BT-GW 190 D Set - Welding machine EINHELL - Free user manual and instructions

USER MANUAL BT-GW 190 D Set EINHELL

Original operating instructions Shielding Gas Welder

1. Safety regulations

2. Layout and items supplied

5. Before starting the equipment

7. Cleaning, maintenance and ordering spare parts

8. Disposal and recycling

Important! When using the equipment, a few safety precautions 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 information 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.

5. Gas bottle support surface

16. Gas supply connector

18. Shielding gas hose

19. Pressure reducer

23. Shielding gas hose connector

27. Handle for housing cover

31. Pressure gage (bottle pressure)

The shielding gas welding set is exclusively designed for welding steel with the MAG (Metal Active Gas) method using the appropriate welding wires and gases. The machine is to be used only for its prescribed purpose. Any other use is deemed to be a case of misuse. The user / operator and not the manufacturer will be liable for any damage or injuries of any kind caused as a result of this. Important information about the power connection This equipment falls under Class A of the standard 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 because 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 filter which reduces the electromagnetic 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 without such a filter. 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 electromagnetic 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 connection”. Anleitung_BT_GW_190_D_SPK1__ 24.01.13 15:07 Seite 1920

Reduction of emissions Main current supply The welder must be connected to the main current supply in accordance with the instructions issued by the manufacturer. If interference occurs, it may be necessary to introduce additional measures, e.g. fitting a filter 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 fields and high electric currents does not affect their devices. For commercial users the guarantee period is 12 months and for normal users 24 months, beginning from the date of purchase.

5. Before starting the equipment

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

5.1.2 Fitting the welding screen (17)

Place the welding glass (l) and the transparent safety glass (m) over it in the frame for the safety glass (k) (Fig. 12). Press the safety glass retaining pins (q) into the holes in welding screen frame (s) from the outside. (Fig. 13) Place the frame for the safety glass (k) with the welding glass (l) and transparent safety glass (m) from the inside into the recess in the welding frame (s), press the safety glass retaining bushes (n) on to the safety glass retaining pins (q) until they engage to secure the frame for the safety glass (k). The transparent safety glass (m) must be on the outside. (Fig. 14) Bend the top of the welding screen frame (s) inwards (Fig. 15/1) and fold down the top corners (Fig. 15/2) Now bend the outer sides of the welding screen frame (s) inwards (Fig. 15/3) and connect them by pressing the top corners and outer sides together. As the retaining pins engage, you should be able to hear to clear clicks on each side (Fig. 15/4). When the top corners of the welding screen are connected as shown in Figure 16, place the screws for the handle (p) from the outside through the three holes in the welding screen. (Fig. 17) Turn over the welding screen and place the handle (r) over the threads on the three screws for the handle (p). Secure the handle (r) to the welding screen the three nuts for the handle (o) (Fig. 18).

Gas shielding is required for welding with continuous wire, the composition of the shielding gas depends on the welding method you wish to use.

5.2.2 Fitting the gas bottle on the unit (Fig. 19-25)

The gas bottle is not supplied. Fit the gas bottle cables as shown in Figures 19 - 21. Ensure that the safety chain (28) is secure and that the welding set cannot tip over. Important. Only gas bottles with a maximum capacity of 20 liters may be fitted on the gas bottle support area (Fig. 19/5). If you wish to use larger gas bottles, Shielding gas CO2 Argon/CO2 Metal to be welded Non-alloyed steel X X Anleitung_BT_GW_190_D_SPK1__ 24.01.13 15:07 Seite 2021

there is a risk that they will tip over and therefore they may only be placed next to the unit. In this case the gas bottle must be secured to prevent it tipping over.

5.2.3 Connecting the gas bottle

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

5.2.4 Information about the pressure reducer

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

6.1.3 for setting the gas delivery rate.

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

5.3 Mains connection

Before you connect the equipment to the mains supply make sure that the data on the rating plate are identical to the mains data. The equipment may only be operated from properly earthed and fused sockets. Please read the following to prevent the risk of fire, an electric shock and personal injury: Never use the welding set with a rated voltage of 400 V if it is set to 230 V. Caution: Fire risk. Disconnect the welding set from the power supply before you adjust the mains voltage. Do not change the rated voltage whilst the welding set is operating. Before using the welding set, ensure that the rated voltage setting is identical to that from the power source. Please note: The welding unit is equipped with a 400 V ~ 16 A CeCon plug. Use the supplied adapter cable No. 30 to operate the welding unit with 230 V~.

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

The wire spool is not supplied.

