PMSG 200 A1 - Welding machine PARKSIDE - Free user manual and instructions

USER MANUAL PMSG 200 A1 PARKSIDE

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 fi re. Single-phase static frequency converter- transformer-commutator. Arc beams can damage your eyes and injure your skin.

Electromagnetic fi elds 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.7GB/IE/NI/CY/MT List of pictograms used / Introduction List of pictograms used Metal inert and active gas welding including the use of fl ux-cored wire Manual arc welding with encased rod electrodes Tungsten inert gas welding Direct current

Rated value of the open circuit voltage

Rated value of the mains voltage

MULTI-WELDER PMSG 200 A1

Introduction Congratulations! You have purchased one of our high-quality devices. Please familiarise yourself with the product before using it for the fi rst time. To do so, please read through the following operating and safety instruc- tions carefully. 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! Intended use The device is designed for MIG welding (welding with welding wire and inert gas), MMA welding (welding with rod electrodes) and TIG welding (tungsten inert gas welding). When using solid wires which do not contain inert gas in solid form, then you must use inert gas in addition. When using aluminium solid wire, then you must use argon as the inert gas. When using self-shielding fl ux- cored wire, you do not need to use any additional gas. In this case, the inert gas is contained in the welding wire in pow- dered form and is therefore channelled straight into the arc. This means that the device is not susceptible to wind when working outdoors. 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 and cast materials, using the appropriate coated electrodes. Refer to the information from the electrode 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 specifi c applications as stated. Keep these instructions in a safe place.8 GB/IE/NI/CY/MT Ensure you hand over all documentation when passing the product on to anyone 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 should only be used by specialists or those who been trained. Commercial use will void the guarantee. Observing the safety instructions and assembly instructions and operating information in the instruc- tions 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 insuffi ciently ventilated rooms, in explosive environments, to defrost pipes, in the vicinity of people with cardiac pacemakers and in close proximity to easily fl ammable 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 multi-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 fi re through sparks and slag particles, Harmful emissions from smoke and gases if there is a lack of air or if closed rooms are insuffi ciently extracted. Reduce the residual risk by carefully using the device as intended and observing all instruction. Package contents 1 Multi-Welder PMSG 200 A1 1 1.0 welding nozzle (pre-fi tted, only for solid aluminium wire) labelling: 1.0 A 4 Welding nozzles for steel/ fl ux-cored wire (1x 0.6 mm; 1x 0.8 mm; 1x 0.9 mm; 1x 1.0 mm) labelling in accordance with the diameter: 0.6; 0.8; 0.9; 1.0 1 Chipping hammer with wire brush 1 Solid aluminium wire 200 g (pre- fi tted, 1.0 mm Ø, type: ER5356 1 Welding mask 1 MMA electrode holder 1 Operating instructions 1 Earth terminal with cable 1 MIG torch with welding cable 1 Flux-cored wire 200 g 1.0 mm Ø, Type: E71T-GS

Cover of the wire feed unit

Earth cable with earth terminal

Rotary switch for setting the welding current

Cable assembly with direct connection

Welding nozzle (0.9 mm)

Chipping hammer with wire brush

Welding mask after fi tting

Protective glass catch

Welding wire selector key

Voltage reducer selector key

Fixing ring Technical specifi cations Input power: 4.3 kW Mains connection: 230 V~ 50 Hz Weight: 8.6 kg Fuse: 16 A Welding with fl ux-cored wire: Welding current: I

= 72–160 A Duty cycle X: 20% at 160 A welding current, 60% at 92 A welding current Open circuit voltage: U

= 53 V Greatest rated value of the mains current:

1max. = 26.5 A Effective value of the greatest mains current:

Characteristic value Flat MMA welding: Welding current: I

= 63–140 A Duty cycle X: 20% at 140 A welding current, 60% at 81 A welding current Open circuit voltage: U

= 53 V Greatest rated value of the mains current:

1max. = 26.3 A Effective value of the greatest mains current:

