846386 - Welding machine SILVERLINE - Free user manual and instructions

USER MANUAL 846386 SILVERLINE

Description of Symbols The rating plate on your tool may show symbols. These represent important information about the product or instructions on its use Wear hearing protection Wear eye protectionWear breathing protectionWear head protectionWear hand protectionRead instruction manualDo not use in rain or damp environmentsRisk of electrocutionDanger of toxic welding fumesDanger of ultraviolet radiationDanger hot SurfacesDanger of FireCaution!Class I construction (protective earth)Conforms to relevant legislation and safety standards Environmental Protection Waste electrical products should not be disposed of with household waste. Please recycle where facilities exist. Check with your local authority or retailer for recycling advice General Safety WARNING! When using electric power tools, basic safety precautions should always be followed to reduce the risk of fire, electric shock and personal injury including the following safety information. Read all these instructions before attempting to operate this product and save these instructions for future use.WARNING: This appliance is not intended for use by persons (including children) with reduced, physical or mental capabilities or lack of experience or knowledge unless they have been given supervision or instruction concerning use of the appliance by a person responsible for their safety. Children must be supervised to ensure that they do not play with the appliance.CAUTION: Use the power tool, accessories and tool bits etc. in accordance with these instructions, taking into account the working conditions and the work to be performed. Use of the power tool for operations different from those intended could result in a hazardous situation.The term "power tool" in the warnings refers to your mains-operated (corded) power tool or battery-operated (cordless) power tool.

1 - Keep work area clear - Cluttered areas and benches invite injuries

2 - Consider work area environment - Do not expose tools to rain - Do not use tools in damp or wet locations - Keep work area well lit - Do not use tools in the presence of flammable liquids or gases

3 - Guard against electric shock - Avoid body contact with earthed or

grounded surfaces (e.g. pipes, radiators, ranges, refrigerators)

4 - Keep other persons away - Do not let persons, especially children,

not involved in the work touch the tool or the extension cord and keep them away from the work area

5 - Store idle tools - When not in use, tools should be stored in a dry

locked-up place, out of reach of children

6 - Do not force the tool - It will perform the job better and safer at the

rate for which it was intended

7 - Use the right tool - Do not force small tools to do the job of a heavy

duty tool Do not use tools for purposes for which they are not intended; for example do not use circular saws to cut tree limbs or logs Specification Input voltage: ................................................................230V~ 50Hz Mains connection: ...................................................................... 16A Input current: .......................... 230V: 17.2A (peak), 12.1A (effective) Output current range: ..........................................................25-100A Rated duty cycle: ....................................50% @ 100A, 60% @ 91A, 100% @ 71A No load output voltage: ...............................................................60V Output voltage:..............................................22.8V(71A), 24V(100A) Electrode rod size:........................................................1.6 – 3.2mm Insulation class: ............................................................................. H Ingress protection: .................................................................. IP21S Welding thickness range (steel):.........................................1 – 6mm Protection class: ......................................................................... Electrode cable length: ............................................................. 2.0m Earth cable length: ................................................................... 1.5m Power cable length: ................................................................. 2.0m Dimensions (L x W x H): ....................................350 x 140 x 240mm Weight:.....................................................................................4.6kg As part of our ongoing product development, specifications of Silverline products may alter without notice. Original Instructions Introduction Thank you for purchasing this Silverline tool. This manual contains information necessary for safe and effective operation of this product. This product has unique features and, even if you are familiar with similar products, it is necessary to read this manual carefully to ensure you fully understand the instructions. Ensure all users of the tool read and fully understand this manual. 846386_Z1MANPRO1.indd 4 20/07/2016 16:31www.silverlinetools.com

8 - Dress appropriately

- Do not wear loose clothing or jewellery, which can be caught in moving parts - Suitable safety footwear is recommended when working outdoors. - Wear protective covering to contain long hair

9 - Use protective equipment

- Use safety glasses - Use face or dust mask if working operations create dust

WARNING: Not using protective equipment or appropriate clothing can cause

personal injury or increase the severity of an injury.

