scheppach WSE900 Inverter Welder Instruction Manual

scheppach WSE900 Inverter Welder Instruction Manual

Explanation of the symbols on the equipment

Introduction

MANUFACTURER:

Dear Customer,

We hope your new tool brings you much enjoyment and success.

NOTE:

According to the applicable product liability laws, the manufacturer of the device does not assume liability for damages to the product or damages caused by the product that occurs due to:

• Improper handling,
• Non-compliance of the operating instructions,
• Repairs by third parties, not by authorized ser- vice technicians,
• Installation and replacement of non-original spare parts,
• Application other than specified,
• A breakdown of the electrical system that oc- curs due to the non-compliance of the electric regulations and VDE regulations 0100, DIN 57113 /

We recommend:

Read through the complete text in the operating instructions before installing and commissioning the device.
The operating instructions are intended to help the user to become familiar with the machine and take advantage of its application possibilities in accordance with the recommendations.
The operating instructions contain important information on how to operate the machine safely, profession- ally and economically, how to avoid danger, costly repairs, reduce downtimes and how to increase reli- ability and service life of the machine.

In addition to the safety regulations in the operating instructions, you have to meet the applicable regula- tions that apply for the operation of the machine in your country.
Keep the operating instructions package with the machine at all times and store it in a plastic cover to protect it from dirt and moisture.
Read the instruction manual each time before oper- ating the machine and carefully follow its informa- tion.
The machine can only be operated by persons who were instructed concerning the operation of the machine and who are informed about the associated dangers. The minimum age requirement must be complied with. In addition to the safety requirements in these operating instructions and your country’s applicable regulations, you should observe the generally recognized technical rules concerning the operation of woodworking machines.

Unpacking

• Open the packaging and remove the device
• Remove the packaging material as well as the packaging and transport bracing (if available).
• Check that the delivery is
• Check the device and accessory parts for trans- port damage.
• If possible, store the packaging until the war- ranty period has

ATTENTION

The device and packaging materials are not toys! Children must not be allowed to play with plastic bags, film and small parts! There is a risk of swal- lowing and suffocation!

Layout (Fig. 1)

1. ON / OFF switch
2. Potentiometer for adjusting the welding current
3. Welding current scale
4. Indicator lamp for operation
5. Warning lamp for overheating
6. Positive quick-lock coupling
7. Negative quick-lock coupling
8. Power cable
9. Cable with electrode holder
10. Cable with ground terminal
11. Carrying strap
12. Combination wire brush with chipping hammer
13. Welding shield
14. Grip

Important information

Please read the directions for use carefully and observe the information provided. It is important to consult these instructions in order to acquaint

yourself with the machine, its proper use and safety precautions.

Safety information

Please note

IMPORTANT

Use this equipment only for the purpose for which it is designed, as described in these instructions.
Handling this system incorrectly may be hazardous for persons, animals and property. The user of this system is responsible for his/her own safety and for the safety of others. Read these operating instruc- tions and follow all the regulations.

• Repairs and/or maintenance work must be left strictly to qualified
• Only the welding cables supplied with the equip- ment and the accessories recommended by the manufacturer are allowed to be
• Ensure that the appliance is looked after prop-
• To ensure that sufficient air can be drawn in through the ventilation slits, the appliance should not be constricted or placed next to a wall while it is operating. Make sure that the appliance is correctly connected to the mains Do not subject the mains lead to any tensile stress. Unplug the appliance before you change its position.
• Check the condition of the welding cables, the electrode tongs and the earth terminals; wear on the insulation and the live parts may result in dangerous conditions and reduce the quality of the welding
• Arc welding generates sparks, molten metal particles and smoke, so the following is re- quired: Remove all inflammable substances and/or materials from the working
• Ensure that there is adequate ventilation.
• Do not weld on tanks, vessels or pipes that have contained inflammable liquids or Avoid all direct contact with the welding circuit; the idling voltage between the electrode tongs and the earth terminal may be dangerous.
• Do not store or use the appliance in wet or damp conditions or in the
• Protect your eyes with specially designed gog- gles (DIN Grad 9-10). Wear gloves and dry safety clothing that are not contaminated by any oil or grease to ensure that your skin is not exposed to ultraviolet radiation from the
• Do not use this welder to defrost pipes

Remember!

