Parkside PFDS 33 A1 Original Instructions Manual

Category
Welding System
Type
Original Instructions Manual
IAN 280331
FLUX-CORED WIRE WELDER PFDS 33 A1
FÜLLDRAHT-SCHWEISSGERÄT
Originalbetriebsanleitung
FLUX-CORED WIRE WELDER
Translation of the original instructions
GB / IE/NI Translation of the original instructions Page 1
DE / AT / CH Originalbetriebsanleitung Seite 17
Before reading, unfold both pages containing illustrations and familiarise yourself with all functions of the
device.
Klappen Sie vor dem Lesen die beiden Seiten mit den Abbildungen aus und machen Sie sich anschließend
mit allen Funktionen des Gerätes vertraut.
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PFDS 33 A1
Contents
Introduction .................................2
Intended use ........................................2
Residual risk.........................................2
Features ............................................2
Package contents.....................................2
Technical details .....................................3
Rating plate and explanation of symbols ..................3
Safety......................................4
Basic safety instructions................................4
Special safety instructions ..............................5
Complementary safety instructions .......................5
Potential hazards ............................6
Risk of injury due to electric shock........................6
Confined spaces and hot rooms .........................6
Accident risks due to poor air supply in confined spaces ......6
Protective clothing ....................................6
Protection against radiation and burns ....................7
Risk of burns due to flying sparks ........................7
Risk of accidents due to spattering slag....................7
Risk of fire due to flying sparks ..........................7
Risk of explosion .....................................7
EMC appliance classification....................7
Unpacking and checking the package contents....8
Assembly ...................................8
Fitting the welding mask ...............................8
Filling with flux-cored wire ..............................8
Operation..................................11
Switching the appliance on and off......................11
Setting the welding current ............................11
Adjusting the wire feed ...............................11
Overload protection .................................11
Welding mask . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Welding...........................................11
Weld types.................................12
Forehand welding ...................................12
Backhand welding...................................12
Welded joints ......................................12
Butt welds .........................................12
Flat butt welds . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Welds on an outer edge ..............................12
Welds on an inner edge ..............................13
Overlap welds......................................13
Cleaning and care ...........................13
Wire feed .........................................13
Cable assembly.....................................13
Welder............................................13
Troubleshooting.............................14
Disposal ...................................15
Kompernass Handels GmbH warranty..........15
Service ....................................15
Importer...................................15
Translation of the original Conformity Declaration 16
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FLUX-CORED WIRE WELDER PFDS 33 A1
Introduction
Congratulations on the purchase of your new appliance. You have selected
a high-quality product. The operating instructions are part of this product.
They contain important information about safety, usage and disposal.
Before using the product, please familiarise yourself with all operating and
safety instructions. Use the product only as described and for the range of
applications specified. Please also pass these operating instructions on to
any future owner.
Intended use
The appliance is suitable for self-shielded flux-core welding using an
appropriate wire. No additional gas is required. The protective gas is
contained in powdered form in the wire itself, is thus fed directly into the
arc and means that the appliance is not susceptible to wind and can be
used outside.
Only the filler wire designed for this appliance may be used.
Proper use also involves compliance with the safety instructions as well as
the assembly instruction and the operating notes in the operating instruc-
tions.
Comply exactly with the applicable accident prevention regulations.
The appliance may not be used:
in rooms with insufficient ventilation,
in damp or wet environments,
in explosive atmospheres,
for the purpose of thawing pipes,
in the vicinity of people with heart pacemakers and
in the vicinity of flammable materials.
Use this appliance only as described in this instruction manual. All other
uses are deemed to be improper and may result in property damage or
even in personal injury.
The manufacturer is not liable for damages caused by improper or incorrect
use.
Residual risk
Even if you operate this appliance properly, there will still be residual risks.
The following risks can occur in the context of the design and construction
of this flux-core welder:
Eye injuries from flashes,
Touching hot parts of the appliance or the workpiece (burns),
In the case of insufficient protection, risk of accidents and burns due to
flying sparks or slag,
Harmful emissions of smoke and gases in the event of poor ventilation
or insufficient extraction in closed rooms.
Reduce the residual risks by using the appliance carefully and in accordance
with all the instructions.
