GE 290 TC - Welding machine Güde - Free user manual and instructions

USER MANUAL GE 290 TC Güde

Translation of the original instructions Electrode welding device

ENGLISH Please read the instructions carefully before starting the machine.

Kindly read this instruction manual carefully before putting the unit in operation.

A.V. 1 Reprint, even partial, requires permission. Technical changes reserved. © Güde GmbH & Co. KG - 2006

Every effort has been made to improve our products continuously. For this reason, technical data and figures are subject to change.

Unit

Body of steel sheet (coated with powder colour) travelling with a cooling fan, 230 / 400V voltage switch over, welding current stepless set-up, thermal protection, for electrodes 2-4 mm, 50V connection of welding cable

Accessories:

The welding site accessories include a welding shield, earthing cable with a terminal, welding cable with the electrodes holder slag hammer and a wire brush, cooling fan and thermal protection.

Scope of Delivery

Fig. 1

1. welding machine
2. casters 2x
3. wheel axis
4. foot
5. handle externsion ti
6. carrying handle
7. slag hammer-brush
8. fixinf assembly

Warranty

Warranty claims according to the warranty certificate attached.

General Safety Instructions

The instruction manual should be read in full prior to the initial use. In case of any doubts regarding connection and operation of the unit, turn to the manufacturer (servicing department).

TO GUARANTEE A HIGH DEGREE OF SAFETY, THE INSTRUCTIONS BELOW SHOULD BE OBSERVED:

CAUTION!

Always wear protective gloves of insulation fabric; avoid any clothing of PVC.
- Wear heavy-duty insulating shoes.
- Make sure that working area is properly ventilated to prevent accumulation of harmful fumes and toxic smoke.
- Never work in wet places without efficient safety measures against electrical discharges.
After the work, the electrode has to be taken from the electrode tongs to prevent undesired arc formation.
- The welding machine should not be used or stored in rain.
- If the unit is in operation, the electrode tongs should not be put on the unit or other electric appliances as the safety device may get damaged or disconnected when grounded.
- Do not touch the electrode or another metal object in contact with the electrode while welding is in progress. Check that all cables are coated (mainly the contacts with the power cable). The cables with insufficient insulation should be immediately replaced with the same size cables meeting the regulations. Disconnect the unit from the source where not used.

The unit may influence supply of other units according to characteristics of the mains. Seek adv from an authority responsible for the power supply whenever in doubt.

Emergency Procedures

Give first aid appropriate to the injury and call a qualified medical help as fast as possible. Protect the injured against more harm and put him/her in a resting position.

Please note that our equipment has not been designed for commercial, craft or industrial use. If the equipment is used in commercial, craft or industrial operation or for similar activities, we cannot assume any liability.

Unit Marking

Meaning of Symbols

Symbols shown below are used in this manual and on the unit:

Product Safety:

CE
Product conforming to respective EU standards

Bans:

General Prohibition (in combination with another pictograph)

Don't pull the cable

Do not use the machine in wet weather

Warnings :

			
Warning/caution	Beware of hazardous volrage	Do not Reach in Equipment	Keep safely distance

Commands/Instructions:

Wear goggles Wear	safety footwear Use protection gloves		Wear protective clothing	Use protection shield Unplug before opening
Read instruction manual before use

Environment Protection:
Packaging:

	PAP
Dispose of the waste in an environment-aware manner.	Cardboard packaging material may be delivered to a salvage point for recycling.	Defective electric and electronic devices or those to be disposed of should be delivered to a salvage point for recycling.

Protect from rain	Packaging placing direction-up	Fragile!

Technical Data:

Mains connection Weight

Product-specific:

Manual arc welding with coated electrode

Short circuit protection

The machine may be used in the electrical shock hazardous areas

Electrode diameter according to welding current

230 V connection 400 V connection

transformer Electrode holder Earthing tongs

Downward characteristic

Mains connection Temperature indicator

Use in Compliance with Determination

The welding unit is designed for metal welding using electrodes. The units and any accessories on the welding site are meeting respective provisions when delivered.

The manufacturer shall not be held liable for any damages if the generally valid regulations and provisions contained herein are not observed.

