Parkside 303284 1907 Assembly, Operating And Safety Instructions

IAN 303284_1907

FLUX CORED WIRE WELDER

SVÁŘEČKA NA PLNĚNOU

DRÁTOVOU ELEKTRODU

FÜLLDRAHT - SCHWEISSGERÄT

Assembly, operating and safety instructions

Translation of the original instructions

Návod k obsluze a bezpečnostní pokyny

Originální návod k obsluze

Bedienungs- und Sicherheitshinweise

Originalbetriebsanleitung

GB

TÖLTÖHUZALOS

HEGESZTŐKÉSZÜLÉK

Kezelési és biztonsági hivatkozások

Az eredeti használati utasítás fordítása

HU

VARILNI APARAT

NA POLNJENO ŽICO

Navodila za upravljanje in varnostna opozorila

Prevod originalnega navodila za uporabo

SI

ZVÁRAČKA

Návod na obsluhu a bezpečnostné upozornenia

Originálny návod na obsluhu

SK

CZ

DE AT CH

FLUX CORED WIRE WELDER PFDS 120 A2

SK

SI

CZ

HU

GB

Before reading, unfold the pages containing the illustrations and familiarise yourself with

all functions of the device.

HU

Olvasás előtt hajtsa ki az ábrát tartalmazó oldalt, és ezután ismerje meg a készülék

mindegyik funkcióját.

SI

Pred branjem odprite stran s slikami in se nato seznanite z vsemi funkcijami naprave.

CZ

Než začnete číst tento návod k obsluze, rozložte stránku s obrázky a seznamte se se všemi

funkcemi zařízení.

SK

Prv než začnete čítať tento návod, rozložte si stranu s obrázkami a potom sa oboznámte

so všetkými funkciami zariadenia.

DE AT CH

Klappen Sie vor dem Lesen die beiden Seiten mit den Abbildungen aus und machen Sie

sich anschließend mit allen Funktionen des Gerätes vertraut.

GB Operation and Safety Notes Page 5

HU Kezelési és biztonsági hivatkozások Oldal 25

SI Navodila za upravljanje in varnostna opozorila Stran 49

CZ Návod k obsluze a bezpečnostní pokyny Strana

70

SK Návod na obsluhu a bezpečnostné upozornenia Strana

90

DE / AT/ CH Montage-, Bedienungs- und Sicherheitshinweise Seite 111

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5GB

Legend of the pictograms used ............................................................. Page 6

Introduction ..................................................................................................... Page 7

Intended use ......................................................................................................... Page 7

Delivery contents ................................................................................................... Page 7

Parts description .................................................................................................... Page 7

Technical speciﬁcations .......................................................................................... Page 8

Safety notes .................................................................................................... Page 8

Danger sources from lightarc welding ...................................................................... Page 10

Welding-screen-speciﬁc safety notes ......................................................................... Page 13

Environments with increased electrical risks ............................................................... Page 13

Welding in conﬁned spaces .................................................................................... Page 14

Adding up of open-circuit voltages ........................................................................... Page 14

Use of shoulder slings............................................................................................. Page 15

Protective clothing .................................................................................................. Page 15

Protection from radiation and burns ......................................................................... Page 15

EMC device classiﬁcation ....................................................................................... Page 16

Before use ........................................................................................................ Page 16

Assembly .......................................................................................................... Page 17

Assembling the welding mask ................................................................................. Page 17

Inserting the ﬂux-cored wire ..................................................................................... Page 17

Commissioning ............................................................................................... Page 18

Switching the device on and off ............................................................................... Page 18

Setting the welding current ...................................................................................... Page 18

Setting the wire feed .............................................................................................. Page 18

Welding ............................................................................................................... Page 19

Creating a weld .................................................................................................... Page 20

Maintenance and cleaning ....................................................................... Page 21

Information about recycling and disposal ....................................... Page 22

EU Declaration of Conformity ................................................................. Page 22

Warranty and service information ...................................................... Page 23

Warranty conditions............................................................................................... Page 23

Warranty period and statutory warranty claims ......................................................... Page 23

Extent of warranty .................................................................................................. Page 23

Processing of warranty claims ................................................................................. Page 23

Service................................................................................................................ Page 24

Table of contents

6 GB

Legend of the pictograms used

Caution!

