Parkside PFDS 120 A2 User manual

IAN 303284_1907
FÜLLDRAHT-SCHWEISSGERÄT
Bedienungs- und Sicherheitshinweise
Originalbetriebsanleitung
DE AT CH
FLUX CORED WIRE WELDER PFDS 120 A2
FLUX CORED WIRE WELDER
Operation and Safety Notes
Translation of the original instructions
GB IE NI
GB IE NI
303284_Fülldrahtschweißgerät_PFDS_120_A2_cover_LB6_GB-IE-NI.indd 3303284_Fülldrahtschweißgerät_PFDS_120_A2_cover_LB6_GB-IE-NI.indd 3 11.12.2019 10:14:4511.12.2019 10:14:45

GB IE NI
Before reading, unfold the page containing the illustrations and familiarise yourself with all
functions of the device.
DE AT CH
Klappen Sie vor dem Lesen die beiden Seiten mit den Abbildungen aus und machen Sie sich
anschließend mit allen Funktionen des Gerätes vertraut.
GB / IE / NI Operation and Safety Notes Page 5
DE / AT/ CH Montage-, Bedienungs- und Sicherheitshinweise Seite 25
303284_Fülldrahtschweißgerät_PFDS_120_A2_cover_LB6_GB-IE-NI.indd 4303284_Fülldrahtschweißgerät_PFDS_120_A2_cover_LB6_GB-IE-NI.indd 4 11.12.2019 10:14:4511.12.2019 10:14:45

1 2
49101112 357 68
A
B
C D
13 1514 16 17 18
22 23 24 25
19
20
21
303284_Fülldrahtschweißgerät_PFDS_120_A2_cover_LB6_GB-IE-NI.indd 5303284_Fülldrahtschweißgerät_PFDS_120_A2_cover_LB6_GB-IE-NI.indd 5 11.12.2019 10:14:5411.12.2019 10:14:54

E
K
H
N
Q R
F
L
I
O
G
M
J
P
28
28
27
26
19
30
30
29
27
28
19
27
30 33 11
11
32
29
9
31
15
15
9 33
31
19
303284_Fülldrahtschweißgerät_PFDS_120_A2_cover_LB6_GB-IE-NI.indd 8303284_Fülldrahtschweißgerät_PFDS_120_A2_cover_LB6_GB-IE-NI.indd 8 11.12.2019 10:14:5711.12.2019 10:14:57

5GB / IE / NI
Legend of the pictograms used ............................................................. Seite 6
Introduction ..................................................................................................... Seite 7
Intended use ......................................................................................................... Seite 7
Delivery contents ................................................................................................... Seite 7
Parts description .................................................................................................... Seite 7
Technical specifications .......................................................................................... Seite 8
Safety notes .................................................................................................... Seite 8
Danger sources from
lightarc welding .................................................................................................... Seite 10
Welding-screen-specific safety notes......................................................................... Seite 13
Environments with increased electrical risks............................................................... Seite 13
Welding in confined spaces.................................................................................... Seite 14
Adding up of open-circuit voltages........................................................................... Seite 14
Use of shoulder slings............................................................................................. Seite 15
Protective clothing.................................................................................................. Seite 15
Protection from radiation and burns ......................................................................... Seite 15
EMC device classification ....................................................................................... Seite 16
Before use ........................................................................................................ Seite 16
Assembly.......................................................................................................... Seite 17
Assembling the welding mask ................................................................................. Seite 17
Inserting the flux-cored wire..................................................................................... Seite 17
Commissioning............................................................................................... Seite 18
Switching the device on and off............................................................................... Seite 18
Setting the welding current...................................................................................... Seite 18
Setting the wire feed .............................................................................................. Seite 18
Welding ............................................................................................................... Seite 19
Creating a weld .................................................................................................... Seite 20
Maintenance and cleaning....................................................................... Seite 22
Information about recycling and disposal....................................... Seite 22
EU Declaration of Conformity ................................................................. Seite 22
Warranty and service information ...................................................... Seite 23
Warranty conditions............................................................................................... Seite 23
Warranty period and statutory warranty claims ......................................................... Seite 23
Extent of warranty.................................................................................................. Seite 23
Processing of warranty claims ................................................................................. Seite 23
Service................................................................................................................ Seite 24
Table of contents
303284_Fülldrahtschweißgerät_PFDS_120_A2_content_LB6_GB-IE-NI.indb 5303284_Fülldrahtschweißgerät_PFDS_120_A2_content_LB6_GB-IE-NI.indb 5 19.12.2019 13:32:4619.12.2019 13:32:46

