GEN SERVICE PBW Operating instructions

PORTABLE BUTT WELDER 110/110V
PBW
GEN SERVICE srl
Via Monte di Sopra 38
37017 LAZISE (VR) - ITALY
Page 1 of 20
USER AND MAINTENANCE MANUAL
English translation from the original Italian language text
This manual is an integral part of the equipment and it should be kept in a proper
manner to maintain its integrity and allow the consultation during the lifetime of the
equipment the equipment.
Carefully consult this manual before
carrying out any operation on the appliance
Manual code : 150922

PORTABLE BUTT WELDER 110/110V
PBW
GEN SERVICE srl
Via Monte di Sopra 38
37017 LAZISE (VR) - ITALY
Page 2 of 20
CONTENTS
1 GENERAL INFORMATION.....................................................................................................3
1.1 Definitions and symbols...................................................................................................3
1.2 Manufacturer Identification ..............................................................................................4
1.3 information about technical support and maintenance.....................................................5
2 FEATURES AND TECHNICAL INFORMATION......................................................................6
2.1 normative references.......................................................................................................6
3 GENERAL DESCRIPTIONS ...................................................................................................7
3.1 Upon receipt of the equipment controls ...........................................................................7
3.2 Storage............................................................................................................................7
4 THE EQUIPMENT FUNCTIONS ............................................................................................8
5 OPERATING INSTRUCTIONS AND COMMANDS............................................................9-14
6 SAFETY AND MAINTENANCE.............................................................................................15
6.1 Maintenance..................................................................................................................15
6.2 Inconveniences and Anomalies.....................................................................................15
7 DISPOSAL............................................................................................................................16
8 INTERVENTION OR SPARE PARTS REQUEST FORM......................................................17
9 SPECIAL DESIGN CLAMP WELDING MACHINE ................................................................18
10 EC DECLARATION OF CONFORMITY ............................................................................19
11 WARRANTY......................................................................................................................20

PORTABLE BUTT WELDER 110/110V
PBW
GEN SERVICE srl
Via Monte di Sopra 38
37017 LAZISE (VR) - ITALY
Page 3 of 20
1. GENERAL INFORMATION
Thank you for the preference you have given us with the purchase our butt-welding machine.
Please follow the instructions contained in this manual, this will be of great help for the optimal use
and to maintain over time the features of your equipment.
This manual forms an integral part with the equipment supplied and constitutes the indispensable
support for proper use.
The manual must accompany the equipment in case of resale.
It is forbidden to reproduce any part of this document without the written permission of
GEN SERVICE srl.
1.1 Definitions and symbols
Below is a set of definitions, terminology and symbols used in this manual
NOTE
Important information that must be read with particular attention for the best
use of the equipment
DANGER
Situation that could cause injury or death, or serious damage to health.
ATTENTION
Situation that could cause damage, directly or indirectly, to people, to
property and to the environment with also economic consequences
WARNING
Follow with particular attention the instructions. Possibility of malfunction or
danger or damage.

PORTABLE BUTT WELDER 110/110V
PBW
GEN SERVICE srl
Via Monte di Sopra 38
37017 LAZISE (VR) - ITALY
Page 4 of 20
1.2 MANUFACTURER IDENTIFICATION
The following illustration is an example the label, it is attached at the back of the machine, in fig.
1.2.1. it is shown an example of data plate
Fig. 1.2.1
Removing or tampering with the equipment identification label is absolutely
forbidden.
In case of accidental damage, immediately contact the manufacturer to request a
duplicate.
100/110V

PORTABLE BUTT WELDER 110/110V
PBW
GEN SERVICE srl
Via Monte di Sopra 38
37017 LAZISE (VR) - ITALY
Page 5 of 20
1.3 INFORMATION ABOUT TECHNICAL SUPPORT AND MAINTENANCE
In case of failure or defective functioning, contact the Service Center:
GEN SERVICE srl
Via Monte di Sopra, 38
37017 LAZISE (VR)-ITALY
Phone/Fax [phone]
e-mail: [e-mail]
For communications or any request for information or for spare parts, send to the service center
the form: “REPLACEMENT ORDER, FAILURE REPORTS, REQUEST FOR INFORMATION” that
can be found in paragraph 8.
In order to maintain the warranty, strictly follow the instructions indicated on
this manual. Failure to comply with the requirements and instructions
contained in this manual will waive GEN SERVICE liability for malfunctions
and damage to the equipment or to third parties. (carefully read the warranty
attachment).
In order to meet new technological improvements or specific production
requirements, the Manufacturer reserves the right to make changes to the
equipment without notice and without incurring in any obligation to upgrade
former models and their manuals. Even if the illustrations in this manual
slightly differ from your equipment, safety and operating instructions are
guaranteed.

