HES 200 - Welding machine Herkules - Free user manual and instructions

USER MANUAL HES 200 Herkules

Danger! - An electric shock from the welding electrode can be fatal Danger! - The inhaling of welding fumes can harm your health Danger! - Welding arc radiation can damage your eyes and injure your skin Danger! - Welding sparks can cause an explosion or fi re Danger! - Electromagnetic fi elds can disturb the operation of pacemakers Danger! Danger from electric shock Anl_HES_200_SPK7.indb 16Anl_HES_200_SPK7.indb 16 09.09.2015 09:59:4209.09.2015 09:59:42GB

Danger! When using the equipment, a few safety pre- cautions must be observed to avoid injuries and damage. Please read the complete operating instructions and safety regulations with due care. Keep this manual in a safe place, so that the in- formation is available at all times. If you give the equipment to any other person, hand over these operating instructions and safety regulations as well. We cannot accept any liability for damage or accidents which arise due to a failure to follow these instructions and the safety instructions.

1. Safety regulations

The corresponding safety information can be found in the enclosed booklet. Danger! Read all safety regulations and instructions. Any errors made in following the safety regula- tions and instructions may result in an electric shock, fi re and/or serious injury. Keep all safety regulations and instructions in a safe place for future use. Safety components: a) Danger from electric shock: An electric shock from a welding electrode can be fatal. Never perform any welding in rain or snow. Wear dry insulating gloves. Do not touch the electrode with your bare hands. Do not wear wet or damaged gloves. Protect yourself from an electric shock by insulating yourself from the workpiece. Do not open the equipment housing. b) Danger from welding fumes: The inhaling of welding fumes can harm your health. Keep your head out of the fumes. Use the equip- ment in open areas. Use a ventilation system to remove the fumes. c) Danger from welding sparks: Welding sparks can cause an explosion or fi re. Keep combustible materials away from the welding area. Do not weld combustible materials. Welding sparks can cause fi res. Keep a fi re extinguisher nearby and someone watching who can use it immediately. Do not weld on drums or any closed containers. d) Danger from welding arc radiation: Wel- ding arc radiation can damage your eyes and injure your skin. Wear a hat and safety gog- gles. Wear ear protection and a high, closed shirt collar. Use a welding helmet and fi lters of the correct size. Wear complete body protec- tion. e) Danger from electromagnetic fi elds: Wel- ding current creates electromagnetic fi elds. Do not use together with medical implants. Never wind the welding cables around your body. Guide welding cables together.

2. Layout and items supplied

3. Adjustment wheel for welding current

4. Selector switch 230 V / 400 V

5. Control lamp for overheating

6. Operating control lamp

7. Welding current scale

Please check that the article is complete as specifi ed in the scope of delivery. If parts are missing, please contact our service center or the sales outlet where you made your purchase at the latest within 5 working days after purchasing the product and upon presentation of a valid bill of purchase. Also, refer to the warranty table in the service information at the end of the operating instructions.

Open the packaging and take out the equip- ment with care.

Remove the packaging material and any packaging and/or transportation braces (if available).

Check to see if all items are supplied.

Inspect the equipment and accessories for transport damage.

If possible, please keep the packaging until the end of the guarantee period. Danger! The equipment and packaging material are not toys. Do not let children play with plastic bags, foils or small parts. There is a danger of swallowing or suff ocating! Anl_HES_200_SPK7.indb 17Anl_HES_200_SPK7.indb 17 09.09.2015 09:59:4209.09.2015 09:59:42GB

Supporting foot (11)

Original operating instructions

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

4. Symbols and technical data

EN 60974-1 European standard for arc welding sets and wel- ding power supplies with limited on time (Part 6).

Symbol for welding power supplies which are sui- table for welding in environments with increased electrical danger. ~ 50 Hz Alternating current and rated frequency value [Hz]

Rated idling voltage [V] 200 A/ 28 V Maximum welding current and the corresponding standardized operating voltage [A/V]

1max Highest rated value of the line current [A]

1eff Eff ective value of the highest line current [A] IP 21 S Protection type

5. Assembly Instructions

See Figure 2, 10-20.

5.1 Installation of the welding screen (13)

Place the welding glass (l) and the transpa- rent safety glass (m) over it in the frame for the safety glass (k) (Fig. 3).

Press the safety glass retaining pins (q) into the holes in welding screen frame (s) from the outside. (Fig. 4)

Place the frame for the safety glass (k) with the welding glass (l) and transparent safety glass (m) from the inside into the recess in the welding frame (s), press the safety glass retaining bushes (n) on to the safety glass retaining pins (q) until they engage to secure the frame for the safety glass (k). The transpa- rent safety glass (m) must be on the outside. (Fig. 5)

Bend the top of the welding screen frame (s) inwards (Fig. 6/1) and fold down the top corners (Fig. 6/2) Now bend the outer sides of the welding screen frame (s) inwards (Fig. 6/3) and connect them by pressing the top corners and outer sides together. As the retai- ning pins engage, you should be able to hear two clear clicks on each side (Fig. 6/4).

