EXTOL INDUSTRIAL 8798222 Welding Cables User Manual

EXTOL INDUSTRIAL 8798222 Welding Cables

Features and purpose of use of welding cables

• The Extol® Industrial 8798221 and 8798222 Welding Cables are intended for welding using coated electrodes (MMA method) with a connection to a welding current source that is equipped with connecting quick couplers (connectors) 30-50. The Extol® Industrial 8798221 Welding Cables are intended for a max. welding current of 160 A and for use with the Extol® Industrial 8796011 Welding Inverter (with max. weld. current of 160 A). The Extol® Industrial 8798222 Welding Cables are intended for a welding current of 200 A and for use with the Extol® 8796012 Welding Inverter (with max. weld. current of 200 A) and likewise with the Extol® Industrial 8796011 Welding Inverter.
• The grounding clamp of the welding cable has a copper contact part connected with a plaited copper band for a perfect conductive connection (fig. 1).

Welding cable specifications

Extol® Industrial 8798221 Welding Cables for welding with a coated electrode (MMA); quick coupler connector 35-50, length 3 m, diameter 16 mm2, for max. welding current 160 A

Intended for max welding electrode diameter: 4 mm

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8796011

Extol® Industrial 8798222 Welding Cables for welding with a coated electrode (MMA); quick coupler connector 35-50, length 3 m, diameter 25 mm2, for max. welding current 200 A

Intended for max welding electrode diameter: 5 mm

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8796011,

8796012

ATTENTION: The necessary equipment and preparation preceding welding using the coated method should be described in the user‘s manual of the welding current source
(welding unit).

WARNING: All installation and maintenance performed on the welding unit must be performed with the el. current into the welding unit disco-nnected.

1. Before connecting the welding unit to a power source (to a power supply line), first insert the welding cable connectors into the welding unit sockets and secure them in place by turning them clockwise. The electrode clamps (holders) (see fig. 2) are connected, in the absolute majority of cases, to the positive pole on the welding unit and the grounding clamp to the negative pole. Nevertheless, verify the necessary polarity for the welding electrode according to the manufacturer‘s instruction on the electrode package since certain acid electrodes are connected to the negative pole.
   WARNING: The welding cables must be properly secured in the quick couplers to prevent transition resistance and their subsequent burning out.

2.  Mount a perfectly dry coated electrode stem into the electrode clamp (see fig. 2). The electrode must not have a damaged coat. Do not use damaged welding electrodes.

3. Perfectly clean the location of the weld. This location must be free of corrosion, paint, grease, mechanical particles (e.g. mud, dust deposits), etc. and it must be dry. For cleaning, use sandpaper, a steel brush or if possi-ble clean the given surface using an angle grinder with a flap disc with abrasive on the pad or with a wire brush installed on an angle grinder or drill. To remove grease, use a grease-free organic solvent, e.g. acetone, which needs to be thoroughly evaporated before continuing (ideally wiped dry using a textile).

4. Connect the grounding clamp directly to the part intended for welding near the weld location. The clamp contact point must be dry, free of corrosion, grease, mechanical particles, mud, paint, etc. to prevent transition resistance. For cleaning, use the specified cleaning agents. Move the already clamped clamp around in order to disturb the oxidised layer on the metal and to achieve the best possible contact with the welded material. Always connect the grounding clamp to the welded material because the material that is to be welded must always be in contact with the ground in order to minimise electromagnetic emissions as much as possible. It is important to make sure that the grounding of the welded material does not increase the risk of injury or damage to another electrical appliance.

5. Before connecting to the power cord of the welding unit to a power source, check that the voltage in the power supply circuit corresponds to a voltage of 220-240 V~50 Hz and that the power supply circuit is suitable for powering the welding unit.

6. Turn on the welding unit and set the desired welding current source.

7. Locate the cables in such a way that their insulation cannot be damaged by flying sparks or slag, and that the welding unit cannot fall in the event that the welding cables were to fall from a height.
    ATTENTION: The selected welding cables should be as short as possible respecting the work conditions, should be close to each other and located at the floor level or near it.

8. Prepare a welder‘s helmet. Check the darkness of the welding filter in DIN units with respect to the nece-ssary welding current, see table 2. In the event that the darkness is insufficient, the user‘s vision could be damaged.

9. Place the end of the electrode above the location of the weld, put the welder‘s face shield on your head and lightly strike the tip of the electrode on the part that you wish to weld until the arc is ignited. A wel-der‘s face shield with an auto-darkening welding filter can be placed on the face immediately, upon ignition of the arc, the welding filter will darken automatically. With welder‘s helmets without a auto darkening filter, it is necessary to put the shield on the face immediately upon the arc being ignited.

10.  Once the arc ignites, guide the electrode above the location of the weld at an angle of approximately 20-30° from the vertical and at a distance of approxi-mately 1.5 times its diameter above the surface and maintain this distance as constantly as possible while welding. To end the weld, disconnect the burning arc by moving the electrode away.

ATTENTION: In the event that burn-through of the welded material is occurring when welding under low current, then this may be caused by the HOT START function, therefore try setting the welding method selector to the TIG function (applies only to welding units that have these functions).