PORTABLE BUTT WELDER 110/110V
PBW
GEN SERVICE srl
Via Monte di Sopra 38
37017 LAZISE (VR) - ITALY
Page 6 of 20
2. FEATURES AND TECHNICAL INFORMATION
Features and technical information
50/60 Hz
Supply voltage input:
100/110V,
Electrical power:
0,6 KVA
Secondary no load voltage1:
2,6 V~
Overload protection:
Single-pole thermal switch
Operating environment:
Temperature:
Relative humidity:
Atmospheric pressure (atm):
10 °C –50 °C
10 - 85% non condensing
0,7 ÷1,04
Storage conditions:
Temperature:
Relative humidity:
-20÷ 50 °C
≤95% non condensing.
Equipment classification for electrical hazards:
Class I
Casing protection degree:
IP402
Weldable material
Steel
Φ 0,8 2 mm
Equipment weight
13 Kg
Power distribution System
TT –TN
1.4 REFERENCE TO NORMATIVES
The legislative references applied to the construction of the equipment are:
2006/95/EC LVD directive
2011/65/CE RoSH2 directive
National and harmonized technical standards applied for the respect of legislative references are:
EN 62135-1 (2008-11)
50581 (2012-09)
1
The Voltage is measured between the electrodes, when the secondary circuit is open and when is applied to the welding the nominal
supply voltage. The secondary voltage is supplied by a safety insulating transformer (EN 61558-2-6).
2
Equipement for indoor use

PORTABLE BUTT WELDER 110/110V
PBW
GEN SERVICE srl
Via Monte di Sopra 38
37017 LAZISE (VR) - ITALY
Page 7 of 20
3. GENERAL DESCRIPTION
The butt welder PWB is capable of welding steel wires with a diameter ranging between 0.8 and 2
mm. The weld power adjustment for the various diameters can be effected by adjusting the welding
current with the two-position switch (1 = normal, 2 = maximum power - see section "operating
instructions for a detailled description of this feature).
The materials and technologies employed in its construction, contribute to make the butt welder
PBW extremely safe during normal use. In particular it is equipped with a safe transformer with
total separation between the primary and the secondary winding, in accordance with EN 61558-2-6.
The voltage applied to the welding wire electrodes is of a type SELV (safety extra-low voltage).
1.5 Controls to be carried out upon receipt of the equipment
Remove all outer packaging and verify the integrity of the equipment.
In case of damage, missing items or defects, do not attempt to repair the
butt welder but promptly contact the service center reporting model, code
and serial number of the equipment (see fig. 1.2.1. Data plate label).
1.6 Storage
In the case of no use of the equipment for long periods, protect the unit
from dust and moisture.

PORTABLE BUTT WELDER 110/110V
PBW
GEN SERVICE srl
Via Monte di Sopra 38
37017 LAZISE (VR) - ITALY
Page 8 of 20
4. EQUIPMENT FUNCTIONS AND COMMANDS
The proper functioning of the equipment and its safe performance are only
guaranteed if it is connected to the electrical system in strict compliance with the
local laws and regulations.
Gen Service srl undertakes no responsibility for whatsoever damage to the
equipment or to third parties which is resulting from the connection to an
installation not conforming with the law and regulations.
Do not use this equipment at locations with presence of explosive atmosphere or
explosive or flammable materials.
The welding process is done by melting the material. At the joint and the nearby
area, the steel can reach a high temperature (steel fusion temperature) with
possible electric shock.
To improve the safety conditions and as a protection against the electrical shock
it is recommended to install upstream a differential circuit breaker of a type A
with a nominal residual current not exceeding 30 mA.

PORTABLE BUTT WELDER 110/110V
PBW
GEN SERVICE srl
Via Monte di Sopra 38
37017 LAZISE (VR) - ITALY
Page 9 of 20
5. OPERATING INSTRUCTIONS
Fig. 4.1.1
Fig. 4.1.1 butt welder description
1. clamp pressure adjustment
2. clamp opening lever
3. locking knobs
4. welding start button
5. function light indicator
Off: equipment is switched off if switch is in the OFF position
if the function light remains off with switch in position LEFTor RIGHT it indicates the
thermal switch intervention.
On: function light on indicates that the equipment is ready-to-use (with selector in LEFT or
RIGHT position)
6. manually resettable thermal circuit breaker
7. multifunction Selector:
centre position: equipment is switched off
left position: equipment on normal output power
right position: equipment on manually adjustable output power selector
8. manual selector of power output when the switch is in the RIGHT position.