10 - Connect dust extraction equipment - If the tool is provided for the

connection of dust extraction and collecting equipment, ensure these are connected and properly used

11 - Do not abuse the power cable - Never pull the power cable to

disconnect it from the socket. Keep the power cable away from heat, oil and sharp edges. Damaged or entangled power cables increase the risk of electric shock

12 - Secure work - Where possible use clamps or a vice to hold the work.

It is safer than using your hands

13 - Do not overreach - Keep proper footing and balance at all times

14 - Maintain tools with care

- Keeping cutting tools sharp and clean makes the tool easier to control and less likely to bind or lock in the workpiece - Follow instructions for lubricating and changing accessories - Inspect tool power cables periodically and have them repaired by an authorised service facility if damaged - Inspect extension cables periodically and replace if damaged - Keep handles dry, clean and free from oil and grease

WARNING: Many accidents are caused by poorly maintained power tools.

15 - Disconnect tools - Disconnect tools from the power supply when not

in use, before servicing and when changing accessories such as blades, bits and cutters

WARNING: The use of accessories or attachments not recommended by the

manufacturer may result in a risk of injury to persons.

16 - Remove adjusting keys and wrenches - Form the habit of checking

to see that keys and adjusting wrenches are removed from the tool before switching it on

17 - Avoid unintentional starting - Ensure switch is in “off” position when

connecting to a mains socket, inserting a battery pack, or when picking up or carrying the tool

WARNING: Unintended starting of a tool can cause major injuries.

18 - Use outdoor extension leads - When the tool is used outdoors, use

only extension cords intended for outdoor use and so marked. Use of an extension cable suitable for outdoor use reduces the risk of electric shock

- Watch what you are doing, use common sense and do not operate the tool when you are tired - Do not use a power tool while you are under the influence of drugs, alcohol or medication

WARNING: A moment of inattention while operating power tools may result in

serious personal injury.

20 - Check damaged parts

- Before further use of tool, it should be carefully checked to determine that it will operate properly and perform its intended function - Check for alignment of moving parts, binding of moving parts, breakage of parts, mounting and any other conditions that may affect its operation - A guard or other part that is damaged should be properly repaired or replaced by an authorised service centre unless otherwise indicated in this instruction manual - Have defective switches replaced by an authorised service centre

WARNING: Do not use the tool if the on/off switch does not switch the tool on

and off. The switch must be repaired before the tool is used.

21 - Have your tool repaired by a qualified person - This electric tool

complies with the relevant safety rules. Repairs should only be carried out by qualified persons, otherwise this may result in considerable danger to the user

WARNING: When servicing use only identical replacement parts.

WARNING: If the power cable is damaged it must be replaced by the

manufacturer or an authorised service centre.

22 - Power tool mains plugs must match the mains socket - Never

modify the plug in any way. Do not use any adapter plugs with earthed (grounded) power tools. Unmodified plugs and matching sockets will reduce risk of electric shock

23 - If operating a power tool outside use a residual current device

(RCD) - Use of an RCD reduces the risk of electric shock NOTE: The term “residual current device (RCD)” may be replaced by the term “ground fault circuit interrupter (GFCI)” or “earth leakage circuit breaker (ELCB)”.

WARNING: Before connecting a tool to a power source (mains switch power

point receptacle, outlet, etc.) be sure that the voltage supply is the same as that specified on the nameplate of the tool. A power source with a voltage greater than that specified for the tool can result in serious injury to the user, and damage to the tool. If in doubt, do not plug in the tool. Using a power source with a voltage less than the nameplate rating is harmful to the motor. Welding Safety

• Welding produces toxic fumes and can reduce oxygen levels in the work area. Always work in a well-ventilated area. Avoid inhaling welding fumes, use a suitable respirator where appropriate

• Some metal parts may have zinc, lead, cadmium or other coatings. Attempting to weld through these coatings can produce highly toxic fumes. Always remove all coatings before welding

• If you experience irritation to the lungs, throat or eyes whilst welding, STOP IMMEDIATELY and seek fresh air

• Welding produces extremely high levels of UV light. To prevent eye damage, ALWAYS use an approved welding face mask. Under no circumstances look directly at the arc

• The light produced when arc welding can be attractive to look at, especially to children. Always prevent other people from viewing the arc welding light with unprotected eyes

• If there is a possibility of other people approaching the work area, erect suitable screening to protect them from the light / glare