Read operating instructions!

Serious to fatal injuries

possible!

Mains input;

Number of phases and

Caution!

Danger of electric shock!

1 ~ 50Hz

Alternating current symbol

and nominal value of the

frequency.

Important note!

Do not dispose of electrical

devices in the household

waste!

Dispose of the packaging

and product in an environ-

mentally-friendly manner!

Do not use the device

outdoors and never use it

in rain!

Self-shielded ﬂux-core

arc welding.

Electrical shock from the

welding electrode may be

fatal!

IP21S Protection type.

Inhaling welding fumes may

endanger your health.

S

Suitable for welding under

increased electrical hazard.

Welding sparks may cause

explosion or ﬁre.

Single-phase transformer.

Arc welding may damage

the eyes and injure the skin.

H Insulation class.

Electromagnetic ﬁelds can

disrupt the function of

cardiac pacemakers.

U

2

Standardized operating

voltage.

Attention, possible dangers! I

1max

Greatest rated value

of the mains current.

X % Duty cycle. I

1eff

Effective value of the grea-

test mains current.

I

2

Rated value of the

welding current.

Earth terminal.

Wire feed drive. Made of recycling material.

7GB

Introduction

FLUX CORED WIRE WELDER

PFDS 120 A2

z Introduction

Congratulations!

You have purchased one of

our high-quality devices.

Familiarize yourself with the product before

using it for the ﬁrst time. Please read the

following operating instructions and safety

instructions carefully. Only trained persons

may set up this tool.

KEEP OUT OF THE REACH OF CHIL-

DREN!

z Intended use

The device is suitable for self-shielded

ﬂux-core welding using an appropriate wire.

No additional gas is required. The protective

gas is contained in powder form in the wire

itself. Thus, it is fed directly into the arc. This

means the device is not susceptible to wind

and can be used outside. Only suitable wire

electrodes may be used for the device. Inten-

ded use also involves compliance with the

safety instructions and assembly instructions

and the operating notes in the operating

instructions.

The applicable accident prevention provi-

sions must be strictly observed. The device

must not be used:

– in rooms with insufﬁcient ventilation,

– in explosive atmospheres,

– for the purpose of thawing pipes,

– in the vicinity of people with cardiac

pacemakers and

– in the vicinity of easily inﬂammable mate-

rials. Use the product only as described and

only for the speciﬁc applications as stated.

Keep these instructions in a safe place. En-

sure you hand over all documentation when

passing the product on to anyone else. Any

use that differs to the intended use as stated

above is prohibited and potentially dange-

rous. Damage caused by disregarding these

instructions or by misuse is not covered by

the warranty or any liability on the part of

the manufacturer.

Residual risk

Even if you operate the device as intended,

there will be residual risks. The following ris-

ks can occur in the context of the design and

construction of this ﬂux-core welding device:

– eye injuries caused by glare

– touching hot parts of the device or the

workpiece (burn injuries),

– in the case of insufﬁcient protection, risk of

accidents and burns due to ﬂying sparks

or slag,

– harmful emissions of smoke and gases cau-

sed by lack of air or insufﬁcient extraction

in closed rooms.

Reduce the residual risk by carefully using

the device as intended and observing all

instruction.

z Delivery contents

1 ﬂux cored wire welder PFDS 120 A2

1 torch nozzle (pre-assembled)

4 welding nozzles (1x 0.9 mm pre-assem-

bled;

1x 0.8 mm; 1x 0.6 mm; 1x 1.0 mm)

1 chipping hammer with wire brush

1 ﬂux-core wire Ø 0.9 mm / 450 g

1 welding mask

1 carrying strap

1 set of operating instructions

z Parts description

1

Cover wire feed unit

2

Carrying strap

3

Mains plug

4

Earth cable with earth terminal

5

Main switch ON/OFF

(incl. power indicator lamp)

8 GB

6

Overload protection control lamp

7

Rotary switch for welding current setting

8

Setting wheel for wire feed

9

Torch nozzle

10

Torch

11

Torch button

12

Hose package with direct connection

13

Welding nozzle (0.6 mm)

14

Welding nozzle (0.8 mm)

15

Welding nozzle (0.9 mm)

16

Welding nozzle (1.0 mm)

17

Flux-core wire spool (wire reel)