PORTABLE BUTT WELDER 110/110V
PBW
GEN SERVICE srl
Via Monte di Sopra 38
37017 LAZISE (VR) - ITALY
Page 10 of 20
Detailled descripton of Selector Positions and functions:
1. Selector set to OFF position: (the function light is turned off). The butt welder is switched off.
2. Selector in the LEFT position (the function light is on) : the butt welder is set to a maximum fixed
power output
3. Selector in the RIGHT position (the function light is on) : the power output of the butt welder can
be manuall adjusted. This control function is particularly recommended with thinner diameter wires,
flux cored welding wires, softer steel wires or any wires which require a power output different than
the maximum adjustment of selector in the above position (selector on LEFT position).
This function allows a controlled annealing of the butt welded joint.

PORTABLE BUTT WELDER 110/110V
PBW
GEN SERVICE srl
Via Monte di Sopra 38
37017 LAZISE (VR) - ITALY
Page 11 of 20
In the below tables are reported the steps for a correct welding procedure:
1
While squeezing the left clamp clip, slide the left
wire end into the groove of the left clamp and push
it until the wire tip touches the right clamp.
2
Lock the left wire by hand tightening the left small
locking knob clockwise.
This will secure the clamp’s grip on the left wire and
will prevent it from slipping out of the groove.
3
Turn the main central knob clockwise to open the
right clamp.

PORTABLE BUTT WELDER 110/110V
PBW
GEN SERVICE srl
Via Monte di Sopra 38
37017 LAZISE (VR) - ITALY
Page 12 of 20
4
Slide the second wire into the groove of the right
clamp until both wire ends touch at the centre of the
gap formed between the two clamps.
Make sure the two wires are perfectly aligned.
Important: always ensure that the two wire ends are
neatly cut and that they offer the maximum surface
contact. Trim the edge with nippers if necessary.
5
Once you have verified that :
1. the two wires are well aligned
2. their ends touch each other
Hand tighten the right smaller locking knob similar to
section 2. This will secure the clamp’s grip on the
right wire and will prevent it from slipping out of the
groove.
6
Adjust pressure on right clamp spring depending on
the wire diameter you are welding.
Hand tighten with large wire diameters
Loosen with smaller wire diameters
IMPORTANT:
It might take several attempts to achieve the optimal
pressure adjustment for the wire diameter you are
welding.
Once adjusted, however, it will work fine until you
change wire diameter.

PORTABLE BUTT WELDER 110/110V
PBW
GEN SERVICE srl
Via Monte di Sopra 38
37017 LAZISE (VR) - ITALY
Page 13 of 20
7
Close the right clamp by rotating the main central
knob counter clock wise.
The welder is now ready to butt weld the two wires.
8
Hold the welding button pressed for a few seconds.
An internal timer will automatically shut the power
off, once the two wires have been joined.
9
Rotate both locking knobs counter-clockwise to
release the grip of clamps on the joined wire.

PORTABLE BUTT WELDER 110/110V
PBW
GEN SERVICE srl
Via Monte di Sopra 38
37017 LAZISE (VR) - ITALY
Page 14 of 20
10
Squeeze the two clamp clips together to pull the
joined wire free.

PORTABLE BUTT WELDER 110/110V
PBW
GEN SERVICE srl
Via Monte di Sopra 38
37017 LAZISE (VR) - ITALY
Page 15 of 20
6. SAFETY WARNINGS AND INFORMATION:
During the welding process it is mandatory the use of protection
glasses as means of individual protection for the operator
During the welding process the circulating
current generates a magnetic field near the
connecting cables of the clamp.
Field levels detected during the welding process
are below the maximum limits specified by the
normative 1999/519/EC:
As a precaution, we recommend to:
keep the cables far from the body;
avoid wearing objects sensitive to
magnetic fields;
carriers of peace makers should refrain
from using the equipment
6.1 MAINTENANCE
The following operations should always be carried out with the equipment
unplugged from the electrical network.
Periodically:
clean the outer casing of the unit using a soft cloth moistened with a neutral
and non-aggressive detergent and dry using a dry cloth;
Verify the integrity of the protective sheath screening the wires between the
power source and the welding clamp. If damaged, do not use the butt welder
and contact the service center immediately.