• Always replace the welder face mask glass as soon as it shows any signs of wear or damage

• To prevent skin damage, ALWAYS wear a suitable fire-proof long sleeved jacket, heat proof gloves, and cap. Keep covered up

• Always remove any flammable materials (e.g. cigarette lighter, matches) from your clothing before welding

• Always keep a fire extinguisher nearby when welding

• Sparks generated while welding can ignite flammable materials easily in the welding area, so it is important to remove flammable materials before commencing welding

• Only weld when the work area and all workpieces are dry

• Do not weld sealed containers (e.g. fuel tanks, air tanks, oil drums). The heat generated from welding can cause sealed containers to burst without warning

• Be aware of transferred heat. Metal parts can conduct heat away from the work area and cause ignition of flammable materials

• Be aware that welded parts will remain hot for some time after joining. Allow to cool completely before handling, or leaving unattended

• Never weld where flammable gases, liquids or dust are present

• Ensure that there is always a responsible person nearby to alert you to any fire, or to call help in an emergency

• Use of welding machines will create powerful magnetic fields. This may disturb the operation of sensitive electronic equipment. Pacemaker wearers should consult a doctor before using a welding machine

• Do not overload power supply. Check that your mains wiring is capable of delivering the required current safely (see Specification) 846386_Z1MANPRO1.indd 5 20/07/2016 16:316

Intended Use Single-phase manual metal arc welder using electrode rods (sticks) to create welds in ferrous metals. Requires a European 16A CEE 7/3 or CEE 7/5 earthed mains socket. Alternatively the CEE 7/7 mains plug can be removed so the welder can be used with a suitable high-current 16A mains connection in the UK. Unpacking Your Tool

• Carefully unpack and inspect your tool. Fully familiarise yourself with all its features and functions• Ensure that all parts of the tool are present and in good condition. If any parts are missing or damaged, have such parts replaced before attempting to use this tool Before Use

WARNING: Ensure the tool is disconnected from the power supply and cool

before attaching or changing any accessories, or making any adjustments.WARNING: Always ensure that there is an appropriate fire extinguisher near to the work area. Assembling the mask Assemble the mask as shown. 1. Use the mask clips (arrowed) to assemble the flat-packed Welding Mask (13) into its normal shape2. Fit the Mask Handle (21) using the Handle Nuts and Bolts (18 & 19). The Mask Handle must be inside the Welding Mask body to protect the operator’s hand from splatter 1 Carrying Handle 2 On/Off Switch 3 Current Dial 4 Electrode Socket 5 Earth Socket 6 Over-Heat Indicator 7 Power Indicator 8 Earth Clamp 9 Earth Cable Connector 10 Electrode Clamp 11 Electrode Cable Connector 12 Electrode Rod Slot 13 Welding Mask 14 Filter Frame 15 Welding Glass 16 Splatter Shield 17 Frame Clips (x 2) 18 Handle Nuts (x 3) 19 Handle Bolts (x 3) 20 Frame Pins (x 2) 21 Mask Handle 22 Hammer Brush Product Familiarisation 3. Assemble the Filter Frame (14) with Welding Glass (15) and Splatter Shield (16) as shown. Ensure the Splatter Shield protects the Welding Glass from weld splatter. If the Welding Glass is fitted as the external layer it may be damaged by splatter and this could allow dangerous ultra-violet light to reach the operator’s eyes4. Fit the glass assembly into the Welding Mask using the Frame Pins (20) and Frame Clips (17) Connecting to mains Note: This tool is earthed and must only be connected to mains with an earth connection. Do not attempt to use it without an earth connection. Warning: This welder requires a 16A mains connection and is not suitable for connection to a UK 13A mains socket when used at 100A. For this reason it is not supplied with a pre-fitted UK converter plug.This arc welder is supplied pre-fitted with a CEE 7/7 earthed 16A mains plug suitable for Germany and France, and other countries that adopt the same CEE 7/3 and 7/5 standards for mains sockets. If you do not have a suitable socket available compatible with a CEE 7/7 plug it will need to be replaced by a suitable plug or replacement cable with plug for your country. Depending on legislation in your country this may require fitting by a qualified electrician. Alternatively a converter may be available to adapt the CEE 7/7 plug, but it must be earthed and capable of handling 16A. Note: For UK use, consult a qualified electrician with regards to installing a high current socket suitable for a welder that requires 16A. A suitable 16A plug (589694) and socket (571518) are available from your Silverline stockist, however the socket must be installed by a qualified electrician. It may be preferable to fit a 32A plug (427717) and socket (457049) to allow your welder to be upgraded to a more powerful model at a later date. Do not attempt to use this welder without an earth connectionDo not connect this welder to a mains socket that is not rated to 16A or moreDo not use an extension cable that is not capable of handling 16A, and always fully unwind cableIMPORTANT: It is recommended to use a plug and socket arrangement so the welder can be fully isolated when necessaryNotes;• The welder must be connected to a consumer unit with a built-in RCD, using a circuit protected by an RCD• Please refer to the Specification for details of the maximum current required by this welder• If in any doubt, do not attempt to connect or use this welder until a professional electrician has been consulted Welding rod selection

