operating instructions welder 151...question, e.g. overhead welding. 4. the safety clothing used as...

t Operating InstructionsWelder

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Art.-Nr.: 15.440.56 I.-Nr.: 01018 CEN 151/2

Anleitung_CEN_151_2_GB_SPK_7:_ 03.02.2009 14:34 Uhr Seite 1

Stephan

Textfeld

Rot: 0%C; 100%M; 100Y; 0%K

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Read and follow the instructions and safety information before using for the first time!

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Before you start to read the instructions, fold out the pages with the illustrations and thenfamiliarize yourself with all the functions of the equipment.

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Table of contents: Page

1. Layout 72. Items supplied 73. Important information 7-104. Symbols and technical data 105. Installation Instructions 116. Mains connection 117. Welding preparations 118. Welding 119. Overheating guard 1110. Maintenance and transport 1211. Ordering spare parts 1212. Disposal and recycling 1213. Circuit diagram 1314. Declaration of conformity 1415. Warranty certificate 15

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� Important.

When using the equipment, a few safetyprecautions must be observed to avoid injuriesand damage. Please read the completeoperating instructions and safety regulationswith due care. Keep this manual in a safeplace so that the information is available at alltimes. If you give the equipment to any otherperson, hand over these operating instructionsand safety regulations as well. We cannotaccept any liability for damage or accidentswhich arise due to a failure to follow theseinstructions and the safety instructions.

1. Layout (Fig. 1)

1. Carry handle2. Welding current scale3. ON/OFF switch4. Earth terminal5. Electrode holder6. Hand wheel for welding current7. Warning lamp for overheating8. Slag hammer with brush9. Welding screen

2. Items supplied (Figure 1+2)

� Welding set� Welding area equipment

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 / operatorand not 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 equivalent

purposes.

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 regulations.

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.

Subject to technical changes

� Safety RegulationsPlease 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 fires burningbuildings, electric shocks, eye injuries, etc. Theuser of this system is responsible for his/herown safety and for the safety of others. Readthese operating instructions and follow all theregulations.� Repairs and/or maintenance work must be

left strictly to qualified personnel.� Only use the welding cables supplied (Ø 10

mm2 rubber-sheathed welding cables).� Ensure that the appliance is looked after

properly.� To ensure that sufficient air can be drawn

in through the ventilation slits, theequipment should not be constricted orplaced next to a wall while it is in operation.Make sure that the appliance is correctlyconnected to the mains supply (see 6.). Donot subject the mains lead to any tensilestress. Unplug the appliance before youchange its position.

� Check the condition of the welding cables,the electrode holder and the earthterminals; wear on the insulation and the

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live parts may result in dangerousconditions and reduce the quality of thewelding work.

� Arc welding generates sparks, moltenmetal particles and smoke, so the followingis required: Remove all inflammablesubstances and/or materials from theworking area.

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

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 appliance 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.Wear gloves and dry safety clothing thatare not contaminated by any oil or greaseto ensure that your skin is not exposed toultraviolet radiation 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 incline, it may need to be secured bytying or by blocking the wheels.

Hazard!

� The radiation from the arc can damageyour eyes and cause burns on skin.

� Arc welding generates sparks and dropletsof molten metal; the welded workpiece maystart to glow and will remain very hot for arelatively long period of time.

� Arc welding releases vapors that may beharmful. Every electric shock is potentiallyfatal.

� Do not approach the arc within a radius of15 m unprotected.

� Protect yourself (and others around you)against the possible hazardous effects ofthe arc.

� Warning: Depending on the mainsconnection conditions at the connectionpoint of the welding set, other consumersconnected to the mains may suffer faults.

Warning!

If the supply mains and circuits are overloaded,other consumers may suffer interferenceduring the welding work. If you have anydoubts, contact your electricity supplycompany.

Sources of danger during arc welding

Danger!

Arc welding results in a number of sources ofdanger. It is therefore particularly important forthe person performing the welding to complywith the following rules so as not to placehimself or others in danger and to avoid injuryto people and damage to equipment.

1. 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.

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

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

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

5. Wear insulating gloves on both hands forwelding. These offer protection fromelectric shocks (idling voltage in thewelding circuit), harmful radiation (heat andUV radiation) and from glowing metal andslag spatter.

6. 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.

7. Wear suitable clothing, do not wearsynthetic clothes.

8. 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, the


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arc 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 has harmfuleffects (similar to sunburn) on unprotectedparts of the body.

9. Personnel or assistants in the vicinity of thearc must also be notified of the dangersand be provided with the requiredprotection; if necessary install safety walls.

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

11. 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 risk ofexplosion.

