when using it. Do not allow children to play with the device. Cleaning and day-to-day mainte- nance must not be performed by children without supervision. Repairs and/or maintenance work must only be carried out by qualified electricians. Only use the weld cable pro- vided in the scope of delivery. During operation, the device should not be positioned directly on the wall, covered or jammed between other devices so that sufficient air can be absorbed through the ventila- tion slats. Make sure that the device is correctly connected to the supply voltage. Avoid any form of tensile stress of the power cable. Disconnect the plug from the socket prior to setting up the device in another location. If the device is not in opera- tion, always switch it off by pressing the ON/OFF switch. Place the electrode holder on an insulated surface and only remove it from the holder after allowing it to cool down for 15 minutes. Pay attention to the condition of the welding cable, electrode holder and the earth terminal. Wear and tear of the insu- lation and the live parts can lead to hazards and reduce the quality of the welding work. Arc welding creates sparks, molten metal parts and smoke. Therefore ensure that: Safety instructions39GB/IE All flammable substances and/ or materials are removed from the work station and its imme- diate surrounding. Ensure the work station is ventilated. Do not weld on containers, vessels or tubes that contain or contained flammable liquids or gases. Avoid any form of direct contact with the welding current circuit. The open circuit voltage between the electrode holder and earth terminal can be danger- ous, there is a risk of electric shock. Do not store the device in a damp or wet environment or in the rain. Protection rating IP21S is applicable in this case. Protect your eyes using the appropriate protective glasses (DIN level 9-10), which are fastened to the supplied weld- ing mask. Wear gloves and dry protective clothing that are free of oil and grease to pro- tect the skin from exposure to ultraviolet radiation of the arc. Do not use the welding power source to defrost pipes. Please note: The light radiation emitted by the electric arc can damage eyes and cause burns to the skin. Arc welding creates sparks and drops of melted metal. The welded workpiece starts to glow and remains hot for a rel- atively long period. Therefore, do not touch the workpiece with bare hands. Arc welding can cause vapours to be release that may be hazardous to health. Be careful not to inhale these vapours. Protect yourself from the harmful effects of the electric arc and keep people that are not involved in the work away from the arc maintaining a distance of at least 2 m. ATTENTION! During the operation of the welding device, other consum- ers may experience problems with the voltage supply depending on the network Safety instructions40 GB/IE conditions at the connection point. In case of doubt, please contact your energy supply company. During the operation of the welding device, other devices may malfunction, e.g. hearing aids, cardiac pacemakers, etc. z Potential hazards during electric arc welding There are a series of potential hazards that can occur during electric arc welding. It is there- fore particularly important for the welder to observe the following rules to avoid endangering him/ herself and others and to prevent damage to people and the device. Work on the voltage side, e.g. on cables, plugs, sockets etc., may only be carried out by qualified electricians according to national and local regulations. In the event of accidents, disconnect the welding device from the mains voltage imme- diately. If electrical contact voltages occur, switch off the device immediately and have it checked by a qualified electri- cian. Always ensure good electrical contacts on the welding current side. Always wear insulating gloves on both hands during welding work. These provide protection from electrical shocks (no-load voltage of the welding current circuit), harmful radiations (heat and UV radiation) and incandescent metal and splashes of slag. Wear sturdy, insulating shoes. The shoes should also insulate when exposed to moisture. Loafers are not suitable as falling incandescent metal droplets can cause burns. Wear suitable protective cloth- ing, no synthetic garments. Do not look into the electric arc without eye protection; only use a welding mask with the prescribed protective glass as per DIN. In addition to light and heat radiation, which can dazzle or cause burns, the electric arc also emits UV radiation. Without suitable protection the invisible ultravi- olet radiation can cause very painful conjunctivitis which Safety instructions41GB/IE is not apparent until several hours later. Furthermore, UV radiation can cause burns sun- burn-like effects on unprotected parts of the body. Any persons in the vicinity of the electric arc or helpers must also be informed of the dangers and be equipped with the necessary