FLUX-CORED WIRE WELDER PFDS 33 B2
IAN 291492
FÜLLDRAHT-SCHWEISSGERÄT
Montage-, Bedienungs- und Sicherheitshinweise
FLUX-CORED WIRE WELDER
Assembly, operating and safety instructions
GB / IE / NI Assembly, operating and safety instructions Page 5
DE / AT / CH Montage-, Bedienungs- und Sicherheitshinweise Seite 25
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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5 GB/IE/NI
Table of contents
List of pictograms used ........................................................................................................ Page 6
Introduction ................................................................................................................................... Page 7
Intended Use .......................................................................................................................................Page 7
Parts Description ..................................................................................................................................Page 7
Technical Data ....................................................................................................................................Page 8
Scope of Delivery ................................................................................................................................Page 8
Safety instructions ...................................................................................................................Page 8
Safety hazards during arc welding ...................................................................................................Page 10
Safety notices specific to the welding shield .....................................................................................Page 12
Tight and moist spaces .......................................................................................................................Page 13
Protective clothing ...............................................................................................................................Page 13
Protecting against rays and burns ......................................................................................................Page 13
EMC Device Classification .................................................................................................................Page 14
Before Use ...................................................................................................................................... Page 15
Assembly .........................................................................................................................................Page 15
Assembling the welding helmet ..........................................................................................................Page 15
Inserting the flux-cored wire ...............................................................................................................Page 15
Initial Use.........................................................................................................................................Page 18
Switching the unit on and off ..............................................................................................................Page 18
Adjusting the welding current .............................................................................................................Page 18
Adjusting the wire feeder ....................................................................................................................Page 18
Welding ............................................................................................................................................... Page 19
Creating a welding seam ...................................................................................................................Page 20
Maintenance and Cleaning ..............................................................................................Page 21
Environmental instructions and disposal information ..............................Page 21
Information about warranty and service processing ...............................Page 22
Warranty terms .........................................................................................................................Page 22
Extent of warranty ............................................................................................................................... Page 22
Processing of warranty claims ............................................................................................................ Page 22
Service ...............................................................................................................................................Page 23
EU Conformity Declaration ............................................................................................... Page 23
6 GB/IE/NI
IntroductionIntroduction
List of pictograms used
Caution! Read instructions for
use!
Severe or fatal injuries may
occur.
Power input; phase number, as
well as
Caution! Danger of electric
shock!
1
~
50 Hz
Alternating current symbol and
rated value of the frequency
Important notice!
Do not dispose of electrical
equipment in household waste!
Dispose of the packaging and
unit in an environmentally-friendly
manner!
Do not use the unit outdoors
and never in rain!
Self-shielded flux-cored arc
welding
Electric shocks from welding
electrodes can prove fatal
IP21S
Protection type
Inhaling welding smoke can
pose a risk to your health.
Suitable for welding with
increased electric risk
Welding sparks can cause an
explosion or fire.
Single-phase transformer
Arc rays can damage the eyes
and injure the skin.
H
Insulation class
Electromagnetic fields can
interfere with the functionality of
pacemakers.
U
2
Standard working voltage
Attention, potential dangers!
I
1max
Highest rated value of mains
current
X %
Duty cycle
I
1eff
Effective value of highest mains
current
I
2
Rated value of welding current Earth terminal
Wire feeder
7 GB/IE/NI
Introduction
Flux-Cored Wire Welder PFDS 33 B2
Introduction
Congratulations! You have
chosen a high-quality unit from
our company. Familiarise your-
self with the product before using it for the first time.
In addition, please carefully read the instructions for
use and the safety instructions below. Initial opera-
tion of this tool must be performed by trained per-
sonnel.
KEEP OUT OF THE REACH OF CHILDREN!
Intended Use
This unit is intended for self-shielded flux-cored arc
welding using the appropriate wire. Additional gas
is not required. The inert gas is contained in a pow-
dered form in the wire, is therefore fed directly into
the arc, and this makes the tool wind-resistant while
working outdoors. Only suitable wire electrodes may
be used for the unit. Intended use also involves ob-
serving the safety instructions, assembly instructions
and operating instructions in the instruction manual.