Ø 0.9 mm / 450 g

18

Chipping hammer with wire brush

19

Feed roll

20

Shield body

21

Dark welding lens

22

Handle

23

Welding mask after assembly

24

Mounting clip

25

Protective glass catch

26

Storage compartment for welding nozzles

27

Setting screw

28

Thrust roller unit

29

Roller holder

30

Feed roll holder

31

Wire outlet

32

Hose package holder

33

Torch neck

z Technical speciﬁcations

Power supply: 230 V~ / 50 Hz

(alternating current)

Welding current I

2

: 25 – 120 A

Duty cycle X: 10% at 120 A

Welding current,

60% at 49 A

Welding current

Open circuit voltage U

0

: 31 V

Greatest rated value

of the mains current: I

1 max.

17.5 A

Effective value of the greatest

rated current: I

1eff

5.9 A

Welding wire reel max.:

approx. 1000 g

Welding wire

diameter max.: 1.0 mm

Fuse: 16 A

Weight: 13.5 kg

Technical and visual changes may be made

in further development without notifying

the customer. All dimensions, notices and

speciﬁcations in the operating instructions

are therefore subject to change. Thus, legal

claims made as a result of the operating

instructions cannot be claimed.

z Safety notes

Please read the usage

instructions with care and

observe the notes des-

cribed. Familiarize yourself with

the device, its proper use and

the safety notes based on these

operating instructions. The rating

plate contains all technical data

of this welding device; please

learn about the technical features

of this device.

 This device can be used by

children 16 years and older

and also by persons with re-

duced physical, sensory or

mental capacities or a lack

of experience and knowled-

ge if they are supervised or

they have been instructed with

regard to the safe use of the

device and they understand

the dangers it presents. Do not

allow children to play with the

product. Cleaning and user

Introduction / Safety notes

9GB

maintenance must not be per-

formed by children without su-

pervision.

 Have repairs and/or mainte-

nance work only conducted by

qualiﬁed electricians.

 Only use the welding ca-

bles (PFDS 120 A2 H01N2-

D1x10 mm²) included in the

scope of delivery.

 The device should not be pla-

ced directly against the wall

in operation; it should not be

covered or caught between

other devices, so that there will

always be enough air ﬂowing

in through the ventilation slits.

Ensure that the device has

been properly connected to

the mains voltage. Avoid any

tension on the mains line. Pull

the mains plug from the socket

before setting up the device in

a different location.

 Always switch the device off

by the ON/OFF switch when

it is not in operation. Put down

the electrode holder on an in-

sulated support and only take

the electrode from the holder

after 15 minutes time to cool

off.

 Take note of the condition of

the welding cables, the elec-

trode holder and the ground

terminals. Wear of the insula-

tion and the current-conducting

parts may cause danger and

reduce the welding quality.

 Light-arc welding produces

sparks, melted metal parts and

smoke. Therefore, note: All

ﬂammable substances and/

or materials must be removed

from the workplace and its di-

rect vicinity.

 Ensure that the workplace is

ventilated.

 Do not weld on containers,

vessels or tubes that contain

or have contained ﬂammable

liquids or gases.

Avoid any

direct contact with the welding

current circuit. The idle volt-

age between the electrode

pliers and the ground terminal

may be dangerous; there is the

danger of electric shock.

 Do not store the device in a

moist or wet environment or in

rain. The protection provisions

IP21S apply to this.

 Protect your eyes with the in-

tended safety glasses (DIN

degree 9-10), which are to be

attached to the enclosed wel-

ding screen. Use gloves and

dry safety clothing that is free

of oil and grease to protect

Safety notes

10 GB

your skin from ultraviolet radia-

tion from the light arc.

Do not use

the welding current source to

unfreeze pipes.

Note:

 The light arc radiation may

damage the eyes and burn the

skin.

 Light arc welding produces

sparks and drips of melted me-

tal; the welded workpiece will

start to glow and remain hot

for a relatively long time. The-

refore, do not touch the wor-

kpiece with your uncovered

hands.

 Light-arc welding releases va-

pors that are hazardous to

health. Make sure that you do

not inhale these if possible.

 Protect yourself from the harm-

ful effects of the light arc and

keep any persons not involved

in the work at a distance of at

least 2m from the light arc.

ATTENTION!