1eff. = 11.8 A Characteristic value Falling TIG welding: Welding current: I

= 63–200 A Duty cycle X: 10% at 200 A welding current, 60% at 82 A welding current Open circuit voltage: U

= 16.9 V Greatest rated value of the mains current:

1max. = 28.2 A Effective value of the greatest mains current:

1eff. = 8.9 A Characteristic value Falling Changes to technical and visual aspects of the product may be made as part of future developments without notice.10 GB/IE/NI/CY/MT Accordingly, no warranty is offered for the physical dimensions, information and specifi cations in these operating instructions. The operating instructions cannot therefore be used as the basis for asserting a legal claim. Note: The use of the term ‘device’ in the following text refers to the multi-welder described in this instruction manual. 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 instructions. The rating plate contains all tech- nical 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 maintenance must not be performed by children without supervision. Repairs and/or maintenance work must only be carried out by qualifi ed electricians. Only use the welding cables

D1x16mm²) included 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 suffi cient 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 Introduction / Safety instructions11GB/IE/NI/CY/MT 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 insulation 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: All fl ammable 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 fl ammable 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 dangerous, 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 haz- ardous to health. Be careful not to inhale these vapours. Protect yourself from the harm- ful 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. Safety instructions12 GB/IE/NI/CY/MT ATTENTION! During the operation of the welding device, other con- sumers may experience prob- lems with the voltage supply depending on the network 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. 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 pre- vent damage to people and the device. Work on the voltage side, e.g. on cables, plugs, sockets etc., may only be carried out by qualifi ed electricians accord- ing to national and local regulations. In the event of accidents, disconnect the welding device from the mains voltage immediately. If electrical contact voltages occur, switch off the device immediately and have it checked by a qualifi ed electrician. 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 cur- rent circuit), harmful radia- tions (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 clothing, 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 Safety instructions13GB/IE/NI/CY/MT 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 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 dan- gers 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 stor- ing 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 fi re 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 certifi ed 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 bond- ing 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. Safety instructions14 GB/IE/NI/CY/MT Risk of electric shock: Electric shock from a weld- ing electrode can be fatal. Do not weld in rain or snow. Wear dry insulating gloves. Do not touch the electrodes with bare hands. Do not wear wet or damaged gloves. Protect yourself from elec- tric 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 fi re. Keep fl ammable substances away from the weld- ing location. Do not weld next to fl ammable substances. Welding sparks can cause fi res. Keep a fi re extinguisher close by and an observer should be present to be able to use it immediately. Do not 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 welding safety helmets and make sure you use the appropriate fi lter setting. Wear complete body protection. Danger from electro- magnetic fi elds: Welding current generates elec- tromagnetic fi elds. Do not use if you have a medical implant. Never wrap the welding cable around your body. Guide welding cables together. Welding mask-specifi c 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 welding lens. Immediately replace damaged or scratched welding lenses. Immediately replace damaged or highly contaminated or splattered components. Safety instructions15GB/IE/NI/CY/MT 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. Always wear a welding mask while welding. If it is not used, you could sustain severe lesions to the retina. Always wear protective cloth- ing during welding operations. Never use the welding mask without the welding lens. There is a risk of damage to the eyes! Regularly replace the welding lens to ensure good visibility and fatigue-proof work. 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 conductiv- ity and where there is a high risk through avoidable or acci- dental touching by the welder; In wet, humid or hot work- places where the air humidity or weld signifi cantly reduces the resistance of human skin and the insulating properties or effect of protective equip- ment. Even a metal conductor or scaf- folding can create an environ- ment with increased electrical hazard. In this type of environment, insu- lated mats and pads must be used. Furthermore gauntlet gloves and head protection made of leather or other insulating mate- rials must be worn to insulate the body against Earth. The welding power source must be located outside the working area or Safety instructions16 GB/IE/NI/CY/MT 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 and covers all mains-powered devices in close proximity. The fault-circuit interrupter must be suitable for all types of current. There must be a way of rapidly disconnecting the welding power source or the welding current cir- cuit (e.g. emergency stop device) which is easy to reach. When using welding devices under electrically-hazardous conditions, the output voltage of the welding device during idle operation must not be higher than 113 V (peak value). Based on the output volt- age this welding device may be used in these conditions. 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 individu- als 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. 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. Protective clothing