6GB / IE / NI
Legend of the pictograms used
Legend of the pictograms used
Caution!
Read operating instructions!
Serious to fatal injuries
possible!
Mains input;
Number of phases and
Caution!
Danger of electric shock!
1 ~ 50Hz
Alternating current symbol
and nominal value of the
frequency.
Important note!
Do not dispose of electrical
devices in the household
waste!
Dispose of the packaging
and product in an environ-
mentally-friendly manner!
Do not use the device
outdoors and never use it
in rain!
Self-shielded flux-core
arc welding.
Electrical shock from the
welding electrode may be
fatal!
IP21S Protection type.
Inhaling welding fumes may
endanger your health. SSuitable for welding under increased electrical hazard.
Welding sparks may cause
explosion or fire. Single-phase transformer.
Arc welding may damage
the eyes and injure the skin. H Insulation class.
Electromagnetic fields can
disrupt the function of
cardiac pacemakers.
U2
Standardized operating
voltage.
Attention, possible dangers! I1max
Greatest rated value
of the mains current.
X % Duty cycle. I1eff
Effective value of the grea-
test mains current.
I2
Rated value of the
welding current. Earth terminal.
Wire feed drive. Made of recycling material.
303284_Fülldrahtschweißgerät_PFDS_120_A2_content_LB6_GB-IE-NI.indb 6303284_Fülldrahtschweißgerät_PFDS_120_A2_content_LB6_GB-IE-NI.indb 6 19.12.2019 13:32:4719.12.2019 13:32:47

7GB / IE / NI
Introduction
FLUX CORED WIRE WELDER
PFDS 120 A2
zIntroduction
Congratulations!
You have purchased one of
our high-quality devices.
Familiarize yourself with the product before
using it for the first time. Please read the
following operating instructions and safety
instructions carefully. Only trained persons
may set up this tool.
KEEP OUT OF THE REACH OF CHIL-
DREN!
zIntended use
The device is suitable for self-shielded
flux-core welding using an appropriate wire.
No additional gas is required. The protective
gas is contained in powder form in the wire
itself. Thus, it is fed directly into the arc. This
means the device is not susceptible to wind
and can be used outside. Only suitable wire
electrodes may be used for the device. Inten-
ded use also involves compliance with the
safety instructions and assembly instructions
and the operating notes in the operating
instructions.
The applicable accident prevention provi-
sions must be strictly observed. The device
must not be used:
– in rooms with insufficient ventilation,
– in explosive atmospheres,
– for the purpose of thawing pipes,
– in the vicinity of people with cardiac
pacemakers and
– in the vicinity of easily inflammable mate-
rials. Use the product only as described and
only for the specific applications as stated.
Keep these instructions in a safe place. En-
sure you hand over all documentation when
passing the product on to anyone else. Any
use that differs to the intended use as stated
above is prohibited and potentially dange-
rous. Damage caused by disregarding these
instructions or by misuse is not covered by
the warranty or any liability on the part of
the manufacturer.
Residual risk
Even if you operate the device as intended,
there will be residual risks. The following ris-
ks can occur in the context of the design and
construction of this flux-core welding device:
– eye injuries caused by glare
– touching hot parts of the device or the
workpiece (burn injuries),
– in the case of insufficient protection, risk of
accidents and burns due to flying sparks
or slag,
– harmful emissions of smoke and gases cau-
sed by lack of air or insufficient extraction
in closed rooms.
Reduce the residual risk by carefully using
the device as intended and observing all
instruction.
zDelivery contents
1 flux cored wire welder PFDS 120 A2
1 torch nozzle (pre-assembled)
4 welding nozzles (1x 0.9 mm pre-assem-
bled;
1x 0.8 mm; 1x 0.6 mm; 1x 1.0 mm)
1 chipping hammer with wire brush
1 flux-core wire Ø 0.9 mm / 450 g
1 welding mask
1 carrying strap
1 set of operating instructions
zParts description
1
Cover wire feed unit
2
Carrying strap
3
Mains plug
4
Earth cable with earth terminal
303284_Fülldrahtschweißgerät_PFDS_120_A2_content_LB6_GB-IE-NI.indb 7303284_Fülldrahtschweißgerät_PFDS_120_A2_content_LB6_GB-IE-NI.indb 7 19.12.2019 13:32:4719.12.2019 13:32:47

