arc welder

� � �ARC WELDEROperation and Safety Notes

ARC WELDER

P-ES 120

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Anleitung_1549054:_ 15.12.2009 14:58 Uhr Seite 1

� � �Before reading, unfold the page containing the illustrations and familiarise yourself with all functions of thedevice.

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Table of contents: Page

1. Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .62. Layout and items supplied . . . . . . . . . . . . . . . . . . . . . . . . . . . . .63. Important information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-94. Symbols and technical data . . . . . . . . . . . . . . . . . . . . . . . . . . .95. Assembling the welding screen . . . . . . . . . . . . . . . . . . . . . . . .96. Welding preparations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .107. Welding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .108. Overheating guard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .109. Transport . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1010. Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1011. Ordering spare parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1112. Disposal and recycling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1113. Circuit diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1214. Declaration of conformity . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1315. Guarantee certificate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14

The reprinting or reproduction by any othermeans, in whole or in part, of documentationand papers accompanying products ispermitted only with the express consent of ISCGmbH. Technical changes subject to change


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1. Introduction

� Important!When using the equipment, a few safetyprecautions must be observed to avoid injuriesand damage. Please read the completeoperating manual with due care. Keep thismanual in a safe place so that the information isavailable at all times. If you give the equipmentto any other person, give them these operatinginstructions as well. We cannot accept anyliability for damage or accidents which arisedue to a failure to follow these instructions andthe safety information.

2. Layout and items supplied(Fig. 1/2)

1. Carry handle2. Welding current scale3. ON/OFF switch4. Earth terminal5. Electrode holder6. Adjustment wheel for welding current7. Warning lamp for overheating8. Welding screen9. Safety glass10. Welding glass11. Welding screen holder12. Wire brush / slag hammer

3. Important information

The equipment is to be used only for itsprescribed purpose. Any other use is deemedto be a case of misuse. The user / operator andnot the manufacturer will be liable for anydamage or injuries of any kind caused as aresult of this.

Please note that our equipment has not beendesigned for use in commercial, trade orindustrial applications. Our warranty will bevoided if the equipment is used in commercial,trade or industrial businesses or for equivalentpurposes.

Please read the operating instructions carefullyand observe the information provided. It isimportant to consult these instructions in orderto acquaint yourself with the equipment, itsproper use and safety information.

� Safety informationPlease note

Warning!Use this equipment only for the purpose forwhich it is designed, as described in theseinstructions: Manual arc welding with coatedelectrodes. Handling this system incorrectlymay be hazardous for persons, animals andproperty and may result in burning buildings,electric shocks, eye injuries, etc. The user ofthis system is responsible for his/her own safetyand for the safety of others. Read theseoperating instructions and follow all theinformation.� Repairs and/or maintenance work must be

left strictly to qualified personnel.� Only use the welding cables supplied

(H07RN-F 3x1.5 mm2 /H01N2-D 1x10 mm2).

� Ensure that the equipment is looked afterproperly.

� To ensure that sufficient air can be drawn inthrough the ventilation slits, the equipmentshould not be constricted or placed next toa wall while it is operating. Make sure thatthe equipment is correctly connected to themains supply (see 4.). Do not subject themains lead to any tensile stress. Unplug theequipment before you change its position.

� Check the condition of the welding cables,the electrode holder and the earthterminals; wear on the insulation and thelive parts may result in dangerousconditions and reduce the quality of thewelding work.

� Arc welding generates sparks, molten metalparticles and smoke, so the following isrequired: Remove all inflammablesubstances and/or materials from theworking area.

� Ensure that there is adequate ventilation.� Do not weld on tanks, vessels or pipes that

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have contained inflammable liquids orgases. Avoid all direct contact with thewelding circuit; the idling voltage betweenthe electrode holder and the earth terminalmay be dangerous.

� Do not store or use the equipment in wet ordamp conditions or in the rain.

� Protect your eyes with specially designedgoggles (DIN level 9-10), which you canattach to the supplied welding screen. Weargloves and dry safety clothing that are notcontaminated by any oil or grease to ensurethat your skin is not exposed to ultravioletradiation from the arc.

� Do not use this welder to defrost pipes.� Make sure that the equipment is set up so it

stands firmly. If the equipment is set up onan angled surface, it may need to besecured by tying or blocking the wheels.