When the top corners of the welding screen are connected as shown in Figure 7, place the screws for the handle (p) from the outside through the three holes in the welding screen. (Fig. 8)

Turn over the welding screen and place the handle (r) over the threads on the three screws for the handle (p). Secure the handle (r) to the welding screen with the three nuts for the handle (o) (Fig. 9).

This welding set can be operated with a rated voltage of 230 V and 400 V. The desired rated voltage can be set by means of the rotary switch (4). Please follow the operating instructions, as described below: 3 ~ 16 A max. 200 A Please observe the following instructions in order to avoid the risk of fi re, electric shock or personal injuries.

Never use the appliance with a rated voltage of 400 V if the appliance is set to 230 V. Cauti- on: Fire risk!

Please disconnect the appliance from the po- wer supply before setting the rated voltage.

Adjusting the rated voltage during operation of the welding set is strictly prohibited. Anl_HES_200_SPK7.indb 19Anl_HES_200_SPK7.indb 19 09.09.2015 09:59:4209.09.2015 09:59:42GB

Before operating the welding set, please ensure that the rated voltage selected on the appliance complies with that of the power source. Note: The welding unit is equipped with a 400 V ~ 16 A CeCon plug. Use the supplied adapter cable No. 12 to operate the welding unit with 230 V~ .

7. Welding preparations

Connect the earth terminal (-) (2) direct to the part to be welded or to the support on which the part is resting. Ensure that the earth terminal (-) is in di- rect contact with the part to be welded. You should therefore avoid coated surfaces and/or insulated materials. The electrode holder cable has a spe- cial clamp at one end, which is used to secure the electrode. The welding safety shield must be used at all times for welding. It protects your eyes from the radiation emitted by the arc and nevertheless enables you to watch the welding process (not included in items supplied).

After you have made all the electrical connections for the power supply and for the welding circuit, you can proceed as follows: Insert the unsheathed end of the electrode into the electrode holder (1) and connect the earth ter- minal (-) (2) to the part you wish to weld. Ensure that a good electric contact is made. Switch on the welding set at the switch (4) and set the welding current using the hand wheel (3) to suit the electrode you wish to use. Hold the safety shield in front of your face and rub the tip of the electrode on the part you wish to weld as if you were striking a match. This is the best method of igniting the arc. Check that you have the correct electrode and current strength on a test part. Electrode (Ø mm): .................Welding current (A) 2...............................................................40-80 A

4 ........................................................ 120 - 200 A Important! Do not dab the workpiece with the electrode since it could be damaged, making it more diffi cult to ignite the arc. As soon as the arc has ignited, attempt to keep it a distance from the workpiece equivalent to the diameter of the electrode. This distance should be kept as constant as pos- sible during the welding process. The angle of the electrode in the direction in which you are working should be 20/30°. Always use tongs to remove spent electrodes and to move parts that you have just welded. Please note that the electrode holder (1) must always be put down so that it is insulated after you have completed the welding work. Do not remove the slag until the weld has cooled. If you want to continue a weld after an interrupti- on, the slag from your initial attempt must fi rst be removed.

9. Overheating guard

The welding set is fi tted with an overheating guard that protects the welding transformer from overheating. If the overheating guard trips, the control lamp (5) on your set will be lit. Allow the welding set to cool for a time.

10. Replacing the power cable

Danger! If the power cable for this equipment is damaged, it must be replaced by the manufacturer or its after-sales service or similarly trained personnel to avoid danger. Anl_HES_200_SPK7.indb 20Anl_HES_200_SPK7.indb 20 09.09.2015 09:59:4209.09.2015 09:59:42GB

11. Cleaning, maintenance and

ordering of spare parts Danger! Always pull out the mains power plug before star- ting any cleaning work.

Keep all safety devices, air vents and the motor housing free of dirt and dust as far as possible. Wipe the equipment with a clean cloth or blow it with compressed air at low pressure.

We recommend that you clean the device immediately each time you have finished using it.

Clean the equipment regularly with a moist cloth and some soft soap. Do not use cleaning agents or solvents; these could at- tack the plastic parts of the equipment. Ensu- re that no water can seep into the device. The ingress of water into an electric tool increases the risk of an electric shock.

There are no parts inside the equipment which require additional maintenance.

11.3 Ordering replacement parts:

Please quote the following data when ordering replacement parts:

Article number of the machine

Identification number of the machine

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

12. Disposal and recycling

The equipment is supplied in packaging to pre- vent it from being damaged in transit. The raw materials in this packaging can be reused or recycled. The equipment and its accessories are made of various types of material, such as metal and plastic. Never place defective equipment in your household refuse. The equipment should be taken to a suitable collection center for proper disposal. If you do not know the whereabouts of such a collection point, you should ask in your local council offi ces.