Features
Cover wire feed unit
Carrying strap
Catch
Mains plug
Earth cable with earth clamp
Cable assembly with direct connection
Torch button
Torch
Steel sleeve
Setting wheel for wire feed
MIN/MAX switch for welding current
1/2 switch for welding current
Main switch ON/OFF (incl. power indicator)
Overload protection control lamp
Torch nozzle (1.0 mm)
Torch nozzle (0.8 mm)
Flux-core wire spool (wire roll) Ø 0.9 mm/510 g
Chipping hammer with
steel brush
Welding mask after assembly, consisting of:
Protective plate
Protective glass catch
Mounting clip
Dark welding lens
Handle
Package contents
1 flux-cored wire welder PFDS 33 A1
1 steel sleeve (pre-assembled)
3 weld nozzles ( 1 x 1.0mm pre-assembled; 1 x 0.8mm; 1 x 1.0mm)
1 chipping hammer with
steel brush
1 flux-core wire Ø 0.9 mm/510 g
1 welding mask
1 carrying strap
1 set of operating instructions
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PFDS 33 A1
Technical details
Model: flux-cored wire welder PFDS 33 A1
Voltage U
1
: 230 V
~
/ 50 Hz
(alternating current)
Welding current I
2
: 48 A/90 A
No-load voltage U
0
: 27.5 V
Protection rating: IP 21S
Insulation class: H
Weight: 12.7 kg
Welding wire: Ø 0.7/0.8/0.9/1.0mm
Welding wire: approx. 450 g
Welding current:
Material thickness
1.0–2.0 mm: with Ø 0.7 / 0.8 mm welding wire,
welding current 48 A – 60 A
Material thickness
2.0–6.0 mm: with Ø 0.8/0.9/1.0mm welding wire,
welding current 70 A – 90 A
Duty cycle X: 10% at 90 A welding current
60% at 48 A welding current
Rating plate and explanation of symbols
PFDS 33 A1 S/N:
EN 60974-1:2012
EN 60974-10:2014/A1:2015
Class A
~
50 Hz
48 A / 16 V – 90 A / 18.5 V
X 10 % 60 %
U
0
= 27.5 V
I
2
90 A 48 A
U
2
18.5 V 16 V
1
~
50 Hz U
1
= 230 V I
1max
= 13 A I
1eff
= 4.8 A
IP21S 12.7 kg
Single-phase transformer
U
0
Nominal no-load voltage
Ø mm
Permissible flux-core wire diameter
Symbol for self-shielded flux-core welder
I
2
Rated value of the welding current
X
Duty cycle in %
U
2
Standardised working voltage
1
~
50 Hz
Mwains supply, number of phases alternating
current symbol and rated value of the frequency
16A
Nominal value of the required mains fuse
U
1
Rated value of the mains voltage
I
1
max.
Max. rated value of the mains current
I
1
eff
Effective value of the max. mains current (A)
IP21S
Protection class
H
Insulation class
12.7 kg
Weight of the appliance
Follow the safety regulations
Read the operating instructions
Do not store or use the appliance in wet environ-
ment or in rain
Symbol for welding power sources that are suit-
able for welding in environments with increased
electrical risks.
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Wear ear protection!
Wear protective goggles!
Wear a dust mask!
Wear protective gloves!
Use the welding mask!
Wear protective clothing!
Wear protective shoes!
Caution! Read instruction manual!
Electric shock from welding electrode can kill!
Breathing welding fumes can be hazardous to
your health!
Welding sparks can cause explosion or fire!
Arc rays can burn eyes and injure skin!
Electromagnetic field can cause pacemaker
malfunction!
Explanation of symbols
The following symbols and signal words are used in these instructions,
on the flux-core welder or on the packaging.
HAZARD!This signal word indicates a hazard
with a high degree of risk that will result in death
or serious injury if not prevented.
WARNING!This signal word indicates a hazard
with a medium level of risk which could lead to
death or serious injury if not prevented.
CAUTION!This signal word indicates a hazard
with a low level of risk which could result in a
minor or moderate injury if not prevented.
NOTE!This signal word warns of possible
damage to property or gives useful additional
information on assembly or operation.
Safety
Basic safety instructions
WARNING! RISK OF ELECTROCUTION!
Dangers for children and persons with limited physical, sensory or
mental capabilities (for example, partially handicapped people or
older people with limitations to their physical or mental abilities) or
lack of experience and knowledge (for example, older children).
The flux-core welder may only be used by adults.
Children should be supervised to ensure they do not play with the flux-
core welder.
Keep children away from the packaging materials and small components.
Swallowing can lead to a risk of suffocation.
Ensure that the appliance is suitably maintained.
Maintenance and/or repairs may only be performed by qualified
persons.
In addition to the notices in these operating instructions, all general
safety and accident prevention legislation must also be complied with.
Always pay attention to what you are doing and always be alert. Do
not work with the flux-core welder if you are distracted or under the in-
fluence of drugs, alcohol or medication. Just one moment of inattention
while operating this appliance may result in an accident and serious
personal injuries.
Check the appliance for any possible defects before use. If the appli-
ance exhibits any faults, it must not be used under any circumstances.
Ensure that the welding lead, nozzle, the torch and earth connections
are all in perfect condition. Wear on the insulation and the live parts
can cause dangerous situations and reduce the quality of the welding
work.
Use this appliance only as described in this instruction manual.
Using this appliance can lead to wear on certain parts. Therefore,
check the appliance regularly for any possible damage or defects.
For your own safety, use only the additional equipment and acces-
sories specified in the operating instructions or recommended by the
manufacturer.
When setting up the appliance, ensure that it is placed on a stable and
safe working surface.
On heavily used supply networks and power circuits, welding work
can lead to problems for other users. If in doubt, consult your electricity
provider.
Comply with all national guidelines and laws when welding. This applies,
in particular, to accident prevention regulations.
The flux-core welder may only be used on a stable and level surface. The
flux-core welder is constructed so that it can be tilted up to a maximum
of 10° from the plane before tipping over. Secure the flux-core welder
against tipping if working on an inclined plane.
To avoid damage to the appliance, always transport the appliance in
an upright position.
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Special safety instructions
WARNING! RISK OF ELECTROCUTION!
Incorrect electrical installation, excessive mains voltage or incorrect
handling can lead to an electric shock. Any electrical shock can be
fatal.