• The radiation from the arc can damage your eyes and cause burns on skin.
• Arc welding generates sparks and droplets of molten metal; the welded workpiece may start to glow and will remain very hot for a relatively long period of time.
• Arc welding releases vapors that may be harm- Every electric shock is potentially fatal.
• Do not approach the arc within a radius of 15 m
• Protect yourself (and others around you) against the possible hazardous effects of the
• Warning: Depending on the mains connection conditions at the connection point of the welding set, other consumers connected to the mains may suffer faults.

Important!

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

Sources of danger during arc welding

Arc welding results in a number of sources of danger. It is therefore particularly important for the welder to comply with the following rules so as not to place himself or others in danger and to avoid endangering people and equipment.

• Have all work on the mains voltage system, for example on cables, plugs, sockets, , performed only by trained electricians. This particularly applies to configuring intermediate cables.
• If an accident occurs, disconnect the welding power source from the mains
• If electric touch voltages occur, switch off the welding set immediately and have it checked by an expert.
• Always check for good electrical contacts on the welding current side.
• Wear insulating gloves on both hands for weld- These offer protection from electric shocks (idling voltage in the welding circuit), harmful radiation (Heat and UV radiation) and from glowing metal and slag spatter.
• Wear firm, insulated footwear. Your shoes should also protect you in wet Opentoed footwear is not suitable since falling droplets of glowing metal will cause burns.
• Wear suitable clothing, do not wear synthetic
• Do not look into the arc with unprotected eyes, use only a welding safety shield with the proper safety glass in compliance with DIN In addition to light and heat, which may cause dazzling and burns, the arc also gives off UV ra- diation. Without proper protection, this invisible ultraviolet radiation causes very painful con- junctivitis, which will only be noticeable several hours later. In addition, UV radiation will cause sunburn-type symptoms on unprotected parts of the body.
• Personnel or assistants in the vicinity of the arc must also be notified of the dangers and pro- vided with the required protection; if necessary install safety walls.
• Ensure adequate ventilation for welding, particu- larly in small rooms since the process causes smoke and harmful
• Do not carry out any welding work on tanks that have been used to store gases, fuels, mineral oil or the like, even if they have been empty for a lengthy period of time, since any residue will result in a danger of
• Special regulations apply in areas where there is a potential risk of fire and/or
• Welds that are exposed to large stresses and must comply with safety requirements may only be completed by specially trained and approved Examples of such welds include pres- sure vessels, rails, trailer hitches, etc.
• Note: It must be noted that the protective con- ductor in electrical systems of appliances may be destroyed by the welding current in the event of negligence, for example if the earth terminal is placed on the welding set casing to which the protective conductor of the electrical system is The welding work is completed on a machine with a protective conductor connection. It is therefore possible to weld on the machine without having connected the earth terminal to it. In this case the welding current will flow from the earth terminal through the protective con- ductor to the machine. The high welding current may cause the protective conductor to melt.
• The fuses on the supply cables to the mains sockets must comply with the relevant regula- To comply with these regulations, only fuses or circuit breakers suitable for the cross- section of the cables may be used. The use of too high a fuse may result in the cable burning and fire damage to the building.

Constricted and wet areas

When working in constricted, wet or hot areas, use insulating supports and intermediate layers as well as slip-on gloves made of leather or other noncon- ductive materials to insulate your body against the floor, walls, conductive parts of the machine and the like. 13 І 72
If you use small welding transformers for welding in places with an increase electrical risk, for example in constricted areas with conductive walls, (tanks, pipes, etc.), in wet areas (which make work clothes wet) and in hot areas (perspiration on work clothes), the output voltage of the welding set when idling must not exceed 85 V (effective value). Therefore, the appliance may not be used for these purposes because its output voltage is higher than this.