Store the equipment and accessories in a dark and dry place at above freezing temperature. The ideal storage temperature is between 5 and 30 °C. Store the electric tool in its original packaging. Anl_HES_200_SPK7.indb 21Anl_HES_200_SPK7.indb 21 09.09.2015 09:59:4309.09.2015 09:59:43GB

For EU countries only Never place any electric power tools in your household refuse. To comply with European Directive 2012/19/EC concerning old electric and electronic equipment and its implementation in national laws, old electric power tools have to be separated from other waste and disposed of in an environment-friendly fashion, e.g. by taking to a recycling depot. Recycling alternative to the return request: As an alternative to returning the equipment to the manufacturer, the owner of the electrical equipment must make sure that the equipment is properly disposed of if he no longer wants to keep the equipment. The old equipment can be returned to a suitable collection point that will dispose of the equipment in accordance with the national recycling and waste disposal regulations. This does not apply to any ac- cessories or aids without electrical components supplied with the old equipment. The reprinting or reproduction by any other means, in whole or in part, of documentation and papers accompanying products is permitted only with the express consent of the iSC GmbH. Subject to technical changes Anl_HES_200_SPK7.indb 22Anl_HES_200_SPK7.indb 22 09.09.2015 09:59:4309.09.2015 09:59:43GB

Service information We have competent service partners in all countries named on the guarantee certifi cate whose contact details can also be found on the guarantee certifi cate. These partners will help you with all service re- quests such as repairs, spare and wearing part orders or the purchase of consumables. Please note that the following parts of this product are subject to normal or natural wear and that the following parts are therefore also required for use as consumables. Category Example Wear parts* Electrode holder, mass tongs Consumables* Missing parts

• Not necessarily included in the scope of delivery! In the eff ect of defects or faults, please register the problem on the internet at www.isc-gmbh.info. Ple- ase ensure that you provide a precise description of the problem and answer the following questions in all cases:

Did the equipment work at all or was it defective from the beginning?

Did you notice anything (symptom or defect) prior to the failure?

What malfunction does the equipment have in your opinion (main symptom)? Describe this malfunction. Anl_HES_200_SPK7.indb 23Anl_HES_200_SPK7.indb 23 09.09.2015 09:59:4309.09.2015 09:59:43GB

Warranty certifi cate Dear Customer, All of our products undergo strict quality checks to ensure that they reach you in perfect condition. In the unlikely event that your device develops a fault, please contact our service department at the address shown on this guarantee card or the sales outlet from where you bought the device. Please note the fol- lowing terms under which guarantee claims can be made:

1. These warranty terms regulate additional warranty services, which the manufacturer mentioned

below promises to buyers of its new products in addition to their statutory rights of guarantee. Your statutory guarantee claims are not aff ected by this guarantee. Our guarantee is free of charge to you.

2. The warranty services cover only defects due to material or manufacturing faults on a product which

you have bought from the manufacturer mentioned below and are limited to either the rectifi cation of said defects on the product or the replacement of the product, whichever we prefer. Please note that our devices are not designed for use in commercial, trade or professional applica- tions. A guarantee contract will not be created if the device has been used by commercial, trade or industrial business or has been exposed to similar stresses during the guarantee period.

3. The following are not covered by our guarantee:

- Damage to the device caused by a failure to follow the assembly instructions or due to incorrect installation, a failure to follow the operating instructions (for example connecting it to an incorrect mains voltage or current type) or a failure to follow the maintenance and safety instructions or by ex- posing the device to abnormal environmental conditions or by lack of care and maintenance. - Damage to the device caused by abuse or incorrect use (for example overloading the device or the use or unapproved tools or accessories), ingress of foreign bodies into the device (such as sand, stones or dust, transport damage), the use of force or damage caused by external forces (for ex- ample by dropping it). - Damage to the device or parts of the device caused by normal or natural wear or tear or by normal use of the device.

4. The guarantee is valid for a period of 60 months starting from the purchase date of the device. Gu-

arantee claims should be submitted before the end of the guarantee period within two weeks of the defect being noticed. No guarantee claims will be accepted after the end of the guarantee period. The original guarantee period remains applicable to the device even if repairs are carried out or parts are replaced. In such cases, the work performed or parts fi tted will not result in an extension of the guarantee period, and no new guarantee will become active for the work performed or parts fi tted. This also applies if an on-site service is used.

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

www.isc-gmbh.info. If the defect is covered by our guarantee, then the item in question will either be repaired immediately and returned to you or we will send you a new replacement device. Also refer to the restrictions of this warranty concerning wear parts, consumables and missing parts as set out in the service information in these operating instructions. Anl_HES_200_SPK7.indb 24Anl_HES_200_SPK7.indb 24 09.09.2015 09:59:4309.09.2015 09:59:43FR

5. Assembly Instructions

10. Raftenging 400 V

= dB (A); guaranteed L