8GB / IE / NI
5
Main switch ON/OFF
(incl. power indicator lamp)
6
Overload protection control lamp
7
Rotary switch for welding current setting
8
Setting wheel for wire feed
9
Torch nozzle
10
Torch
11
Torch button
12
Hose package with direct connection
13
Welding nozzle (0.6 mm)
14
Welding nozzle (0.8 mm)
15
Welding nozzle (0.9 mm)
16
Welding nozzle (1.0 mm)
17
Flux-core wire spool (wire reel)
Ø 0.9 mm / 450 g
18
Chipping hammer with wire brush
19
Feed roll
20
Shield body
21
Dark welding lens
22
Handle
23
Welding mask after assembly
24
Mounting clip
25
Protective glass catch
26
Storage compartment for welding nozzles
27
Setting screw
28
Thrust roller unit
29
Roller holder
30
Feed roll holder
31
Wire outlet
32
Hose package holder
33
Torch neck
zTechnical specifications
Power supply: 230 V~ / 50 Hz
(alternating current)
Welding current I2: 25–120 A
Duty cycle X: 10% at 120 A
Welding current,
60% at 49 A
Welding current
Open circuit voltage U0: 31 V
Greatest rated value
of the mains current: I1 max. 17.5 A
Effective value of the greatest
rated current: I1eff 5.9 A
Welding wire reel max.: approx. 1000 g
Welding wire
diameter max.: 1.0 mm
Fuse: 16 A
Weight: 13.5 kg
Technical and visual changes may be made
in further development without notifying
the customer. All dimensions, notices and
specifications in the operating instructions
are therefore subject to change. Thus, legal
claims made as a result of the operating
instructions cannot be claimed.
zSafety notes
Please read the usage instructions
with care and observe the notes
described. Familiarize yourself
with the device, its proper use
and the safety notes based on
these operating instructions. The
rating plate contains all techni-
cal data of this welding device;
please learn about the technical
features of this device.
This device can be used by
children 16 years and older
and also by persons with re-
duced physical, sensory or
mental capacities or a lack
of experience and knowled-
ge if they are supervised or
they have been instructed with
regard to the safe use of the
device and they understand
the dangers it presents. Do not
Introduction/ Safety notes
303284_Fülldrahtschweißgerät_PFDS_120_A2_content_LB6_GB-IE-NI.indb 8303284_Fülldrahtschweißgerät_PFDS_120_A2_content_LB6_GB-IE-NI.indb 8 19.12.2019 13:32:4719.12.2019 13:32:47

9GB / IE / NI
allow children to play with the
product. Cleaning and user
maintenance must not be per-
formed by children without su-
pervision.
Have repairs and/or mainte-
nance work only conducted by
qualified electricians.
Only use the welding ca-
bles (PFDS 120 A2 H01N2-
D1x10 mm²) included in the
scope of delivery.
The device should not be pla-
ced directly against the wall
in operation; it should not be
covered or caught between
other devices, so that there will
always be enough air flowing
in through the ventilation slits.
Ensure that the device has
been properly connected to
the mains voltage. Avoid any
tension on the mains line. Pull
the mains plug from the socket
before setting up the device in
a different location.
Always switch the device off
by the ON/OFF switch when
it is not in operation. Put down
the electrode holder on an in-
sulated support and only take
the electrode from the holder
after 15 minutes time to cool
off.
Take note of the condition of
the welding cables, the elec-
trode holder and the ground
terminals. Wear of the insula-
tion and the current-conducting
parts may cause danger and
reduce the welding quality.
Light-arc welding produces
sparks, melted metal parts and
smoke. Therefore, note: All
flammable substances and/
or materials must be removed
from the workplace and its di-
rect vicinity.
Ensure that the workplace is
ventilated.
Do not weld on containers,
vessels or tubes that contain
or have contained flammable
liquids or gases.
Avoid any
direct contact with the welding
current circuit. The idle voltage
between the electrode pliers
and the ground terminal may be
dangerous; there is the danger of
electric shock.
Do not store the device in a
moist or wet environment or in
rain. The protection provisions
IP21S apply to this.
Protect your eyes with the in-
tended safety glasses (DIN
degree 9-10), which are to be
attached to the enclosed wel-
ding screen. Use gloves and
Safety notes
303284_Fülldrahtschweißgerät_PFDS_120_A2_content_LB6_GB-IE-NI.indb 9303284_Fülldrahtschweißgerät_PFDS_120_A2_content_LB6_GB-IE-NI.indb 9 19.12.2019 13:32:4719.12.2019 13:32:47