 During operation of the wel-

ding unit, the voltage supply

to other consumers may be

impaired, depending on the

mains conditions at the con-

nection point. In doubt, contact

your power supply company.

 There may be function pro-

blems with other devices du-

ring operation of the welding

unit, e.g. hearing aids, car-

diac pacemakers, etc.

z Danger sources from

lightarc welding

There are a number of danger

sources from light-arc welding.

Therefore, it is particularly im-

portant that the welder observe

the following rules in order not to

endanger himself and others and

to avoid damage to persons and

the device.

 Have work on the mains-volta-

ge side, e.g. on cables, plugs,

etc. only performed by an

electrician according to the na-

tional and local provisions.

 Disconnect the welding unit

from the mains voltage at once

in case of accidents.

 If there are any electrical con-

tact voltages, switch off the de-

vice at once and have it chec-

ked by an electrician.

 Always observe good electri-

cal contacts on the welding

current side.

 Always wear insulating glo-

Safety notes

11GB

ves on both hands when wel-

ding. They protect from electric

shock (idle voltage of the wel-

ding current circuit), harmful

radiation (heat and UV radia-

tion) and from glowing metal

and splashes.

 Wear ﬁrm, insulating shoes.

The shoes should be insulating

even when wet. Low-cut shoes

are not suitable, since falling,

glowing metal drops may cau-

se burns.

 Wear suitable protective clo-

thing; do not wear any synthe-

tic clothes.

 Never look into the light arc

with unprotected eyes; only

use a welders' welding screen

with the required protective

glass according to DIN. The li-

ght arc emits light and heat ra-

diation that will cause blinding

or burns, as well as UV-radia-

tion. This invisible ultraviolet

radiation will cause conjunc-

tivitis, which is very painful

but will only become apparent

after a few hours, if sufﬁcient

protection is used.

UV radiation also causes burns

similar to sunburn on unprotec-

ted parts of the body.

 Persons and helpers near the

light arc must be informed of

the dangers as well and pro-

tected as necessary. If neces-

sary, set up protective walls.

 When welding, in particular in

small rooms, ensure sufﬁcient

fresh air supply, since smoke

and harmful gases will deve-

lop.

 No welding is permitted on

containers that are or have

been used to store gases,

fuels, mineral oils and similar

- even if they have been emp-

tied a long time ago -, since re-

sidues may cause explosion.

 Special provisions apply in

ﬁre-hazardous and potentially

explosive rooms.

 Welds subject to high stress

and required to meet cer-

tain safety requirements must

only be produced by specia-

lly trained and tested welders.

Examples of these are pressure

tanks, running rails, trailer cou-

plings, etc.

ATTENTION!

 Always connect the ground

terminal as close as possible

to the welding point so that the

welding current can take the

shortest possible path from the

electrode to the ground termi-

nal. Never connect the ground

Safety notes

12 GB

terminal to the housing of the

welding unit! Never connect

the ground terminal to any ear-

thed parts that are far away

from the workpiece, such as a

water pipe in a different cor-

ner of the room. This may cau-

se damage to the protective

ground system of the room in

which you are welding.

 Do not use the welding unit in

rain.

 Only put down the welding

unit in a level location.

 The output is calculated for

an ambiance temperature of

20°C. The welding time may

be reduced at higher tempera-

tures.

Danger from

electrical shock:

Electrical shock from a welding

electrode may be fatal. Never

weld in rain or snow. Wear dry

insulating gloves. Never touch

the electrode with your unprotec-

ted hand. Never wear any wet or

damaged gloves. Protect yourself

from electric shock by insulation

against the workpiece. Do not

open the device's housing.

Danger from welding

smoke:

Inhaling welding smoke may en-

danger health. Do not hold your

head into the smoke. Use facili-

ties in open areas. Use the vent

to discharge the smoke.

Danger from welding sparks:

Welding sparks may cause ex-

plosion or ﬁre. Keep ﬂammable

substances away when welding.

Do not weld next to ﬂammable

substances. Welding sparks may

cause ﬁres. Keep a ﬁre extingui-

sher at hand and an observer

who can use it at once nearby.

Do not weld on drums or any

closed containers.

Dangers from arc welding:

Arc welding may damage the

eyes and injure the skin. Wear

hat and goggles. Wear hearing

protection and a high shirt collar.