Do not connect the flux-core welder unless the mains voltage from the
socket outlet corresponds to the requirement given on the type plate.
Connect the flux-core welder only to an easily accessible socket, so
that it can be quickly disconnected from the mains in the event of an
accident.
Do not operate the flux-core welder if it has any visible damage or the
mains cable or plug are defective.
The mains connection cable used is a high-quality line that must not be
damaged. While working, ensure that it does not come into contact with
any hot objects. If the connecting lead is damaged it must be replaced
by a specific connecting lead that is available from the manufacturer or
its customer service. The main connecting lead may only be replaced
by the manufacturer or its customer service or a similarly qualified
person.
Do not open the housing except as described in these instructions.
Have all repairs carried out by qualified specialists. Contact a specialist
workshop. Unauthorised repairs, improper connection or incorrect
operation will invalidate any liability or guarantee claims.
Never insert any pointed and/or metallic objects into the interior of the
appliance.
Repairs may only be made using parts that correspond to the original
appliance specifications. This flux-core welder contains electrical and
mechanical parts that are vital as protection against sources of danger.
Protect the flux-core welder from damp and use it only in dry, interior
rooms.
Never immerse the flux-core welder, the power cable or the plug in
water or other liquids.
Never touch the flux-core welder or the plug with wet hands.
Avoid all direct contact with the welding current circuit. The no-load volt-
age between the flow nozzle and the earth clamp can be dangerous.
Do not pull on the mains cable to remove the plug from the socket;
always pull on the plug itself.
Avoid any tensile load on the mains cable.
Unplug the appliance before setting it up at a different location.
Keep the flux-core welder, mains plug and power cable away from
open flames and hot surfaces.
Do not kink the mains cable.
Protect all cables from oil, sharp edges and high temperatures.
If you are not using the flux-core welder, cleaning or calibrating it or if
there is a malfunction, switch off the flux-core welder and pull the plug
out of the power socket.
WARNING! RISK OF INJURY!
Improper handling can lead to severe injuries!
Position the power cable so that it does not present a tripping hazard.
The light radiation emitted by the electric arc can cause damage to the
eyes. Protect your eyes using suitable protective glasses (DIN EN 166,
DIN EN 169/protection level 10) that you can attach to the supplied
welding mask.
The light radiation emitted by the electric arc can cause burns to the skin.
Use gloves and dry protective clothing that is free of oil and grease to
protect the skin from exposure to the ultraviolet radiation of the electric
arc.
The welded workpiece starts to glow and remains very hot for quite a
long time. Make sure that it has cooled down before touching it.
Arc welding can cause vapours to be released that may be hazardous
to health.
Ensure that there is no one within a radius of 15 m of the electric arc
who is not wearing protective clothing and eye protection. Protect
yourself and any bystanders from the possible hazardous effects of the
electric arc!
WARNING! RISK OF FIRE!
Improper handling can lead to fires or explosions.
Arc welding causes sparks, melted metal parts and smoke. Therefore
ensure that you remove all flammable substances and/or materials
from the working area.
The welded workpiece starts to glow and remains very hot for quite a
long time. It can thus come into contact with flammable materials and
cause a fire.
Do not weld receptacles, containers or pipes that have been used for
flammable liquids or gases.
WARNING! ELECTROMAGNETIC FIELDS!
The flux-core welder and the electric arc can generate electrical or
electromagnetic fields that can cause electronic systems and appli-
ances to malfunction. These include IT systems, telecommunications
systems, electronically controlled appliances and machines. Mains and
signal lines can be interrupted. Pacemakers may also be affected.
Observe the maintenance instructions.
Unwind the earth cable
and the cable assembly completely.
Coiled cables can enhance electromagnetic fields.
Provide sufficient shielding for appliances or machines sensitive to radiation.
If you wear a pacemaker, consult your doctor before welding.
CAUTION!
Improper handling can lead to overheating of the flux-core welder
and property damage.
The flux-core welder may not be restricted or placed directly against
the wall during its functional life to ensure that enough air can always
be taken up through the ventilation slit.
Make sure that there is always adequate ventilation.
Complementary safety instructions
Risk of electric shock: Electric shock from welding electrode can kill.
Do not weld in the rain or snow. Wear dry insulating gloves. Do not
touch electrode with bare hands. Do not wear wet or damaged gloves.
Protect yourself from electric shock by insulating yourself from work-
piece. Do not open the equipment enclosure.
Risk induced by welding fumes: Breathing welding fumes can be haz-
ardous to your health. Keep your head out of the fumes. Use equipment
in an open area. Use ventilating fan to remove fumes.
Risk induced by welding sparks: Welding sparks can cause explo-
sion or fire. Keep flammables away from welding. Do not weld near
flammables. Welding sparks can cause fires. Have a fire extinguisher
nearby and have a watchperson ready to use it. Do not weld on drums
or any closed containers.
Risk induced by the arc: Arc rays can burn eyes and injure skin. Wear
hat and safety glasses. Use ear protection and button shirt collar.
Use welding helmet with correct shade of filter. Wear complete body
protection.
Risk induced by electromagnetic fields: Welding current produces elec-
tromagnetic field. Do not use with medical implants. Never coil welding
cables around your body. Route the welding cables together. The
safety instructions for engine driven power sources shall also include:
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Potential hazards
There are a number of potential hazards that can occur during arc welding.