At work, the welder must pro- tect his/her whole body by Safety instructions17GB/IE/NI/CY/MT 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. – 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 fl ying sparks and burns. When specifi c work, e.g. overhead welding, is required, a protective suit must be worn and, if necessary, even head protection. Protection against rays and burns Warn of the danger to the eyes by hanging up a sign saying “Caution! Do not look into fl ames!”. 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 vicinity of fi xed workplaces should neither be bright coloured or shiny. Windows up to head height must be protected to prevent rays from penetrating or refl ecting through them, e.g. by using suitable paint. EMC Device Classifi cation According to the standard IEC 60974-10, this is a welding device in electromagnetic compat- ibility Class A. Class A devices are devices that are suitable for use in all other areas except living areas and areas that are directly connected to a low-voltage supply mains that (also) supplies residen- tial buildings. Class A devices must adhere to the Class A limit values. WARNING NOTICE: Class A devices are intended for use in an industrial environment. Due to the power-related as well as the radiated interference variables, diffi culties might arise in ensuring electromagnetic compatibility in other environments. Safety instructions18 GB/IE/NI/CY/MT Even if the device complies with the emission limit values in accordance with the standard, such devices can still cause elec- tromagnetic interference in sensi- tive systems and devices. The user is responsible for faults caused by the arc while working, and the user must take suitable protective measures. In doing so, the opera- tor must consider the following: – Mains, control, signal and telecommunication cables – Computers and other micropro- cessor-controlled devices – TVs, radios and other playback devices – Electronic and electrical safety equipment – Persons with heart pacemakers or hearing aids – Measuring and calibration equipment – Interference immunity of other nearby equipment – The time of day at which the work is being done The following is recommended to reduce possible interference radiation: – Fit a mains fi lter to the mains connection – Service the device regularly and keep it in good condition – Welding cables should be completely unwound and run as parallel as possible on the fl oor – If possible, devices and systems at risk from interference radi- ation should be removed from the work area or shielded. The product is intended solely for professional use. Before use Take all parts from the packaging and check whether the fl ux-core wire multi-welder or parts show any damage. If this is the case, do not use the multi-welder. Contact the manufacturer via the indicated service address. Remove all protective fi lms and other transport packaging. Check that the delivery is complete. Mounting Assembling the welding mask Insert the dark welding lens

with the writing facing up into the shield body

(see Fig. C). To do this, if necessary, press gently from the front against the disc, until it clicks into place The labelling on the dark weld- ing 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 Fig. D). Safety instructions / Before use / Mounting19GB/IE/NI/CY/MT MIG welding Prevent the risk of an electric shock, injury or damage. To do this always unplug the mains plug from the socket prior to each maintenance task or preparatory work. Note: Different welding wires will be needed depending on the application. Welding wires with a diameter of 0.6–1.0 mm can be used with this device. 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 5000 g. Use aluminium wire to weld aluminium and steel wire to weld steel and iron. Adaptation of device to solid welding wire with inert gas The correct connections for solid wire welding when using inert gas are shown in Fig. S. When using the aluminium solid wire delivered with the product, then you must use argon as the inert gas (not included with the delivery).

First connect the plug

with the connector marked with the “+” (see Fig. S). To fi x it in place, rotate in a clockwise direction. If you are in any doubt, then please contact a professional. Now connect the cable assembly with direct connection

to the appropriate connector (see Fig. S). Fix the connection in place by tight- ening the fi xing ring

in a clock- wise direction. Then connect the earth cable

with the corresponding connector, marked with the “-” (see Fig. S). To fi x the connection in place, rotate in a clockwise direction.

