WSE3200 - Welding machine SCHEPPACH - Free user manual and instructions

USER MANUAL WSE3200 SCHEPPACH

Cored-wire welding machine Translation of original instruction manual

Explanation of the symbols on the equipment Caution - Read the operating instructions to reduce the risk of inquiry EN 60974-1 European standard for welding sets for manual arc welding with limited on time.

Single-phase transformer Symbol for self-shielding cored-wire welding Suitable for welding with increased electric risk Power input; phase number, as well as Alternating current symbol and rated value of the frequency

Rated idling voltage

max Rated maximum mains current

Effective value of the highest line current [A] IP21S Protection type

Insulation class Caution! Risk of electric shock! Inhaling welding smoke can be hazardous to your health. Electromagnetic fields can interfere with the functionality of pacemakers. Welding sparks can cause an explosion or fire. Arc rays can damage the eyes and injure the skin. Do not use the device outdoors and never in rain! Do not throw old equipment away with household waste. The product complies with the applicable European directives. www.scheppach.com / [e-mail] / +(49)-08223-4002-99 / +(49)-08223-4002-58

Table of contents: Page:

4. Hose assembly with direct connection

5. Earth cable with earth clamp

6. Locking mechanism

7. Carry strap (already attached)

8. Cover for wire feeding device

12. Switch for setting the welding current

15. Adjusting wheel for wire feed (potentiometer)

3. Scope of delivery

2. Hose assembly, complete

• Open the packaging and remove the device care- fully.

• Remove the packaging material as well as the packaging and transport bracing (if available).

• Check that the delivery is complete.

• Check the device and accessory parts for transport damage.

• If possible, store the packaging until the warranty period has expired. ATTENTION The device and packaging materials are not toys! Children must not be allowed to play with plastic bags, film and small parts! There is a risk of swallow- ing and suffocation! Important information Please read the directions for use carefully and ob- serve the information provided. It is important to con- sult these instructions in order to acquaint yourself with the machine, its proper use and safety precau- tions.

Manufacturer: scheppach Fabrikation von Holzbearbeitungsmaschinen GmbH Günzburger Straße 69 D-89335 Ichenhausen Dear customer, We hope your new tool brings you much enjoyment and success. Note: According to the applicable product liability laws, the manufacturer of the device does not assume liability for damages to the product or damages caused by the product that occurs due to:

• Non-compliance of the operating instructions,

• Repairs by third parties, not by authorized service technicians,

• Installation and replacement of non-original spare parts,

• Application other than specified,

• A breakdown of the electrical system that occurs due to the non-compliance of the electric regu- lations and VDE regulations 0100, DIN 57113 / VDE0113. We recommend: Read through the complete text in the operating in- structions before installing and commissioning the device. The operating instructions are intended to help the user to become familiar with the machine and take advantage of its application possibilities in accord- ance with the recommendations. The operating instructions contain important informa- tion on how to operate the machine safely, profes- sionally and economically, how to avoid danger, cost- ly repairs, reduce downtimes and how to increase reliability and service life of the machine. In addition to the safety regulations in the operating instructions, you have to meet the applicable regula- tions that apply for the operation of the machine in your country. Keep the operating instructions package with the machine at all times and store it in a plastic cover to protect it from dirt and moisture. Read the instruction manual each time before operating the machine and carefully follow its information. The machine can only be operated by persons who were instructed con- cerning the operation of the machine and who are in- formed about the associated dangers. The minimum age requirement must be complied with. In addition to the safety notices contained in this operating manual and the particular instructions for your country, the generally recognised technical reg- ulations for the operation of identical devices must be complied with. We accept no liability for damage or accidents which arise due to non-observance of these instructions and the safety information. www.scheppach.com / [e-mail] / +(49)-08223-4002-99 / +(49)-08223-4002-58

• Always pay attention and watch what you are do- ing. Never carry out work with this device if you are distracted or under the influence of drugs, alcohol or medication. Just a moment of carelessness when using this device can result in serious acci- dents and injuries. Remember!

• The radiation from the arc can damage your eyes and cause burns on skin.

• Arc welding generates sparks and droplets of molten metal; the welded workpiece may start to glow and will remain very hot for a relatively long period of time.

• Arc welding releases vapors that may be harmful.

• Every electric shock is potentially fatal.

• Do not approach the arc within a radius of 15 m unprotected.

• Protect yourself (and others around you) against the possible hazardous effects of the arc.

• Warning: Depending on the mains connection con- ditions at the connection point of the welding set, other consumers connected to the mains may suf- fer faults.