WARNING: y Tap the slag away from the weld once the weld cools down. When tapping away the slag, use eye protection. The weld can subsequently be ground down using an angle grinder with a flap disc with an abrasive pad or a wire brush, etc. When the weld is finished or interrupted, place the holder with the electrode or without it away from the welded workpiece so that an arc is not inadvertently ignited. Place the hot remaining piece of electrode and holder on to a non flammable surface so that persons or animals cannot suffer burns. Release the cooled burnt out electrodes out of the clamps by opening the clamp‘s jaws.

BASIC SAFETY INSTRUCTIONS

When using a welding unit, the welder must use a special welder‘s helmet equipped with welding filters with darkness levels based on the set welding current and based on the welding method used, as per table 2 below. For eye protection during welding, it is necessary to look through a welding helmet filter with a corresponding filter darkness in DIN units. This infor-mation must be shown on the helmet‘s welding filter. When using a welding helmet with an auto-darkening filter, the darkness of the filter is set using the manual control element to the required darkness, otherwise eye damage may result; in any case, the welding helmet must have the necessary darkness range in DIN units. The used welding helmet must meet the requi-rements of valid standards and respective annexes, namely standards EN 175, EN 169, EN 166 respectively EN 379+A1 (this norm applies only for auto-darkening welding filters), otherwise injury to the vision or face of the user could result. Set/select the filter darkness intensity based on the welding current according to the following table 2. Never look into the location of the weld without the required welding helmet with the required filter darkness and prevent access to persons without required protective equipment and access to animals. Do not use damaged or worn out personal protective equipment, e.g. a welding helmet with a cracked filter.

SYMBOL EXPLANATIONS

• SMAW = Shielded metal arc welding (manual arc welding with a coated electrode)
• MIG (heavy) = Metal inert gas welding (arc wel-ding of heavy metals with an electrode in inert gas)
• MIG (light) = Metal inert gas welding (arc welding of light alloys with an electrode in inert gas)
• TIG, GTAW = Tungsten inert gas, Gas tungsten arc welding (arc welding with tungsten electrode in inert gas)
• MAG/CO2= Metal active gas (arc welding with mel-ting electrode in active gas)
• SAW = Submerged arc welding (automatic welding under flux)
• PAC = Plasma arc cutting
• PAW = Plasma arc welding

Furthermore, other personal protective aids must be used: suitable protective work clothing, gloves, leather work footwear for protection against flying sparks, slag and burns. Likewise, it is necessary to ensure that the welder does not inhale the smoke emissions created during the welding process because they are damaging to health. The welder must use an appro-priate breathing mask. Exhaust for the emissions and ventilation must be provided for. Consult the suitability of the usability of personal protective aids at a personal protective aids store. Prevent access to persons without the required personal protective aids to the welding location. Ensure sufficient distance of persons without personal protective aids and animals from the welding location, and when appropriate, inform persons wit-hout welding helmets that may come in the vicinity of the welding location not to look into the welding location, as otherwise their vision may be damaged. When appropriate, protect the welding location by means of suitable protection against unwanted views of passerbys into the welding location.