The applicable accident prevention regulations are
to be adhered to as strictly as possible. The unit
may not be used:
- in insufficiently ventilated spaces,
- in a damp or wet environment,
- in explosive environments,
- for the purposes of thawing pipes,
- in the vicinity of people with pacemakers and
- in the vicinity of inflammable materials.
Only use the product as described and for the
specified purpose. Keep these instructions in a safe
place. When passing this product on to others, please
also include all the documents. Any use other than
the intended is prohibited and potentially dangerous.
Damages resulting from noncompliance or misuse
are not covered by the warranty and are not included
in the manufacturer's liability.
Residual risk
Even if you use the unit correctly, there will always
be residual risks. The following hazards can arise
due to the design and performance of this flux-cored
arc welding unit:
- Eye damage due to being dazzled,
- Touching hot parts of the unit or the work piece
(burns),
- In the case of insufficient protection, a risk of
accidents and fire exists due to sparks or slag,
- Harmful gas and smoke emissions in the case of a
lack of air and / or insufficient extraction in enclosed
spaces.
Reduce the residual risk by using the unit carefully
and correctly and following all the instructions as
stated.
Parts Description
1
Cover for wire feeder unit
2
Carrying strap
3
Mains plug
4
Earth cable with earth terminal
5
Main switch ON / OFF (including mains
control lamp)
6
Control lamp for overload protection
7
Burner nozzle
8
MIN / MAX switch for welding current setting
9
1 / 2 Switch for welding current setting
10
Adjustment wheel for wire feeder
11
Burner
12
Burner button
13
Cable assembly with direct connection
14
Welding nozzle (0.6 mm)
15
Welding nozzle (0.8 mm)
16
Handle
17
Welding nozzle (0.9 mm)
18
Flux-cored wire welding coil (wire reel)
Ø 0.9 mm / 450 g
19
Chipping hammer with wire brush
20
Welding helmet after assembly, consisting of:
21
Dark welding lens
22
Mask
23
Mounting clip
24
Protective glass locking mechanism
25
Roll holder
Introduction
8 GB/IE/NI
Safety instructionsIntroduction / Safety instructions
26
Wire outlet
27
Adjusting knob
28
Pressing roller unit
29
Feed roller
30
Feed roller holder
31
Cable assembly intake
32
Torch neck
Technical Data
Mains connection: 230 V∼ / 50 Hz
(alternating current)
Welding current I
2
: 40–90 A
Duty cycle X: 10 % at 90 A
welding current,
60 % at 40 A
welding current
Open-circuit voltage U
0
: 32 V
Highest rated value
for the mains current: I
1
max.
14 A
Effective value for highest
rated current: I
2
eff
4.4 A
Welding wire drum max.: approx. 450 g
Welding wire diameter: 0.9 mm
Fuse: 16 A
Weight: 13.65 kg
Scope of Delivery
1 Flux-cored arc welding unit PFDS 33 B2
1 Burner nozzle (pre-installed)
3 Welding nozzles (1x 0.9 mm pre-installed; 1x
0.8 mm; 1x 0.6 mm)
1 Chipping hammer with wire brush
1 Flux-cored wire Ø 0.9 mm / 450 g
1 Welding helmet
1 Carrying strap
1 Instructions for use
Safety instructions
Please carefully read the instructions
for use and follow the specified no-
tices. Familiarise yourself with the
tool, its proper use and the safety
notices using these instructions for
use. The nameplate contains all the
technical data for this welding tool,
please learn about the technical
facts of this tool.
This device may be used by
children aged 16 years and up,
as well as by persons with reduced
physical, sensory or mental ca-
pacities, or lacking experience
and / or knowledge, so long as
they are supervised or instructed
in the safe use of the device and
understand the associated risks.
Do not allow children to play with
the appliance. Cleaning and user
maintenance should not be per-
formed by children without super-
vision.
Only have repairs and / or main-
tenance performed by electrically
skilled persons.
Only use the welding cables
included (PFDS 33 B2 H01N2-
D1x10 mm²).
9 GB/IE/NI
Safety instructions
During use the equipment should
not be located directly against a
wall, be covered, or be jammed
between other equipment to en-
sure ample air can be taken in
through the ventilation louvres.