• Protect yourself and others in the vicinity from the hazardous effects of the electric arc. Important! If the supply mains and circuits are overloaded, other consumers may suffer interference during the weld- ing work. If you have any doubts, contact your elec- tricity supply company. Sources of danger during arc welding Arc welding results in a number of sources of dan- ger. It is therefore particularly important for the welder to comply with the following rules so as not to place himself or others in danger and to avoid endangering people and equipment.

• Have all work on the mains voltage system, for ex- ample on cables, plugs, sockets, etc., performed only by trained electricians. This particularly ap- plies to configuring intermediate cables.

• If an accident occurs, disconnect the welding pow- er source from the mains immediately.

• If electric touch voltages occur, switch off the weld- ing set immediately and have it checked by an ex- pert.

• Always check for good electrical contacts on the welding current side.

• Wear insulating gloves on both hands for welding. These offer protection from electric shocks (idling voltage in the welding circuit), harmful radiation (Heat and UV radiation) and from glowing metal and slag spatter.

• Wear firm, insulated footwear. Your shoes should also protect you in wet conditions. Open toe foot- wear is not suitable since falling droplets of glowing metal will cause burns.

• Wear suitable clothing, do not wear synthetic clothes.

4. Safety information

Please note IMPORTANT Use this equipment only for the purpose for which it is designed, as described in these instructions. Handling this system incorrectly may be hazardous for persons, animals and property. The user of this system is responsible for his/her own safety and for the safety of others. Read these operating instruc- tions and follow all the regulations.

• This device is not designed to be operated by per- sons (including children) with impaired physical, sensory or mental capabilities, or who have insuf- ficient experience and/or insufficient knowledge unless they are being supervised by a person who is responsible for their safety or they are receiving instructions about how this device is to be used. It is forbidden for children to use this device!

• Repairs and/or maintenance work must be left strictly to qualified personnel.

• For your own safety, use only accessories and ad- ditional equipment that are expressly cited in the operating manual or have been recommended by the manufacturer.

• Ensure that the appliance is looked after prop- erly. To ensure that sufficient air can be drawn in through the ventilation slits, the appliance should not be constricted or placed next to a wall while it is operating.

• Make sure that the appliance is correctly connect- ed to the mains supply. Do not subject the mains lead to any tensile stress.

• Unplug the appliance before you change its posi- tion.

• Pay attention to the condition of the welding cable, the contact tip, the burner and the earthing clamp. Wear on the insulation or on the parts carrying the electrical power can lead to a hazardous situation and reduce the quality of the welding work.

• Arc welding generates sparks, molten metal par- ticles and smoke, so the following is required: Re- move all inflammable substances and/or materials from the working area.

• Ensure that there is adequate ventilation.

• Do not weld on tanks, vessels or pipes that have contained inflammable liquids or gases.

• Avoid direct contact with the welding circuit. The off-load voltage arising between the contact tip and the earthing clamp can be dangerous.

• Do not store or use the appliance in wet or damp conditions or in the rain.

• Protect your eyes with specially designed goggles (DIN EN 166 & DIN EN 169 degree of protection 9-10). Wear gloves and dry safety clothing that are not contaminated by any oil or grease to ensure that your skin is not exposed to ultraviolet radiation from the arc.

• While working, the welder must protect his entire body from radiation and burns by wearing suitable clothing and a face guard.

• Slip-on gloves made of a suitable material (leather) must be worn on both hands. They must be in per- fect condition.

• Suitable aprons must be worn to protect clothing from sparks and burns. A safety suit and, if neces- sary, head protection must be worn if required by the type of work in question, e.g. overhead welding.

• The protective clothing used as well as all acces- sories must be in compliance 89/686/EWG with the “Personal safety equipment” EU Directive. Protection from radiation and burns

• Provide information about the risk to eyes at the working site in the form of a poster with the wording “Caution – do not look at the flames”. Workplaces are to be screened off wherever possible so that personnel in the vicinity are protected. Unauthor- ized persons are to be kept away from the welding work.

• The walls in the immediate vicinity of station- ary workplaces should not have a light color or a sheen. Windows up to head height are to be pro- tected against radiation passing through them or reflecting off them, for example by coating them with a suitable paint.