Safety clothing

• While working, the welder must protect his entire body from radiation and burns by wearing suitable clothing and a face
• Slip-on gloves made of a suitable material (leather) must be worn on both hands. They must be in perfect
• Suitable aprons must be worn to protect cloth- ing from sparks and A safety suit and, if necessary, head protection must be worn if required by the type of work in question, e.g. overhead welding.
• The protective clothing used as well as all accessories must be in compliance with the “Personal safety equipment” EU

Protection from radiation and burns

• Provide information about the risk to eyes at the working site in the form of a poster with the wording “Caution – do not look at the flames”. Workplaces are to be screened off wherever possible so that personnel in the vicinity are Unauthorized persons are to be kept away from the welding work.
• The walls in the immediate vicinity of station- ary workplaces should not have a light color or a sheen. Windows up to head height are to be protected against radiation passing through

them or reflecting off them, for example by coat- ing them with a suitable paint.

Proper use

The machine is to be used only for its prescribed purpose. Any other use is deemed to be a case of misuse. The user / operator and not the manufac- turer will be liable for any damage or injuries of any kind caused as a result of this. Please note that our equipment has not been de- signed for use in commercial, trade or industrial ap- plications. Our warranty will be voided if the machine is used in commercial, trade or industrial businesses or for equivalent purposes.
Important information about the power connection This equipment falls under Class A of the stand- ard EN 60974-10, i.e. it is not designed for use in
residential areas in which the power supply is based on a public low-voltage supply system because given unfavorable conditions in the power supply the equipment may cause interference. If you want to use the equipment in residential areas in the which the power supply is based on a public low- voltage supply system, you must use an electromagnetic filter which reduces the electromagnetic interference to the point where the user no longer notices any disturbance.
In industrial parks or other areas in which the power supply is not based on a public low-voltage supply system the equipment can be used without such a filter.

General safety information

It is the user’s responsibility to install and use the equipment properly in accordance with the instruc- tions issued by the manufacturer. If electromagnetic interference is noticed, it is the user’s responsibility to eliminate said interference with the technical de- vices mentioned in the section “Important informa- tion about the power connection”.

Reduction of emissions

Main current supply

The welder must be connected to the main current supply in accordance with the instructions issued by the manufacturer. If interference occurs, it may be necessary to introduce additional measures, e.g. fit- ting a filter to the main current supply (see above in the section “Important information about the power connection”). The welding cables should be kept as short as possible

Pacemakers

Persons using an electronic life support device (e.g. a pacemaker) should consult their doctor before they go near electric sparking, cutting, burning or spotwelding equipment in order to be sure that the combination of magnetic fields and high electric cur- rents does not affect their devices.

Technical data

Mains connection                                   230V~ 50Hz

Welding current                                           20 – 160 A
On-load factor X
23%| 160 A
60%| 100 A
100%| 80 A
Idling voltage (V)| 85 V
Weight| 6.6 kg

Fitting the carrying strap (Fig. 2)

Attach the carrying strap (11) as shown in Fig.2.

Installing the welding shield (Fig. 3/4)

• Install the handle (14) on the welding shield (13) as shown in 4.
• Install the protective glass (15) on the welding shield (13) as shown in 4.
• Then fold the three sides of the welding shield. The two sides each connect to the top with two press studs.

Starting up

Connecting to the mains power supply

Before you connect the power cable (8) to the mains power supply, make sure that the data on the rating plate is the same as that for your mains supply.
Connect the machine to a properly installed protec- tive contact socket, with at least 16A circuit breaker

| | Electrode| (Ø| mm):| Welding current| (A)
---|---|---|---|---
1.6| 40 – 50 A
2| 40 – 80 A
2.5| 60 – 110 A
3.2| 80 – 130 A
4.0| 120 – 160 A

Danger! The mains plug may only be replaced by a qualified electrician.