10 GB / IE / NI
dry safety clothing that is free
of oil and grease to protect
your skin from ultraviolet radia-
tion from the light arc.
Do not use
the welding current source to
unfreeze pipes.
Note:
The light arc radiation may
damage the eyes and burn the
skin.
Light arc welding produces
sparks and drips of melted me-
tal; the welded workpiece will
start to glow and remain hot
for a relatively long time. The-
refore, do not touch the wor-
kpiece with your uncovered
hands.
Light-arc welding releases va-
pors that are hazardous to
health. Make sure that you do
not inhale these if possible.
Protect yourself from the harm-
ful effects of the light arc and
keep any persons not involved
in the work at a distance of at
least 2m from the light arc.
ATTENTION!
During operation of the wel-
ding unit, the voltage supply
to other consumers may be
impaired, depending on the
mains conditions at the con-
nection point. In doubt, contact
your power supply company.
There may be function pro-
blems with other devices du-
ring operation of the welding
unit, e.g. hearing aids, car-
diac pacemakers, etc.
zDanger sources from
lightarc welding
There are a number of danger
sources from light-arc welding.
Therefore, it is particularly im-
portant that the welder observe
the following rules in order not to
endanger himself and others and
to avoid damage to persons and
the device.
Have work on the mains-volta-
ge side, e.g. on cables, plugs,
etc. only performed by an
electrician according to the na-
tional and local provisions.
Disconnect the welding unit
from the mains voltage at once
in case of accidents.
If there are any electrical con-
tact voltages, switch off the de-
vice at once and have it chec-
ked by an electrician.
Always observe good electri-
cal contacts on the welding
current side.
Safety notes
303284_Fülldrahtschweißgerät_PFDS_120_A2_content_LB6_GB-IE-NI.indb 10303284_Fülldrahtschweißgerät_PFDS_120_A2_content_LB6_GB-IE-NI.indb 10 19.12.2019 13:32:4719.12.2019 13:32:47

11GB / IE / NI
Always wear insulating glo-
ves on both hands when wel-
ding. They protect from electric
shock (idle voltage of the wel-
ding current circuit), harmful
radiation (heat and UV radia-
tion) and from glowing metal
and splashes.
Wear firm, insulating shoes.
The shoes should be insulating
even when wet. Low-cut shoes
are not suitable, since falling,
glowing metal drops may cau-
se burns.
Wear suitable protective clo-
thing; do not wear any synthe-
tic clothes.
Never look into the light arc
with unprotected eyes; only
use a welders' welding screen
with the required protective
glass according to DIN. The li-
ght arc emits light and heat ra-
diation that will cause blinding
or burns, as well as UV-radia-
tion. This invisible ultraviolet
radiation will cause conjunc-
tivitis, which is very painful
but will only become apparent
after a few hours, if sufficient
protection is used.
UV radiation also causes burns
similar to sunburn on unprotec-
ted parts of the body.
Persons and helpers near the
light arc must be informed of
the dangers as well and pro-
tected as necessary. If neces-
sary, set up protective walls.
When welding, in particular in
small rooms, ensure sufficient
fresh air supply, since smoke
and harmful gases will deve-
lop.
No welding is permitted on
containers that are or have
been used to store gases,
fuels, mineral oils and similar
- even if they have been emp-
tied a long time ago -, since re-
sidues may cause explosion.
Special provisions apply in
fire-hazardous and potentially
explosive rooms.
Welds subject to high stress
and required to meet cer-
tain safety requirements must
only be produced by specia-
lly trained and tested welders.
Examples of these are pressure
tanks, running rails, trailer cou-
plings, etc.
ATTENTION! Always connect
the ground terminal as close as
possible to the welding point
so that the welding current
can take the shortest possible
path from the electrode to the
ground terminal. Never connect
Safety notes
303284_Fülldrahtschweißgerät_PFDS_120_A2_content_LB6_GB-IE-NI.indb 11303284_Fülldrahtschweißgerät_PFDS_120_A2_content_LB6_GB-IE-NI.indb 11 19.12.2019 13:32:4719.12.2019 13:32:47

12 GB / IE / NI
the ground terminal to the hou-
sing of the welding unit! Never
connect the ground terminal to
any earthed parts that are far
away from the workpiece, such
as a water pipe in a different
corner of the room. This may
cause damage to the protective
ground system of the room in
which you are welding.
Do not use the welding unit in
rain.
Only put down the welding
unit in a level location.
The output is calculated for
an ambiance temperature of
20°C. The welding time may
be reduced at higher tempera-
tures.
Danger from
electrical shock:
Electrical shock from a welding
electrode may be fatal. Never
weld in rain or snow. Wear dry
insulating gloves. Never touch
the electrode with your unprotec-
ted hand. Never wear any wet or
damaged gloves. Protect yourself
from electric shock by insulation
against the workpiece. Do not
open the device's housing.
Danger from welding
smoke:
Inhaling welding smoke may en-
danger health. Do not hold your
head into the smoke. Use facili-
ties in open areas. Use the vent
to discharge the smoke.
Danger from welding sparks:
Welding sparks may cause ex-
plosion or fire. Keep flammable
substances away when welding.
Do not weld next to flammable
substances. Welding sparks may
cause fires. Keep a fire extingui-
sher at hand and an observer
who can use it at once nearby.
Do not weld on drums or any
closed containers.
Dangers from arc welding:
Arc welding may damage the
eyes and injure the skin. Wear
hat and goggles. Wear hearing
protection and a high shirt collar.
Wear welding protection helmet
and use the proper filter size.
Wear complete body protection.
Danger from electromagne-
tic fields:
Welding current produces electro-
magnetic fields. Never use toge-
ther with medical implants. Never
wind the welding lines around
your body. Combine welding
lines.
Safety notes
303284_Fülldrahtschweißgerät_PFDS_120_A2_content_LB6_GB-IE-NI.indb 12303284_Fülldrahtschweißgerät_PFDS_120_A2_content_LB6_GB-IE-NI.indb 12 19.12.2019 13:32:4719.12.2019 13:32:47