• Flying welding sparks can cause painful burns and so the following instructions must be observed: - Always wear a protective leather apron - Always wear leather gloves - Wear suitable headgear for overhead welding work - Always wear sturdy and insulated footwear Risk of injury from flying pieces of slag The slag is hard and brittle once solidified. After- wards, this will be smashed to small sharp-edged pieces with the slag hammer. These can cause dan- gerous eye injuries. For this reason, protect your eyes with suitable protective goggles when removing the slag. Indirect electrical contact Injuries due to live parts in the event of electrical parts being opened up or being defective. Always pull out the mains plug before carrying out maintenance work. Only operate via an RCD breaker.

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. Please note that our equipment has not been de- signed for use in commercial, trade or industrial ap- plications. Our warranty will be voided if the machine is used in commercial, trade or industrial businesses or for equivalent purposes.

• Do not look into the arc with unprotected eyes, use only a welding safety shield with the proper safety glass in compliance with (DIN EN 166 & DIN EN 169 degree of protection 9-10) standards. In addi- tion to light and heat, which may cause dazzling and burns, the arc also gives off UV radiation. With- out proper protection, this invisible ultraviolet radia- tion causes very painful conjunctivitis, which will only be noticeable several hours later. In addition, UV radiation will cause sunburn-type symptoms on unprotected parts of the body.

• Also, persons in the vicinity of the electric arc must be advised of the hazard and equipped with the necessary protective equipment. Protective parti- tions or walls may have to be erected.

• Ensure adequate ventilation for welding, particular- ly in small rooms since the process causes smoke and harmful gases.

• Do not carry out any welding work on tanks that have been used to store gases, fuels, mineral oil or the like, even if they have been empty for a lengthy period of time, since any residue will result in a dan- ger of explosion.

• Special regulations apply in areas where there is a potential risk of fire and/or explosion.

• Welds that are exposed to large stresses and must comply with safety requirements may only be com- pleted by specially trained and approved welders. Examples of such welds include pressure vessels, rails, trailer hitches, etc.

• Note: It must be noted that the protective conduc- tor in electrical systems of appliances may be de- stroyed by the welding current in the event of neg- ligence, for example if the earth terminal is placed on the welding set casing to which the protective conductor of the electrical system is connected. The welding work is completed on a machine with a protective conductor connection.

• The fuses on the supply cables to the mains sock- ets must comply with the relevant regulations. To comply with these regulations, only fuses or circuit breakers suitable for the cross-section of the ca- bles may be used. The use of too high a fuse may result in the cable burning and fire damage to the building. Constricted and wet areas When working in constricted, wet or hot areas, use insulating supports and intermediate layers as well as slip-on gloves made of leather or other nonconduc- tive materials to insulate your body against the floor, walls, conductive parts of the machine and the like. If you use small welding transformers for welding in places with an increase electrical risk, for example in constricted areas with conductive walls, (tanks, pipes, etc.), in wet areas (which make work clothes wet) and in hot areas (perspiration on work clothes), the output voltage of the welding set when idling must not exceed 48 V (effective value). Therefore, the ap- pliance may not be used for these purposes because its output voltage is higher than this. www.scheppach.com / [e-mail] / +(49)-08223-4002-99 / +(49)-08223-4002-58

• Now press the adjusting screw (7b) upwards and slide the pressing roller (7a) to the side (Fig. 9).

• Unscrew cover (7d) to check the feed roller (10a).

• The corresponding wire thickness is marked on the top side of the feed roller (fig. 10). If the size stipulated there does not match with the actual wire thickness, turn the feed roller or replace it if neces- sary.

• Now take the wire end off the edge of the reel and trim it with side cutters or wire shears. Ensure that the wire does not become loose or unroll.

• Now feed the wire through the wire guide (7c) along the feed roller and into the hose assembly fitting.

• Tension the pressing roller (7a) again.

• Remove the burner nozzle (1) by simply pulling it off. Unscrew the contact tip (11) too.

• Route the hose assembly (4) as straight as possible as it runs away from the welding machine.

• Switch the welding machine on by setting the on/off switch (13) to the “ON” position.

• Now press the burner button (2) to activate the wire feed. Press the button until the wire emerges from the front of the burner. When doing so, pay atten- tion to the feed roller. If this is slipping, re-tension the pressing roller (7a) with the adjusting screw (7b).

• Do not touch the welding wiring during this proce- dure as there is a risk of injury with this!

• As soon as the wire projects ca. 5 cm from the front, release the burner button again. Then switch the machine off again and pull out the mains plug!

• Now, screw the contact tip (11) on again and ensure that the contact tip matches with the diameter of the welding wire used.

• Finally, re-attach the burner nozzle (1).