Pull the protective cap off the gas connection

Now connect the inert gas feed including the pressure reducer (not included with the delivery) to the gas connection

(see Fig. T). Inert gas is required if you are not using fl ux-cored wire with integrated solid inert gas. If necessary, observe the notes for your pressure reducer (not included with the delivery). You can use the following formula as a guide- line for adjusting the gas fl ow:

MIG welding20 GB/IE/NI/CY/MT Wire diameter in mm x 10 = gas fl ow in l/min For example, using 0.8 mm wire, will give a value of approx. 8 l/min. Adaptation of device to fl ux-cored welding wire without inert gas. If you are using fl ux-cored welding wire with integrated inert gas, then you do not have to have an external inert gas supply. First connect the plug

with the connector marked with the “-”. To fi x it in place, rotate in a clockwise direction. If you are in any doubt, then please contact a professional. Connect the cable assembly with direct connection

to the appropri- ate connector. To fi x the connection, tighten the fi xing ring

in a clock- wise direction. Then connect the earth cable

with the corresponding connector, marked with the “+” and to fi x the connec- tion in place rotate in a clockwise direction. Insert welding wire Unlock and open the cover of the wire feed unit

, by pushing the release knob upwards. Unlock the roller unit by turning the roller mount

off the shaft (see Fig. F). 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 welding wire reel

, so that it can unrolled with- out diffi culty. 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 clockwise (see Fig. G). Undo the adjustment screw

and swing it downwards (see Fig. H). Turn the thrust roller unit

to the side (see Fig. I). Loosen the feed roll holder

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

, check whether the appropriate wire thick- ness is indicated. If necessary, the feed roll

has to be turned over or replaced (see Fig. E). The supplied welding wire (Ø 1.0 mm) must be used in the feed roll

with the spec- ifi ed wire thickness of Ø 1.0mm. The welding wire must be positioned in the upper groove! Erect the feed roll holder

again and screw clockwise direction. Remove the torch nozzle

pulling and turning it clockwise (see Fig. K). Unscrew the welding nozzle

(see Fig. K). Guide the cable assembly with direct connection

away from the weld- ing device as straight as possible (place it on the fl oor). Take the wire end out of the edge of the spool (see Fig. L). Trim the wire end with wire scis- sors or a diagonal cutter in order to remove the damaged, bent ends of the wire (see Fig. L). Note: The welding wire must be kept under tension the entire time in order MIG welding21GB/IE/NI/CY/MT to avoid a releasing and a roll out! Therefore it is recommended to carry out the work with an additional person. Push the welding wire through the wire feed guide

(see Fig. M). Guide the welding wire along the feed roll

and push it into the cable assembly holder

towards the feed roll

screw (see Fig. O). Set the counter pressure with the adjustment screw

. The weld- ing wire must be fi rmly positioned between the thrust roller and feed roll

in the upper guide without being crushed (see Fig. O). Switch on the welding device on the main

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

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

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

back on. Make sure that the welding noz- zle

matches the diameter of the welding wire used (see Fig. Q). With the welding wire delivered with the product, the welding nozzle

with the labelling 1.0 or 1.0 A must be used when using solid aluminium wire. Push the torch nozzle

back on to the torch neck with a turn to the right

(see Fig. R). 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. Using the device Switching the device on andoff 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. Select welding wire First set to “MIG” mode by pressing the welding mode selector key

. Then select the welding wire which has been inserted by pressing the upper welding wire selector key

Welding Overload protection The welding device is protected against overheating by means of an automatic protection device (thermostat with automatic restart). The protective device breaks the electrical circuit if overheat- ing occurs. 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. Overcurrent indicator In the event of misuse, the output current may exceed the intended maximum value. In this case, the protective device breaks the welding current circuit and MIG welding / Using the device22 GB/IE/NI/CY/MT the “O.C” overcurrent indicator is shown on the display. If the overcurrent indicator is shown, switch the device off using the main switch