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

13. Welds that are exposed to large stressesand must comply with certain safetyrequirements may only be performed byspecially trained and approved welders. Examples of such welds include pressurevessels, rails, trailer hitches, etc.

14. Notes:It must be noted that the protectiveconductor in electrical systems ofappliances may be destroyed by thewelding current in the event of negligence,for example if the earth terminal is placedon the welding set casing to which theprotective conductor of the electricalsystem is connected. The welding work isperformed 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.

15. The fuses on the supply cables to themains sockets must comply with the

relevant regulations. To comply with theseregulations, only fuses or circuit breakerssuitable for the cross-section of the cablesmay be used. 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 machine and the like.

If you use small welding transformers forwelding in places with an increased electricalrisk, for example in constricted areas withconductive walls, (tanks, pipes, etc.), in wetareas (which make work clothes wet) and inhot areas (perspiration on work clothes), theoutput voltage of the welding set when idlingmust not exceed 42 V (effective value).Therefore, the appliance may not be used forthese purposes because its output voltage ishigher than this.

Safety clothing

Caution!

1. While working, the welder must protect hisentire body from radiation and burns bywearing suitable clothing and a face guard.

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

3. 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.

4. The safety clothing used as well as allaccessories must comply with the directiveon “Personal Safety Equipment”.


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Protection from radiation and burns

Caution!

1. Provide information about the risk to eyesat the working site in the form of a posterwith the wording “Caution – do not look atthe flames”. Workplaces are to be screenedoff wherever possible so that personnel inthe vicinity are protected. Unauthorizedpersons are to be kept away from thewelding work.

2. The walls in the immediate vicinity ofstationary workplaces must not have a lightcolor or sheen. Windows at least up tohead height must be safeguarded againstradiation passing through them or reflectingoff them, for example by coating them witha suitable paint.

4. Symbols and technical data

EN 60974-6 European standard for arc welding sets and welding power supplies with limited on time (Part 6).

Symbol for welding powersupplies which are suitable for welding in environments with increased electrical danger.

~ 50 Hz Alternating current and ratedfrequency value [Hz]

U0 Rated idling voltage [V]

80 A/ 21,2 V Maximum welding current and the corresponding standardized operating voltage [A/V]

Ø Electrode diameter [mm]

I2 Welding current [A]

tw Average load time [s]

tr Average reset time [s]

Line input; number of phases, the alternating current symbol and the rated frequency value

U1 Line voltage [V]

I1max Highest rated value of the line

current [A]

I1eff Effective value of the highest line

current [A]

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

IP 21 S Protection type

H Insulation class

The set is interference-suppressed incompliance with EC Directive 2004/108/EC.

Mains connection: 230 V ~ 50 HzWelding current (A) at cos Ê = 0.73: 40 - 80 ø (mm) 1.6 2.0 2.5I2 (A) 40 55 80tw (s) 230 V 207 124 69tr (s) 230 V 2110 1774 1669Idling voltage (V): 48Power input: 4 kVA at 80 A cos Ê = 0.73 Fuse (A): 16Weight: 12,6 kg

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

1 ~ 50 Hz

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5. Installation Instructions

Assembling the welding screen (Fig. 2-5)

Insert the safety glass (10) and then thewelding glass (11) in the welding screen (9).Now fasten the welding screen holder (12) tothe welding screen, as shown in Fig. 5.

6. Mains connection

Before you connect the equipment to themains supply make sure that the data on therating plate are identical to the mains data.

7. Welding preparations

Connect the earth terminal (4) directly to thepart to be welded or to the support on whichthe part is resting. Ensure that the earthterminal is in direct contact with the part to bewelded.You should therefore avoid coatedsurfaces and/or insulated materials. Theelectrode holder cable has a special clamp atone end, which is used to secure the electrode.The welding screen (9) must be used at alltimes for welding. It protects your eyes fromthe radiation emitted by the arc andnevertheless enables you to watch the weldingprocess.

8. 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.Ensure that a good electric contact is made.Switch on the welding set at the ON/OFFswitch (3) and set the welding current using thehand wheel (6) to suit the electrode you wish touse.Hold the welding screen in front of your faceand rub the tip of the electrode on the part you

wish 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 40-802.5 60-100

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 distancemust be kept as constant as possible duringthe welding process. The angle of theelectrode in the direction in which you areworking must be 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 not remove the slag until the weld hascooled. If you want to continue a weld after aninterruption, the slag from your initial attemptmust first be removed.

9. Overheating guard

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


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10. Maintenance and transport

Remove dust and dirt from the machine atregular intervals. Cleaning is best carried outwith a fine brush or a cloth. Lift the equipmentby the carry handle (1) to transport it.

