INSTRUCTIONS FOR Manual Metal Arc Welder Stock No.43942 Part No.AW1472AT 43943 AW162AT 43944 AW222AT 43945 AW242AT IMPORTANT: PLEASE READ THESE INSTRUCTIONS CAREFULLY TO ENSURE THE SAFE AND EFFECTIVE USE OF THIS PRODUCT. \_ 43942 & 43943 shown. N | GENERAL INFORMATION Read all these instructions before operating this product and save these instructions. This manual has been compiled by Draper Tools and is an integrated part of the product with which it is enclosed and should be kept with it for future references. This manual describes the purpose for which the product has been designed and contains all the necessary information to ensure its correct and safe use. We recommend that this manual is read before any operation or, before performing any kind of adjustment to the product and prior to any maintenance tasks. By following all the general safety instructions contained in this manual, it will ensure both product and operator safety, together with longer life of the product itself. All photographs and drawings in this manual are supplied by Draper Tools to help illustrate the operation of the product. Whilst every effort has been made to ensure accuracy of information contained in this manual, the Draper Tools policy of continuous improvement determines the right to make modifications without prior warning. | CONTENTS | Contents /GUarantee ..…...........................erereeeeeee nee nee ne eee eee ere eee nee eee eee eee eee eee eee eee are ee ae een 1 SPECI ICALION. «eee K ER ERERERRARAKAKERERERERERKARANEREREREREREREARERAREREREREREREAUERERERERERERERUARERELEREREAERERUELELKREEAEKEAEG 2 General safety INSTTUCTIONS ...... cu ieee eee errr eee rere tease serra eases ner ener aaa nana r en aenns 3 Additional safety INSTrUCLIONS ..….................+erraerere rene en re rene nee eee ne nee area etes eee eee eee arrete ana 4 Getting to know your arc Welder...…..…................…cesressesener eee eee aa e ae e sense eee era e eee sen e eee e ete e nee ane ae Sanaa 5 a RY 00 | een n nenn HERR RRRRRRRARARERERERRERERAREREREREARARARARUREREARLEARARARAREREARLEARARAREREREAEKLELRARELELLAERARLELRLRELEERALAELELEEKEETG 6 Operation I <TR RE EE 7-8 Maintenance/Disposal................................eíereererere erre e ee eee eet e eter ratte eae eater e teen narra nanan ann anae 9 Explanation of symbols/pictograms ..................-...exe..eereeeveererereereer ener reer reer reese rere nn ener ans 10 [ID Ta = = 10 PUPP EEE enclosed | GUARANTEE | Draper tools have been carefully tested and inspected before shipment and are guaranteed to be free from defective materials and workmanship for a period of 12 months from the date of purchase except where tools are hired out when the guarantee period is ninety days from the date of purchase. A proof of purchase must be provided with the tool. Should the machine develop any fault, please return the complete tool to your nearest authorized warranty repair agent or contact Draper Tools Limited, Chandler's Ford, Eastleigh, Hampshire, SO53 1YF England. Telephone Sales Desk: (023) 8049 4333 or Product Helpline (023) 8049 4344. If upon inspection it is found that the fault occurring is due to defective materials or workmanship, repairs will be carried out free of charge. This guarantee does not apply to normal wear and tear, nor does it cover any damage caused by misuse, careless or unsafe handling, alterations, accident, or repairs attempted or made by any personnel other than the authorised Draper warranty repair agent. NOTE: If the tool is found not to be within the terms of warranty, repairs and carriage charges will be quoted and made accordingly. This guarantee applies in lieu of any other guarantee expressed or implied and variations of its terms are not authorised. Your Draper guarantee is not effective unless you can produce upon request a dated receipt or invoice to verify your proof of purchase within the 12 month period. Please note that this guarantee is an additional benefit and does not affect your statutory rights. Draper Tools Limited DRAPER Y | SPECIFICATION The Draper Tools policy of continuous improvement determines the right to change specification without notice. Stock no. ...................... 43942 ............. 0... 43943... ss 43944... 43945 Rated voltage ............ 230V~50Hz.............. 230V~50Hz............. 230V~50Hz ......... 230V~50Hz Rated max supply current....31A ................. 22... 6A... 34A-26A................. 39A-28A No load voltage ............... 48V............. emma. 48V..................... 43.549V................... 43-48V Welding current........... 40-140A................... 40-1604A................... 45-200A-.............