It is therefore particularly important for the welder to comply with the
following rules to avoid endangering himself or others and prevent injuries
or damage to the appliance.
Do not use this flux-core welder on a surface that is inclined by more
than 10°.
Work on the voltage side, e.g. on cables, plugs, sockets, etc., may only
be carried out by qualified specialists. This applies especially to the
fitting of intermediary cables.
In the event of an accident, disconnect immediately from the welding
power source.
If electrical contact voltages occur, switch off the appliance immediately
and have it checked by a qualified specialist.
Always ensure good electrical contacts on the welding current side.
Always wear insulating gloves on both hands during welding work.
These protect the user from electric shock (no-load voltage of the welding
current circuit), harmful radiation (heat and UV radiation) as well as
from incandescent metal and splashes of slag.
Wear sturdy insulating shoes (should also be waterproof). Loafers are
not suitable as falling incandescent metal droplets can cause burns.
Wear suitable clothing, no synthetic fibres.
Do not look into the electric arc without eye protection; always use the
welding mask with the prescribed protective glass as per DIN. In addition
to the light and heat radiation, which can dazzle and/or cause burns,
the electric arc also emits UV radiation. If not properly protected, this
invisible ultraviolet radiation can cause a very painful conjunctivitis that
is not apparent until several hours later. In addition, this UV radiation
can cause sunburn-like effects on unprotected parts of the body.
Any persons in the vicinity of the electric arc or helpers must be appraised
of the dangers and be equipped with the necessary protective equip-
ment. If necessary, put up protective walls.
No welding work may be carried out on containers that have been
used for storing gases, fuels, mineral oils or similar – even if they have
been empty for a long time – as possible residues may present a risk of
explosion.
Special regulations apply in rooms where there is a risk of fire or
explosion.
Welded joints that are subject to heavy stress loads and are required
to comply with safety requirements may only be carried out by trained
and qualified welders. Examples of this are: pressure vessels, running
rails, tow bars, etc.
Risk of injury due to electric shock
When there is no electric arc, there is a nominal no-load voltage of U
0
be-
tween the earth clamp and the flow nozzle. This voltage can be potentially
fatal if the welder touches the flow nozzle, torch nozzle, welding wire or
the workpiece with his/her bare hands.
It is important to bear in mind that the protective conductor in electrical
systems or appliances can be damaged by negligence by the welding
current:
e.g. the earth clamp is placed on the welder housing which is connect-
ed to the protective conductor of the electrical system. The welding
work is carried out on a machine with a protective conductor connec-
tion. It is also possible to weld the machine without attaching the earth
clamp to it. In this case, the welding current flows from the earth clamp
via the protective conductor to the machine. The high welding current
can cause the protective conductor to melt.
The supply to the mains socket must be secured as per regulations
(VDE 0100). In accordance with these regulations, only fuses or circuit
breakers with a corresponding wire cross section may be used (16 amp
circuit breaker). A too high fuse amperage can cause cable fires or
building fire damage.
Confined spaces and hot rooms
When working in confined spaces or hot rooms, use insulated underlays,
filler layers and gauntlets made of leather or a different non-conduc-
tive material to insulate your body against the floor, walls, conductive
appliance parts and similar.
When using welding transformers to weld in environments with in-
creased electrical risks, e.g. in confined rooms with electrically conduc-
tive walls (boilers, pipes, etc.), in hot rooms (sweating through the work
clothes), the output voltage of the flux-core welder in no-load operation
may not be higher than 48 V~ (effective value). Due to its output volt-
age in no-load operation, the appliance may be used in this case.
Accident risks due to poor air supply in confined
spaces
Considerable quantities of smoke and gases are produced during
welding. Ensure that there is a suitable opening for the extraction of
smoke and gases. Never feed oxygen into the room. This increases the
risk of fire.
Protective clothing
While working, the welder must protect all body parts from radiation
and against burns by means of clothing and the welding mask.
Wear gauntlets made of a suitable material (leather) on both hands.
They must be in perfect condition.
To protect your clothes from flying sparks and burns, wear a suitable
apron. If the type of work requires it, e.g. overhead welding, wear a
protective suit and, if necessary, also the corresponding headgear.
The clothing worn and all accessories must comply with the guideline
“Personal protective equipment” (89/686/EEC).
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Protection against radiation and burns
Warn of the danger to the eyes by hanging up a sign saying “Caution,
do not look into the flames!”.
Work areas are to be shielded so as to protect people in the vicinity.
Keep unauthorised persons away from the welding work.
Do not set up fixed welding locations in the immediate vicinity of
light-coloured or glossy walls.
Windows should be blocked off to at least head height to prevent the
escape or reflection of radiation, e.g. by painting with a suitable paint.
Risk of burns due to flying sparks
The spraying welding sparks can cause painful burns. Therefore, observe
the following guidelines:
Always wear a leather apron.
Use leather gloves.
For overhead welding, wear suitable headgear.
Ensure that your trouser cuffs fall over your shoes.
Wear sturdy and insulated shoes.
Risk of accidents due to spattering slag
When it sets, the slag is hard and brittle. Afterwards, it can be chipped off
using the chipping hammer – sharp-edged particles may fly up that could
seriously injure your eyes.