Verify the equipment is correctly
connected to the mains voltage.
Avoid any tensile load on the
mains. Unplug the mains plug
from the socket before transfer-
ring the equipment to a different
location.
Always switch the equipment off
with the ON / OFF switch when
not in use. Set the electrode
holder down on an insulated
pad and allow to cool for
15 minutes before removing the
electrodes from the holder.
Pay attention to the condition of
the welding cables, the electrode
holders and the earth terminals.
Worn insulation and conducting
parts can produce hazards and
reduce the welding quality.
Arc welding produces sparks,
melted metal parts and smoke.
Therefore note: Remove any
flammable substances and / or
materials from the work area
and its immediate surroundings.
Ensure the work area is ventilated.
Do not weld atop containers, re-
ceptacles or pipes, which do or
did contain flammable liquids or
gasses.
Avoid any
direct contact with the welding
circuit. The no-load voltage be-
tween the electrode holder and
earth terminal can be danger-
ous, there is a risk of electric
shock.
Do not store or use the equipment
in a moist or wet environment or
in the rain. The Protection Provision
IP21S applies in this respect.
Protect the eyes with the appro-
priate safety glass (DIN Grad
9-10) to be installed in the
included welding shield. Use
gloves and dry protective cloth-
ing free from oil and grease to
protect the skin from ultraviolet
rays and the arc.
Do not use the
welding power source to thaw
pipes.
Remember:
The arc ray can damage the
eyes and cause burns to the skin.
Arc welding produces sparks and
drops of molten metal, the welded
work piece begins to glow and
remains very hot for a relatively
Introduction / Safety instructions
10 GB/IE/NI
Safety instructionsSafety instructions
long time. Therefore do not touch
the work piece with bare hands.
Arc welding releases noxious
fumes. Be careful not to inhale
these as best possible.
Protect yourself from the danger-
ous effects of the arc and keep
persons not involved in the work
at least 2 m away from the arc.
ATTENTION!
Depending on mains conditions
at the connection point, operat-
ing the welding equipment may
interfere with the voltage supply
for other loads. When in doubt,
please contact your power sup-
ply company.
Operating the welding equipment
may interfere with the functional-
ity of other devices, e.g. hearing
aids, pacemakers, etc.
Safety hazards
during arc welding
Arc welding produces a variety of
safety hazards. It is therefore par-
ticularly important for the welder to
observe the following rules to avoid
putting himself and others in danger
and to prevent damage to persons
and the equipment
Only have work to the mains
voltage end, e.g. to cables, plugs,
outlets, etc. performed by a elec-
trically skilled person in accord-
ance with national and local
regulations.
In the event of an accident, im-
mediately disconnect the welding
equipment from the mains voltage.
If electrical contact voltage occurs,
immediately switch the equipment
off and have it inspected by an
electrically skilled person.
Always ensure good electrical
contacts on the welding current
end.
Always wear insulating gloves on
both hands whilst welding. These
will protect from electric shock
(no-load voltage of the welding
current), from hazardous rays
(heat and UV rays) and glowing
metal and weld splashes.
Wear solid, insulating shoes. The
shoes should also insulate when
exposed to moisture. Low shoes
are not suitable, as glowing metal
drops falling could cause burns.
Wear suitable protective clothing,
no synthetic garments.
Do not look into the arc with
unprotected eyes, only use a
welding shield with approved
protective glass per DIN. In
11 GB/IE/NI
Safety instructions
addition to light- and heat rays
which could result in blinding or
burns, the arc also emits UV rays.
Without adequate protection,
this invisible ultraviolet radiation
causes very painful conjunctivitis
which is only noticed a few hours
later. UV rays further cause burns
similar to a sunburn in unprotected
areas of the body.
Persons near the arc or assistants
must also be informed of the risks
and outfitted with the necessary
protection. If necessary, set up
protective panels.
Ensure an adequate supply of
fresh air whilst welding,
particu-
larly in small spaces, as it produces
smoke and harmful gasses.
Do not weld containers in which
gasses, fuels, mineral oils, etc.
were stored - even if emptied a
long time ago - as residue poses
an explosion hazard.