Wear welding protection helmet

and use the proper ﬁlter size.

Wear complete body protection.

Danger from electromagne-

tic ﬁelds:

Welding current produces electro-

magnetic ﬁelds. Never use toge-

ther with medical implants. Never

wind the welding lines around your

body. Combine welding lines.

Safety notes

13GB

z Welding-screen-speciﬁc

safety notes



Use a bright light source (e.g.

lighter) to convince yourself of

the proper function of the wel-

ding screen every time before

starting welding.

 Welding splashes may dama-

ge the protective screen. Ex-

change damaged or scratched

protective screens at once.

 Replace damaged or badly

contaminated or splashed com-

ponents without delay.

 The device must only be ope-

rated by persons who are at

least 16 years old.

 Familiarize yourself with the

safety provisions for welding.

For this, also observe the safe-

ty notes of your welding unit.

 Always put on the welding

screen when welding. Non-

use may cause severe injury to

your retina.

 Always wear pr

otective clo-

thing when welding.

 Never

use the welding screen

without the protective glass,

since the visual unit may

otherwise be damaged. The-

re is a risk of damage to the

eyes!

 Ex

change the protective glass

in time for a good view and

non-fatiguing work.

z Environments with in-

creased electrical risks

When using welding devices in

environments with increased elec-

trical risks, observe the following

safety notes.

Environments with increased elec-

trical risks include:

 Workplaces with conﬁned

spaces, so that the welder is

working in a conﬁned posture

(e.g. kneeling, sitting, lying)

and touches electrically con-

ductive parts;

 In workplaces that are who-

lly or partially surrounded by

electrically conductive ma-

terials, and where there is a

high risk from avoidable or ac-

cidental contact by the welder;

 In wet, moist or

hot workplaces, where humi-

dity or sweat will considerably

reduce the resistance of human

skin and the insulating pro-

perties of the protective equip-

ment.

Safety notes

14 GB

Metal ladders or scaffolding may

also create an environment with

an increased electrical risk.

When working such an environ-

ment, insulating supports and

interim layers must be used, as

well as long gloves and heat co-

verings made of leather or other

insulating materials, in order to

insulate your body against the

ground. The welding current

source must be located outside of

the work area or the electrically

conductive areas, and outside of

the welder's reach.

Additional protection from elec-

trical shock from the mains cu-

rrent in case of a fault may be

provided by the use of a residual

current circuit breaker operated

with a discharge current not ex-

ceeding 30 mA and supplying all

mains-operated devices nearby.

The residual current circuit

breaker must be suitable for any

current type.

Means for quick electrical dis-

connection of the welding current

source or the welding circuit (e.g.

emergency off device) must be

easily accessible.

When using welding units subject

to electrically hazardous condi-

tions, the output voltages of the

welding device in no-load ope-

ration must not be higher than

48 Volts (effective value). This

welding unit may be used in such

cases based on its output voltage.

z Welding in conﬁned spa-

ces

Welding in conﬁned

spaces may lead to a danger

from toxic gases (danger of suffo-

cation).

Welding is only permitted in

narrow spaces when instructed

persons are in the direct vicini-

ty so that they can take steps if

necessary.

Before starting welding, an ex-

pert must conduct an assessment

to determine the steps necessary

to ensure safe work, and which

precautions should be taken whi-

le actually welding.

z Adding up of open-circuit

voltages

If more than one welding current

source is in operation at the same

time, their open-circuit voltages

may add up and case an increa-

sed electrical risk. Welding cu-

Safety notes

15GB

rrent sources must be connected

to minimize this risk. The indivi-

dual welding current sources with

their separate controls and con-

nections must be clearly marked

to show what belongs to which

welding circuit.

z Use of shoulder slings

Welding is not permitted while

the welding current source or

wire feed unit are carried, e.g.

with a shoulder sling.

This is to prevent:

 The risk of losing one's balan-

ce when connected lines or ho-

ses are pulled

 The increased risk of electrical

shock since the welder tou-

ches the ground when using a

welding current source of ca-

tegory I with a housing that is

earthed through its protective

earth.

z Protective clothing



The welder's entire body must

be protected from radiation

and burns with the correspon-

ding clothing and facial protec-

tion during work. The following

steps should be oserved:

– Put on protective clothing

before welding.