Therefore protect your eyes by wearing suitable protective goggles when
removing slag.
Risk of fire due to flying sparks
If molten or incandescent metal and slag particles fall onto flammable sub-
stances, these can ignite and cause a fire. Therefore, remove all flammable
objects from the working area before commencing welding work. Keep a
suitable fire extinguisher at hand.
Pay particularly close attention to the following materials.
Paper
Rags
Textiles
Wood and wood fibres
Rubber
Plastic
Petrol
Oils
Tar-like substances
Paints and solvent
Risk of explosion
Both the welding function and the superheated weld joint itself can cause
explosions. Therefore, do not use the appliance in a potentially explosive
environment containing combustible liquids, gases or paint mist.
Please also note:
When the flux-core welder is in operation, do not lay the torch on the
flux-core welder itself or any other electrical appliance.
Before finishing the welding work, do not touch the flow nozzle or any
other metal object with which the flow nozzle is in contact.
Disconnect the appliance from the power immediately after completing
your welding work.
Ensure that no cable is wrapped around any body part.
Make sure that you are not within the welding current circuit. The welding
torch and earth must always be on the same side.
EMC appliance classification
As per the standard IEC 60974-10, this appliance is a welding unit with
class A electromagnetic compatibility. Thus it complies with the correspond-
ing requirements for industrial and domestic use. In residential areas, it
may be connected to the low voltage electricity supply.
Even the flux-core welder complies with the emission limits of the standard,
arc welding appliances can nevertheless cause interference to sensitive
systems and appliances.
The user is responsible for any interference caused by the electric arc during
welding and must take appropriate preventive measures. The user must
pay close attention to the following:
Power, control, signal and telecommunication lines
Computers and microprocessor-controlled appliances
TVs, radios and other playback appliances
Electronic and electrical safety appliances
People with pacemakers or hearing aids
Measurement and calibration systems
The electromagnetic immunity of other systems in the vicinity
The time of the day at which the welding work is to be carried out.
To prevent possible interference radiation, we recommend:
Fitting a mains filter to the mains connection or shielding it with a metal
pipe
Maintaining the flux-core welder regularly and keeping it in good
condition
Weld cables should be as short as possible, completely unwound and
running as close to parallel with the floor as possible
An equipotential bonding should be provided
The workpieces should be properly earthed
Any appliances susceptible to interference radiation should moved out
of the welding area, if possible, or shielded.
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Unpacking and checking the package
contents
1.) Remove all components from the packaging and check whether the
flux-core welder or the individual components show any signs of
damage. If this is the case, do not use the flux-core welder. Contact the
manufacturer via the service address provided on the warranty card.
2.) Remove all protective films and other transport packaging.
3.) Check that the delivery is complete.
Assembly
Fitting the welding mask
Fold the side parts of the mask inwards.
Press the integrated clips into the corresponding holes so that they click
into each other (see fig. D).
Lay the dark welding lens
into the mask with the writing at the
top (see fig. E).
The writing on the dark welding lens
must now be visible from the
front side of the welding mask.
Push the handle
from the inside into the corresponding recess on
mask, until it clicks into place (see fig. F).
Filling with flux-cored wire
WARNING!
To avoid the danger of electric shock, injury or damage:
Before maintenance or pre-work preparation activity,
always disconnect the mains plug from the mains
power socket.
NOTE
Depending on the application, different types of flux-core wires will
be required. This appliance can use wires with a diameter from
0.7–1.0 mm.
The feed roller, torch nozzle and wire diameter must always match.
The appliance is designed for wire rolls of up to a maximum of 450 kg.
Open the cover of the wire feed unit
by turning the catch (see
arrow marking) to the position UNLOCK (see fig. 1).
Fig. 1
Unlock the roller unit by turning the roller mount A 90° anticlockwise
(see fig. 2).
Pull the roller unit from the shaft (see fig. 2).
Fig. 2
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.
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Unpack the wire roll completely so that it can be unrolled unimpeded.
Do not release the wire end yet (see fig. 3).
Place the wire roll onto the shaft. Make sure that the roll unwinds on
the same side as the wire feed guide C (see fig. 3).
Put the roll mount A back on and lock it by pressing and turning it
clockwise 90° (see fig. 3).
Fig. 3
Undo the adjustment screw D and swing it upwards (see fig. 4).
Fig. 4
Push the press roller unit E to the side (see fig. 5).
Fig. 5
Undo the feed roll holder F by turning it anticlockwise and pulling it
upwards and off (see fig. 6).
Check the upper side of the feed roll G to see if it is the correct wire
size. If required, the feed roll must be turned over or exchanged. The
supplied welding wire (Ø 0.9 mm) must be used in the feed roll G
with the next biggest specified wire thicknesses of Ø 1.0 mm.
The wire must be positioned in the upper groove!
Replace the feed roll holder F and screw it tight.
Fig. 6
Remove the torch nozzle
by turning it to the right (see fig. 7).
Unscrew the flow nozzle
(see fig. 7).
Route the cable assembly
away from the welder as straight as
possible (laying on the floor).
Fig. 7
Pull the wire end from the edge of the spool (see fig. 8).