Residual Hazard and Preventive Action

Electrical Residual Hazards

Threat Description Preventive Action Residual Hazard

Indirect electric contact Simultaneous contact with earthing terminal and the electrode cable may result in electrical shock.

prevent contact Indirect electric contact

Residual heat hazards

Threat Description Preventive Action Residual Hazard

Burns, frostbites

• Contact with the piece to be welded may cause serious burns.

• Do not touch the piece being welded use protective gloves

Burns, frostbites

• Splashes released in the course of welding may harm both the welder and his clothing.

Radiation hazard

Threat Description Preventive Action Residual Hazard

Infrared, visible and UV light Looking in the arc may result in severe injury of eyes,

Always use welder protection shield

Infrared, visible and UV light

Material and other substances hazards

Threat Description Preventive Action Residual Hazard

Contact, inhalation Long-lasting inhalation of fumes in the course of welding may be health hazardous.

• Have the fumes extracted when welding
  Work in a properly ventilated area
• Avoid direct inhalation of fumes
• Do not work near inflammable materials.
  Tanks of any kind should be completely emptied, cleaned

Fire or explosion

• Easily inflammable materials may ignite in direct area of welding.

Oil, fuel or gas tanks may

explode at welding and well-ventilated. Only properly trained professionals are allowed to weld tanks.

Failure to Observe Human-Factor Principles
Disposal

Threat Description Preventive Action Residual Hazard
Negligent use of personal protection equipment	Welding without required personal protection equipment may result in health hazard.	Use required personal protection equipment for welding.

The instructions for disposal are expressed in the pictographs on the unit or the packaging. For description of individual meaning see chapter "Unit Marking".

Operator Requirements

The operator is required to read the instruction manual carefully before using the unit.

Qualification

The unit is designed to be used by trained arc welders or instructed persons of similar qualification.

Minimum Age

The unit shall be operated by persons above 18 years of age.

Operation by juvenile operators is an exception, if it is as a part of professional training under supervision of a teacher with an aim to obtain skills.

Training

Only trained persons should operate the unit. This operating manual should be made available to each user.

Technical Data

Voltage/Frequency:	230 V/400 V; 50 Hz
Max. welding current :	245 A
Regulated zone :	60 – 210 A
Electrode diameter Ø :	2 – 4 mm
Idling voltage :	48 V
Protection class :	IP 21
Insulation class :	H
Weight :	ca 25 kg
Ordering no.: 20007

Transport and Storage

The unit should be stored at a dry place out of the reach of unauthorised persons. Make sure that the unit is unplugged.

Remember that the electrodes too have to be kept at a dry place.

Assembly and Initial Putting in Operation

Assembly Group 1 Parts of Delivery
Fig. 2		Fig. 1 – Pos. 2Fig. 1 – Pos. 5Fig. 1 – Pos. 6Fig. 1 – Pos. 7
Assembly Group 2 Parts of Delivery
Fig. 3		Fig. 1! Pos. 2Fig. 1! Pos. 3/2xFig. 1! Pos. 4Fig. 1! Pos. 12
Assembly Group 4 Assembly Groups Required Parts of Delivery
Fig. 4	Assembly Group 3 Fig. 1! Pos.9Fig. 1! Pos. 10Fig. 1! Pos. 12

Safety Instructions for First Putting in Operation

• Check the power supply for sufficient protection (16 A, inertial)
• Wear required clothing (see Fig. 6)
• Make sure that no other persons are present on the working site or the area of hazard.
• Take care for no inflammable material being on the site.

Procedure

Carry out the assembly of separate parts in the order as indicated in figures. Mind the correct arrangement of the parts.

Operation

Fig. 7 S.8

Fig. 8 -> S.9

Having changed from 230V to 400V , take steps as follows:

1. Unplug the unit.
2. Put the switch at %0#.
3. Remove the lock screw and fit it on the 400V side.
4. Before putting the unit in operation again, make sure that the knob may be turn in position 400V and cannot be turned in position 230V .

The unit may be used at a room temperature from 20^ without the thermal protection being put on with the number of reference electrodes 0 and h from warm condition without switching the thermal protection on.
The earthing tongs need to be connected with the piece to be welded in a way providing for a good contact. The touch points should be cleaned so that no grease or other impurities that could adversely affect the welding output are present.
- The unit has a main switch, yellow light indicator, thermal protection and a hand wheel to control the welding current. The control is done with regard to welding current valuea and electrode diameter.