Hazard!The radiation from the arc can damage youreyes and cause burns on skin.Arc welding generates sparks and droplets ofmolten metal; the welded workpiece may startto glow and will remain very hot for a relativelylong period of time. Never touch the workpiecewith bare hands.Arc welding releases vapors that may beharmful. Every electric shock is potentially fatal.Do not approach the arc within a radius of 15 munprotected.Protect yourself (and others around you)against the possible hazardous effects of thearc.Warning: depending on the mains connectionconditions at the connection point of thewelding set, other consumers connected to themains may suffer faults.

Warning!If the supply mains and circuits are overloaded,other consumers may suffer interference duringthe welding work. If you have any doubts,contact your electricity supply company.

Sources of danger during arc welding

Hazard!Arc welding results in a number of sources ofdanger. It is therefore particularly important forthe welder to comply with the following rules soas not to place himself or others in danger andto avoid endangering people and equipment. � Have all work on the mains voltage system,

for example on cables, plugs, sockets, etc.,performed only by trained electricians. Thisparticularly applies to configuringintermediate cables.

� If an accident occurs, disconnect thewelding power source from the mainsimmediately.

� If electric touch voltages occur, switch offthe welding set immediately and have itchecked by an expert.

� Always check for good electrical contactson the welding current side.

� Wear insulating gloves on both hands forwelding. These offer protection from electricshocks (idling voltage in the welding circuit),harmful radiation (heat and UV radiation)and from glowing metal and slag spatter.

� Wear firm, insulated footwear. Your shoesmust also be suitable to protect you in wetconditions. Open-toed footwear is notsuitable since falling droplets of glowingmetal will cause burns.

� Wear suitable clothing, do not wearsynthetic clothes.

� Do not look into the arc with unprotectedeyes, use only a welding screen with theproper safety glass in compliance with DINstandards. In addition to light and heat,which may cause dazzling and burns, thearc also gives off UV radiation. Withoutproper protection, this invisible ultravioletradiation causes very painful conjunctivitis,which will only be noticeable several hourslater. In addition, UV radiation will causeharmful sunburn-type symptoms onunprotected parts of the body.

� Personnel or assistants in the vicinity of thearc must also be notified of the dangers andprovided with the required protection; ifnecessary install safety walls.


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� Ensure adequate ventilation for welding,particularly in small rooms since theprocess causes smoke and harmful gases.

� Do not carry out any welding work on tanksthat have been used to store gases, fuels,mineral oil or the like, even if they havebeen empty for a lengthy period of time,since any residue will result in a danger ofexplosion.

� Special regulations apply in areas wherethere is a potential risk of fire and/orexplosion.

� Welds that are exposed to large stressesand must comply with safety requirementsmay only be completed by specially trainedand approved welders. Examples of suchwelds include pressure vessels, rails, trailerhitches, etc.

� Notes:It must be noted that the protectiveconductor in electrical systems orequipment may be destroyed by thewelding current in the event of negligence,for example if the earth terminal is placed onthe welding set casing to which theprotective conductor of the electrical systemis connected. The welding work iscompleted on a machine with a protectiveconductor connection. It is thereforepossible to weld on the machine withouthaving connected the earth terminal to it. Inthis case the welding current will flow fromthe earth terminal through the protectiveconductor to the machine. The high weldingcurrent may cause the protective conductorto melt.

� The fuses on the supply cables to the mainssockets must comply with the relevantregulations (VDE 0100). To comply withthese regulations, only fuses or circuitbreakers suitable for the cross-section ofthe cables may be used (for earthingcontact sockets max. 13 A fuses or 13 Acircuit breakers). The use of too high a fusemay result in the cable burning and firedamage to the building.

Constricted and wet areas

Caution!When working in constricted, wet or hot areas,use insulating supports and intermediate layersas well as slip-on gloves made of leather orother non-conductive materials to insulate yourbody against the floor, walls, conductive partsof the equipment and the like.

If you use small welding transformers forwelding in places with an increase electricalrisk, for example in constricted areas withconductive walls, (tanks, pipes, etc.), in wetareas (which make work clothes wet) and in hotareas (perspiration on work clothes), the outputvoltage of the welding set when idling must notexceed 42 V (effective value). Therefore, theequipment may not be used for these purposesbecause its output voltage is higher than this.