Special regulations apply in rooms
posing fire- and explosion hazards.
Welded joints exposed to great
strain and needing to meet cer-
tain safety requirements must be
made by specially trained and
certified welders. Examples are
pressure vessels, running rails,
tow couplings, etc.
ATTENTION! Always connect
the earth terminal as close as
possible to the point of weld to
provide the shortest possible path
for the welding current from the
electrode to the earth terminal.
Never connect the earth terminal
to the housing of the welding
equipment!
Never connect the earth terminal
to earthed parts far away from
the work piece, e.g. a water pipe
in another corner of the room. This
could otherwise damage the
protective bonding system of the
room you are welding.
Do not use the welding equipment
in the rain.
Do not use the welding equipment
in a moist environment.
Only place the welding equip-
ment in a level location.
The output is rated at an ambient
temperature of 20 °C. The weld-
ing time may be reduced in
higher temperatures.
Danger of electric shock:
Electric shock from a weld-
ing electrode can be fatal.
Do not weld in rain or snow. Wear
dry insulating gloves. Do not touch
the electrode with bare hands. Do
not wear wet or damaged gloves.
Safety instructions
12 GB/IE/NI
Safety instructionsSafety instructions
Protect yourself from electric shock
by insulating from the work piece.
Do not open the equipment housing.
Danger due to welding
smoke:
Inhaling welding smoke can jeop-
ardize your health. Keep your head
out of the smoke. Use facilities in
open areas. Use ventilation to remove
smoke.
Danger due to welding
sparks:
Welding sparks can cause an
explosion or fire. Keep flammables
away from the welding area. Do
not weld next to flammables. Weld-
ing sparks can cause a fire. Keep a
fire extinguisher nearby and an ob-
server ready to use it. Do not weld
on top of drums or any closed con-
tainers.
Danger due to arc rays:
Arc rays can damage the eyes and
injure the skin. Wear a hat and
safety goggles. Wear hearing
protection and a closed, high shirt
collar. Wear welding helmets and
proper filter sizes. Wear full per-
sonal protection.
Danger due to electromag-
netic fields:
Welding current produces electro-
magnetic fields. Do not use along
with medical implants. Never wrap
the welding cables around the
body. Consolidate welding cables.
Safety notices specific to
the welding shield
Using a hot light source (e.g.
lighter) always check the weld-
ing shield is working properly
before starting to weld.
Welding splashes can damage
the glass shield. Replace dam-
aged or scratched glass shields
immediately.
Promptly replace damaged or
heavily soiled / splashed compo-
nents.
The equipment may only be
operated by persons who have
turned 16.
Familiarise yourself with the safety
instructions for welding. Also refer
to the safety instructions of your
welding equipment.
Always use the welding shield
when welding. Failure to use the
shield may result in serious inju-
ries to the retina.
13 GB/IE/NI
Safety instructions
Always wear protective clothing
when welding.
Never use the welding shield
without protective glass, as the
optics can otherwise be damaged.
Replace the protective glass
early to ensure good visibility
and fatigue-proof working.
Tight and moist spaces
When working in tight, moist or
hot spaces, use insulating pads
and intermediate layers in addi-
tion to gauntlet gloves made from
leather or other insulating mate-
rials to insulate the body from
earth.
When using welding equipment
in electrically dangerous condi-
tions, e.g. in tight spaces from
conductive walls (kettles, pipes,
etc.), in wet spaces (soaking of
work clothes), the output voltages
of the welding equipment may
not be higher than 48 Volts (rms
value) in open loop. Based on
the output voltage this welding
equipment may be used in these
conditions.
Protective clothing
Whilst working the welder must
be protected against rays and
burns all over the body with the
appropriate clothing and face
protection. Remember the follow-
ing steps:
- Put on protective clothing before
welding.
- Put on gloves.
- Open windows or vent to ensure
air supply.
- Wear safety goggles and a
mask.
Wear gauntlet gloves made
from suitable material (leather)
on both hands. These must be in
good condition.
Wear suitable aprons to protect
the clothing from sparks and
burns. When required based on
the working method, e.g. welding
overhead, wear a protective suit
and, if necessary, a head guard.