PORTABLE BUTT WELDER 110/110V
PBW
GEN SERVICE srl
Via Monte di Sopra 38
37017 LAZISE (VR) - ITALY
Page 16 of 20
6.2 PROBLEMS AND ANOMALIES
Problem
Probable cause
Corrective actions/Notes
The equipment is ready for
operation but does not weld.
Status light is off.
Intervention of the thermal or
differential switch
Reset or reactivate the
thermal or differential switch.
If the proposed corrective action does not resolve the malfunctions
encountered, stop operations and contact the service center.
Never open the housing of the equipment unless expressly authorized
in writing by Gen Service srl. Non-compliance with this rule will result
in an immediate termination of the guarantee and shall release the
Manufacturer/Supplier from any liability related to the safety and the
correct functioning of the equipment.
7. DISPOSAL
INFORMATION FOR USERS
Pursuant to art. 13 of Legislative Decree n. 151 July 25, 2005
"implementation of directives 2002/95/CE, 2002/96/CE and
2003/108/CE, regarding the reduction use of hazardous substances in
electrical and electronic equipment, as well as waste disposal"
The crossed bin symbol on the appliance indicates that the product at
the end of its life must be collected separately from other waste. The
user must therefore hand the equipment at the end of its life to the
suitable separate waste collection centers of electronic and electrical
waste, or return it to the retailer when purchasing a new equipment of
the same type, at a rate of one to one. The appropriate differentiated
collection and subsequent equipment recycling, treatment and
environmentally compatible disposal helps to avoid possible negative
effects on the environment and health and promote the recycling of the
materials of which it is composed. Improper disposal of the product by
the user entails the administrative sanctions provided by law.

PORTABLE BUTT WELDER 110/110V
PBW
GEN SERVICE srl
Via Monte di Sopra 38
37017 LAZISE (VR) - ITALY
Page 17 of 20
8. INTERVENTION OR SPARE PARTS REQUEST FORM
Spett.le:
GEN SERVICE srl
Via Monte di Sopra 9
37017 LAZISE (VR) - ITALY
Tel./Fax [phone]
e-mail: [e-mail]
Data __________________.
REPLACEMENT PARTS ORDER –NOTIFICATION OF FAULTS –INFORMATION
Client:
Model
Location
Code
Address
Serial Number
Phone:
Fax :
Trasmitted by:
Spare parts table:
Article code
Qty
Notes
________________________________________
STAMP AND SIGNATURE OF THE APPLICANT
Technical visit request due to the presence of the following problems:
Notes or description of the problems

PORTABLE BUTT WELDER 110/110V
PBW
GEN SERVICE srl
Via Monte di Sopra 38
37017 LAZISE (VR) - ITALY
Page 18 of 20
9. SPECIAL DESIGN CLAMP WELDING MACHINE - LIST OF COMPONENTS AND PARTS

PORTABLE BUTT WELDER 110/110V
PBW
GEN SERVICE srl
Via Monte di Sopra 38
37017 LAZISE (VR) - ITALY
Page 19 of 20
10. EC DECLARATION OF CONFORMITY

PORTABLE BUTT WELDER 110/110V
PBW
GEN SERVICE srl
Via Monte di Sopra 38
37017 LAZISE (VR) - ITALY
Page 20 of 20
11. WARRANTY
CONDITIONS AND LIMITATIONS:
GEN Service Srl guarantees the equipment for the duration of 12 months.
The warranty starts from the date of purchase indicated on the commercial invoice issued upon
delivery of the equipment.
GEN Service Srl undertakes to repair or replace free of charge within the warranty period, any
parts showing manufacturing defects and failure; this warranty, however, does not include any form
of compensation for direct or indirect damages to persons or things.
During the warranty period, if the customer requires that the repair is to be carried out by the
technicians of the GEN Service srl, he must send a written request to GEN Service Srl. and he
shall bear all the travel and accomodation expenses incurred by the GEN Service technicians.
In case of repairs of defects or faults which are not attributable to the material or the manufacturer,
all related expenses, repair and/or replacement of parts shall be charged to the customer.
No additional warranty extension will be granted following a repair intervention.
In case of a return of any equipment parts, the customer will be authorized to effect the shipment
only after having received the written permission by the GEN Service Srl. The packaging and
shipping costs will be charged to the customer (unless otherwise agreed).
The following occurrances are excluded from warranty: accidental damage during transport and
handling, negligence, improper use not in accordance with the instructions in this manual and all
those occurrances not related with the normal use of the equipment.
The warranty is void if the butt welder is repaired by unauthorized technicians or if non original
equipment or accessories are used which are not recommended or approved by Service Srl or, in
the case of unathorized removal or alteration of the serial number during the warranty period.
The warranty validity shall immediately be terminated in the case of the customer's delayed
payment or non-payment, partial or complete.
GEN Service Srl declines any responsibility for damage to persons or things caused by misuse or
imperfect use of the equipment.
For any controversy the competent Court is the Judicial Forum in Verona (ITALY).