On / Off switch Switch the device on by setting the on/off switch (13) to “ON”. The switch (13) illuminates. Switch the de- vice off by setting the on/off switch (13) to “OFF”. The switch (13) is no longer illuminated. Welding current The desired welding current can be selected with the switch (12). If the switch is set to the top position, the welding current is 90A and the duty cycle is 10%. If switched to the bottom position, the welding current is 45A with a duty cycle of 60%. Wire feed In order to achieve constant welding, the adjustment wheel (15) can be used for the fine adjustment of the wire feed. It is recommended to start with a medium setting and then reduce or increase the feed rate if required. 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 com- bination of magnetic fields and high electric currents does not affect their devices.

Duty cycle X 90 A ~ 10% 45 A ~ 60% Safeguarding 16 A Protection category H Insulation class IP 21S Type of cooling AF Welding wire Ø 0,6 - 0,9 mm Weight of the welding wire reel max. 1 kg weight 12.5 kg Subject to technical changes! Duty cycle X Based on a ten minute period for example, this means that it is permitted to weld continuously at 60% for six minutes and then the machine must be allowed to cool for four minutes.

• Place the ancillary glass (20) in the recess in the welding mask. Then place the protective glass (21) on the ancillary glass and fasten it in place with the plastic frame (17).

• Fasten the frame in place by turning the fasteners (3a).

• Fasten the handle (19) onto the welding mask using the three knurled screws and nuts (18). Installing the welding wire reel (fig. 6 - 13)

• Open the cover for the wire feeding device (8) by turning the lock (6) clockwise and folding the cover upwards.

• Now you can see the wire feeding device and the welding wire reel (fig. 7).

• Unlock the reel mounting by turning it 90° counter- clockwise and then pull it off the shaft.

• Remove all packaging from the wire reel (10) so that it can unroll freely.

• Fit the wire reel (10) onto the reel mounting. Ensure that the reel will unwind on the same side as the wire guide (7c). www.scheppach.com / [e-mail] / +(49)-08223-4002-99 / +(49)-08223-4002-58

• A well adjusted electric arc creates a soft, even buzzing sound. The penetration depth should be as deep as possible but the weld pool should not drop through the workpiece.

• If there is a rough or hard crackling sound, reduce the wire feed rate or switch to a higher power level (increase welding current). If the wire feed rate is too high and/or the welding current is too low, the welding wire cannot melt properly and repeatedly dips into the weld pool on the workpiece.

• A quiet, muffled sound with a flickering electric arc indicates that the wire feed rate is too low. Increase the wire feed rate or switch to the lower welding current setting. If the welding current is too high, the wire melts before it has even reached the weld pool. This results in drops forming on the welding wire as well as a sputtering and unsettled arc.

• The slag should only be removed from the seam once it has cooled. If continuing with an interrupted weld seam, the slag should first be removed from the point of attachment. The electric arc is struck in the weld groove, guided to the connection point, properly melted there and then continued along the weld seam.

• Attention! Always used tongs to move hot, welded workpieces. Ensure that the burner is always set down on an insulated surface after welding. Always switch the welding machine off and pull out the plug after the welding work is complete and during breaks.

10. Electrical connection

The electrical motor installed is connected and ready for operation. The connection complies with the applicable VDE and DIN provisions. The customer‘s mains connection as well as the extension cable used must also comply with these regulations. Damaged electrical connection cable The insulation on electrical connection cables is of- ten damaged. This may have the following causes:

• Passage points, where connection cables are passed through windows or doors.

• Kinks where the connection cable has been im- properly fastened or routed.

• Places where the connection cables have been cut due to being driven over.

• Insulation damage due to being ripped out of the wall outlet.

• Cracks due to the insulation ageing. Such damaged electrical connection cables must not be used and are life-threatening due to the insula- tion damage. Check the electrical connection cables for damage regularly. Make sure that the connection cable does not hang on the power network during the inspection. Electrical connection cables must comply with the applicable VDE and DIN provisions. Only use con- nection cables with the marking „H05VV-F“. Overload protection The welding machine is equipped with a thermal pro- tective device, which interrupts the welding current supply automatically as soon as a higher temperature is reached. In this case, the indicator lamp (14) illumi- nates. If the overload protection device is triggered, allow to device to cool down for ca. 15 min. Once the indicator lamp has extinguished, the device is ready for use again.