—.—... 40-240A Coupling device............. [BJ] (= of Direct................ Type 1x10-25mm”... Type1x10-25mm* Degree of protection ....... IP21 ........ 0.0 ea ene see IP21 ....... 00 caen se nucs 174 co es esse case nneees IP21 Cooling... Air(fan)..….....….….……….….…. Airffan)..................... Air(fan} Air(fan) Max. working temp.......... 40°... ie 40° coe 40°.....нннкеннвнквнкннннннное 40° Weight............................ [No] (e E 19.3KG..................... 19.7KG.........…..…..…..……. 29.8kg ALWAYS WEAR AN APPROVED SAFETY HELMET AND GLOVES. GENERAL SAFETY INSTRUCTIONS General Arc-Welder Safety War nings - Use a welding mask with adiactinic glass suited for /\ WARNING: Read all safety warnings and all instructions. Failure to follow the warnings and instructions may result in electric shock, fire and/or serious injury. Save all warnings and instructions for future reference. MMA manual metal arc welding systems using coated electrodes with limited service are referred to herein as “welding machines”. - Make sure that the welding machine is installed and repaired only by qualified persons or experts in compliance with the law and with the accident prevention regulations. Make sure that the operator is trained in the use and risks connected to the arc-welding processes and in the necessary measures of protection and emergency procedures. Detailed information can be found in the “Installation and use of arc-welding equipment” brochure: IEC or CLC/TS 62081. Make sure that the power socket to which the welding machine is connected is protected by suitable safety devices (fuses or automatic switch) and that it is grounded. Make sure that the plug and power cable are in good condition. Before plugging into the power socket, make sure that the welding machine is switched off. Switch the welding machine off and pull the plug out of the power socket as soon as you have finished working. Switch the welding machine off and pull the plug out of the power socket before connecting the welding cables, installing the continuous wire, replacing any parts in the torch or wire feeder, carrying out maintenance operations, or moving it (use the carrying handle on the welding machine.) Do not touch any electrified parts with bare skin or wet clothing. Insulate yourself from the electrode, the piece to be welded and any grounded accessible metal parts. Use gloves, footwear and clothing designed for this purpose and dry, non-flammable insulating mats. Use the welding machine in a dry, ventilated space. Do not expose the welding machine to rain or direct sunshine. Use the welding machine only if all panels and guards are in place and mounted correctly. Do not use the welding machine if it has been dropped or struck, as it may not be safe. Have it checked by a qualified person or an expert. Eliminate any welding fumes through appropriate natural ventilation or using a smoke exhauster. A systematic approach must be used to assess the limits of exposure to welding fumes, depending on their composition, concentration and the length of exposure. Do not weld materials that have been cleaned with chloride solvents or that have been near such substances. welding. Replace the mask if damaged; it may let in radiation. Wear fireproof gloves, footwear and clothing to protect the skin from the rays produced by the welding arc and from sparks. Do not wear greasy garments as a spark could set fire to them. Use protective screens to protect people nearby. Do not allow bare skin to come into contact with hot metal parts, such as the torch, electrode holder grippers, electrode stubs, or freshly welded pieces. Metal-working gives off sparks and splinters. Wear safety goggles with protective side eye guards. Welding sparks can trigger fires. Do not weld or cut anywhere near inflammable materials, gasses or vapours. Do not weld or cut containers, cylinders, tanks or piping unless a qualified technician or expert has checked that it is possible to do so, or has made the appropriate preparations. Remove the electrode from the electrode holder gripper when you have completed the welding operations. Make sure that no part of the electrode holder gripper electric circuit touches the ground or earth circuits; accidental contact could cause overheating or trigger a fire. The magnetic fields deriving from the welding current may interfere with electrical and electronic equipment. People fitted with vital electrical devices (pacemakers etc.) should consult a doctor prior to coming into contact with welding equipment. This welding machine satisfies the requirements of the technical product