• Prevent the use of the welding unit by children, persons with reduced mobility, mental perception or mental disorders, or persons with insufficient experience or knowledge or persons not acquainted with these instruction to not use this equipment. Children must not play with the welding unit. National regulations may limit the age of the user.
• A welding unit creates an electromagnetic field during operation, which may negatively affect the operation of active or passive medical implants (pacemakers) and threaten the life of the user. Prior to using this power tool, ask a doctor or the manufacturer of the implant, whether you may work with this power tool.
• Prior to welding, it is necessary to check that no hidden electrical wires or cables, gas or water lines, etc. will be impacted by the welding process. Otherwise there is a risk of injury, explosion or other damages.
•  The welded workpieces, electrode clamps and the area around the welding unit are very hot and there is a risk of burns. Take steps to prevent burns. Also inform the people around you if there is a possibility of them coming into contact with the welding location. Prevent access to children.
• The work environment must be perfectly ventilated or the welder must wear protection against the inhalation of fumes.
• The safety instructions for welders, welders of metals and for arc welding are provided in national standards or directives; in the Czech Republic these standards are ČSN 050601, ČSN 050630 as further amended. In different states, other technical regulations and standards apply.
• Regular audits of electrical parts of the welding current source are performed by an electrical audit technician or an authorised qualified person in the extent and deadlines specified by Czech national standard ČSN 33 1500. Requirements may differ as per the regulations of a different state. Requirements for regular inspections and audits of arc welding equipment are governed by a European standard.
• Do not weld with power cords and welding cables with insufficient conductor core cross-section. For reason of cooling by ambient air, conductors (cables) must be unwound.
• In the event that the TIG torch or power cord or welding cables overheat, stop welding in order to prevent damaging the insulation.
•  Never touch the charged parts of the electrical circuit. After use, carefully disconnect the welding torch from the welding current source and prevent it from coming into contact with grounded parts.
• When welding alloys and metals containing toxic metals such as lead, mercury, cadmium, zinc and beryllium, it is necessary to adhere to special safety regulations and prevent the inhalation of smoke emissions containing toxic metal fumes by means of gas masks, etc.
• To prevent the release of toxic gases while welding, thoroughly remove any paint coats, grease and other substances from the parts being welded.
• Always thoroughly ventilate work locations. Do not weld in locations where there is a suspicion of leaking natural gas or another flammable gas or in the vicinity of combustion engines.
•  Do not weld in an environment or in the vicinity of liquid chlorofluorocarbons (e.g. in degreasing pans), since during the welding process UV radiation is crea-ted, which transforms chlorofluorocarbon fumes into highly toxic gases.
• For safety reasons, welding work must not be perfor-med on tanks containing flammable substances (tanks storing gas, oils, fuels, etc.), pressure tanks, etc. This presents an explosion or fire hazard. Welding works must not be performed even on empty storage tanks used for flammable substances or empty pressure tanks. Welding must be performed pursuant to special regulations and the tanks must pass audit tests prior to being filled up. For welding in an environment with an explosion hazard, special safety regulations apply.
• In the event that it is necessary to use the source of the welding current on a sloping surface, it must be secured against overturning, sliding off or falling. The equip-ment has perfect stability up to an incline of 10%,
• Welding current (arc) must not be used for defrosting pipes.
• When working in heights, it is necessary to ensure the secure stability of the welder, the source of the welding current and the welding cables, and to ensure that accidents cannot occur as a result of tripping on the welding cables or that long welding cables do not hang from a height and by their weight overturn or pull down the welding unit from the height downwards. It is necessary to minimise the risk of the welding unit and the welder falling from a height.
• For safety reasons, the welding work must not be per-formed on metals containing inner fillings (e.g. pipes filled with water, flammable substances, pressurised steam, pressure vessels filled with gases, etc.), otherwi-se this presents a fire, explosion and injury, etc. hazard.
• The welding current source must not be operated in an environment with an explosion or fire hazard. Do not weld materials that contained flammable substances, or materials that create toxic or flammable fumes when heated. Do not start welding before identifying the substances that the materials contained. Even a very small amount of flammable gas or liquid may be the cause of a fire or explosion.
• To minimise the risk of tripping over a welding cable or power cord, or burns, prevent access to persons without necessary protective aids as well as animals and children.
• Ensure that insulation on the power cord or welding cables cannot be damaged by flying sparks, slag, etc. It is necessary to adhere to fire safety rules when working (e.g. do not place flammable materials on hot surfaces, etc.).
• The user or the user‘s employer must assess the specific risks that may arise as the result of every use. The user bears responsibility for foreseeable incorrect use if according to experience it could occur.
• Only use the welding cables to the extent of permitted use. Do not use them for currents higher than for which they are intended. Do not custom modify them for higher welding currents, for powering other equipment or for another purpose of use.

Storage

Store the cleaned equipment and cooled accessories in a safe location that is out of reach of children where temperatures do not exceed 40°. Protect the tool again-st direct sunlight, radiant heat sources, humidity and ingression of water.

Waste disposal

PACKAGING MATERIALS

• Throw packaging materials into a container for the respective sorted waste.

ELECTRICAL EQUIPMENT AND CONDUCTORS

• Do not dispose of unserviceable commodities in house-hold waste, but dispose of them in an environmentally safe manner. According to Directive 2012/19 EU, electrical appliances must not be thrown out with household waste, but rather handed over for eco- logical disposal at an electrical equip- ment disposal point. You can find infor- mation about collection points and collection conditions at your local town council office.

• Warranty, maintenance and servicing

• The product is covered by 24-month guarantee (respon-sibility for defects) from the date of sale.

• Free warranty repairs relate only to manu-facturing defects on the product (hidden and external) and do not relate to the wear of the product as a result of excessive load
  or normal use or damage of the product caused by incorrect use.

• For warranty repairs of the product, please contact the vendor from whom you purchased the product and they will organise repairs at an authorised service centre for the Extol® brand. For a post warranty repair, please contact the authorised service centre of the Extol® brand directly (you will find the repair locations at the website at the start of this user‘s manual).

• Original parts from the manufacturer must be used for any repairs and the repairs must be performed by a per-son with necessary professional qualifications.

• In the event of a dispute between the buyer and the vendor in respect to the purchase contract that was not resolved directly between the parties, the buyer has the right to the trade inspection authority for an out–of-court settlement of the a consumer dispute. At the website of the trade inspection authority there is a link to the tab „ADR-amicable dispute resolution“.

Reference to the pictogram and label

• Read the user’s manual before use.
• Meets respective EU requirements.
• Electrical waste (see above).
• Max. permitted conductor cross-section range.

Contacts

Contact our customer and consulting centre for any questions at: www.extol.eu
service@madalbal.cz Manufacturer: Madal Bal a. s., Průmyslová zóna Příluky 244, 76001 Zlín, Czech Republic

References

• | Extol.cz
• Extol
• | Extol.hu
• Köszöntjük a Madal Bal cégcsoportnál!

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