protective equipment. If necessary, set up protective walls. Ensure an adequate supply of fresh air whilst welding, particularly in small spaces, as it produces smoke and harmful gases. No welding work may be carried out on containers that have been used for storing gases, fuels, mineral oils or similar – even if they have been empty for a long time– as possible residues may present a risk of explosion. Special regulations apply in rooms where there is a risk of fire or explosion. Welded joints that are subject to heavy stress loads and are required to comply with certain safety requirements may only be carried out by specially trained and certified welders. Examples of this are pressure vessels, running rails, tow bars, etc. ATTENTION! Always connect the earth terminal as close as possible to the point of weld to provide the shortest possible path for the welding current from the electrode to the earth terminal. Never connect the earth terminal to the housing of the welding device! Never connect the earth terminal to earthed parts far away from the workpiece, e.g. a water pipe in another corner of the room. This could otherwise damage the protective bonding system of the room you are welding. Do not use the welding device in the rain. Only place the welding device on a level surface. The output is rated at an ambi- ent temperature of 20°C. The welding time may be reduced in higher temperatures. Risk of electric shock: Electric shock from the welding electrode can be fatal. Do not weld in rain or snow. Wear dry insulating gloves. Do not touch the electrodes with Safety instructions42 GB/IE bare hands. Do not wear wet or damaged gloves. Protect yourself from electric shock with insulation against the workpiece. Do not open the device housing. Danger from welding fumes: Inhalation of welding fumes can endanger health. Do not keep your head in the fumes. Use the equipment in open areas. Use extractors to remove the fumes. Danger from welding sparks: Welding sparks can cause an explosion or fire. Keep flammable substances away from the weld- ing location. Do not weld next to flammable substances. Welding sparks can cause fires. Keep a fire extinguisher close by and an observer should be present to be able to use it immediately. Donot weld on drums or any other closed containers. Danger from arc beams: Arc beams can damage your eyes and injure your skin. Wear a hat and safety goggles. Wear hearing protection and high, closed shirt collars. Wear weld- ing safety helmets and filter sizes in perfect condition. Wear complete body protection. Danger from electro- magnetic fields: Welding current generates elec- tromagnetic fields. Do not use if you have a medical implant. Never wrap the welding cable around your body. Guide weld- ing cables together. z Welding mask-specific safety instructions With the help of a bright light source (e.g. lighter) examine the proper functioning of the welding shield prior to starting with any welding work. Weld spatters can damage the protective screen. Immediately replace damaged or scratched protective screens. Immediately replace damaged or highly contaminated or splattered components. The device must only be operated by people over the age of 16. Please familiarise yourself with the welding safety instructions. Also refer to the safety instruc- tions of your welding device. Safety instructions43GB/IE Always wear a welding mask while welding. If it is not used, you could sustain severe lesions to the retina. Always wear protective clothing during welding operations. Never use the welding shield without the protective screen because this could damage the optical unit. There is a risk of damage to the eyes! Regularly replace the protective screen to ensure good visibility and fatigue-proof work. z Environment with increased electrical hazard When welding in environments with increased electrical hazard, the following safety instructions must be observed. Environments with increased electrical hazard may be encoun- tered, for example: In workplaces where the space for movement is restricted, such that the welder is working in a forced posture (e.g.: kneeling, sitting, lying) and is touching electrically conductive parts; In workplaces which are restricted completely or in part in terms of electrical conductivity and where there is a high risk through avoidable or accidental touching by the welder; In wet, humid or hot work- places where the air humidity or weld significantly reduces the resistance of human skin and the insulating properties or effect of protective equipment. Even a metal conductor or scaf- folding can create an environment with increased electrical hazard. In this type of environment, insulated mats and pads must be used. Furthermore gauntlet gloves and head protection made of leather or other insulating materials must be worn to insu- late the body against Earth. The welding power source must be located outside the working area or electrically conductive surfaces