standard exclusively for professional and industrial use. Compliance with electromagnetic compatibility for domestic use is not guaranteed. The welding machine is installed and used under your own responsibility. In the event of electromagnetic disturbance, this should be reduced so that it does not cause problems. Ask a competent expert for technical assistance if required. Welding in conditions of risk If welding needs to be done in conditions of risk (electric discharges, suffocation, the presence of inflammable or explosive materials), make sure that an authorised expert evaluates the conditions beforehand. Make sure that trained people are present who can intervene in the event of an emergency. Use protective equipment described in the IEC or CLC/TS 62081 technical specification. If you are required to work in a position raised above ground level, always use a safety platform. If more than one welding machine has to be used on the same piece, or in any case on pieces connected electrically, the sum of the no-load voltages on the electrode holders or on the torches may exceed the safety levels. Make sure that an authorised expert evaluates the conditions beforehand to see if such risk exists and adopt the protective measures described in 5.9 of the IEX or CLC/TS 62081 technical specification if required. ADDITIONAL SAFETY INSTRUCTIONS ADDITIONAL SAFETY INSTRUCTIONS FOR ARC-WELDERS - Do not use the welding machine for purposes other than those described. For example to thaw frozen water pipes. - Place the welding machine on a flat stable surface. and make sure that it cannot move. It must be positioned in such a way as to allow it to be controlled during use but without the risk of being covered with welding sparks. - Do not work with the welding machine hung from the body, using straps or any other device. - Do not lift the welding machine. No lifting devices are fitted on the machine. - Do not use cables with damaged insulation or loose connections. | GETTING TO KNOW YOUR ARC-WELDERS Power cable. On/off foot switch. Welding current adjustment. Current adjustment indicator. Thermal cutout signal. Connections for welding cables. [some machines have directly connected cables). 809060005 ( UNPACKING: After removing the packing material, make sure the product is in perfect condition and that there are no visible damaged parts. If in doubt, do not use the product and contact the dealer from whom it was purchased. The packaging materials (plastic bags, polystyrene, etc.), must be disposed of in an appropriate refuse collection container. These materials must not be left within the reach of children as they are potential sources of danger. -5- | ASSEMBLY Remove the plug from the socket befor - carrying out adjustment, servicing or maintenance. Assemble the detached parts found in the nm L Ta E "A packaging as shown in Fig. 1. : : Check that the electrical supply delivers the a в a voltage and frequency corresponding to the CD a a 2 = welding machine and that it is fitted with a delayed fuse suited to the maximum delivered rated current. Fig.2.+—- JED: To select two supply voltages in the welding machines fitted with a switch, ensure that the limit switch is on and allows the use of (FIG. 2 РИ в only one voltage. Fig.3. - NOTE: The welding machines are set to the highest voltage at the factory. - PREPARING THE WELDING CIRCUIT: Connect the ground “lead” to the welding w= : A | DA El machine and to the piece to be welded. 324 | ПВА | TEA | 40 Connect the cable with the electrode holder SGA | HOA | 16 gripper (this component may not be included 184, | 164 with some models) to the welding machine N and mount the electrode on the gripper. - NOTE: In welding machines delivering alternate current, it is not important which connection the electrode is connected to. - NOTE: The recommended sections (mm2) of the welding cable based on the maximum delivered rated current (12maxj, are shown in "19.7. ини J A data plate is affixed to the welding machine. Fig.4. shows and example of this plate. A) Constructor name and address B) European reference standard for the construction and safety of welding equipment. C) Delivered alternate current frequency. D) Input power required: 1" alternate single phase voltage, frequency. E) Level of protection from solids and liquids. F) Symbol indicating the possibility to use the S welding machine in environments potentially subject to electric discharges. G) 1 Symbol indicating class Il protection. H) WELDING CIRCUIT PERFORMANCE Uov Minimum and maximum open circuit voltage (open welding circuit). D.mm Diameter of weldable electrodes. IZA Value of the current