Protecting against
rays and burns
Mark the work area with a
sign „Danger! Do not look into
flames!“ to indicate the risk to
the eyes. If possible, shield the
Safety instructions
14 GB/IE/NI
Safety instructions / Before Use / AssemblySafety instructions
work areas to protect persons
nearby. Keep unauthorised per-
sons away from the welding area.
Walls in the direct vicinity of fixed
work areas should be neither
light coloured nor glossy.
Protect windows against rays
passing through or reflecting at
a minimum to head height, e.g.
with suitable paint.
EMC Device Classification
This is a welding unit with Class A
electromagnetic compatibility in ac-
cordance with the IEC 60974-10
standard. Therefore, it fulfils the ap-
plicable requirements for industrial
and domestic use. It may be con-
nected to the public low voltage
electricity supply in residential areas.
Even when the flux-cored arc weld-
ing unit complies with standardized
emission thresholds, electric arc
welding units may cause electro-
magnetic interference in sensitive
systems and devices.
The user is responsible and must
undertake the appropriate safety
measures for interference which
results from arcs during the welding
process. In doing so, the user must
take the following into account in
particular:
- Power, control, signal and tele-
communications cables
- Computers and other microproces-
sor-controlled devices
- Televisions, radios and other play-
back devices
- Electronic and electric safety
equipment
- People with pacemakers or hearing
aids
- Measuring devices and calibration
devices
- Interference immunity of other
devices in the vicinity
- The time of day during which
welding work is being carried out.
To reduce potential interference
radiation, it is recommended that
you:
- Equip the mains connection with a
mains filter or shield it with a metal
pipe
- Regularly perform maintenance
work on the flux-cored arc welding
unit and keep it in good condition
- Weld cables should be as short
as possible, fully unwound and
run as parallel on the ground as
possible
- Potential equalization should be
provided
15 GB/IE/NI
Safety instructions / Before Use / Assembly
- The work pieces should be prop-
erly earthed
- Devices and systems susceptible
to interference radiation should be
removed from the welding area if
possible or shielded.
Before Use
Remove all parts from the packaging and inspect
whether the flux-cored arc welding unit or the
individual parts are visibly damaged. If this is
the case, do not use the flux-cored arc welding
unit. Contact the manufacturer using the service
address stated.
Remove all protective film and other transport
packaging.
Check that all items included in the scope of
delivery are present.
Assembly
Assembling the
welding helmet
Insert the dark welding lens
21
into the mask
with the writing to the top
22
(see Fig. A).
The marking on the dark welding lens
21
must
be visible from the front of the welding helmet.
Push the handle
16
into the suitable notch on
the mask from the inside until it clicks in (See
Fig. B).
Inserting the flux-cored wire
To prevent the hazard of an
electrical shock, injury or damage, pull the mains
plug from the socket before maintenance or prepar-
ing for work.
Note: Depending on the application, different
welding wires may be required. Welding wires with
a diameter from 0.6 – 0.9 mm can be used with this
unit.
The feed roller, welding nozzle and wire cross-section
must always be compatible.
The unit is suitable for wire reels up to a maximum
of 450g.
Unlock and open the cover for the wire feeder
unit
1
by lifting the threaded rod up from the
slotted hole.
Unlock the roller unit by turning the roller
holder
25
clockwise (see Fig. C).
Remove the roller holder
25
from the shaft (see
Fig. C).
C
25
Note: Please ensure that the wire end does not
loosen and that the roll does not automatically
roll away. The wire end may only be loosened
during assembly.
Unwrap the flux-cored wire welding coil
18
completely so that it can be unrolled freely.
However, do not loosen the wire end just yet
(see Fig. D).
Place the wire reel onto the shaft. Ensure that
the roll uncoils on the side with the wire outlet
26
(see Fig. D).
Reattach the roller holder
25
and lock it by
pressing on it and turning it counterclockwise
(see Fig. D).
Safety instructions
16 GB/IE/NI
AssemblyAssembly
D
26
18
Loosen the adjusting knob
27
and pivot it up-
wards (see Fig. E).
E
27
Turn the pressing roller unit
28
to the side (see
Fig. F).