Connecting the welding cable (Fig. 5)

Danger! Always make sure the device is unplugged before carrying out any connection work on the welding cable (9/10)! Connect the welding cable as shown in Fig. 5. To do so, connect the two connec- tors on the electrode holder (9) and the ground ter- minal (10) to the corresponding quick-lock couplings (6/7) and lock the connectors in place by turning them in a clockwise direction.

The cable with the electrode holder (9) is normally connected to the positive pole (6) and the cable with the ground terminal (10) to the negative pole (7).

Switching ON/OFF (Fig. 1)

Switch on the machine by moving the On/Off switch
(1) to the “I” position. The indicator lamp for opera- tion (4) then comes on. Switch off the machine by moving the On/Off switch (1) to the “0” position. The indicator lamp for operation (4) then goes out.

Welding preparations

Connect the earth terminal (10) direct to the part to be welded or to the support on which the part is resting.
Ensure that the earth terminal is in direct contact with the part to be welded. You should therefore avoid coated surfaces and/or insulated materials. The electrode holder cable has a special clamp at one end, which is used to secure the electrode.
The welding safety shield must be used at all times for welding. It protects your eyes from the radiation emitted by the arc and nevertheless enables you to watch the welding process.

Welding (Fig.1/5)

Connect all the electrical connections for the power supply and for the welding current circuit. Most coat- ed electrodes are connected to the positive pole.

However, some types of electrode have to be con- nected to the negative pole. Ensure that you observe the information supplied by the manufacturer in rela- tion to the type of electrode and correct polarity. Fit the welding cables (9/10) to the quick-lock couplings (6/7) accordingly. Then fasten the unsheathed end of the electrode in the electrode holder (9) and con- nect the ground terminal (10) to the part you wish to weld. Ensure that a good electric contact is made.
Switch on the device and set the welding current, depending on the electrode used, using the poten- tiometer (2). Hold the safety shield in front of your face and 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 an arc. Check that you have the correct electrode and current strength on a test part.

Maintenance

There are no parts inside the equipment which require additional maintenance.

Storage

Store the device and its accessories in a dark, dry and frost-proof place that is inaccessible to children. The optimum storage temperature is between 5 and 30˚C.
Store the electrical tool in its original packaging. Cover the electrical tool in order to protect it from dust and moisture.
Store the operating manual with the electrical tool

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Important!

Do not dab the workpiece with the electrode since it could be damaged, making it more diffi cult to ignite the arc.

As soon as the arc has ignited, attempt to keep it a distance from the workpiece equivalent to the diam- eter of the electrode.

This distance should be kept as constant as pos- sible during the welding process. The angle of the electrode in the direction in which you are working should be 20/30°.

Always use tongs to remove spent electrodes and to move parts that you have just welded. Please note that the electrode holder (9) must always be put down so that it is insulated after you have completed the welding work.

Do not remove the slag until the weld has cooled. If you want to continue a weld after an interrup- tion, the slag from your initial attempt must first be removed.

Overheating guard

The welding set is fitted with an overheating guard that protects the welding transformer from overheat- ing. If the overheating guard trips, the control lamp

(5) on your set will be lit. Allow the welding set to cool for a time.

Replacing the power cable Danger!

If the power cable for this equipment is damaged, it must be replaced by the manufacturer or its after- sales service or similarly trained personnel to avoid danger.

Maintenance and Care

Danger!

Always pull out the mains power plug before starting any cleaning work.

Cleaning

• Keep all safety devices, air vents and the motor housing free of dirt and dust as far as possible. Wipe the equipment with a clean cloth or blow it with compressed air at low pressure.
• We recommend that you clean the device im- mediately each time you have finished using

Clean the equipment regularly with a moist cloth and some soft soap. Do not use cleaning agents or solvents; these could attack the plastic parts of the equipment. Ensure that no water can seep into the device. The ingress of water into an electric tool increases the risk of an electric shock.

References

• scheppach | scheppach

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