• In order to produce a good quality weld, the correct type of welding rod must be used. Welding rods are available in a variety of thicknesses and materials, and with a range of coatings• Refer to the rod manufacturer’s guidelines to select the correct rod for your requirementsGuide to current and electrode selection Electrode/rod diameter Welding current 1.6mm 40-50A 2.0mm 50-70A 2.5mm 75-100A 3.2mm 110-130A 4.0mm 140-200A Operation

WARNING: ALWAYS wear a welding mask, gloves and heat-resistant clothing

when working with this tool.

WARNING: Toxic fumes can be given off by welding and suitable respiratory

protection may be required. Read the ‘welding safety’ section in this manual and contact your national health and safety government body for additional information. In the UK information is available from www.hse.gov.uk/welding WARNING: Always inspect your machine for damage or wear. Pay particular attention to leads and cables. If any damage is found, DO NOT USE. 846386_Z1MANPRO1.indd 6 20/07/2016 16:31www.silverlinetools.com

100A MMA Inverter Arc Welder Kit846386 Note: Before use, check that all casings or covers are properly closed and secured. Note: Position the welder to ensure that it will not move, or tip, in use. Ensure that there is at least 500mm of clear space around the welder, to allow proper ventilation. Switching on and off

• Switch the welding machine on by moving the On/Off Switch (2) (located at rear of welder) into the ‘I’ position• Switch the welding machine off by moving the On/Off Switch into the ‘O’ position Current selection
• In order to achieve a good quality weld, the Current Dial (3) must be set correctly• Turn the Current Dial clockwise to increase the welding current; turn the knob anti-clockwise to reduce the welding current Duty Cycle
• This machine is not designed to weld constantly at higher current settings. Excessive continuous welding will cause overheating and damage to internal components• This machine is equipped with a thermal cut-out. If the machine is overloaded, or used beyond its duty cycle, it will automatically shut down• The duty cycle (see Specification) defines the number of minutes in every ten minutes that the machine can weld• For a duty cycle of 30%, the machine may be used for 3 minutes then must be allowed 7 minutes to cool• If the duty cycle is exceeded, the machine will automatically cut out• Using the machine at reduced current settings and maintaining good ventilation will maximise the duty cycle• When the duty cycle limit is reached, the Over-Heat Indicator (6) will illuminate. The light will cut out when the machine has cooled and is ready to be used again • As a precaution, it is recommended the machine is allowed to cool for a further three minutes after the Over-Heat Indicator has switched off, to ensure the cool-down temperature has been met Weld preparation
• Ensure the joining surfaces of the workpiece are clean, free from rust, paint, or other finishes• All parts should be well supported, with a gap of approximately 1mm where the weld is intended to be formed• Check that there are no flammable materials in the vicinity of the work area• Attach the Earth Clamp (6) to a cleaned area of one of the parts, as near as practical to where the joint will beNote: Improve connectivity between the Earth Clamp and the workpiece by wrapping a piece of scrap copper wire, with the insulation removed, around the teeth of the clamp.• Squeeze lever, to open the Electrode Clamp (10). Place an electrode into the jaws, and release. The electrode should be firmly gripped with the clamp contacting the clean metal part of the rod (not the coated part)• Connect the machine to the mains power supply Welding WARNING: Using a welder correctly is a technical skill. An incorrectly-used welder can be highly dangerous. The information below is general guidance only. If you are not entirely confident in your ability to use this tool safely DO NOT USE.1. Move the On/Off Switch (2) into the ‘I’ position (located at rear of welder)2. Hold the Electrode Clamp (10) in one hand, and the Welding Mask (13) in the other3. Position the rod at an angle of approximately 80˚ to the surface, with the tip approximately 30mm away from the metal4. Hold the Welding Mask over your face and tap the rod against the metal5. An arc should strike between the metal and the tip. Try to maintain a distance between the welding rod and the workpiece equivalent to the diameter of the rod. Maintain the arc for one-to-two seconds, then move the rod away6. Allow the weld to cool slightly and move the mask away from your face. If the settings were correct, a round ‘spot’ weld should have formed7. If the weld has not fully penetrated the metal, increase the current setting. If a hole has been made in the metal, reduce the current setting8. Practice making ‘spot’ welds until you are confident in using the machine and selecting settings9. In order to form a ‘seam’ weld, maintain the arc for longer and slowly move the rod along the path of the join. The speed at which the rod is moved is crucial to achieving a good weld• If the machine settings are correct, the arc should be steady and should produce a crackling sound. Be aware that you will have to gradually move the electrode clamp closer to the metal as the rod is used up• Once the weld bead is complete, remove excess and splatters using a chipping hammer or wire brush. Do not attempt to weld over beads unless properly cleaned• Creating neat, high quality welds is a skill that takes time to master. Practice and good preparation will help to make satisfactory welds Accessories
• A range of other accessories and consumables, including Welders Helmet (868520, 934295 and 757060), Welders Chipping Hammer (515858), Welders Apron (633505) and Welders Gauntlets (282389), is available from your Silverline stockist. Spare parts can be obtained from toolsparesonline.com Maintenance

