HSG 190D - Welding machine Herkules - Free user manual and instructions

USER MANUAL HSG 190D Herkules

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.

2. Layout and items supplied

5. Gas bottle support surface

16. Gas supply connector

18. Shielding gas hose

19. Pressure reducer

23. Shielding gas hose connector

27. Handle for housing cover

31. Pressure gage (bottle pressure)

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 shielding gas welding set is exclusively desi- gned for welding steel with the MAG (Metal Active Gas) method using the appropriate welding wires and gases. The machine is to be used only for its prescribed purpose. Any other use is deemed to be a case of misuse. The user / operator and not the manu- facturer will be liable for any damage or injuries of any kind caused as a result of this. Important information about the power con- nection This equipment falls under Class A of the stan- dard EN 60974-10, i.e. it is not designed for use in residential areas in which the power supply is based on a public low-voltage supply system be- cause given unfavorable conditions in the power supply the equipment may cause interference. If you want to use the equipment in residential areas in the which the power supply is based on a public low-voltage supply system, you must use an electromagnetic fi lter which reduces the elec- tromagnetic interference to the point where the user no longer notices any disturbance. In industrial parks or other areas in which the power supply is not based on a public low-voltage supply system the equipment can be used wit- hout such a fi lter. General safety information It is the user’s responsibility to install and use the equipment properly in accordance with the instructions issued by the manufacturer. If elec- tromagnetic interference is noticed, it is the user’s responsibility to eliminate said interference with the technical devices mentioned in the section “Important information about the power connec- tion”. Reduction of emissions Main current supply The welder must be connected to the main cur- rent supply in accordance with the instructions issued by the manufacturer. If interference occurs, it may be necessary to introduce additional mea- sures, e.g. fi tting a fi lter to the main current supply (see above in the section “Important information about the power connection”). The welding cables should be kept as short as possible. Pacemakers Persons using an electronic life support device (e.g. a pacemaker) should consult their doctor before they go near electric sparking, cutting, burning or spot-welding equipment in order to be sure that the combination of magnetic fi elds and high electric currents does not aff ect their devices. For commercial users the guarantee period is 12 months and for normal users 24 months, begin- ning from the date of purchase.

4. Symbols and technical data

EN 60974-1 European standard for arc welding sets and wel- ding power supplies with limited on time

Rated idling voltage

Mains voltage Ø mm Welding wire diameter

1max Rated maximum mains current

Welding current ~ 50 Hz Mains frequency IP 21 Protection type

Symbol for falling characteristic curve Transformer Fuse with rated value in A in the mains connec- tion Do not store or use the equipment in wet or damp conditions or in the rain Read the operating instructions carefully before using the welding set and follow them Mains connection: ...............230 V/400 V ~ 50 Hz Welding current: ...............25-160 A (max. 190 A) Duty cycle r X%: 10 15 25 35 60 100 Welding current I

5. Before starting the equipment

(6/14) Install the castors (6) and guide rollers (14) as shown in Figures 7, 9, 10 and 11.

5.1.2 Fitting the welding screen (17)

Place the welding glass (l) and the transpa- rent safety glass (m) over it in the frame for the safety glass (k) (Fig. 12).

Press the safety glass retaining pins (q) into the holes in welding screen frame (s) from the outside. (Fig. 13)

Place the frame for the safety glass (k) with the welding glass (l) and transparent safety glass (m) from the inside into the recess in the welding frame (s), press the safety glass retaining bushes (n) on to the safety glass retaining pins (q) until they engage to secure the frame for the safety glass (k). The transpa- rent safety glass (m) must be on the outside. (Fig. 14)

Bend the top of the welding screen frame (s) inwards (Fig. 15/1) and fold down the top corners (Fig. 15/2) Now bend the outer sides of the welding screen frame (s) inwards (Fig. 15/3) and connect them by pressing the top corners and outer sides together. As the retai- ning pins engage, you should be able to hear to clear clicks on each side (Fig. 15/4).