– Wear gloves.

– Open windows to ensure air

supply.

– Wear protective goggles.

 Wear long gloves of a suita-

ble material (leather) on both

hands. They must be in an im-

peccable condition.

 Wear suitable aprons to pro-

tect your clothes from sparks

and burns. If the type of work,

such as overhead welding,

requires, safety garments and,

if necessary, head protection

must be worn.

z Protection from radiation

and burns



Put up a sign "Caution! Do not

look into the ﬂames!" at the

workplace to draw attention

to the danger to the eyes. The

workplaces must be shielded

so that any persons nearby are

protected as far as possible.

Unauthorized persons must be

kept away from the welding

work.

 The walls in direct proximi-

ty of stationary workplaces

should not be of a light color

Safety notes

16 GB

or glossy. Windows must be

secured against letting through

or reﬂecting radiation at least

up to head height, e.g. by a

suitable coating.

z EMC device classiﬁcation

As per the standard IEC 60974-

10, this welding device is a

welding unit with class A electro-

magnetic compatibility. Thus, it

complies with the corresponding

requirements for industrial and

domestic use. In residential areas,

it can be connected to the public

low-voltage supply systems.

Even if the ﬂux cored wire wel-

der complies with the emission

limit values of the standard, arc

welding devices can still result in

electromagnetic interferences in

sensitive systems and devices.

The user will be held responsible

for any interference caused by

the electric arc during welding

and must also take appropriate

safety measures. In doing so, the

user must observe the following:

– network, control, signal and

telecommunication lines

– computers and other micropro-

cessor-controlled devices

– TVs, radios and other playback

devices

– electronic and electrical safety

equipment

– people with cardiac pace-

makers or hearing aids

– measurement and calibration

devices

– interference immunity of other

equipment nearby

– the time at which the welding

work is carried out.

The following is recommended

to reduced possible interference

radiation:

– equip the mains connection

with a

mains ﬁlter

– regularly maintain the ﬂux

cored

wire welder and keep it in a

good condition

– welding cables should be

completely uncoiled and run as

close to parallel with the ﬂoor

as possible

– devices and systems that are

compromised by the interferen-

ce radiation must be removed

from the welding area or shiel-

ded.

z Before use

 Take all parts from the packaging and

check whether the ﬂux cored wire welder

or parts show any damage. If this is the

case, do not use the ﬂux-core wire wel-

ding device. Contact the manufacturer

via the indicated service address.

Safety notes / Before use

17GB

 Remove all protective ﬁlms and other

transport packaging.

 Check that the delivery is complete.

 The welding nozzles can be stowed

away in the storage compartment for

welding nozzles

26

.

z Assembly

z Assembling the welding

mask

 Place the dark welding glass

21

into the

mask with the writing on the top

20

(see

Fig. C). The writing on the dark welding

glass

21

must now be visible from the

front of the welding mask.

 Push the handle

22

from the inside into

the corresponding notch of the mask, un-

til it snaps into place (see Fig. D).

z Inserting the ﬂux-cored

wire

Always unplug the mains

plug from the mains socket prior to each

maintenance task or preparatory work in

order to prevent the risk of an electric shock,

injury or damage.

Note: Different welding wires will be nee-

ded depending on the application. Welding

wires with a diameter of 0.6 – 1.0 mm can

be used with this device.

Feed roll, welding nozzle and wire cross

section must be compatible with one another.

The device is suitable for wire reels weighing

up to maximum 1000 g.

 Unlock and open the cover of the wire

feed unit

1

by raising the threaded rod

along the elongated hole.

 Unlock the roller unit by turning the roller

mount

29

anti-clockwise (see Fig. F).

 Pull the roller mount

29

off the shaft (see

Fig. F).

Note: Make sure that the end of the wire

does not come loose and cause the roll to

roll out on its own. The end of the wire may

not be released until during assembly.

 Completely unpack the ﬂux-cored wire

welding reel

17

, so that it can unrolled

without difﬁculty. Do not release the wire

end yet (see Fig. G).

 Place the wire reel on the shaft.

Make sure that the roll unwinds on the

side of the

31

wire feed guide (see Fig.

G).

 Place the roll mount

29

back on and lock

it by pressing and turning it clockwise

(see Fig. G).