and out of the welder’s reach. Additional protection against a shock from the mains power in the event a fault can be provided by using a fault-circuit interrupter, which is operated with a leakage current of no more than 30 mA Safety instructions44 GB/IE and covers all mains-powered devices in close proximity. The fault-circuit interrupter must be suitable for all types of current. There must be means of rapid electrical isolation of the welding power source or the welding circuit (e.g. emergency stop device) which are easily accessi- ble. When using welding devices under electrically dangerous conditions, the output voltage of the welding device must be greater than 113 volt when idling (peak value). Based on the output voltage this welding device may be used in these conditions. z Welding in tight spaces When welding in tight spaces this may pose a hazard through toxic gases (risk of suffocation). In tight spaces you may only weld if there are trained individuals in the immediate vicinity who can intervene if necessary. In this case, before starting the welding procedure, an expert must carry out an assessment in order to determine what steps are neces- sary, in order to guarantee safety at work and which precautionary measures should be taken during the actual welding procedure. z Total of open circuit voltages When more than one welding power source is operated at the same time, their open circuit voltages may add up and lead to an increased electrical hazard. Welding power sources must be connected in such a way that the danger is minimised. The indi- vidual welding power sources, with their individual control units and connections, must be clearly marked, in order to be able to identify which device belongs to which welding power circuit. z Protective clothing At work, the welder must protect his/her whole body by using appropriate clothing and face protection against radia- tions and burns. The following steps must be observed: – Wear protective clothing prior to welding work. – Wear gloves. – Open windows to guarantee air supply. Safety instructions45GB/IE – Wear protective goggles. Gauntlet gloves made of a suitable material (leather) must be worn on both hands. They must be in perfect condition. A suitable apron must be worn to protect clothing from flying sparks and burns. When specific work, e.g. overhead welding, is required, a protective suit must be worn and, if necessary, even head protection. When screwing in the gas cylinder, you must wear gloves to protect your hands. z Protection against rays and burns Warn of the danger to the eyes by hanging up a sign saying “Caution! Do not look into flames!”. The workplaces must be shielded so that the persons in the vicinity are protected. Unauthorised persons must be kept away from welding work. The walls in the immediate vicin- ity of fixed workplaces should neither be bright coloured or shiny. Windows up to head height must be protected to prevent rays from penetrating or reflecting through them, e.g. by using suitable paint. z EMC Device Classification As per the standard IEC 60974- 10, this welding device is a welding unit with class A electro- magnetic compatibility. Thus it complies with the corresponding requirements for industrial and domestic use. In residential areas, it can be connected to the public low-voltage supply network. Even if the 4-in-1 compact welder complies with the emission limit values of the standard, arc welding devices can still result in electro- magnetic interferences in sensitive systems and devices. The operator is responsible for malfunctions that occur through the arc while welding and must take suitable protective measures. In doing so, the operator must consider the following: – network, control, signal and telecommunication lines – computers and other micropro- cessor-controlled devices – TVs, radios and other playback devices Safety instructions46 GB/IE – electronic and electrical safety equipment – people with cardiac pacemak- ers or hearing aids – measurement and calibration devices – interference immunity of other equipment nearby – the time at which the welding work is carried out. The following is recommended to reduce possible interference radiation: – equip the mains connection with a mains filter – the 4-in-1 compact welder must be regularly maintained and kept in a good condition – welding cables should be completely uncoiled and run as close to parallel with the floor as possible – devices and systems that are compromised by the inter- ference radiation must be removed from the welding area or shielded. z Before use Take all parts from the packaging and check whether the 4-in-1 compact welder or parts show any damage. If this is the case, do not use the 4-in-1 compact welder. Contact the manufacturer via the indicated service address. Remove all protective films and other transport packaging. Check that the delivery is complete. z Mounting z Assembling the welding mask Insert the dark welding lens