13GB / IE / NI
zWelding-screen-specific
safety notes
Use a bright light source (e.g.
lighter) to convince yourself of
the proper function of the wel-
ding screen every time before
starting welding.
Welding splashes may dama-
ge the protective screen. Ex-
change damaged or scratched
protective screens at once.
Replace damaged or badly
contaminated or splashed com-
ponents without delay.
The device must only be ope-
rated by persons who are at
least 16 years old.
Familiarize yourself with the
safety provisions for welding.
For this, also observe the safe-
ty notes of your welding unit.
Always put on the welding
screen when welding. Non-
use may cause severe injury to
your retina.
Always wear protective clo-
thing when welding.
Never use the welding screen
without the protective glass,
since the visual unit may
otherwise be damaged. The-
re is a risk of damage to the
eyes!
Exchange the protective glass
in time for a good view and
non-fatiguing work.
zEnvironments with in-
creased electrical risks
When using welding devices in
environments with increased elec-
trical risks, observe the following
safety notes.
Environments with increased elec-
trical risks include:
Workplaces with confined
spaces, so that the welder is
working in a confined posture
(e.g. kneeling, sitting, lying)
and touches electrically con-
ductive parts;
In workplaces that are who-
lly or partially surrounded by
electrically conductive ma-
terials, and where there is a
high risk from avoidable or ac-
cidental contact by the welder;
In wet, moist or
hot workplaces, where humi-
dity or sweat will considerably
reduce the resistance of human
skin and the insulating pro-
perties of the protective equip-
ment.
Safety notes
303284_Fülldrahtschweißgerät_PFDS_120_A2_content_LB6_GB-IE-NI.indb 13303284_Fülldrahtschweißgerät_PFDS_120_A2_content_LB6_GB-IE-NI.indb 13 19.12.2019 13:32:4719.12.2019 13:32:47

14 GB / IE / NI
Metal ladders or scaffolding may
also create an environment with
an increased electrical risk.
When working such an environ-
ment, insulating supports and
interim layers must be used, as
well as long gloves and heat co-
verings made of leather or other
insulating materials, in order to
insulate your body against the
ground. The welding current
source must be located outside of
the work area or the electrically
conductive areas, and outside of
the welder's reach.
Additional protection from elec-
trical shock from the mains cu-
rrent in case of a fault may be
provided by the use of a residual
current circuit breaker operated
with a discharge current not ex-
ceeding 30 mA and supplying all
mains-operated devices nearby.
The residual current circuit
breaker must be suitable for any
current type.
Means for quick electrical dis-
connection of the welding current
source or the welding circuit (e.g.
emergency off device) must be
easily accessible.
When using welding units subject
to electrically hazardous condi-
tions, the output voltages of the
welding device in no-load ope-
ration must not be higher than
48 Volts (effective value). This
welding unit may be used in such
cases based on its output voltage.
zWelding in confined spa-
ces
Welding in confined
spaces may lead to a danger
from toxic gases (danger of suffo-
cation).
Welding is only permitted in
narrow spaces when instructed
persons are in the direct vicini-
ty so that they can take steps if
necessary.
Before starting welding, an ex-
pert must conduct an assessment
to determine the steps necessary
to ensure safe work, and which
precautions should be taken whi-
le actually welding.
zAdding up of open-circuit
voltages
If more than one welding current
source is in operation at the same
time, their open-circuit voltages
may add up and case an increa-
sed electrical risk. Welding cu-
rrent sources must be connected
to minimize this risk. The indivi-
dual welding current sources with
Safety notes
303284_Fülldrahtschweißgerät_PFDS_120_A2_content_LB6_GB-IE-NI.indb 14303284_Fülldrahtschweißgerät_PFDS_120_A2_content_LB6_GB-IE-NI.indb 14 19.12.2019 13:32:4719.12.2019 13:32:47