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

5.4.2 Wire spool capacity

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

5.4.3 Inserting the wire spool

Open the housing cover (Fig. 2/4) by pushing the handle for the housing cover (Fig. 2/27) backwards and opening the housing cover (Fig. 2/4). Check that the windings on the spool do not overlap so as to ensure that the wire can be unwound evenly. Description of the wire guide unit (Fig. 26-27) A Spool lock B Spool holder C Cam pin D Adjusting screw for roller brake E Screws for feed roller holder F Fee roller holder G Feed roller H Hose package mounting I Pressure roller J Pressure roller holder K Pressure roller spring L Adjusting screw for counter-pressure M Guide tube N Wire spool Anleitung_BT_GW_190_D_SPK1__ 24.01.13 15:07 Seite 2122

O Cam opening in wire spool Inserting the wire spool (Fig. 26, 27) Place the wire spool (N) on the spool holder (B). Ensure that the end of the welding wire is unwound on the side of the wire guide, see arrow. Ensure that the spool lock (A) is pushed in and the cam pin (C) is engaged in the cam opening in the wire spool (O). The spool lock (A) must engage again over the wire spool (N). (Fig. 27) Inserting the welding wire and adjusting the wire guide (Fig. 28-34) Push the pressure roller spring (K) upwards and swing it forwards (Fig. 28). Pull the pressure roller holder (J) with the pressure roller (I) and pressure roller spring (K) downwards (Fig. 29). Undo the screws for the feed roller holder (E) and pull off the feed roller holder (F) upwards (Fig. 30). Check the feed roller (G). The appropriate wire thickness must be specified on the top of the feed roller (G). The feed roller (G) is fitted with two guide grooves. Turn the feed roller (G) over if necessary or replace it. (Fig. 31) Position the feed roller holder (F) again and secure it. Remove the gas nozzle (Fig. 5/12) from the burner (Fig. 5/13) by turning it clockwise, unscrew the contact tube (Fig. 6/26). (Fig. 5 – 6). Place the hose package (Fig. 1/11) on the floor as straight as possible pointing away from the welding set. Cut off the first 10 cm of the welding wire to produce a straight cut with no shoulders, warping or dirt. Deburr the end of the welding wire. Push the welding wire through the guide tube (M) between the pressure and feed rollers (G/I) into the hose package mounting (H). (Fig. 32) Carefully push the welding wire by hand into the hose package until it projects out of the hose package by approx. 1 cm at the burner (Fig. 5/13). Undo the adjusting screw for counter-pressure (L) a few turns. (Fig. 34) Push the pressure roller holder (J) with pressure roller (I) and pressure roller spring (K) upwards again and attach the pressure roller spring (K) to the adjusting screw for counter-pressure (L) again (Fig. 33). Now set the adjusting screw for counter-pressure (L) so that the welding wire is positioned firmly between the pressure roller (I) and feed roller (G) without being crushed. (Fig. 34) Screw the appropriate contact tube (Fig. 6/26) for the welding wire diameter on to the burner (Fig. 5/13) and fit the gas nozzle, turning it clockwise (Fig. 5/12). Set the adjusting screw for the roller brake (D) so that the wire can still be moved and the roller stops automatically after the wire guide has been braked.

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

6.1.1 Setting the welding current

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

6.1.2 Setting the wire feed speed

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

6.1.3 Setting the gas delivery rate

The gas delivery rate can be infinitely adjusted on the pressure reducer (Fig. 4/19). It is shown on the pressure gage (Fig. 4/20) in liters per minute (l/min). Recommended gas delivery rate in rooms with no drafts: 5 – 15 l/min. To set the gas flow rate, first release the clamp lever (Fig. 26/K) on the wire feed unit to prevent unnecessary wire wear (Fig. 5.4.3). Connecting to the mains (see point 5.3), set the ON/OFF/Welding current switch (Fig. 1/7;8) to setting 1; 230 V/400 V and press the burner switch (Fig. 5/25) to start the gas flow. Now set the required gas delivery rate on the pressure reducer (Fig. 4/19). Turn the rotary knob (Fig. 4/24) counter-clockwise: Lower gas delivery rate Turn the rotary knob (Fig. 4/24) clockwise: Higher gas delivery rate Anleitung_BT_GW_190_D_SPK1__ 24.01.13 15:07 Seite 2223

Secure the pressure roller spring (Fig. 26/K) to the wire feed unit again.

6.2 Electrical connection

Connect the welding setʼs earth terminal (10) in the immediate vicinity of the welding position if possible. Ensure that the contact point is bare metal.