When the top corners of the welding screen are connected as shown in Figure 16, place the screws for the handle (p) from the outside through the three holes in the welding screen. (Fig. 17)

Turn over the welding screen and place the handle (r) over the threads on the three screws for the handle (p). Secure the handle (r) to the welding screen the three nuts for the handle (o) (Fig. 18).

Gas shielding is required for welding with conti- nuous wire, the composition of the shielding gas depends on the welding method you wish to use. Shielding gas CO2 Argon/CO2 Metal to be welded: Non-alloyed steel

5.2.2 Fitting the gas bottle on the unit (Fig.

19-25) The gas bottle is not supplied. Fit the gas bottle cables as shown in Figures 19 - 21. Ensure that the safety chain (28) is secure and that the welding set cannot tip over. Anl_HSG_190_D_SPK7.indb 22Anl_HSG_190_D_SPK7.indb 22 12.08.2015 17:41:5412.08.2015 17:41:54GB

Danger! Only gas bottles with a maximum ca- pacity of 20 liters may be fi tted on the gas bottle support area (Fig. 19/5). If you wish to use larger gas bottles, there is a risk that they will tip over and therefore they may only be placed next to the unit. In this case the gas bottle must be secured to prevent it tipping over.

5.2.3 Connecting the gas bottle

After removing the protective cap (Fig. 22/A), open the bottle valve (Fig. 22/B) briefl y, ensuring it is pointing away from your body. Clean any dirt off the connecting thread (Fig. 22/C) if necessary using a dry cloth without ad- ding any cleaning products. Check whether there is a seal on the pressure reducer (19) and that it is in perfect condition. Turn the pressure reducer (19) clockwise on to the connection thread (Fig. 23/C) on the gas bottle (Fig. 23). Place the two hose clips (d) over the shielding gas hose (18). Connect the shielding gas hose (18) to the shiel- ding gas hose connection (23) on the pressure reducer (19) and gas supply connector (16) on the welding set and secure it to both connectors using the hose clips (d). (Fig. 24-25) Danger! Check all gas and other connection for leaks. Check the connections using leak spray or soap suds.

5.2.4 Information about the pressure reducer

(Fig. 4/19) The pressure gage (31) shows the bottle pressu- re in bar. The gas delivery rate can be adjusted using the rotary knob (24). The set gas delivery rate can be read off the pressure gage (20) in liters per minute (l/min). The gas is discharged at the shielding gas hose connector (23) and is then forwarded to the welding set through the shielding gas hose (Fig. 3/18). (see 5.2.3) Important. Always proceed as described in point

6.1.3 for setting the gas delivery rate.

The pressure reducer is fi tted on the gas bottle using the screw connector (21) (see 5.2.3). Danger! The pressure reducer may only be adjusted and repaired by trained personnel. Send defective pressure reducers to the service address if necessary.

5.3 Mains connection

Before you connect the equipment to the mains supply make sure that the data on the rating plate are identical to the mains data.

The equipment may only be operated from properly earthed and fused sockets. Please read the following to prevent the risk of fi re, an electric shock and personal injury:

Never use the welding set with a rated volta- ge of 400 V if it is set to 230 V. Caution: Fire risk.

Disconnect the welding set from the power supply before you adjust the mains voltage.

Do not change the rated voltage whilst the welding set is operating.

Before using the welding set, ensure that the rated voltage setting is identical to that from the power source. Please note: The welding unit is equipped with a 400 V ~ 16 A CeCon plug. Use the supplied adapter cable No. 30 to operate the welding unit with 230 V~.

5.4 Fitting the wire spool (Fig. 1, 5, 6, 26 – 34)

The wire spool is not supplied.

Various welding wires are required for diff erent applications. The welding set can be used with welding wires with a diameter of 0.6/0.8 and 1.0 mm. The appropriate feed rollers and contact tubes are supplied with the set. The feed roller, contact tube and wire cross-section must always match each other.

5.4.2 Wire spool capacity

Wire spools with a maximum weight of 5 kg can be fi tted in the welding set.