WARNING: ALWAYS disconnect from the power supply before carrying out

any inspection, maintenance or cleaning.• If the mains cable becomes damaged or worn it must be replaced by a qualified technician, with a cable equal or superior in current capacity to the original fitted cable• If the internal fuse blows, it must be replaced with a fuse of exactly the same type and rating as originally fitted. If the replacement fuse blows immediately, it is likely to indicate a fault condition and a service technician should be consulted immediately General inspection

• Regularly check that all the fixing screws are tight• Inspect the supply cord of the tool, prior to each use, for damage or wear. Repairs should be carried out by an authorised Silverline service centre. This advice also applies to extension cords used with this tool Cleaning
• Keep your tool clean at all times. Dirt and dust will cause internal parts to wear quickly, and shorten the machine’s service life. Clean the body of your machine with a soft brush, or dry cloth. If available, use clean, dry, compressed air to blow through the ventilation holes• Clean the tool casing with a soft damp cloth using a mild detergent. Do not use alcohol, petrol or strong cleaning agents• Never use caustic agents to clean plastic parts Storage
• Store this tool carefully in a secure, dry place out of the reach of children Disposal Always adhere to national regulations when disposing of power tools that are no longer functional and are not viable for repair.• Do not dispose of power tools, or other waste electrical and electronic equipment (WEEE), with household waste• Contact your local waste disposal authority for information on the correct way to dispose of power tools 846386_Z1MANPRO1.indd 7 20/07/2016 16:318

Problem Possible cause Solution No powerMains circuit breaker operated or fuse blown Check circuit is capable of required current then reset mains circuitInternal fuse blown Have fuse replaced by a qualified electricianDuring use the welder stops workingDuty cycle exceeded and Over-Heat Indicator (6) is illuminatedLeave the welder for 20-30 minutes to cool downPoor weldIncorrect current setting Adjust Current Dial (3)Wrong electrode rod/stick Replace electrode rod/stickPoor earth connection on workpieceCheck Earth Clamp (8). Ensure there is no grease, paint or other surface coating that would cause a bad electrical connection with the workpiece Troubleshooting 846386_Z1MANPRO1.indd 8 20/07/2016 16:31www.silverlinetools.com

100A MMA Inverter Arc Welder Kit846386 Terms & Conditions Silverline Tools Guarantee This Silverline product comes with a 3 year guarantee Register this product at www.silverlinetools.com within 30 days of purchase in order to qualify for the 3 year guarantee. Guarantee period begins according to the date of purchase on your sales receipt. Registering your purchase Registration is made at silverlinetools.com by selecting the Guarantee Registration button. You will need to enter:-• Your personal details• Details of the product and purchase information Once this information is entered your guarantee certificate will be created in PDF format for you to print out and keep with your purchase. Guarantee period becomes effective from the date of retail purchase as detailed on your sales receipt.