Trim the wire end with a wire cutter or a diagonal cutter to remove any
damaged/bent wire (see see fig. 8).
NOTE
THE WIRE MUST BE HOLD ON TENSION ALL THE TIME, TO AVOID
A RELEASING AND ROLL OUT! We recommend that you always
carry out work with the help of a second person.
Fig. 8
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Push the flux-core wire through the wire feed guide C (see fig. 9).
Fig 9
Guide the wire along the feed roll G and then push it into the cable
assembly opening I (see fig. 10).
Fig. 10
Swivel the press roller unit E in the direction of the feed roll G
(See fig. 11).
Hook the adjustment screw D into place (see fig. 11).
Set the adjustment screw so that the welding wire sits firmly between
the press roller and the feed roll G in the upper guide without being
pinched (see fig. 11).
Fig. 11
Switch on the welder using the main switch
.
Press the torch button
.
Now the wire feed system pushes the welding wire through the cable
assembly
and the torch .
As soon as the wire juts 1–2 cm out of the torch neck M, release the
torch button
(see fig. 12).
Fig. 12
Switch off the welder.
Screw the flow nozzle back on.
Make sure that the flow nozzle
matches the diameter of the
welding wire being used (see fig. 13).
With the supplied welding wire (Ø 0.9 mm) the flow nozzle
must be used with the next largest diameter of 1.0 mm .
Fig. 13
Push the torch nozzle
back onto the torch neck M with a turn to the
right (see fig. 14).
Fig. 14
WARNING!
To avoid the danger of electric shock, injury or damage:
Before maintenance or pre-work preparation activity,
always disconnect the mains plug from the mains
power socket.
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PFDS 33 A1
Operation
Switching the appliance on and off
Switch the welder on and off using the main switch .
If you do not intend to use the welder for an extended period, remove the
plug from the power socket. This is the only way to completely de-energise
the appliance.
Setting the welding current
Use the switches
on the front of the welder to set the required
welding current.
If, for example, the MIN switch
und the switch 1 are set to the
up position, the welding current is 48 A and the duty cycle is at 60%.
If the MAX switch und the switch 2 are set to the down position,
the welding current is 90 A and the duty cycle is at 10%.
The required welding current is dependent on the diameter of the welding
wire being used, the material thickness and the desired penetration
depth.
MIN MAX
1 48 A 70 A
2 60 A 90 A
Adjusting the wire feed
To achieve a consistent weld result, you can make fine adjustments to
the wire feed using the setting wheel for the wire feed
.
We recommend using a setting in the middle range to start with and
then increasing or reducing the speed as required.
The required welding flow is dependent on the diameter of the welding
wire being used, the material thickness and the desired penetration
depth as well as the bridging distance between the two pieces being
welded.
Overload protection
The welder is protected against overheating by an automatic protection
appliance (thermostat with automatic restart) metal clad. The protection
appliance interrupts the power supply in the event of an overload and
the yellow overload protection control lamp lights up.
If the protection appliance activates, allow the appliance to cool down
(approx. 15 minutes). As soon as the yellow overload protection control
lamp
goes off, the appliance is again ready for use.
Welding mask
WARNING! HEALTH HAZARD!
If you do not use the welding mask, the harmful UV radiation and the
heat coming from the electric arc can damage your eyes.
Always use the welding mask when you weld.
Welding
WARNING! RISK OF BURNS!
Welded, hot workpieces are very hot so that you could burn yourself.
Always use pliers to move welded, hot workpieces.
After you have connected the welder to the power, proceed as follows:
Connect the earth cable to the workpiece that is to be welded using
the earth clamp
.
Ensure that there is a good electrical connection.
The workpiece should be free of rust and paint where the weld is to
made.
Select the desired welding current and the wire feed depending on
the welding wire diameter, material thickness and desired penetration
depth.
Switch the appliance on.
Hold the welding mask
in front of your face and guide the torch
nozzle
to the position on the workpiece where you want to weld.
Press the torch button
to generate an electric arc.
Once the electric arc is burning, the appliance feeds wire into the weld
pool.
Once the weld nugget is big enough, guide the torch
slowly along
the desired edge.
The distance between the torch nozzle and the workpiece should be
as small as possible (never more than 10 mm).
If required, oscillate a little to increase the size of the weld pool.
For inexperienced welders, it is often difficult initially to create a decent
electric arc, i.e. in terms of the correct setting of welding current and wire
feed rate.
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 tone.
The penetration depth should be as deep as possible, the weld pool,
however, should not be able to fall through the workpiece.
If you hear a raw or hard rattle, reduce the wire feed rate and switch
up to a higher load level (increase the welding current).
If the wire feed rate is too high and/or the welding current too low, the
welding wire cannot melt properly and dips repeatedly into the weld
bed as far as the workpiece.
A quiet dull sound with a guttering electric arc indicates that the wire
feed is insufficient.
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 bed. This leads to droplet formation on the welding
wire as well as splash and an irregular electric arc.
The slag may not be removed until the weld has cooled down.
To resume a weld on an interrupted joint:
Start by removing the slag at the starting point.
Ignite the electric arc in the groove, guide it to the continuation point,
melt properly and then continue the weld joint.
PFDS 33 A1
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CAUTION!
Please note that the torch must always be put down on an insulated
surface after welding.