F
28
Loosen the feed roller holder
30
by turning it
counterclockwise and remove it by pulling it
upwards (see Fig. G).
Check the top of the feed roller
29
to see if the
appropriate wire thickness is set. If necessary,
the feed roller must be turned around or replaced.
The welding wire supplied (Ø 0.9 mm) must be
used in the feed roller
29
with the next highest
wire thickness diameter of Ø 0.9 mm.
The wire must be in the upper notch!
Reattach the feed roller holder
30
and screw it
tightly.
G
3029
Remove the burner nozzle
7
by rotating it
clockwise (see Fig. H).
Unscrew the welding nozzle
14
(see Fig. H).
Lead the cable assembly
13
away from the
welding unit in as straight a line as possible
(place it on the floor).
H
7
14
Remove the wire end from the coil edge (see
Fig. I).
Shorten the wire end using a wire cutter or side
cutter to remove the damaged/ bent wire (see
Fig. I).
Note: The wire must be kept taut the entire
time to prevent it from loosening and unrolling!
17 GB/IE/NI
Assembly
It is recommended that you always carry out
work with another person.
I
Push the flux-cored wire through the wire outlet
26
(see Fig. J).
J
26
Lead the wire along the feed roller
29
and
then push it into the cable assembly intake
31
(see Fig. K).
K
2931
Pivot the pressing roller unit
28
in the direction
of the feed roller
29
(see Fig. L).
Mount the adjusting knob
27
(see Fig. L).
Adjust the counter-pressure using the adjusting
knob in such a way that the welding wire sits
tightly between the pressing roller and the feed
roller
29
in the upper duct without being
squashed (see Fig. L).
L
29 28 27
Switch the welding unit on using the main
switch
5
.
Press the burner button
12
.
Now the wire feeder system will push the weld-
ing wire through the cable assembly
13
and
the burner
11
.
As soon as the wire protrudes 1 – 2 cm from
the torch neck
32
you can release the burner
button
12
once more (see Fig. M).
Assembly
18 GB/IE/NI
Initial UseAssembly / Initial Use
M
32 12
Switch the welding unit off again.
Screw the welding nozzle
14
back on.
Ensure that the welding nozzle
14
matches the
diameter of the welding wire being used (see
Fig. N).
For the welding wire supplied (Ø 0.9 mm) the
welding nozzle
14
with the next highest
diameter of 1.0 mm must be used.
N
14 12
Push the burner nozzle
7
back onto the torch
neck
32
by rotating it clockwise (see Fig. O).
O
7 32
To prevent the hazard of an
electrical shock, injury or damage, pull the mains
plug from the socket before maintainance or pre-
paring for work.
Initial Use
Switching the unit on and off
Switch the welding unit on and off using the
main switch
5
. If you do not use the welding
unit for an extended period, pull the plug out
of the mains socket. It is only then that the unit
will not be supplied with any current.
Adjusting the welding current
You can adjust the desired welding current using
the switches
8
9
on the front of the welding unit.
If, for example, the MIN switch
8
and switch 1
9
are up, the welding current amounts to 40 A and
the duty cycle is 60 %.
If, for example, the MAX switch
8
and switch 2
9
are down, the welding current amounts to 90 A
and the duty cycle is 10 %.
The required welding current depends on the weld-
ing wire diameter, the material thickness and the
desired weld penetration depth.
Adjusting the wire feeder
To achieve a consistent weld, the adjustment wheel
for the wire feeder
10
can be used to finely adjust
the wire feeder. It is recommended that you start
with a setting in the centre position and reduce or
increase the speed if necessary.
The required welding current depends on the weld-
ing wire diameter used, the material thickness, the
desired weld penetration depth and the gaps to be
bridged on the work pieces to be welded.
Overload protection
The welding unit is protected against thermal over-
load with an automatic protective device (thermostat
with an autorecloser). The overload protection inter-
rupts the process when the circuit has been over-
loaded and the yellow control lamp
6
illuminates.
If the protective device has been activated, al-
low the unit to cool down (approx. 15 minutes).
As soon as the yellow control lamp for overload
19 GB/IE/NI
Initial Use
protection
6
turns off, the unit is ready to use
once more.