 Undo the adjustment screw

27

and swing

it upwards (see Fig. H).

 Turn the thrust roller unit

28

to the side

(see Fig. I).

 Loosen the feed roll holder

30

by turning

it anti-clockwise and pull it upwards and

off

(see Fig. J).

 On the top of the feed roll

19

, check

whether the appropriate wire thickness

is indicated. If necessary, the feed roll

has to be turned over or replaced. The

supplied welding wire (Ø 0.9 mm) must

be used in the feed roll

19

with the spe-

ciﬁed wire thickness of Ø 0.9 mm. The

wire must be positioned in the upper

groove!

 Put on the feed roll holder

30

again and

screw clockwise direction.

 Remove the torch nozzle

9

by pulling it

and turning it clockwise (see Fig. K).

 Unscrew the welding nozzle

15

(see Fig.

K).

 Guide the hose package

12

away from

the welding device as straight as possi-

ble (place it on the ﬂoor).

 Take the wire end out of the edge of the

spool (see Fig L).

 Trim the wire end with wire scissors or a

diagonal cutter in order to remove the da-

maged, bent ends of the wire (see Fig. L).

Before use / Assembly

18 GB

Note: The wire must be kept under ten-

sion the entire time in order to avoid re-

leasing and rolling out!

Therefore, it is recommended to carry out

the work with an additional person.

 Push the ﬂux-cored wire through the wire

feed guide

31

(see Fig.. M)

 Guide the wire along the feed roll

19

and push it into the hose package holder

32

(see Fig. N).

 Swivel the thrust roller unit

28

towards

the feed roll

19

(see Fig. O).

 Mount the adjustment screw

27

(see Fig.

O).

 Set the counter pressure with the adjust-

ment screw. The welding wire must be

ﬁrmly positioned between the thrust roller

and feed roll

19

in the upper guide wi-

thout being crushed (see Fig. O).

 Switch on the welding device on the

main

5

switch.

 Press the torch button

11

.

 Now the wire feed system pushes the

welding wire through the cable assembly

12

and the torch

10

.

 As soon as 1 – 2 cm of the wire protru-

des from the torch neck

33

, release the

torch button

11

again (see Fig. P).

 Switch off the welding device on the

main switch.

 Screw the welding nozzle

15

back on.

Make sure that the welding nozzle

15

matches the diameter of the welding

wire used (see Fig. Q). When using the

delivered welding wire (Ø 0.9 mm), the

welding nozzle

15

with the labeling 0.9

mm must be used.

 Push the torch nozzle

9

back on to the

torch neck with a turn to the right

33

(see

Fig. R).

Always unplug the mains

plug from the power socket prior to each

maintenance task or preparatory work in

order to prevent the risk of an electric shock,

injury or damage.

z Commissioning

z Switching the device on and

off

 Switch on the welding device on and off

the main switch

5

. If you do not intend

to use the welding device for an exten-

ded period, remove the plug from the

power socket. This is the only way to

completely de-energize the device.

z Setting the welding current

The rotary switch for the welding current

setting

7

on the front of the welding device

can be used to set the desired welding

currents.

The corresponding settings can be found in

the following table.

Voltage (V) Wire feed

Welding

current (A)

A 2 – 4 25 – 75

B 3 – 5 55 – 85

C 3 – 6 60 – 100

D 4 – 8 65 – 105

E 5 – 9 75 – 110

F 5 – 10 80 – 115

G 5 – 10 85 – 120

The necessary welding current depends on

the welding wire diameter used, the material

thickness and the desired penetration depth.

z Setting the wire feed

In order to generate a constant arc, the set-

ting wheel for the wire feed

8

can be used

to ﬁne-tune the wire feed. It is recommended

to use a setting in the middle range to start

Assembly / Commissioning

19GB

with, and then reduce or increase the speed

as required.

The necessary welding current depends on

the welding wire diameter used, the material

thickness and the desired penetration depth.

Similarly, the gaps to be bridged between

the workpieces to be welded must be obser-

ved.

Overload protection

The welding device is protected against over-

heating by means of an automatic protection

device (thermostat with automatic restart).

The protective device interrupts the overload

of the current circuit and the yellow overload

protection control lamp

6

illuminates.

 Allow the device to cool down (approx.