with the writing facing up into the shield body

(see Figure C). To do this, if necessary, press gently from the front against the disc, until it clicks into place The labelling on the dark welding lens

must now be visible from the front of the protective shield. Push the handle

from the inside into the corresponding notch of the mask, until it snaps into place (see Figure C). z Welding with flux-cored wire Always unplug the mains plug from the mains socket prior to each maintenance task or preparatory work in order to prevent the risk of an electric shock, injury or damage. Note: Different welding wires will be needed depending on the application. Welding wires with a diameter of

0.6 – 0.8 mm can be used with this

device. Safety instructions / Before use / Mounting / Welding with flux-cored wire47GB/IE Feed roll, welding nozzle and wire cross-section must be compatible with one another. The device is suitable for wire reels weighing up to maximum 1000 g. z Fit the gas cylinder Note: When screwing in the gas cylinder

, you must wear gloves to protect your hands. First remove the plastic protective cap by turning it in a clockwise direction and pull it off the 0.95 litre argon gas cylinder

. With the connecting thread aligned with the pressure regulator

place the gas cylinder in the bracket inside the device which has been provided for this purpose, see FigureE. Make sure that the retaining straps

go right round the gas cylinder

However, do not tighten these yet. Make sure that the switch on the pressure regulator

is set to the “Off” position. To do this, turn the regulator on the pressure regulator in an anti-clock- wise direction. Now guide the connect- ing thread of the gas cylinder

to the inlet of the pressure regulator

. Then connect the inert gas inlet tubing

the quick connector of the pressure reg- ulator

into the quick connector of the pressure regulator

until it clicks into place. Rotate the gas cylinder

shown in Figure E, in order to connect it to the pressure regulator

. When fixing the pressure regulator

gas will leak for a short time. The gas will stop leaking once it has been connected properly. In order to make a solid connection, undo the bracket screw

of the pressure regulator

onto the gas cylinder

while holding the gas cylinder

, until they are firmly connected together and there is no gas leak. When doing this, grip the bracket of the pressure regulator

and not the pressure regulator

itself, in order to avoid any damage. Rotate the pressure regulator

and the gas cylinder

(which are now connected), until the pressure regulator

is back in a vertical position and re-tighten the bracket screw

of the pressure regula- tor

. Now fix the gas cylinder

tightening the retaining strap

Remove the gas cylinder

from the device once the welding work is complete. z Adaptation of device to flux-cored welding wire with inert gas The correct connections for welding with flux-cored wire when using inert gas are shown in Figure U.

First connect the plug

with the connector marked with the “+” (see Figure U) and rotate it in a clockwise direction to fix it in place. If you are in any doubt, then please contact a professional. Then connect the earth cable

with the corresponding connector, marked Welding with flux-cored wire48 GB/IE with the “-” (see Figure U) and rotate in a clockwise direction to fix it in place.

The gas flow can now be adjusted using the pressure regulator

(see Figure V). Rotating the regulator on the pressure regulator in a clockwise direction will increase the gas flow. If you would like to use inert gas from an external source (e.g. 20 l gas cylinder), then you will need a separate pressure regulator (not included with the delivery). Connect the external inert gas source with the insert gas inlet tubing

of the weld- ing device. To do this an adapter may be required (not included with delivery). Also observe the notes for your separate pressure regulator. You can use the following formula as a guideline for adjusting the gas flow: Flux-cored wire diameter in mm x 10 = gas flow in l/min For example, using 0.8 mm wire, will give a value of approx. 8 l/min. z Adaptation of device to flux-cored welding wire without inert gas If you are using solid wire with integrated inert gas, then you do not have to have an external inert gas supply. First connect the plug

with the con- nector marked with the “-” and rotate it in a clockwise direction to fix it in place. If you are in any doubt, then please contact a professional. Then connect the earth cable

with the corresponding connector, marked with the “+” and rotate in a clockwise direction to fix it in place. z Inserting the flux-cored wire Unlock and open the cover of the wire feed unit

, by pushing the release knobs

upwards (see Figure T). Unlock the roller unit by turning the roller mount

clockwise (see Figure G). Pull the roller mount

off the shaft (see Figure G). Note: Make sure that the end of the wire does not come loose and cause the roll to roll out on its own. The end of the wire may not be released until during assembly. Completely unpack the flux-cored wire welding spool