Welding helmet
HEALTH HAZARD! If you
do not use the welding helmet, harmful UV rays
and heat emitting from the arc can damage your
eyesight.
Always use the welding helmet when you weld.
Welding
RISK OF BURNS! Hot,
welded work pieces are very hot, meaning that you
can burn yourselves on them.
Always use a pliers to move hot, welded work
pieces.
After you have connected the welding
unit to the electricity supply, proceed as
follows:
Connect the earth cable with the earth terminal
4
to the work piece to be welded.
Ensure that good electrical contact exists.
The workpiece should be free of rust and paint
on the area to be welded.
Select the desired welding current and the wire
feeder depending on welding wire diameter,
material thickness and desired weld penetra-
tion depth.
Switch on the unit.
Hold the welding helmet
20
in front of your
face and lead the burner nozzle
7
along the
area of the work piece to be welded.
Press the burner button
12
to generate an arc.
When the arc burns, the unit feeds wire into the
weld pool.
If the welding spot is big enough, the burner
11
is slowly led along the desired edge.
The gap between the burner nozzle and work
piece should be as small as possible (in any
case, no more than 10 mm).
If necessary, oscillate it gently to enlarge the
weld pool somewhat. For those who are less
experienced, it can be difficult to form a decent
arc i.e. the correct setting for the welding current
and wire feeder speed.
You can figure out the best welding current and
wire feeder speed settings by practicing on a
test piece. A well-adjusted arc has a soft, steady
humming sound.
The weld penetration depth should be as deep
as possible, however, the weld pool should not
fall through the work piece.
In the case of rough or harsh rattling, decrease
the wire feeder speed or switch to a higher
power setting (increase welding current).
If the wire feeder speed is too high and / or the
welding current is too low, the welding wire
may not melt properly and may dip into the
welding seam and into the work piece.
A quiet, dull sound with a flickering arc indicates
too low a wire feed.
Increase the wire feeder speed or switch to a
lower welding current.
The wire melts even before it has reached the
welding seam with a welding current that is too
high. The result is that drops form on the welding
wire, as well as spraying and an inconsistent
arc.
The slag may only be removed from the seam
when it has cooled down.
To continue the welding process on an inter-
rupted seam:
Firstly, remove the slag from the point of attach-
ment.
Ignite the arc in the weld groove, lead it to the
connection point, properly melt the material
there and then continue along the welding
seam.
CAUTION! Ensure that the burner is always
put down on an insulated surface after welding.
Always switch the welding unit after finishing
welding work and during breaks, and always
pull the mains plug out of the socket.
Assembly / Initial Use
20 GB/IE/NI
Initial Use / Maintenance and Cleaning / Environmental instructions ... Initial Use
Creating a welding seam
Spot-welded seam or forehand welding
The burner is pushed forwards.
Result: The penetration depth is lower, seam width
is larger, weld bead is flatter and fault tolerance is
greater.
Pull-welded seam or backhand welding
The burner is pulled away from the welding seam.
Result: The penetration depth is higher, seam width
is smaller, weld bead is higher and the fault tolerance
is lower.
Welded joints
There are two basic joint types in welding technology:
butt welding and angle welding (outside edge, in-
side edge and overlapping).
Butt welded joints
For butt welded joints up to 2mm thick, the welding
edges are brought together completely.
For larger thicknesses, see the table below:
P
Flat butt welded joints
Welding processes should be carried out without
interruption and with a sufficient penetration depth.
Therefore, good preparation is essential.
Factors which effect the quality of the welding
results include: the welding current, the distance
between the welding edges, the burner tilt and the
respective welding wire diameter.
The steeper the burner is held in relation to the
work piece, the higher the penetration depth and
vice versa.
Q
To forestall or reduce deformations which could
arise during material hardening it is a good idea
where possible to fix the work pieces using a piece
of equipment which counteracts the contraction or
deformation of the material.
It is recommended that you avoid hardening the
welded structure to prevent fractures in the welded
seam. These difficulties can be reduced if you are
able to rotate the work piece in such a way that the
welding process can be carried out in two opposite
runs.
R
Welded joints on outside edges
Preparation for this is very simple.
S
However, this is not practical for stronger materials.