Cuation: The indicators will light at overloading only.

Thermal protection is provide on the unit to switch off the welding current supply automatically as soon as the inner temperature. As it drops to a value of correct operation, the unit switches on again.

Operation Safety Precautions

See also chapter Residual hazards and safety measures and safety action arising therefrom.

• Do not use the unit before you have read the instruction manual.
• Observe all the safety instruction contained herein.
• Be responsible to other persons.

Step by Step Instructions

The welding area should be free of any rust and varnish. The electrode is selected by the type of material. It is recommended to test the electrode and the current intensity on scrap at the beginning. Place the electrode ca 2cm above the starting point. Always use a welding shield, welder's gloves and protective clothing. Touch the piece and slightly pull the electrode.

Wrong

(arc too long)

Correct

(ca 1-1.5 multiple of the electrode diameter)

Precise length of the arc is critical as the current and voltage intensity varies. Poor intensity of current makes both the weld and resistance worse. The electrode angle support should be 70-80 degree forward with regard to the piece worked. Too big (??) angle makes the slag slide under the edging material. If the angle is too small, the arc will fluctuate and splash. In either of the cases the wells is porous and weakened

Wrong Wrong

Correct

The slag should not be removed before the weld gets cooled. Continue welding of an interrupted weld after the slag is removed.

Wrong

Correct

The welder should try to keep the arc length constant. As the electrode gets worn, it should typically get nearer. It is recommended to remove the electrode in the direction of the weld to avoid forming a porous crater.

Faults - Causes - Troubleshooting

CAUTION: ALWAYS CHECK POWER FUSES FIRST!

Fault Cause Troubleshooting
Fuse activated	1. Welding current too high for the fuse. 1.	Use a stronger fuse. 2. Use inertial fuse.
Even welding impossible	1. Poor earthing contact on the cable /tongs	1. Clean the piece and provide for a good contact 2. Check the cable and clean if necessary.
Fragile or porous weld	1. Unclean piece	1. Remove any rust, grease and other impurities before getting down to the welding job.
Welding current not available	1. Reverse conduct of the welding current does not provide right contact Thermal protection light on 2. Defective electronics	1. Check the reverse line of welding current for good contact 2. Let the unit cool down. The work may be continued when the light indicator goes off . 3. Inform servicing department

Checks and Maintenance

Checks and Maintenance Safety Instructions

The unit may be a reliable tool only if maintained and cared for on a regular basis. Insufficient maintenance and care may cause unexpected accidents and injuries.

Check and Maintenance Schedule

Time Interval Description Other		Details
Before each start of work	Check the unit for correct function. Never work with defective unit. Check the cable for damage. Replace it with a new one of same quality if necessary.

Spare Parts

Returns of goods and orders of spare parts will be carried out fast in an expeditious manner by means of an applicable servicing form to be downloaded at

http://www.guede.com/support

The form may be also requested at

Tel.: [phone] / 700-0

Fax: [phone] / 700-250

E-Mail: [e-mail]

Class A (IEC 60974-10):

If you intend to use the apparatus in residential surroundings supplied by the low voltage mains supply, an electromagnetic filter may be required to suppress electrical disturbance to a level where they will no longer be a nuisance to the user.

The apparatus may be used in industrial or other areas where power is not supplied by municipal LV mains. Class A apparatus are not intended for use in residential areas where power is supplied via municipal LV mains, since unfavourable power conditions may cause interference.

As a user, you must make sure, after consultation with your energy provider, if necessary, that your point of connection on which the machine is to be operated meets the requirements above.

The user is responsible for faults arising from the welding.

Translation of the EC-Declaration of Conformity

We, hereby declare the conception and construction of the below mentioned appliances correspond - at the type of construction being launched - to appropriate basic safety and hygienic requirements of EC Directives.

In case of any change to the appliance not discussed with us the Declaration expires.

Notified Body Name: No: Adress:

Type Ex.Cert.-No.:

97/68/EC_&2016/1628/EU
Emission No.:
2000/14/EC_2005/88/EC