Safety clothing

Caution!� While working, the welder must protect his

entire body from radiation and burns bywearing suitable clothing and a face guard.

� Slip-on gloves made of a suitable material(leather) must be worn on both hands. Theymust be in perfect condition.

� Suitable aprons must be worn to protectclothing from sparks and burns. A safetysuit and, if necessary, head protection mustbe worn if required by the type of work inquestion, e.g. overhead welding.

� The safety clothing used as well as allaccessories must comply with the directiveon “personal safety equipment”.

Protection from radiation and burns

Caution!� Provide information about the risk to eyes at

the working site in the form of a poster withthe wording “Caution – do not look at theflames”. Workplaces are to be screened offwherever possible so that personnel in thevicinity are protected. Unauthorized personsare to be kept away from the welding work.


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� The walls in the immediate vicinity ofstationary workplaces may not have a lightcolor or a sheen. Windows up to headheight are to be protected against radiationpassing through them or reflecting off them,for example by coating them with a suitablepaint.

4. Symbols and technical data

EN 60974-6 European standard for arcwelding sets and weldingpower supplies with limitedon time (part 6).

Symbol for welding powersupplies which are suitablefor welding inenvironments withincreased electricaldanger.

~ 50 Hz Alternating current andrated frequency value [Hz]

U0 Rated idling voltage [V]

40A/19.6V - 80 A/21,2 VMaximum welding currentand the correspondingstandardized operatingvoltage [A/V]

Ø Electrode diameter [mm]

I2 Welding current [A]

tw Average load time [s]

tr Average reset time [s]

Line input; number ofphases, the alternatingcurrent symbol and therated frequency value

Do not store or use theequipment in wet or dampconditions or in the rain.Use the equipment onlyindoors.

U1 Line voltage [V]

I1max Highest rated value of the line current [A]

I1eff Effective value of the highest line current [A]

IP 21S Protection type

H Insulation class

Mains connection: 230 V ~ 50 HzWelding current (A) at cos ϕ= 0.73: 40 - 80ø (mm) 1.6 2.0 2.5I2 40 55 80tw (s) 217 116 64tr (s) 1450 1381 1351Idling voltage (V): 48Power input: 4 kVA at 80 A cos ϕ = 0.73Fuse (A): 13Weight: 10.6 kg

The welding times apply for an ambienttemperature of 40° C.

5. Assembling the weldingscreen (fig. 2-5)

Insert the safety glass (9) and then the weldingglass (10) in the welding screen (8). Now fastenthe welding screen holder (11) to the weldingscreen, as shown in fig. 5.

1~ 50 Hz

S


6. Welding preparations

Connect the earth terminal (4) direct to the partto be welded or to the support on which the partis resting. Ensure that the earth terminal is indirect contact with the part to be welded. Youshould therefore avoid coated surfaces and/orinsulated materials. The electrode holder cablehas a special clamp (electrode holder (5)) atone end, which is used to secure the electrode.The welding screen (8) must be used at alltimes for welding. It protects your eyes from theradiation emitted by the arc and neverthelessenables you to watch the welding process.

7. Welding

After you have made all the electricalconnections for the power supply and for thewelding circuit, you can proceed as follows:Insert the unsheathed end of the electrode intothe electrode holder (5) and connect the earthterminal (4) to the part you wish to weld. Ensurethat a good electric contact is made.Switch on the welding set at the ON/OFF switch(3) and set the welding current using the settingwheel (6) to suit the electrode you wish to use.Hold the welding screen in front of your faceand rub the tip of the electrode on the part youwish to weld as if you were striking a match.This is the best method of igniting the arc.Check on a test part that you have the correctelectrode and current strength.

Electrode (Ø mm): Welding current (A)1.6 402 552.5 80

Important!Do not dab the workpiece with the electrodesince it could be damaged, making it moredifficult to ignite the arc.As soon as the arc has ignited, attempt to keepit a distance from the workpiece equivalent tothe diameter of the electrode. This distanceshould be kept as constant as possible during

the welding process. The angle of the electrodein the direction in which you are working shouldbe 20/30°.

Important!Always use tongs to remove spent electrodesand to move parts that you have just welded.Please note that the electrode holder (5) mustalways be put down so that it is insulated afteryou have completed the welding work. Do notremove the slag until the weld has cooled. Ifyou want to continue a weld after aninterruption, the slag from your initial attemptmust first be removed.