In this situation, it is better to prepare a joint as
21 GB/IE/NI
Initial Use / Maintenance and Cleaning / Environmental instructions ...
depicted in the figure opposite, in which the edge
of a plate is angled.
45°
T
Welded joints on inside edges
Preparation for this welded joint is very simple and
can be carried out on materials up to 5mm thick.
The measurement "d" must be reduced to a minimum
and should in any case be less that 2mm.
d
U
However, this is not practical for stronger materials.
In this situation it is better to prepare a joint as de-
picted in Figure V, in which the edge of a plate is
angled.
90°
V
Overlapping welded joints
The most common preparation for this is to use
straight welding edges. The welding process can
be carried out with a normal angle weld seam. Both
work pieces must be brought together as closely as
possible.
W
Maintenance and Cleaning
Note: The welding tool requires regular maintena
nce
and reconditioning to work properly and to comply
with safety requirements. Improper and incorrect
operation may result in malfunctions and damage
the tool.
Switch off the main power supply and the main
switch on the device before maintaining or re-
pairing the welding tool.
Regularly clean the inside and outside of the
welding tool. Remove dirt and dust inside the
device with air, steel wool, or a brush.
Current regulators, earthing equipment, internal
cables, the blowpipe coupler and adjusting
screw should be maintained regularly. Tighten
loose screws and replace rusty screws.
Regularly check the leakage resistance of the
welding tool. Use suitable measuring instruments
for this purpose.
In the event of a defect or if components need
to be replaced, please contact the correspond-
ing professional.
Environmental instructions
and disposal information
Don‘t waste,
recycle!
Device, accessories and packaging
should be recycled in an environmen-
tally friendly manner.
Do not dispose of the inverter welder equipment w
ith
your household waste, or throw into fire or water. If
possible, non-operational equipment should be re-
cycled. Contact your local retailer for information.
Initial Use
22 GB/IE/NI
Service / EU Conformity Declaration Information about warranty and service processing / Warranty terms
Information about warranty
and service processing
Creative Marketing Consulting GmbH
warranty
Dear customer, the warranty for this device is
3 years from the date of purchase. In the event of
product defects, you have legal rights against the
retailer of this product. Your statutory rights are not
limited in any way by our warranty detailed below.
Warranty terms
The warranty period begins on the date of purchase.
Please retain the original receipt safely. This docu-
ment is required as your proof of purchase.
Should this device show any fault in materials or
manufacture within three years from date of pur-
chase, it will be repaired or replaced - at our choice
- by us free of charge. This warranty is conditional
on the defective device and the receipt of purchase
(store receipt) being presented within the three year
warranty period, and that there is a brief written
description of the nature of the defect and of the
date it arose.
If the defect is covered by our warranty, we will
return the repaired equipment or replacement thereof.
A repair or exchange of the equipment does not
extend a new warranty period.
Extent of warranty
The appliance has been manufactured to strict
quality guidelines and meticulously examined
before delivery.
The warranty applies to faults in material or manu-
facture. This warranty does not apply to product
parts subject to normal wear and tear and which
can therefore be considered as wear items, or to
damage to fragile parts, e.g. switches, storage
batteries or glass parts.
This warranty becomes void if the device has been
damaged or improperly used or maintained. All
instructions provided in the operating instructions
must be followed strictly to constitute proper use of
the product. Purposes and practices which the op-
erating instructions warn of or advise against must
be avoided without fail.
This product is intended for private, non-commercial
use only. Any incorrect or improper use of the device,
use of force and changes not performed by our au-
thorized service branch will void the warranty.
Processing of warranty claims
Please follow the instructions below to ensure your
claim is processed quickly:
When inquiring about your product please have
your receipt and product number (e.g. IAN 12345)
ready as your proof of purchase.
The product number can be found on the type plate,
an engraving, the cover page of your instructions
(bottom left) or the decal at the back or bottom.
In the event of malfunctions or other defects please
first contact the service department below by
phone or e-mail.
A product recorded as defective, along with the
proof of purchase (sales receipt) and a description
of the defect and when it occurred, can then be re-
turned free of charge to you to the service address
provided.
Notice:
Download this and many other manuals,
product videos and software from
www.lidl-service.com.
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