IW 100 - Welding machine Herkules - Free user manual and instructions

USER MANUAL IW 100 Herkules

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.

2. Layout and items supplied

1. Potentiometer for adjusting the welding cur-

rent / ON/OFF switch

2. Welding current scale

3. Indicator lamp for operation

4. Warning lamp for overheating

5. Positive quick-lock coupling

6. Negative quick-lock coupling

8. Cable with electrode holder

9. Cable with ground terminal

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!

Original operating instructions

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 Anl_IW_100_SPK7.indb 14Anl_IW_100_SPK7.indb 14 23.11.2015 16:14:3323.11.2015 16:14:33GB

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 welding sets for manual arc welding with limited on time.

Single-phase static frequency converter transfor- mer rectifi err 50 Hz Mains frequency

1 max Rated maximum mains current

1eff Eff ective value of the highest line current [A] Fuse with rated value in A

Rated idling voltage

Welding current Ø mm Electrode diameter Symbol for falling characteristic curve Symbol for manual arc welding with sheathed rod electrodes Single-phase mains connection Do not store or use the appliance in wet or damp conditions or in the rain. Thoroughly read and understand the operating instructions prior to using the welder. IP 21S Protection type

5. Fitting the carrying strap (Fig. 3/4)

Attach the carrying strap (11) as shown in Fig. 3/4.

Connecting to the mains power supply Before you connect the power cable (7) to the mains power supply, make sure that the data on the rating plate is the same as that for your mains supply. Danger! The mains plug may only be replaced by a qualifi ed electrician. Connecting the welding cable (Fig. 5) Danger! Always make sure the device is un- plugged before carrying out any connection work on the welding cable (8/9)! Connect the welding cable as shown in Fig. 5. To do so, connect the two connectors (12) on the electrode holder (8) and the ground terminal (9) to the corresponding quick-lock couplings (5/6) and lock the connec- tors (12) in place by turning them in a clockwise direction. The cable with the electrode holder (8) is nor- mally connected to the positive pole (5) and the cable with the ground terminal (9) to the negative pole (6). Switching ON/OFF (Fig. 2) To switch on the device, turn the potentiometer (1) in a clockwise direction from the zero position on the welding current scale (2). The indicator lamp for operation (3) then comes on. To switch off the device, turn the potentiometer (1) in a counter- clockwise direction back to the zero position on the welding current scale (2). The indicator lamp for operation (3) then goes out.

7. Welding preparations

Connect the earth terminal (9) direct to the part to be welded or to the support on which the part is resting. Ensure that the earth terminal is in direct contact with the part to be welded. You should therefore avoid coated surfaces and/or insulated materials. The electrode holder cable has a special 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.

Connect all the electrical connections for the pow- er supply and for the welding current circuit. Most coated electrodes are connected to the positive pole. However, some types of electrode have to be connected to the negative pole. Ensure that you observe the information supplied by the ma- nufacturer in relation to the type of electrode and correct polarity. Fit the welding cables (8/9) to the quick-lock couplings (5/6) accordingly. Then fasten the unsheathed end of the electrode in the electrode holder (8) and connect the ground ter- minal (9) to the part you wish to weld. Ensure that a good electric contact is made. Switch on the device and set the welding current, depending on the electrode used, using the potentiometer. 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 an arc. Check that you have the correct electrode and current strength on a test part. Electrode (Ø mm): .................Welding current (A) 1,6............................................................40-50 A 2 ............................................................40 - 80 A 2,5 .......................................................60 - 110 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 Anl_IW_100_SPK7.indb 16Anl_IW_100_SPK7.indb 16 23.11.2015 16:14:3323.11.2015 16:14:33GB

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 (4) 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.

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_IW_100_SPK7.indb 17Anl_IW_100_SPK7.indb 17 23.11.2015 16:14:3323.11.2015 16:14:33GB

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_IW_100_SPK7.indb 18Anl_IW_100_SPK7.indb 18 23.11.2015 16:14:3323.11.2015 16:14:33GB

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?

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_IW_100_SPK7.indb 20Anl_IW_100_SPK7.indb 20 23.11.2015 16:14:3323.11.2015 16:14:33FR

= dB (A); guaranteed L