8. Overheating guard

The welding set is fitted with an overheatingguard that protects the welding transformerfrom overheating. If the overheating guard trips,the control lamp (7) on your set will be lit. Allowthe welding set to cool for a time.

9. Transport

Before transporting the welder you must firstdisconnect the power plug and remove theground terminal from the workpiece. Then windup the cable properly. Now you can carry thewelder to a different place by the carry handle(1).

10. Maintenance

Remove dust and dirt from the equipment atregular intervals. Cleaning is best carried outwith a fine brush or a cloth.

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11. Ordering spare parts

Please provide the following information on allorders for spare parts:� Model/type of the equipment� Article number of the equipment� ID number of the equipmentFor our latest prices and information please goto www.isc-gmbh.info

12. Disposal and recycling

The equipment is supplied in packaging toprevent it from being damaged in transit. Theraw materials in this packaging can be reusedor recycled. The equipment and its accessoriesare made of various types of material, such asmetal and plastic. Defective components mustbe disposed of as special waste. Ask yourdealer or your local council.

For EU countries only

Never place any electric tools inyour household refuse!

To comply with European Directive 2002/96/ECconcerning old electric and electronicequipment and its implementation in nationallaws, old electric power tools have to beseparated from other waste and disposed of inan environment-friendly fashion, e.g. by takingto a recycling depot.

Recycling alternative to the return request:Instead of returning the equipment to themanufacturer, the owner of the electricalequipment is obliged to ensure that theequipment is properly disposed of if heabandons ownership. The old equipment canbe returned to a suitable collection point, thatwill dispose of the equipment in accordancewith the national recycling and waste disposalregulations. This does not apply to anyaccessories or aids without electricalcomponents supplied with the old equipment.

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13. Circuit diagram


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14. Declaration of conformity

k erklärt folgende Konformität gemäß EU-Richtlinie und Normen für Artikel

t explains the following conformity according to EU directives and norms for the following product

p déclare la conformité suivante selon la directive CE et lesnormes concernant l’article

C dichiara la seguente conformità secondo la direttiva UE ele norme per l’articolo

N verklaart de volgende overeenstemming conform EUrichtlijn en normen voor het product

m declara la siguiente conformidad a tenor de la directiva ynormas de la UE para el artículo

O declara a seguinte conformidade, de acordo com a directiva CE e normas para o artigo

l attesterer følgende overensstemmelse i medfør af EU-direktiv samt standarder for artikel

U förklarar följande överensstämmelse enl. EU-direktiv ochstandarder för artikeln

q vakuuttaa, että tuote täyttää EU-direktiivin ja standardienvaatimukset

. tõendab toote vastavust EL direktiivile ja standarditelej vydává následující prohlášení o shodě podle směrnice

EU a norem pro výrobekX potrjuje sledečo skladnost s smernico EU in standardi za

izdelekW vydáva nasledujúce prehlásenie o zhode podľa smernice

EÚ a noriem pre výrobokA a cikkekhez az EU-irányvonal és Normák szerint a

következő konformitást jelenti ki

P deklaruje zgodność wymienionego poniżej artykułu znastępującymi normami na podstawie dyrektywy WE.

e декларира съответното съответствие съгласноДиректива на ЕС и норми за артикул

H paskaidro šādu atbilstību ES direktīvai un standartiemG apibūdina šį atitikimą EU reikalavimams ir prekės

normomsQ declară următoarea conformitate conform directivei UE

şi normelor pentru articolulz δηλώνει την ακόλουθη συμμόρφωση σύμφωνα με την

Οδηγία ΕΚ και τα πρότυπα για το προϊόνB potvrđuje sljedeću usklađenost prema smjernicama EU

i normama za artiklf potvrđuje sljedeću usklađenost prema smjernicama EU

i normama za artikl4 potvrđuje sledeću usklađenost prema smernicama EZ i

normama za artikal T следующим удостоверяется, что следующие

продукты соответствуют директивам и нормам ЕС1 проголошує про зазначену нижче відповідність

виробу директивам та стандартам ЄС на виріб5 ја изјавува следната сообрзност согласно