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

6.4 Safety equipment

The welding set is fitted with an overheating guard that protects the welding transformer from overheating. If the overheating guard trips, the control lamp (3) on your set will be lit. Allow the welding set to cool for a time.

7. Cleaning, maintenance and ordering

of spare parts Always pull out the mains power plug before starting any cleaning work.

n 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. n We recommend that you clean the device immediately each time you have finished using it. n Clean the equipment regularly with a moist cloth and some soft soap. Do not use cleaning agents or solvents; these could attack the plastic parts of the equipment. Ensure that no water can seep into the device.

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

7.3 Ordering replacement parts

Please quote the following data when ordering replacement parts: n Type of machine n Article number of the machine n Identification number of the machine n Replacement part number of the part required For our latest prices and information please go to www.isc-gmbh.info

8. Disposal and recycling

The unit is supplied in packaging to prevent its being damaged in transit. This packaging is raw material and can therefore be reused or can be returned to the raw material system. The unit and its accessories are made of various types of material, such as metal and plastic. Defective components must be disposed of as special waste. Ask your dealer or your local council. Anleitung_BT_GW_190_D_SPK1__ 24.01.13 15:07 Seite 2324

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

Dirty / damaged feed roller (see

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

No / too little gas (see 6.1.3) Check setting Check setting and filling pressure of the gas bottle

EN 60974-1 European standard for arc welding sets and welding power supplies with limited on time Do not store or use the appliance in wet or damp conditions or in the rain. Fuse with rated value in A in the mains connection mains connection

Mains voltage 50 Hz Mains frequency

max Rated maximum mains current Symbol for falling characteristic curve Read the operating instructions carefully before using the welding set and follow them Metal inert and active gas welding including the use of filler wire

Rated idling voltage IP 21 Protection type

The product meets the requirements of EN 61000-3-11 and is subject to special connection conditions. This means that use of the product at any freely selectable connection point is not allowed. Given unfavorable conditions in the power supply the product can cause the voltage to fluctuate temporarily. The product is intended solely for use at connection points that a) do not exceed a maximum permitted supply impedance Zmax = 0,2 Ω(Ohm), or b) have a continuous current-carrying capacity of the mains of at least 100 A per phase. As the user, you are required to ensure, in consultation with your electric power company if necessary, that the connection point at which you wish to operate the product meets one of the two requirements, a) or b), named above.

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 ISC GmbH.

GUARANTEE CERTIFICATE 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. Of course, if you would prefer to call us then we are also happy to offer our assistance under the service number printed below. Please note the following terms under which guarantee claims can be made:

1. These guarantee terms cover additional guarantee rights and do not affect your statutory warranty rights.

We do not charge you for this guarantee.

2. Our guarantee only covers problems caused by material or manufacturing defects, and it is restricted to the

rectification of these defects or replacement of the device. Please note that our devices have not been designed for use in commercial, trade or industrial applications. Consequently, the guarantee is invalidated if the equipment is used in commercial, trade or industrial applications or for other equivalent activities. The following are also excluded from our guarantee: compensation for transport damage, damage caused by failure to comply with the installation/assembly instructions or damage caused by unprofessional installation, failure to comply with the operating instructions (e.g. connection to the wrong mains voltage or current type), misuse or inappropriate use (such as overloading of the device or use of non-approved tools or accessories), failure to comply with the maintenance and safety regulations, ingress of foreign bodies into the device (e.g. sand, stones or dust), effects of force or external influences (e.g. damage caused by the device being dropped) and normal wear resulting from proper operation of the device. This applies in particular to rechargeable batteries for which we nevertheless issue a guarantee period of 12 months. The guarantee is rendered null and void if any attempt is made to tamper with the device.

3. The guarantee is valid for a period of 2 years starting from the purchase date of the device. Guarantee

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 fitted will not result in an extension of the guarantee period, and no new guarantee will become active for the work performed or parts fitted. This also applies when an on-site service is used.

4. In order to assert your guarantee claim, please send your defective device postage-free to the address

shown below. Please enclose either the original or a copy of your sales receipt or another dated proof of purchase. Please keep your sales receipt in a safe place, as it is your proof of purchase. It would help us if you could describe the nature of the problem in as much detail as possible. If the defect is covered by our guarantee then your device will either be repaired immediately and returned to you, or we will send you a new device. Of course, we are also happy offer a chargeable repair service for any defects which are not covered by the scope of this guarantee or for units which are no longer covered. To take advantage of this service, please send the device to our service address. Anleitung_BT_GW_190_D_SPK1__ 24.01.13 15:07 Seite 102103