15GB / IE / NI
their separate controls and con-
nections must be clearly marked
to show what belongs to which
welding circuit.
zUse of shoulder slings
Welding is not permitted while
the welding current source or
wire feed unit are carried, e.g.
with a shoulder sling.
This is to prevent:
The risk of losing one's balan-
ce when connected lines or ho-
ses are pulled
The increased risk of electrical
shock since the welder tou-
ches the ground when using a
welding current source of ca-
tegory I with a housing that is
earthed through its protective
earth.
zProtective clothing
The welder's entire body must
be protected from radiation
and burns with the correspon-
ding clothing and facial protec-
tion during work. The following
steps should be oserved:
– Put on protective clothing
before welding.
– Wear gloves.
– Open windows to ensure air
supply.
– Wear protective goggles.
Wear long gloves of a suita-
ble material (leather) on both
hands. They must be in an im-
peccable condition.
Wear suitable aprons to pro-
tect your clothes from sparks
and burns. If the type of work,
such as overhead welding,
requires, safety garments and,
if necessary, head protection
must be worn.
zProtection from radiation
and burns
Put up a sign "Caution! Do not
look into the flames!" at the
workplace to draw attention
to the danger to the eyes. The
workplaces must be shielded
so that any persons nearby are
protected as far as possible.
Unauthorized persons must be
kept away from the welding
work.
The walls in direct proximi-
ty of stationary workplaces
should not be of a light color
or glossy. Windows must be
secured against letting through
Safety notes
303284_Fülldrahtschweißgerät_PFDS_120_A2_content_LB6_GB-IE-NI.indb 15303284_Fülldrahtschweißgerät_PFDS_120_A2_content_LB6_GB-IE-NI.indb 15 19.12.2019 13:32:4719.12.2019 13:32:47

16 GB / IE / NI
or reflecting radiation at least
up to head height, e.g. by a
suitable coating.
zEMC device classification
As per the standard IEC 60974-
10, this welding device is a
welding unit with class A electro-
magnetic compatibility. Thus, it
complies with the corresponding
requirements for industrial and
domestic use. In residential areas,
it can be connected to the public
low-voltage supply systems.
Even if the flux cored wire wel-
der complies with the emission
limit values of the standard, arc
welding devices can still result in
electromagnetic interferences in
sensitive systems and devices.
The user will be held responsible
for any interference caused by
the electric arc during welding
and must also take appropriate
safety measures. In doing so, the
user must observe the following:
– network, control, signal and
telecommunication lines
– computers and other micropro-
cessor-controlled devices
– TVs, radios and other playback
devices
– electronic and electrical safety
equipment
– people with cardiac pace-
makers or hearing aids
– measurement and calibration
devices
– interference immunity of other
equipment nearby
– the time at which the welding
work is carried out.
The following is recommended
to reduced possible interference
radiation:
– equip the mains connection
with a
mains filter
– regularly maintain the flux
cored
wire welder and keep it in a
good condition
– welding cables should be
completely uncoiled and run as
close to parallel with the floor
as possible
– devices and systems that are
compromised by the interferen-
ce radiation must be removed
from the welding area or shiel-
ded.
zBefore use
Take all parts from the packaging and
check whether the flux cored wire welder
or parts show any damage. If this is the
case, do not use the flux-core wire wel-
ding device. Contact the manufacturer
via the indicated service address.
Remove all protective films and other
transport packaging.
Safety notes / Before use
303284_Fülldrahtschweißgerät_PFDS_120_A2_content_LB6_GB-IE-NI.indb 16303284_Fülldrahtschweißgerät_PFDS_120_A2_content_LB6_GB-IE-NI.indb 16 19.12.2019 13:32:4719.12.2019 13:32:47

17GB / IE / NI
Check that the delivery is complete.
The welding nozzles can be stowed
away in the storage compartment for
welding nozzles
26
.
zAssembly
zAssembling the welding
mask
Place the dark welding glass
21
into the
mask with the writing on the top
20
(see
Fig. C). The writing on the dark welding
glass
21
must now be visible from the
front of the welding mask.
Push the handle
22
from the inside into
the corresponding notch of the mask, un-
til it snaps into place (see Fig. D).
zInserting the flux-cored
wire
Always unplug the mains
plug from the mains socket prior to each
maintenance task or preparatory work in
order to prevent the risk of an electric shock,
injury or damage.
Note: Different welding wires will be nee-
ded depending on the application. Welding
wires with a diameter of 0.6 – 1.0 mm can
be used with this device.
Feed roll, welding nozzle and wire cross
section must be compatible with one another.
The device is suitable for wire reels weighing
up to maximum 1000 g.
Unlock and open the cover of the wire
feed unit
1
by raising the threaded rod
along the elongated hole.
Unlock the roller unit by turning the roller
mount
29
anti-clockwise (see Fig. F).
Pull the roller mount
29
off the shaft (see
Fig. F).
Note: Make sure that the end of the wire
does not come loose and cause the roll to
roll out on its own. The end of the wire may
not be released until during assembly.
Completely unpack the flux-cored wire
welding reel
17
, so that it can unrolled
without difficulty. Do not release the wire
end yet (see Fig. G).
Place the wire reel on the shaft.
Make sure that the roll unwinds on the
side of the
31
wire feed guide (see Fig.
G).
Place the roll mount
29
back on and lock
it by pressing and turning it clockwise
(see Fig. G).
Undo the adjustment screw
27
and swing
it upwards (see Fig. H).
Turn the thrust roller unit
28
to the side
(see Fig. I).
Loosen the feed roll holder
30
by turning
it anti-clockwise and pull it upwards and
off
(see Fig. J).
On the top of the feed roll
19
, check
whether the appropriate wire thickness
is indicated. If necessary, the feed roll
has to be turned over or replaced. The
supplied welding wire (Ø 0.9 mm) must
be used in the feed roll
19
with the spe-
cified wire thickness of Ø 0.9 mm. The
wire must be positioned in the upper
groove!
Put on the feed roll holder
30
again and
screw clockwise direction.
Remove the torch nozzle
9
by pulling it
and turning it clockwise (see Fig. K).
Unscrew the welding nozzle
15
(see Fig.
K).
Guide the hose package
12
away from
the welding device as straight as possi-
ble (place it on the floor).
Take the wire end out of the edge of the
spool (see Fig L).
Trim the wire end with wire scissors or a
diagonal cutter in order to remove the da-
maged, bent ends of the wire (see Fig. L).
Note: The wire must be kept under ten-
sion the entire time in order to avoid re-
Before use / Assembly
303284_Fülldrahtschweißgerät_PFDS_120_A2_content_LB6_GB-IE-NI.indb 17303284_Fülldrahtschweißgerät_PFDS_120_A2_content_LB6_GB-IE-NI.indb 17 19.12.2019 13:32:4719.12.2019 13:32:47