PLEASE KEEP YOUR SALES RECEIPT

If this product develops a fault within 30 days of purchase, return it to the stockist where it was purchased, with your receipt, stating details of the fault. You will receive a replacement or refund.If this product develops a fault after the 30 day period, return it to:Silverline Tools Service Centre PO Box 2988 Yeovil BA21 1WU, UKThe guarantee claim must be submitted during the guarantee period.You must provide the original sales receipt indicating the purchase date, your name, address and place of purchase before any work can be carried out.You must provide precise details of the fault requiring correction.Claims made within the guarantee period will be verified by Silverline Tools to establish if the deficiencies are related to material or manufacturing of the product.Carriage will not be refunded. Items for return must be in a suitably clean and safe state for repair, and should be packaged carefully to prevent damage or injury during transportation. We may reject unsuitable or unsafe deliveries.All work will be carried out by Silverline Tools or its authorized repair agents.The repair or replacement of the product will not extend the period of guaranteeDefects recognised by us as being covered by the guarantee shall be corrected by means of repair of the tool, free of charge (excluding carriage charges) or by replacement with a tool in perfect working order.Retained tools, or parts, for which a replacement has been issued, will become the property of Silverline Tools. The repair or replacement of your product under guarantee provides benefits which are additional to and do not affect your statutory rights as a consumer. What is covered: The repair of the product, if it can be verified to the satisfaction of Silverline Tools that the deficiencies were due to faulty materials or workmanship within the guarantee period.If any part is no longer available or out of manufacture, Silverline Tools will replace it with a functional replacement part.Use of this product in the EU. What is not covered: Silverline Tools does not guarantee repairs required as a result of:Normal wear and tear caused by use in accordance with the operating instructions eg blades, brushes, belts, bulbs, batteries etc.The replacement of any provided accessories drill bits, blades, sanding sheets, cutting discs and other related items.Accidental damage, faults caused by negligent use or care, misuse, neglect, careless operation or handling of the product.Use of the product for anything other than normal domestic purposes.Change or modification of the product in any way.Use of parts and accessories which are not genuine Silverline Tools components.Faulty installation (except installed by Silverline Tools).Repairs or alterations carried out by parties other than Silverline Tools or its authorized repair agents.Claims other than the right to correction of faults on the tool named in these guarantee conditions are not covered by the guarantee. Battery Guarantee Silverline batteries are guaranteed for 30 days. If a defect occurs on a registered battery during the term of the Battery Guarantee, due to material or manufacturing fault, then Silverline will replace it free of charge. This guarantee does not apply to commercial use nor does it extend to normal wear and tear or damage as a result of accident, abuse or misuse. CE Declaration of Conformity The undersigned: Mr Darrell Morrisas authorised by: Silverline ToolsDeclares thatThis declaration has been issued under the sole responsibility of the manufacturer.The object of the declaration is in conformity with the relevant Union harmonisation Legislation.Identification code: 846386Description: 100A MMA/TIG Inverter Arc Welder Kit Conforms to the following directives and standards: • Low Voltage Directive 2014/35/EU • EMC Directive 2014/30/EU• RoHS Directive 2011/65/EU • EN60974-1:2012• EN60974-10:2014Notified body: TÜV SÜD Product ServiceThe technical documentation is kept by: Silverline Tools Date: 18/07/2016Signed: Mr Darrell MorrisManaging DirectorName and address of the manufacturer:Powerbox International Limited, Company No. 06897059. Registered address: Powerbox, Boundary Way, Lufton Trading Estate, Yeovil, Somerset BA22 8HZ, United Kingdom. 846386_Z1MANPRO1.indd 9 20/07/2016 16:3110