, so that it can unrolled without difficulty. Do not release the wire end yet. Place the wire reel on the shaft. Make sure that the roll unwinds on the side of the

back on and lock it by pressing and turning it anti-clockwise (see Figure H). Undo the adjustment screw

and swing it forwards (see Figure I). Turn the thrust roller unit

to the side (see Figure J). Loosen the feed roll holder

turning it anti-clockwise and pull it forwards and off (see Figure K). On the top of the feed roll

check whether the appropriate wire thickness is indicated. If necessary, the feed roll has to be turned over or replaced. The supplied welding wire (Ø 0.8 mm) must be used in the feed roll

with the specified wire thick- ness of Ø 0.8mm. The wire must be positioned in the front groove! Erect the feed roll holder

again and screw clockwise direction. Make sure that the feed roll holder is properly aligned (see Figures I, J). Remove the torch nozzle

pulling and turning it anti-clockwise (see Figure L). Unscrew the welding nozzle

(see Figure L). Guide the torch

away from the welding device as straight as possible (place it on the floor). Take the wire end out of the edge of the spool (see Figure M). Trim the wire end with wire scissors or a diagonal cutter in order to remove the damaged, bent ends of the wire (see Figure M). Note: The wire must be kept under ten- sion the entire time in order to avoid a releasing and a roll out! Therefore it is recommended to carry out the work with an additional person. Push the flux-cored wire through the wire feed guide

(see Figure N). Guide the wire along the feed roll

and then push it into the flux-cored wire holder

towards the feed roll

(see Figure P). Mount the adjustment

screw (see Figure P). Set the counter pressure with the adjustment screw

. The welding wire must be firmly positioned between the thrust roller and feed roll

in the front groove without being crushed (see Figure P). Switch on the welding device on the main

Now the wire feed system pushes the welding wire through the cable assembly and the torch

As soon as 1 – 2 cm of the wire protrudes from the torch neck

button again (see Figure Q). Switch off the welding device on the main switch. Screw the welding nozzle

back on. Make sure that the welding nozzle

matches the diameter of the welding wire used (see Figure R). When using the delivered welding wire (Ø 0.8 mm), the welding nozzle with the

labelling 0.8 mm must be used. Push the torch nozzle

back on to the torch neck by turning it anti-clockwise at the same time

(see Figure S). Always unplug the mains plug from the socket prior to each maintenance task or preparatory work in order to prevent the risk of an electric shock, injury or damage. Welding with flux-cored wire50 GB/IE z Using the device z Switching the device on and off Switch the welding device on and off on the main

switch. If you do not intend to use the welding device for an extended period, remove the plug from the power socket. This is the only way to completely de-energise the device. z Select welding with flux-cored wire Set “MIG/MAG” mode by pressing the welding mode selector switch

z Setting the welding current The control dial for adjusting the welding current

on the front of the welding device can be used to set the desired welding current. The necessary welding current depends on the welding wire diameter used, the material thickness and the desired penetration depth. z Setting the wire feed In order to generate a constant arc, the control dial for the wire feed

can be used to fine-tune the wire feed. You are recommended to use a setting in the middle range to start with, and then reduce or increase the speed as required. The necessary welding current depends on the welding wire diameter used, the material thickness and the desired penetration depth. Similarly, the gaps to be bridged between the work- pieces to be welded must be observed. Guideline values for wire feed and welding current and for common flux- cored wires can be taken from the table on the inside of the cover for the wire feed unit

z Welding Overload protection The welding device is protected against overheating by means of an automatic protection device (thermostat with automatic restart). The protective device interrupts the overload of the current circuit and the yellow overload protec- tion control lamp

illuminates. Allow the device to cool down for the activation of the protection device. After approx. 15 minutes, the device is ready to be used again. Welding mask HEALTH HAZARD! If you do not use the welding mask, harmful UV radiation and heat emitted by the electric arc could damage your eyes. Always use the welding mask for welding work. RISK OF BURNS! Welded workpieces are very hot and can cause burns. Always use pliers to move hot, welded workpieces. Please proceed as follows once you have electrically connected the welding device: Connect the earth cable to

the workpiece that is to be welded using the earth terminal. Please ensure good electrical conductivity. Using the device51GB/IE The area to be welded on the work- piece must be free of rust and paint. Choose the desired welding current and wire feed depending on the welding wire diameter, material thickness and desired penetration depth, as previously described. Guide the torch nozzle

