Manual 13293139
 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
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Iw 420 7d J
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| 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.
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