. After approx. 15 minutes, the device is ready to be used again and can be switched on using the main switch

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. ATTENTION! With MIG welding, we recommend a material thickness of 2.0 mm to

3.0 mm when welding aluminium

and a thickness of 0.8 mm – 3.0 mm when welding iron/steel. 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. The area to be welded on the work- piece must be free of rust and paint. Choose the desired welding cur- rent depending on the welding wire diameter, material thickness and desired penetration depth. Guide the torch nozzle

and hold the welding mask

in front of the face. Press the torch button

, in order to feed the welding wire. Once the electric arc is burning, the device feeds welding wire into the weld pool. You can work out the ideal settings for the welding current by carrying out trial welds on a test piece. A properly set electric arc has a mild, uniform buzzing sound. In case of a rough or hard rat- tle, 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 diffi cult initially to create a decent electric arc. To do so, the welding current 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 welding current is 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 fi nally the weld seam is continued. Using the device23GB/IE/NI/CY/MT Setting appropriate parameters for current and voltage for weld- ing aluminium with aluminium wire. For welding aluminium we recommend using lower voltages than you would use for welding iron/steel. To set the appropriate voltage range, you can proceed as follows: prepare the device as described under “Adaptation of device to solid welding wire with inert gas”. To weld aluminium wire select the setting “1.0/Al(5356)” by pressing the welding wire selector key

. Now press the voltage reducer selector key

, until the LED next to “U” fl ashes. Now set a current of approx. 0.5 A. Press the voltage reducer selector key

, until the LEDs next to the “U” and “A/VRD” are no longer illuminated. The voltage when MIG welding can now be adjusted in a lower voltage range which is more suited for aluminium welding. If the rotary switch for adjusting the welding current

is simultaneously pressed and rotated, then the welding current can be altered in 10 A steps. As guideline values, to weld 2 mm aluminium sheet you can set 14.5 Volt and a current of 91 Amps. The optimum welding settings should be determined by welding on a sample workpiece. CAUTION! Please note that the torch must always be placed on 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. Create a weld seam Forehand welding Push the torch forwards. Result: The penetration depth is lower, broader weld width, fl atter weld bead (visible surface of the seam) and greater fusion error tolerance. Backhand welding The torch is dragged from the weld seam (Fig. U). Result: Greater penetra- tion depth, narrower weld width, higher weld bead and lower fusion error tolerance. Welded joints There are two-basic types of joints in welding: Butt welds (outer edge) and angle welding (inner edge and overlap- ping). Butt welds With butt welds of up to 2 mm material thickness, the weld edges are com- pletely brought together. For greater thicknesses, a gap of 0.5–4 mm must be selected. The ideal gap depends on the welded material (aluminium or steel), the material com- position as well as the type of welding selected. This gap should be determined by welding on a sample workpiece. Flat butt welds Welds should be made without inter- ruption and with a suffi cient penetration depth. Therefore, it is extremely impor- tant to be well prepared. The quality of the weld result is affected by: the amper- age, the gap between weld edges, the inclination of the torch and the diameter of the welding wire. The steeper you hold the torch against the workpiece, the higher the penetration depth and vice versa. Using the device24 GB/IE/NI/CY/MT

To forestall or reduce deformations that can happen during the material harden- ing process, it is good to fi x the work- piece 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 work- piece 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 (Fig. V, W).

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 (Fig. X).

Fillet weld connections A fi llet 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 fi llet (Fig. Y, Z). Welds on an inner edge The preparation for this weld joint is very simple 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 (Fig. Y).

However, it is no longer expedient for thicker materials. In this case, it is better to prepare a joint as shown in Figure X, in which the edge of the plate is angled. Using the device25GB/IE/NI/CY/MT

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 possi- ble, as shown in Fig. AB.