and hold the welding mask

in front of the face. Press the torch button

, in order to generate an arc. Once the electric arc is burning, the device feeds wire into the weld pool. You can work out the ideal settings for the welding current and the wire feed rate by carrying out trial welds on a test piece. A properly set electric arc has a mild, uniform buzzing sound. Reduce the wire feed rate in case of a rough or hard rattle or switch to a higher power level (increase welding current). If the welding lens is big enough, the torch

is slowly guided along the desired edge. The distance between the torch nozzle and workpiece should be as small as possible (it must not be greater than 10 mm). If necessary, oscillate a little to increase the size of the weld pool. For inexperienced welders, it is often difficult initially to create a decent electric arc. To do so, the welding current and wire feed rate must be set correctly. The penetration depth (corresponds to the depth of the welding seam in the material) should be as deep as possible without allowing the welding pool to fall through the workpiece. If the wire feed rate is too high and/ or the welding current too low, the welding wire will not melt properly. Consequently, the welding wire repeatedly dips in the welding pool as far as the workpiece. The slag can only be removed from the seam once it has cooled down. To continue welding an interrupted seam: First remove the slag at the starting point. The electric arc is ignited in the weld groove, guided to the connection point, melted properly and finally the weld seam is continued. CAUTION! Please note that the torch must always be placed onto an insulated surface after welding. Always switch off the welding device after completing welding work and during breaks and pull the plug

from the mains socket. z Create a weld seam Forehand welding Push the torch forwards. Result: The penetration depth is lower, broader weld width, flatter weld bead (visible surface of the seam) and greater fusion error tolerance. Backhand welding The torch is dragged from the weld seam (Figure W). Result: Greater penetration depth, narrower weld width, higher weld bead and lower fusion error tolerance.

Using the device52 GB/IE Welded joints There are two-basic types of joints in welding: Butt welds (outer edge) and angle welding (inner edge and overlapping). Butt welds With butt welds of up to 2 mm, the weld edges are completely brought together. For greater thicknesses, please proceed as per the following table (Figure X):

S = 1–3 mm 3–4 mm 4–6 mm d = surface 0.5–1.5 mm 1.5–2.5 mm 2–3 mm d = vertical 1–1.5 mm 1.5–2.5 mm 2–3 mm d = front surface 1–2 mm 2–3 mm 3–4 mm Flat butt welds Welds should be made without inter- ruption and with a sufficient penetration depth. Therefore, it is extremely impor- tant to be well prepared. The factors that influence the quality of the weld result are: the amperage, the distance between weld edges, the inclination of the torch and the corresponding diame- ter of the welding wire. The steeper you hold the torch against the workpiece, the higher the penetration depth and vice versa. To forestall or reduce defor- mations that can happen during the material hardening process, it is good to fix the workpiece with a device. Avoid stiffening the welded structure to prevent cracks in the weld. These problems can be avoided if there is a possibility of turning the workpiece so that the weld can be carried out in two passes running in opposite directions. Welds on the outer edge The preparation for this is very simple (Figures Y, Z).

However, it is no longer expedient for thicker materials. In this case, it is better to prepare a joint as shown below, in which the edge of the plate is angled (Figure AB).

Using the device53GB/IE Fillet weld connections A fillet weld is created if the workpieces are perpendicular to each other. The weld should be shaped like a triangle with sides of equal length and a slight fillet (Figures AC, AD). Welds on an inner edge The preparation for this weld joint is very simply and is carried out for thicknesses of 5 mm. The dimension “d” needs to be reduced to a minimum and should always be less than 2 mm (Figure AC).

However, it is no longer expedient for thicker materials. In this case, it is better to prepare a joint as shown in Figure AB, in which the edge of the plate is angled.

Overlap welds The most common preparation is that with the straight weld edges. The weld can be released using a standard angle weld seam. Both workpieces must be brought as close to each other as possible, as shown in Figure AE.

z MMA welding For MMA welding please follow the instructions for your MMA electrode holder. In addition, observe the safety instructions in these Operating instruc- tions. You can select MMA mode by pressing the welding mode selector switch

(lower position). z TIG welding For TIG welding please follow the instruc- tions for your TIG torch. You can select TIG mode by pressing the welding mode selector switch