Always switch off the welder after completing welding work and
during breaks and pull the plug out of the mains socket.
Weld types
Forehand welding
The torch is pushed forwards.
Result: lower penetration depth, broader weld, flatter weld bead and
greater fusion error tolerance.
Backhand welding
The torch is dragged from the weld joint.
Result: higher penetration depth, narrower weld, higher weld bead and
lower fusion error tolerance.
Welded joints
There are two basic types of joint types in welding: Butt welds and angle
welding (outer edge, inner edge and overlapping).
Butt welds
With butt welds of up to 2 mm, the weld edges are moved completely
together.
For greater thicknesses, see the table below:
S
d
S= 1–3 mm 3–4 mm 4–6 mm
Area d= 0.5–1.5 mm 1.5–2.5 mm 2–3 mm
Fusion face
d=
1–2 mm 2–3 mm 3–4 mm
Vertical
d=
1–1.5 mm 1.5–2.5 mm 2–3 mm
Flat butt welds
Welds should be made without interruption and with a sufficient penetra-
tion depth. Therefore, good preparation is extremely important.
The factors that influence the quality of the weld result are: the amper-
age, 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.
To forestall or reduce deformations that can happen during the material
hardening process, it is good to fix the workpiece, where possible,
using a clamp that counteracts the contraction and deformation of the
material.
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.
Welds on an outer edge
The preparation for this is very simple.
For thicker materials, however, it is no longer expedient. In this case, it is
better to prepare a joint as shown opposite in which the edge of a plate is
angled.
45°
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PFDS 33 A1
Welds on an inner edge
The preparation for this weld joint is very simple and is carried out for thick-
nesses of 5 mm. The dimension “d” needs to be reduced to a minimum
and should always be less than 2 mm.
d
For thicker materials, however, it is no longer expedient. In this case, it is better
to prepare a joint as shown opposite in which the edge of a plate is angled.
45°45°
Overlap welds
The most usual preparation is that with straight weld edges. The weld can
be undone using a standard angle weld seam. Both workpieces must be
brought as close to each other as possible.
Cleaning and care
WARNING!
To avoid the danger of electric shock, injury or damage:
Before cleaning, always disconnect the mains plug
from the mains power socket.
Never immerse the flux-core welder or the accessories
in water.
Allow the flux-core welder and accessories to cool
down before cleaning them.
Never use abrasive, caustic or scratching cleaning
agents. These can damage the appliance.
Keep the flux-core welder clean. Welding equipment must be kept free
of dust to ensure adequate cooling. In especially dirty air, a monthly
cleaning using compressed air is necessary.
Protect the flux-core welder from metal dust.
Store the flux-core welder in a dry room, secured from access by un-
authorised persons or children.
Ensure that the welding lead, the torch and earth clamp are all in
perfect condition.
Cables and current-carrying parts of the flux-core welder with dam-
aged insulation are dangerous and can impair the proper functioning
of the appliance.
Repairs may only be carried out by authorised repair shops or similarly
qualified persons.
Always disconnect the appliance from the mains power supply before
all maintenance and repair work.
Wire feed
Regular cleaning of the wire feed drive and replacement of worn wire
feed rolls.
Blow out the steel core with compressed air.
Do not tighten the tension spring on the pressure roller too tightly. Ex-
cessive pressure lead to higher abrasion of the steel wire. The dust thus
created deposits in the guide spring and causes an uneven discharge
of the welding wire making it impossible to create an even weld.
Cable assembly
Protect the cable assembly from external damage.
Never pull it over sharp edges or other objects.
Never drive a vehicle over it.
Clean the cable assembly regularly.
The steel sleeve and torch nozzle are wearing parts.
The torch nozzle is exposed to heat radiation and friction from the wire
and must be checked and replaced regularly.
Weld splatter collects on the torch nozzle. This must be removed
regularly.
For overhead welding, frequent cleaning is necessary.
Use nozzle grease or nozzle spray before and after welding. This
prevents too much splatter from accumulating.
Welder
The transformer of the welder must be freed of accumulated dust to
ensure that the cooling works properly. In especially dirty air, a monthly
cleaning using compressed air is necessary.
Protect the welder from metal dust.
PFDS 33 A1
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Troubleshooting
Malfunction Possible cause Remedy
No function. Incorrect mains connection. Check mains fuse or have the mains supply checked by a technician.
The overload protection has
activated.
Allow the appliance to cool down.
Irregular wire feed. Not enough pressure on the
feed roll.
Increase pressure.
Wire not lying correctly in the
groove of the feed roll or the
groove is too big or the wire
feed roll is worn.
Place wire correctly in the groove of the feed roll or, if necessary, replace the
feed roll.
Poorly wound wire; crossed
wires.
Replace wire roll.
No wire feed. Torch switch or control line in
cable assembly defective.
Please contact our service department.
Wire feed not adjustable. Adjusting wheel or control circuit
defective.
Please contact our service department.
No welding current with
normally functioning wire
feed.
Cable assembly or earth cable
defective.
Check cable assembly and earth cable and, if necessary, contact the service
department.
Control circuit defective.
Torch is getting too hot. Flow nozzle loose or too large. Tighten or replace flow nozzle.
Welding current too low. Bad earth contact. Check the earth clamp and cable as well as the cable assembly.