18 GB / IE / NI
leasing and rolling out!
Therefore, it is recommended to carry out
the work with an additional person.
Push the flux-cored wire through the wire
feed guide
31
(see Fig.. M)
Guide the wire along the feed roll
19
and push it into the hose package holder
32
(see Fig. N).
Swivel the thrust roller unit
28
towards
the feed roll
19
(see Fig. O).
Mount the adjustment screw
27
(see Fig.
O).
Set the counter pressure with the adjust-
ment screw. The welding wire must be
firmly positioned between the thrust roller
and feed roll
19
in the upper guide wi-
thout being crushed (see Fig. O).
Switch on the welding device on the
main
5
switch.
Press the torch button
11
.
Now the wire feed system pushes the
welding wire through the cable assembly
12
and the torch
10
.
As soon as 1 – 2 cm of the wire protru-
des from the torch neck
33
, release the
torch button
11
again (see Fig. P).
Switch off the welding device on the
main switch.
Screw the welding nozzle
15
back on.
Make sure that the welding nozzle
15
matches the diameter of the welding
wire used (see Fig. Q). When using the
delivered welding wire (Ø 0.9 mm), the
welding nozzle
15
with the labeling 0.9
mm must be used.
Push the torch nozzle
9
back on to the
torch neck with a turn to the right
33
(see
Fig. R).
Always unplug the mains
plug from the power socket prior to each
maintenance task or preparatory work in
order to prevent the risk of an electric shock,
injury or damage.
zCommissioning
zSwitching the device on and
off
Switch on the welding device on and off
the main switch
5
. If you do not intend
to use the welding device for an exten-
ded period, remove the plug from the
power socket. This is the only way to
completely de-energize the device.
zSetting the welding current
The rotary switch for the welding current
setting
7
on the front of the welding device
can be used to set the desired welding
currents.
The corresponding settings can be found in
the following table.
Voltage (V) Wire feed Welding
current
A 2 – 4 25 – 75
B 3 – 5 55 – 85
C 3 – 6 60 – 100
D 4 – 8 65 – 105
E 5 – 9 75 – 110
F 5 – 10 80 – 115
G 5 – 10 85 – 120
The necessary welding current depends on
the welding wire diameter used, the material
thickness and the desired penetration depth.
zSetting the wire feed
In order to generate a constant arc, the set-
ting wheel for the wire feed
8
can be used
to fine-tune the wire feed. It is recommended
Assembly / Commissioning
303284_Fülldrahtschweißgerät_PFDS_120_A2_content_LB6_GB-IE-NI.indb 18303284_Fülldrahtschweißgerät_PFDS_120_A2_content_LB6_GB-IE-NI.indb 18 19.12.2019 13:32:4719.12.2019 13:32:47