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 equipment� Part number of the required spare partFor 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 Directive2002/96/EC concerning old electric andelectronic equipment and its implementation innational laws, old electric tools have to beseparated from other waste and be disposed ofin an environment-friendly fashion, e.g. bytaking to a recycling depot.

Recycling alternative to returning the electricalequipment:The owner of the electrical equipment isobligated to arrange for its proper disposal if he

no longer wants to keep the equipment in hispossession and does not want to return it. Inthis case the old equipment can be taken to arecycling depot where it is disposed of inaccordance with national recycling and wastedisposal laws. This does not apply toaccessory parts and aids which supplementthe old equipment and contain no electricalparts.


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13. Circuit diagram


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

t declares conformity with the EU Directive and standards marked below for the article

p déclare la conformité suivante selon la directive CE et les normes concernant lʼarticle

� verklaart de volgende conformiteit in overeen-stemming met de EU-richtlijn en normen voor het artikel

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

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

U förklarar följande överensstämmelse enl. EU-direktiv och standarder för artikeln

q ilmoittaa seuraavaa Euroopan unionin direkti-ivien ja normien mukaista yhdenmukaisuutta tuotteelle

� erklærer herved følgende samsvar med EU-direktiv og standarder for artikkel

T заявляет о соответствии товара следующим директивам и нормам EC

B izjavljuje sljedeću uskladjenost s odredbama i normama EU za artikl.

Q declarå urmåtoarea conformitate cu linia direc-toare CE μi normele valabile pentru articolul.

Z ürün ile ilgili olarak AB Yönetmelikleri ve Normlar∂ gere©ince aμa©∂daki uygunluk aç∂klamas∂n∂ sunar.

z ‰ËÏÒÓÂÈ ÙËÓ ·ÎfiÏÔ˘ıË Û˘ÌÊˆÓ›· Û‡ÌÊˆÓ· ÌÂ ÙËÓ √‰ËÁ›· ∂∂ Î·È Ù· ÚfiÙ˘Ô ÁÈ· ÙÔ ÚÔ˚fiÓ

C dichiara la seguente conformità secondo la direttiva UE e le norme per lʼarticolo

l attesterer følgende overensstemmelse i henhold til EU-direktiv og standarder for produkt

j prohlašuje následující shodu podle směrnice EU a norem pro výrobek.

A a következő konformitást jelenti ki a termékek-re vonatkozó EU-irányvonalak és normák szerint

X pojasnjuje sledečo skladnost po smernici EU in normah za artikel.

� deklaruje zgodność wymienionego poniżej artykułu z następującymi normami na podstawie dyrektywy WE.

W vydáva nasledujúce prehlásenie o zhode podľa smernice EÚ a noriem pre výrobok.

e деклаpиpа следното съответствие съгласно диpективите и ноpмите на ЕС за пpодукта.

1 заявляє про відповідність згідно з Директивою ЄС та стандартами, чинними для даного товару

. deklareerib vastavuse järgnevatele EL direktiividele ja normidele

G deklaruoja atitikti pagal ES direktyvas ir normas straipsniui

4 izjavljuje sledeçi konformitet u skladu s odredbom EZ i normama za artikl

H Atbilstības sertifikāts apliecina zemāk minēto prečuatbilstību ES direktīvām un standartiem

E Samræmisyfirl‡sing sta›festir eftirfarandi samræmi samkvæmt reglum Evfrópubandalagsins og stö›lum fyrir vörur

Konformitätserklärung Einhell Germany AG · Wiesenweg 22 · D-94405 Landau/Isar

Elektro-Schweißgerät CEN 151/2

Art.-Nr.: 15.440.56 I.-Nr.: 01018 Archivierung: 1544056-46-4155050-08

Subject to change without notice

EN 60974-1; EN 60974-6; EN 60974-10

Landau/Isar, den 07.01.2009Yu Feng Qing

Product-ManagementWeichselgartner

General-Manager

98/37/EC

2006/95/EC

97/23/EC

2004/108/EC

90/396/EEC

89/686/EEC

87/404/EEC

R&TTED 1999/5/EC

2000/14/EG_2005/88/EC:

95/54/EC:

97/68/EC:

X

X

14. Declaration of conformity


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15. WARRANTY 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.


EH 02/2009 (01)

� Einhell UK LtdMorpeth WharfTwelve QuaysBirkenhead, WirralCH41 1NGTel. 0151 6491500, Fax 0151 6491501


operating instructions welder 151...question, e.g. overhead welding. 4. the safety clothing used as...

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