MMA welding Make sure that the main switch

is set to position “O” (“OFF”) or that the power plug

is not plugged into the socket. Connect the electrode holder

and the earth terminal

to the welding device, as shown in Fig. AC). Also refer to the information from the electrode manufacturer. Put on appropriate protective cloth- ing in accordance with the specifi ca- tions and prepare your workspace. Connect the earth terminal

to the workpiece. Clamp the electrode into the elec- trode holder

Switch the device on by setting the main switch to the

“I” (“ON”) position. Select “MMA” mode by pressing the selector switch for welding mode

until the small indicator lamp next to MMA lights up. Adjust the welding current using the rotary switch for welding current adjustment

depending on the electrode you are using.

Note: Guideline values for the welding current to be used, depending on the electrode diameter can be taken from the following table. Ø Electrode Welding current

Note: By pressing the voltage reducer selector key

you can activate the voltage reducer function (VRD). The LED next to “A/VRD” lights up. By doing this the output voltage is reduced and the safety for the user during breaks from welding will be increased. Using the device / MMA welding26 GB/IE/NI/CY/MT Attention: Do not bring the earth terminal

and the electrode holder

electrodes into direct contact with one another. Attention: When welding with rod electrodes, the electrodeholder

and the earth terminal

must be connected in accordance with the information from the electrode manufacturer. Hold the welding mask

in front of your face and start the welding procedure. To stop the procedure, set the main switch ON/OFF

to “O” (“OFF”) position. Attention: When the thermal sensor is triggered, “O.H.” will be shown on the digital display. In this case, it will not be possible to continue welding. The device will remain in operation so that the fan can cool the device. As soon as the device is ready for operation again, the “O.H.” display will disappear. The welding function can now be used again. Attention: Do not dab on the workpiece with the electrode. It could be damaged and make it more diffi cult to ignite the arc. As the soon as the arc is ignited, try to maintain a distance to the workpiece which corresponds to the diameter of the electrode being used. The gap should remain as constant as possible while you are welding. The inclination of the electrode in the direction of operation should be 20–30degrees. Attention: Always use pliers to remove used electrodes or hot work- pieces. Make sure that the electrode holder is always placed onto an insu- lated surface after welding. 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 connec- tion point. The electric arc is ignited in the weld groove, guided to the connection point, melted properly there and then continues from that point. Attention: Welding generates heat. Therefore the welding device must run idle for at least half an hour after use. Alternatively, you can leave the device to cool for an hour. The device can only be packed away and stored once the temperature of the device is normal again. Attention: A voltage which is 10% below the rated input voltage of the welding device can have the following consequences: The power to the device will reduce. The arc stops or becomes unstable. Attention: The arc radiation can lead to infl am- mation of the eyes and skin burns. Casting and welding slag can cause eye injuries and burns. Fit the welding mask as described below in the section “Fit welding mask”. 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. It is essential that you only use the welding cable which is included with the delivery (16 mm

). Choose between push and drag welding. The following section shows the impact MMA welding27GB/IE/NI/CY/MT of the direction of movement on the properties of the weld seam: Note: You decide for yourself which type of welding is most suitable, once you have welded a sample piece. Note: Once it has worn down com- pletely, the electrode must be replaced. Push welding Drag welding Burn smaller larger Weld seam width larger smaller Weld bead fl atter higher Weld seam fault larger smaller TIG welding For TIG welding please follow the instructions for your TIG torch. You can select TIG mode by pressing the welding mode selector key