Open the housing cover (Fig. 2/4) by pushing the handle for the housing cover (Fig. 2/27) backwards and opening the housing cover (Fig. 2/4).

Check that the windings on the spool do not overlap so as to ensure that the wire can be unwound evenly. Description of the wire guide unit (Fig. 26-27) A Spool lock B Spool holder C Cam pin D Adjusting screw for roller brake Anl_HSG_190_D_SPK7.indb 23Anl_HSG_190_D_SPK7.indb 23 12.08.2015 17:41:5512.08.2015 17:41:55GB

E Screws for feed roller holder F Fee roller holder G Feed roller H Hose package mounting I Pressure roller J Pressure roller holder K Pressure roller spring L Adjusting screw for counter-pressure M Guide tube N Wire spool O Cam opening in wire spool Inserting the wire spool (Fig. 26, 27) Place the wire spool (N) on the spool holder (B). Ensure that the end of the welding wire is unw- ound on the side of the wire guide, see arrow. Ensure that the spool lock (A) is pushed in and the cam pin (C) is engaged in the cam opening in the wire spool (O). The spool lock (A) must enga- ge again over the wire spool (N). (Fig. 27) Inserting the welding wire and adjusting the wire guide (Fig. 28-34)

Push the pressure roller spring (K) upwards and swing it forwards (Fig. 28).

Pull the pressure roller holder (J) with the pressure roller (I) and pressure roller spring (K) downwards (Fig. 29).

Undo the screws for the feed roller holder (E) and pull off the feed roller holder (F) upwards (Fig. 30).

Check the feed roller (G). The appropriate wire thickness must be specified on the top of the feed roller (G). The feed roller (G) is fitted with two guide grooves. Turn the feed roller (G) over if necessary or replace it. (Fig. 31)

Position the feed roller holder (F) again and secure it.

Remove the gas nozzle (Fig. 5/12) from the burner (Fig. 5/13) by turning it clockwise, unscrew the contact tube (Fig. 6/26). (Fig. 5 – 6). Place the hose package (Fig. 1/11) on the floor as straight as possible pointing away from the welding set.

Cut off the first 10 cm of the welding wire to produce a straight cut with no shoulders, warping or dirt. Deburr the end of the welding wire.

Push the welding wire through the guide tube (M) between the pressure and feed rollers (G/I) into the hose package mounting (H). (Fig. 32) Carefully push the welding wire by hand into the hose package until it projects out of the hose package by approx. 1 cm at the burner (Fig. 5/13).

Undo the adjusting screw for counter-pressu- re (L) a few turns. (Fig. 34)

Push the pressure roller holder (J) with pres- sure roller (I) and pressure roller spring (K) upwards again and attach the pressure roller spring (K) to the adjusting screw for counter- pressure (L) again (Fig. 33).

Now set the adjusting screw for counter-pres- sure (L) so that the welding wire is positioned firmly between the pressure roller (I) and feed roller (G) without being crushed. (Fig. 34)

Screw the appropriate contact tube (Fig. 6/26) for the welding wire diameter on to the burner (Fig. 5/13) and fit the gas nozzle, turning it clockwise (Fig. 5/12).

Set the adjusting screw for the roller brake (D) so that the wire can still be moved and the roller stops automatically after the wire guide has been braked.

Since the welding set must be set to suit the spe- cifi c application, we recommend that the settings be made on the basis of a test weld.

6.1.1 Setting the welding current

The welding current can be set to 6 diff erent levels using the welding current switch (Fig. 1/7). The required welding current depends on the material thickness, the required penetration depth and the welding wire diameter.

6.1.2 Setting the wire feed speed

The wire feed speed is automatically adjusted to the current setting. The fi nal wire feed speed set- ting can be made on the welding wire speed cont- roller (Fig. 1/29). We recommend that you start the setting work at level 5 which is the middle value, and then adjust it from there. The required quanti- ty of wire depends on the material thickness, the penetration depth, the welding wire diameter and also of the size of the gap to be bridged between the workpieces you wish to weld.