If necessary, contact our service department.
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PFDS 33 A1
Disposal
The packaging is made from environmentally friendly material
and can be disposed of at your local recycling plant.
Do not dispose of power tools in your normal
household waste!
European Directive 2012/19/EU requires that worn-out power tools
be collected separately and recycled in an environmentally compatible
manner.
Take the appliance to a nearby collection facility.
Please consult your local authorities regarding suitable disposal of worn-
out power tools.
Kompernass Handels GmbH warranty
Dear Customer,
This appliance has a 3-year warranty valid from the date of purchase. If this
product has any faults, you, the buyer, have certain statutory rights. Your stat-
utory rights are not restricted in any way by the warranty described below.
Warranty conditions
The validity period of the warranty starts from the date of purchase. Please
keep your original receipt in a safe place. This document will be required
as proof of purchase.
If any material or production fault occurs within three years of the date of
purchase of the product, we will either repair or replace the product for
you at our discretion. This warranty service is dependent on you presenting
the defective appliance and the proof of purchase (receipt) and a short
written description of the fault and its time of occurrence.
If the defect is covered by the warranty, your product will either be repaired
or replaced by us. The repair or replacement of a product does not signify
the beginning of a new warranty period.
Warranty period and statutory claims for defects
The warranty period is not prolonged by repairs effected under the
warranty. This also applies to replaced and repaired components. Any
damage and defects present at the time of purchase must be reported im-
mediately after unpacking. Repairs carried out after expiry of the warranty
period shall be subject to a fee.
Scope of the warranty
This appliance has been manufactured in accordance with strict quality
guidelines and inspected meticulously prior to delivery.
The warranty covers material faults or production faults. The warranty does
not extend to product parts subject to normal wear and tear or fragile parts
such as switches, batteries, baking moulds or parts made of glass.
The warranty does not apply if the product has been damaged, improperly
used or improperly maintained. The directions in the operating instructions
for the product regarding proper use of the product are to be strictly fol-
lowed. Uses and actions that are discouraged in the operating instructions
or which are warned against must be avoided.
This product is intended solely for private use and not for commercial
purposes. The warranty shall be deemed void in cases of misuse or improper
handling, use of force and modifications/repairs which have not been
carried out by one of our authorised Service centres.
Warranty claim procedure
To ensure quick processing of your case, please observe the following
instructions:
Please have the till receipt and the item number (e.g. IAN 12345)
available as proof of purchase.
You will find the item number on the type plate, an engraving on the
front page of the instructions (bottom left), or as a sticker on the rear or
bottom of the appliance.
If functional or other defects occur, please contact the service depart-
ment listed either by telephone or by e-mail.
You can return a defective product to us free of charge to the service
address that will be provided to you. Ensure that you enclose the proof
of purchase (till receipt) and information about what the defect is and
when it occurred.
You can download these instructions along with many other
manuals, product videos and software on
www.lidl-service.com.
Service
WARNING!
Have the power tool repaired by the service centre or a qualified
electrician and only using genuine replacement parts.
This will ensure that the safety of the appliance is maintained.
Always ensure that the power plug or the mains cable is replaced
only by the manufacturer of the appliance or by an approved
customer service provider. This will ensure that the safety of the
appliance is maintained.
Service Great Britain
Tel.: 0871 5000 720 (£ 0.10/Min.)
IAN 280331
Service Ireland
Tel.: 1890 930 034
(0,08 EUR/Min., (peak))
(0,06 EUR/Min., (off peak))
IAN 280331
Importer
KOMPERNASS HANDELS GMBH
BURGSTRASSE 21
44867 BOCHUM
GERMANY
www.kompernass.com
PFDS 33 A1
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Translation of the original Conformity
Declaration
We, KOMPERNASS HANDELS GMBH, documents officer:
Mr. Semi Uguzlu, BURGSTR. 21, 44867 BOCHUM, GERMANY, hereby
declare that this product complies with the following standards, normative
documents and EC directives:
EC Low Voltage Directive
(2014/35/EU)
EMC (Electromagnetic Compatibility)
(2014/30/EU)
RoHS Directive
(2011/65/EU)*
*The manufacturer bears the full responsibility for compliance with this
conformity declaration. The object of the declaration described above
complies with the requirements of the Directive 2011/65/EU of the Euro-
pean Parliament and Council of 8 June 2011 on the limitations of use of
certain dangerous substances in electrical and electronic appliances.
Applied harmonised standards:
EN 60974-1: 2012
EN 60974-10: 2014/A1: 2015
EN 50581: 2012
Type/appliance designation:
Flux-cored wire welder PFDS 33 A1
Year of manufacture: 08 - 2016
Serial number: IAN 280331
Bochum, 29/07/2016
Semi Uguzlu
- Quality Manager -
The right to effect technical changes in the context of further development
is reserved.
IAN 280331
KOMPERNASS HANDELS GMBH
BURGSTRASSE 21
44867 BOCHUM
DEUTSCHLAND / GERMANY
www.kompernass.com
Last Information Update · Stand der Informationen:
08 / 2016 · Ident.-No.: PFDS33A1-082016-3
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Parkside PFDS 33 A1 Original Instructions Manual

Category
Welding System
Type
Original Instructions Manual

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