needed to weld using different electrode diameters. tw Welding time running from thermal cutout reset until the next tripping with the transformer at the operating temperature. tr Cooling time running from thermal cutout tripping until the next reset with the transformer at the operating temperature. A/V Conventional welding current (maximum) and corresponding normalised voltage. I) POWER SUPPLY DATA Ul Input voltage (permitted tolerance: +/- 10%) 11 eff Effective absorbed current. IT max Maximum absorbed current. L) Serial number M) Weight N) Safety symbols | OPERATION AND USE (FIG.4 DDR DONS DOUX Iw 420 7d J  Da 7” À [email protected] À À À À A и | OPERATION AND USE - NOTE: (e FIG.5 NN Once you have put the welding machine into " operation, switch it on and carry out the required adjustments. - ADJUSTING THE WELDING CURRENT: Select the welding current depending on the electrode, the joint and the welding position. Indicatevely, the currents to be used with the different electrode diameters are listed in Fig.5. - NOTE: Do not force the adjustment flywheel as this could damage the welding machine. Check the adjustment on the current adjustment indicator. - NOTE: N J To strike the welding arc with the coated . electrode, brush it onto the piece to be welded (©) Plate thickness and as soon as the arc is struck, hold it (P) RCD Diameter constantly at a distance equal to the electrode diameter and at an angle of approximately 20-30 ~~ (@) Welding amperage degrees in the direction in which you are welding. - THERMAL CUTOUT SIGNAL: The warning light switched on means that the thermal protection is running. If the welding time “tw” indicated in the data plate is exceeded, a thermal cutout stops operation before the welder is damaged. Wait for operation to be resumed and, if possible, wait a few minutes more. If the thermal cutout continues to cut in, the welding machine is being pushed beyond its normal performance levels. - RECOMMENDATIONS FOR USE: Only use an extension lead when absolutely necessary and providing it has an equal or larger section to the power cable and is fitted with a grounding conductor. Do not block the welder air intakes. Do not store the welder in containers or on shelving that does not guarantee suitable ventiliation. Do not use the welder in any environment in the presence of gas, vapours, conductive powders (e.g. iron shavings), brackish air, caustic fumes or other agents that could damage the metal parts and electical insulation. - NOTE: The electric parts of the welder have been treated with protective resins. When used for the first time, smoke may be noticed; this is caused by the resin drying out completely. The smoke should only last for a few minutes. | MAINTENANCE & PARTS REPLACEMENT | Regular inspection and cleaning reduces the necessity for maintenance operations and will keep your tool in good working condition. The motor must be correctly ventilated during tool operation. For this reason avoid blocking the air inlets. After use disconnect the tool from the power supply and vacuum the ventilation slots. If the replacement of the supply cord is necessary, this has to be done by the manufacturer or his agent in order to avoid a safety hazard. Соле Й | DISPOSAL | - At the end of the machines working life, or when it can no longer be repaired, ensure that it is disposed of according to national regulations. - Contact your local authority for details of collection schemes in your area. In all circumstances: = Do not dispose of power tools with domestic waste. = Do not incinerate. = Do not abandon in the environment. = Do not dispose of WEEE* as unsorted municipal waste. * Waste Electrical & Electronic Equipment. (DRAPER Y | EXPLANATION OF SYMBOLS/PICTOGRAMS | Attention. Danger of electric shock. A A A A Danger of explosion. Danger of welding fumes. Danger of ultraviolet radiation. Danger of burning splashes. | CONTACTS - DRAPER TOOLS LIMITED, Hursley Road, Chandler's Ford, Eastleigh, Hampshire. SO53 1YE U.K. - Helpline: (023) 8049 4344 - Sales Desk: (023) 8049 4333 - Internet: www.draper.co.uk - E-mail: salesedrapertools.com - Sales Fax: (023) 8049 4209 - General Enquiries: (023) 8026 6355 - Service/Warranty Repair Agent For aftersales servicing or warranty repairs, please contact the Draper Tools Helpline for details of an agent in your local area. YOUR DRAPER STOCKIST OADH140509 OPublished by Draper Tools Limited. No part of this publication may be reproduced, stored in a retrieval system or transmitted in any form or by any means, electronic, mechanical photocopying, recording or otherwise without prior permission in writing from Draper Tools Ltd.