19GB / IE / NI
to use a setting in the middle range to start
with, and then reduce or increase the speed
as required.
The necessary welding current depends on
the welding wire diameter used, the material
thickness and the desired penetration depth.
Similarly, the gaps to be bridged between
the workpieces to be welded must be obser-
ved.
Overload protection
The welding device is protected against over-
heating by means of an automatic protection
device (thermostat with automatic restart).
The protective device interrupts the overload
of the current circuit and the yellow overload
protection control lamp
6
illuminates.
Allow the device to cool down (approx.
15 minutes) after activation of the protec-
tion device. As soon as the yellow over-
load protection control lamp
6
goes out,
the device is ready for operation again.
Welding mask
HEALTH HAZARD!
If you do not use the welding mask, harmful
UV radiation and heat emitted by the electric
arc could damage your eyes.
Always use the welding mask for welding
work.
zWelding
RISK OF BURNS!
Welded workpieces are very hot and can
cause burns.
Always use pliers to remove welded, hot
workpieces.
Please proceed as follows once
you have electrically connected the
welding device:
Connect the earth cable to the workpie-
ce that is to be welded using the earth
terminal
4
. Ensure that there is good
electrical contact.
The area to be welded on the workpiece
must be free of rust and paint.
Choose the desired welding current and
wire feed depending on the welding wire
diameter, material thickness and desired
penetration depth.
Switch the device on.
Hold the welding mask
23
in front of
your face and guide the torch nozzle
9
to the position on the workpiece that is to
be welded.
Press the torch button
11
, in order to ge-
nerate an arc. Once the electric arc is
burning, the device feeds wire into the
weld pool.
If the welding lens is big enough, the
torch
10
is slowly guided along the desi-
red edge. The distance between the torch
nozzle and workpiece should be as small
as possible (it must not be greater than
10 mm).
If necessary, oscillate a little to increase
the size of the weld pool. For inexperien-
ced welders, it is often difficult initially to
create a decent electric arc. To do so, the
welding current and wire feed rate must
be set correctly.
You can work out the ideal settings for
the welding current and the wire feed
rate by carrying out trial welds on a test
piece. A properly set electric arc has a
mild, uniform buzzing sound.
The penetration depth (corresponds to
the depth of the weld in the material)
should be as deep as possible without
allowing the welding pool to fall through
the workpiece.
Reduce the wire feed rate in case of a
rough or hard rattle or switch to a higher
power level (increase welding current).
If the wire feed rate is too high and/or
the welding current too low, the welding
wire will not melt properly. Consequently,
the welding wire repeatedly dips in the
welding pool as far as the workpiece.
A quiet, muffled sound with a flickering
electric arc indicates the wire feed is too
Commissioning
303284_Fülldrahtschweißgerät_PFDS_120_A2_content_LB6_GB-IE-NI.indb 19303284_Fülldrahtschweißgerät_PFDS_120_A2_content_LB6_GB-IE-NI.indb 19 19.12.2019 13:32:4719.12.2019 13:32:47

20 GB / IE / NI
low.
Increase the wire feed rate or switch to
a lower welding current. If the welding
current is too high, the wire will melt
before it even reaches the weld pool.
This results in droplet formation on the
welding wire as well as splash and an
irregular electric arc.
The slag must only be removed from the
weld after cooling off. To continue wel-
ding on an interrupted weld:
First remove the slag at the starting point.
The electric arc is ignited in the weld
groove, guided to the continuation point,
melted properly and finally the weld is
continued.
CAUTION! Note that the torch always
must be put down on an insulating
support after welding.
Always switch off the welding device af-
ter completing welding work and during
breaks and pull the plug from the mains
socket.
zCreating a weld
Forehand welding
Push the torch forwards.
Result: The penetration depth is lower,
broader weld width, flatter weld bead (visi-
ble surface of the weld) and greater fusion
error tolerance (defect in material fusion).
Backhand
welding
The torch is dragged from the weld. Result:
Greater penetration depth, narrower weld
width, higher weld bead and lower fusion
error tolerance.
Welded joints
There are two-basic types of joints in wel-
ding: Butt welds (outer edge) and fillet welds
(inner edge and overlapping).
Butt welds
With butt welds of up to 2 mm, the weld
edges are completely brought together.
For greater thicknesses, please proceed as
per the following table:
S
Flat butt welds
Welds should be made without interruption
and with a sufficient penetration depth. The-
refore, it is extremely important to prepare
them well. The factors that influence the qua-
lity of the weld result are: the amperage, the
distance between weld edges, the inclination
of the torch and the corresponding diameter
of the welding wire.
The steeper you hold the torch against the
workpiece, the higher the penetration depth
and vice versa.
T
To forestall or reduce deformations that can
happen during the material hardening pro-
cess, it is good to fix the workpiece with a
device. Avoid stiffening the welded structure
to prevent cracks in the weld. These pro-
blems can be avoided if there is a possibility
of turning the workpiece so that the weld
Commissioning
303284_Fülldrahtschweißgerät_PFDS_120_A2_content_LB6_GB-IE-NI.indb 20303284_Fülldrahtschweißgerät_PFDS_120_A2_content_LB6_GB-IE-NI.indb 20 19.12.2019 13:32:4719.12.2019 13:32:47