6.1.3 Setting the gas delivery rate

To set the gas fl ow rate, fi rst release the clamp lever (Fig. 26/K) on the wire feed unit to prevent unnecessary wire wear (Fig. 5.4.3). Connecting to the mains (see point 5.3), set the ON/OFF/Wel- ding current switch (Fig. 1/7;8) to setting 1; 230 V/400 V and press the burner switch (Fig. 5/25) to start the gas fl ow. Now set the required gas deli- very rate on the pressure reducer (Fig. 4/19). Turn the rotary knob (Fig. 4/24) counter-clockwi- se: Lower gas delivery rate Turn the rotary knob (Fig. 4/24) clockwise: Higher gas delivery rate Secure the pressure roller spring (Fig. 26/K) to the wire feed unit again.

6.2 Electrical connection

1/10) Connect the welding set’s earth terminal (10) in the immediate vicinity of the welding position if possible. Ensure that the contact point is bare metal.

When all the electrical connections for the power supply and welding current circuit have been made and the shielding gas has also been con- nected, you can proceed as follows: The workpieces for welding must be clear of paint, metallic coatings, dirt, rust, grease and moisture in the area where they are to be welded. Set the welding current, wire feed and gas fl ow rate (see 6.1.1 – 6.1.3) as required. Hold the welding screen (Fig. 3/17) in front of your face and move the gas nozzle to the point on the workpiece where you wish to complete the weld. Now press the burner switch (Fig. 5/25). When the arc is burning, the welding set will feed wire into the weld pool. When the weld nugget is large enough, move the burner slowly along the required edge. Move it to and fro if necessary to enlarge the weld pool a little. Find the ideal setting of the welding current, wire feed speed and gas delivery rate by carrying out a test weld. Ideally an even welding noise will be audible. The penetration depth should be as deep as possible, but the weld pool must not be allo- wed to fall through the workpiece.

6.4 Safety equipment

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 (3) on your set will be lit. Allow the welding set to cool for a time.

7. 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.

8. 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.

8.3 Ordering replacement parts:

Please quote the following data when ordering replacement parts:

Article number of the machine

Identification number of the machine

Replacement part number of the part required For our latest prices and information please go to www.isc-gmbh.info

9. 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_HSG_190_D_SPK7.indb 26Anl_HSG_190_D_SPK7.indb 26 12.08.2015 17:41:5512.08.2015 17:41:55GB

Fault Cause Remedy Feed roller does not turn - Power supply not connected - Wire feed controller set to 0 - Check connection - Check setting Feed roller turns, but does not feed any wire - Incorrect roller pressure (see 5.4.3) - Roller brake set too fi rmly (see

- Dirty / damaged feed roller (see

- Damaged hose package - Contact tube wrong size / dirty / worn (see 5.4.3) - Welding wire welded to the gas nozzle / contact tube - Check setting - Check setting - Clean or replace - Check the wire guide jacket - Clean or replace - Release After a lengthy period of use the welding set does not work any longer, the thermostat (3) control light is lit - The welding set has overheated due to being used for too long and a failure to observe the reset time - Leave the set to cool down for at least 20 – 30 minutes Very poor weld - Incorrect current / feed setting (see

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_HSG_190_D_SPK7.indb 28Anl_HSG_190_D_SPK7.indb 28 12.08.2015 17:41:5512.08.2015 17:41:55GB

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* Feed roller, wire core, mass tongs Consumables* Welding wire, nozzles, contact tube 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 or the sales outlet from where you bought the device. Please note the fol- lowing terms under which guarantee claims can be made:

1. 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 60 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. Please report the defective device on the following internet address to register your guarantee claim:

www.isc-gmbh.info. 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 device. 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_HSG_190_D_SPK7.indb 30Anl_HSG_190_D_SPK7.indb 30 12.08.2015 17:41:5612.08.2015 17:41:56FR

5. Oppbevaringsfl ate for gassfl asker

31. Manomeeter (ballooni surve)

= dB (A); guaranteed L