Connecting to the mains power supply Before you connect the power cable to the mains power supply, make sure that the data on the rating plate is the same as that for your mains supply. Connect the machine to a properly installed protec- tive contact socket, with at least 16A circuit breaker. Danger! The mains plug may only be replaced by a qualified electrician. Welding preparations Connect the earth terminal (5) 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. Welding

• Put on appropriate clothing for welding, see „Pro- tective clothing“ point.

• Switch the device on.

• Select the desired welding current and the wire feed rate to suit the welding wire diameter, the ma- terial thickness and the desired penetration depth.

• Hold the welding mask in front of your face and guide the burner nozzle to the point on the work- piece that you wish to weld and actuate the burner switch to create the electric arc.

• Once the arc is lit, the device feeds wire into the weld pool. If the spot is large enough, guide the burner slowly along the desired edge. The distance between the burner nozzle and the workpiece should be kept as short as possible (never larger than 10 mm). If necessary, swing the burner nozzle slightly in order to enlarge the weld pool a little.

• For those with little experience, the initial difficulty lies in creating a stable electric arc. This means the correct setting of welding current and wire feed rate.

• The optimum setting of the welding current and wire feed rate can be determined by trial and error on a test piece. www.scheppach.com / [e-mail] / +(49)-08223-4002-99 / +(49)-08223-4002-58

Store the device and its accessories in a dark, dry and frost-proof place that is inaccessible to children. The optimum storage temperature is between 5 and 30˚C. Store the electrical tool in its original packaging. Cover the electrical tool in order to protect it from dust and moisture. Store the operating manual with the electrical tool.

13. Disposal and recycling

The equipment is supplied in packaging to prevent it from being damaged in transit. The raw materials in this packaging can be reused or recycled. Never place batteries in your household refuse, in re or in water. Batteries should be collected, recycled or dis- posed of by environment-friendly means. The equipment and its accessories are made of vari- ous types of material, such as metal and plastic. De- fective components must be disposed of as special waste. Ask your dealer or your local council. Old devices must not be disposed of with house- hold waste! This symbol indicates that this product must not be disposed of together with domestic waste in compliance with the Directive (2012/19/EU) pertaining to waste electrical and electronic equipment (WEEE). This product must be disposed of at a designated collection point. This can occur, for example, by handing it in at an author- ised collecting point for the recycling of waste elec- trical and electronic equipment. Improper handling of waste equipment may have negative consequenc- es for the environment and human health due to po- tentially hazardous substances that are often con- tained in electrical and electronic equipment. By properly disposing of this product, you are also con- tributing to the e󰀨ective use of natural resources. You can obtain information on collection points for waste equipment from your municipal administration, public waste disposal authority, an authorised body for the disposal of waste electrical and electronic equipment or your waste disposal company. The printing of the type designation on the connec- tion cable is mandatory. AC motor

• The mains voltage must be 230 V~

• Extension cables up to 25 m long must have a cross-section of 1.5 mm

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. Connections and repairs of electrical equipment may only be carried out by an electrician. Please provide the following information in the event of any enquiries: Type of current for the motor

11. Maintenance and care

Danger! Always pull out the mains power plug before starting any cleaning work. Cleaning Keep all safety devices, air vents and the motor hous- ing free of dirt and dust as far as possible. Wipe the equipment with a clean cloth or blow it with com- pressed air at low pressure. We recommend that you clean the device immedi- ately 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 attack the plastic parts of the equipment. Ensure that no water can seep into the device. The ingress of water into an electric tool in- creases the risk of an electric shock. Maintenance There are no parts inside the equipment which re- quire additional maintenance. Service information Please note that the following parts of this product are subject to normal or natural wear and that the fol- lowing parts are therefore also required for use as consumables. Wear parts*: Earth clamp, burner nozzle, contact tip

• Not necessarily included in the scope of delivery! www.scheppach.com / [e-mail] / +(49)-08223-4002-99 / +(49)-08223-4002-58

The table below contains a list of error symptoms and explains what you can do to solve the problem if your tool fails to work properly. If the problem persists after working through the list, please contact your nearest service workshop. Malfunction Possible cause Remedy The machine will not switch on No mains voltage Check the socket, mains cable, cable, mains plug; have these repaired by a qualied electrician if nec- essary. The main fuse has tripped Check the main fuse On / o󰀨 switch defective Repair by customer service department Motor defective Repair by customer service department No ignition spark Earth clamp not connected to the device / Earth clamp not tted on the workpiece Connect the earth clamp to the welding machine / Fit the earth clamp on the workpiece www.scheppach.com / [e-mail] / +(49)-08223-4002-99 / +(49)-08223-4002-58