. To do this select the “TIG” position. Maintenance and cleaning Note: The welding device must be regularly serviced and overhauled for proper function and for compliance with the safety requirements. Improper and wrong operation may cause fail- ures and damage to the device. Repairs must only be carried out by qualifi ed electricians. Switch off the main power supply and the main switch of the device off prior to performing any mainte- nance work on the welding device. Clean the welding device and accessories regularly using air, cotton waste or a brush. In case of a defect or a necessary replacement of equipment parts, please contact the appropriate qualifi ed personnel. Information about recycling and disposal Don’t throw away – recycle! Please return this device, accessories and packaging to your local recycling depot. Donot dispose of the welding device in household waste, in fi re or in water. Devices that are no longer functional should be recycled wherever possible. Ask your local stockist for advice. To do this, please see 2012/19/EU. ... / TIG welding / Maintenance and cleaning / Information about recycling ...28 GB/IE/NI/CY/MT EU Declaration of Conformity We, C. M. C. GmbH Responsible for documentation: Dr Christian Weyler Katharina-Loth-Str. 15 66386 St. Ingbert GERMANY hereby take sole responsibility for declaring that the product Multi-Welder Item number: 2336 Year of manufacture: 2021/18 IAN: 337263_2007 Model: PMSG 200 A1 meets the basic safety requirements as specifi ed in the European Directives EC low-voltage directive 2014/35/EU EC Guideline on Electromagnetic Compatibility 2014/30/EU RoHS directive 2011/65/EU+2015/863/EU and the amendments to these Directives. The manufacturer will be solely respon- sible for the creation of the declaration of conformity. The object of the declara- tion described above meets the require- ments of Directive 2011/65/EU of the European Parliament and of the Council of 8 June 2011 on the restriction of the use of certain hazardous substances in electrical and electronic equipment. This conformity assessment is based on the following harmonised standards: EN 60974-1:2018/A1:2019 EN 60974-10:2014/A1:2015 St. Ingbert, 01/10/2020 pp Dr Christian Weyler – Quality Assurance – Warranty and service information Warranty from Creative Marketing & Consulting GmbH Dear Customer, The warranty for this equipment is 3years from the date of purchase. In the event of product defects, you have legal rights against the retailer of this product. Your statutory rights are not affected in any way by our warranty conditions, which are described below. Warranty conditions The warranty period begins on the date of purchase. Please retain the original sales receipt. This document is required as your proof of purchase. Should this product show any defect in materials or manufacture within 3years from the date of purchase, we willrepair or replace it – at our dis- cretion – free of charge. This warranty service requires that you retain proof of purchase (sales receipt) for the defective device for the three year period and that you briefl y explain in writing what the fault entails and when it occurred. If the defect is covered by our warranty, we will repair and return your product or send you a replacement. The original EU Declaration of Conformity / Warranty and service information29GB/IE/NI/CY/MT Warranty and service information warranty period is not extended when a device is repair or replaced. Warranty period and statutory claims for defects The warranty period is not extended by the guarantee. This also applies to replaced and repaired parts. Any dam- ages or defects detected at the time of purchase must be reported immediately after unpacking. Any incidental repairs after the warranty period are subject to a fee. Extent of warranty This device has been manufactured according to strict quality guidelines and carefully inspected before delivery. The warranty applies to material and manufacturing defects only. This warranty does not extend to product parts, which are subject to normal wear and tear and can thus be regarded as consumable parts, or for damages to fragile parts, e.g. switches, rechargea- ble batteries or parts made from glass. This warranty is voided if the product becomes damaged or is improperly used or maintained. For proper use of the product, all of the instructions given in the operating instructions must be followed precisely. If the operating instructions advise you or warn you against certain uses or actions, these must be avoided in all circumstances. The product is for consumer use only and is not intended for commercial or trade use. The warranty becomes void in the event of misuse and improper use, use of force, and any work on the device that has not been carried out by our authorised service branch. Processing of warranty claims To ensure prompt processing of your claim, please follow the instructions given below. Please retain proof of purchase and the article number (e.g. IAN) for all inquiries. The product number can be found on the type plate, an engraving, the cover page of your instructions (bottom left), or the sticker on the back or underside of the device. In the event of malfunctions or other defects, please fi rst contact our service department below by phone or email. If your product is found to be defective, you can then send your product with proof of purchase (till receipt) and a statement describing what the fault involves and when it occurred free of charge to the service address given. Note: You can download this hand- book and many more, as well as product videos and software at www.lidl-service.com. With this QR code you can gain immediate access to the Lidl Service page (www.lidl-service.com) and you can open your operating instructions by entering the article number (IAN)