15 minutes) after activation of the protec-

tion device. As soon as the yellow over-

load protection control lamp

6

goes out,

the device is ready for operation again.

Welding mask

HEALTH HAZARD!

If you do not use the welding mask, harmful

UV radiation and heat emitted by the electric

arc could damage your eyes.

Always use the welding mask for welding

work.

z Welding

RISK OF BURNS!

Welded workpieces are very hot and can

cause burns.

Always use pliers to remove welded, hot

workpieces.

Please proceed as follows once

you have electrically connected the

welding device:

 Connect the earth cable to the workpiece

that is to be welded using the earth termi-

nal

4

. Ensure that there is good electrical

contact.

 The area to be welded on the workpiece

must be free of rust and paint.

 Choose the desired welding current and

wire feed depending on the welding wire

diameter, material thickness and desired

penetration depth.

 Switch the device on.

 Hold the welding mask

23

in front of your

face and guide the torch nozzle

9

to the

position on the workpiece that is to be

welded.

 Press the torch button

11

, in order to ge-

nerate an arc. Once the electric arc is bur-

ning, the device feeds wire into the weld

pool.

 If the welding lens is big enough, the

torch

10

is slowly guided along the desi-

red edge. The distance between the torch

nozzle and workpiece should be as small

as possible (it must not be greater than 10

mm).

 If necessary, oscillate a little to increase

the size of the weld pool. For inexperien-

ced welders, it is often difﬁcult initially to

create a decent electric arc. To do so, the

welding current and wire feed rate must be

set correctly.

 You can work out the ideal settings for the

welding current and the wire feed rate by

carrying out trial welds on a test piece. A

properly set electric arc has a mild, uniform

buzzing sound.

 The penetration depth (corresponds to the

depth of the weld in the material) should

be as deep as possible without allowing

the welding pool to fall through the wor-

kpiece.

 Reduce the wire feed rate in case of a

rough or hard rattle or switch to a higher

power level (increase welding current).

 If the wire feed rate is too high and/or the

welding current too low, the welding wire

will not melt properly. Consequently, the

welding wire repeatedly dips in the wel-

ding pool as far as the workpiece.

 A quiet, mufﬂed sound with a ﬂickering

electric arc indicates the wire feed is too

low.

Commissioning

20 GB

 Increase the wire feed rate or switch to

a lower welding current. If the welding

current is too high, the wire will melt

before it even reaches the weld pool.

This results in droplet formation on the

welding wire as well as splash and an

irregular electric arc.

 The slag must only be removed from the

weld after cooling off. To continue wel-

ding on an interrupted weld:

 First remove the slag at the starting point.

 The electric arc is ignited in the weld

groove, guided to the continuation point,

melted properly and ﬁnally the weld is

continued.

CAUTION! Note that the torch always

must be put down on an insulating

support after welding.

 Always switch off the welding device af-

ter completing welding work and during

breaks and pull the plug from the mains

socket.

z Creating a weld

Forehand welding

Push the torch forwards.

Result: The penetration depth is lower,

broader weld width, ﬂatter weld bead (visi-

ble surface of the weld) and greater fusion

error tolerance (defect in material fusion).

Backhand

welding

The torch is dragged from the weld. Result:

Greater penetration depth, narrower weld

width, higher weld bead and lower fusion

error tolerance.

Welded joints

There are two-basic types of joints in wel-

ding: Butt welds (outer edge) and ﬁllet welds

(inner edge and overlapping).

Butt welds

With butt welds of up to 2 mm, the weld

edges are completely brought together.

For greater thicknesses, please proceed as

per the following table:

S

Flat butt welds

Welds should be made without interruption

and with a sufﬁcient penetration depth. The-

refore, it is extremely important to prepare

them well. The factors that inﬂuence the qua-

lity of the weld result are: the amperage, the

distance between weld edges, the inclination

of the torch and the corresponding diameter

of the welding wire.

The steeper you hold the torch against the

workpiece, the higher the penetration depth

and vice versa.

T

To forestall or reduce deformations that can

happen during the material hardening process,

it is good to ﬁx the workpiece with a device.

Avoid stiffening the welded structure to prevent

cracks in the weld. These problems can be

avoided if there is a possibility of turning the

workpiece so that the weld can be carried out

in two passes running in opposite directions.

Commissioning

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