ЕУ-директивата и нормите за артиклиZ Ürünü ile ilgili AB direktifleri ve normları gereğince

aşağıda açıklanan uygunluğu belirtirL erklærer følgende samsvar i henhold til EU-direktivet

og standarder for artikkelE Lýsir uppfyllingu EU-reglna og annarra staðla vöru

KonformitätserklärungEinhell Germany AG · Wiesenweg 22 · D-94405 Landau/Isar

Elektro-Schweißgerät P-ES 120 (Parkside)

Standard references: EN 60974-1; EN 60974-6; EN 60974-10

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x

2009/105/EC2006/95/EC2006/28/EC2005/32/EC2004/108/EC2004/22/EC1999/5/EC97/23/EC90/396/EC89/686/EC_96/58/EC

Landau/Isar, den 16.11.2009

First CE: 06 Archive-File/Record: 1549050-06-4155050-09Art.-No.: 15.490.54 I.-No.: 01019 Documents registrar: Daniel Protschka Subject to change without notice Wiesenweg 22, D-94405 Landau/Isar

Weichselgartner/General-Manager Wang/Product-Management

2006/42/EC

2004/26/ECEmission No.:

2000/14/EC_2005/88/EC

Annex IVNotified Body:Notified Body No.:Reg. No.:

Annex VAnnex VINoise: measured LWA = dB (A); guaranteed LWA = dB (A)P = KW; L/Ø = cmNotified Body:


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15. GUARANTEE CERTIFICATEDear Customer,

All of our products undergo strict quality checks to ensure that they reach you in perfect condition. In the unlikelyevent that your device develops a fault, please contact our service department at the address shown on thisguarantee card. Of course, if you would prefer to call us then we are also happy to offer our assistance underthe service number printed below. Please note the following terms under which guarantee claims can be made:

1. These guarantee terms cover additional guarantee rights and do not affect your statutory warranty rights.We do not charge you for this guarantee.

2. Our guarantee only covers problems caused by material or manufacturing defects, and it is restricted to therectification of these defects or replacement of the device. Please note that our devices have not beendesigned for use in commercial, trade or industrial applications. Consequently, the guarantee is invalidatedif the equipment is used in commercial, trade or industrial applications or for other equivalent activities. Thefollowing are also excluded from our guarantee: compensation for transport damage, damage caused byfailure to comply with the installation/assembly instructions or damage caused by unprofessionalinstallation, failure to comply with the operating instructions (e.g. connection to the wrong mains voltage orcurrent type), misuse or inappropriate use (such as overloading of the device or use of non-approved toolsor accessories), failure to comply with the maintenance and safety regulations, ingress of foreign bodiesinto the device (e.g. sand, stones or dust), effects of force or external influences (e.g. damage caused bythe device being dropped) and normal wear resulting from proper operation of the device. This applies inparticular to rechargeable batteries for which we nevertheless issue a guarantee period of 12 months.

The guarantee is rendered null and void if any attempt is made to tamper with the device.

3. The guarantee is valid for a period of 3 years starting from the purchase date of the device. Guaranteeclaims should be submitted before the end of the guarantee period within two weeks of the defect beingnoticed. No guarantee claims will be accepted after the end of the guarantee period. The original guaranteeperiod remains applicable to the device even if repairs are carried out or parts are replaced. In such cases,the work performed or parts fitted will not result in an extension of the guarantee period, and no newguarantee will become active for the work performed or parts fitted. This also applies when an on-siteservice is used.

4. In order to assert your guarantee claim, please send your defective device postage-free to the addressshown below. Please enclose either the original or a copy of your sales receipt or another dated proof ofpurchase. Please keep your sales receipt in a safe place, as it is your proof of purchase. It would help us ifyou could describe the nature of the problem in as much detail as possible. If the defect is covered by ourguarantee then your device will either be repaired immediately and returned to you, or we will send you anew device.

Of course, we are also happy offer a chargeable repair service for any defects which are not covered by thescope of this guarantee or for units which are no longer covered. To take advantage of this service, please sendthe device to our service address.

Einhell UK LtdMorpeth Wharf ·Twelve Quays

Birkenhead, WirralCH41 1LF

Tel. 0151 6491500 · Fax 0151 6491501


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IAN: 45846Einhell Germany AGWiesenweg 22D-94405 Landau/Isar

Last Information Update: 11/2009 Ident.-No.: 15.490.54 112009 - 6 6
