SIP Weldmate T251P User manual

32
FOR HELP OR ADVISE ON THIS PRODUCT PLEASE CONTACT YOUR DISTRIBUTOR, OR
SIP DIRECTLY ON:
TEL: [phone]
EMAIL: [e-mail] or [e-mail]
www.sip-group.com
Ref: 010814
Please dispose of packaging for the product in a responsible
manner. It is suitable for recycling. Help to protect the
environment, take the packaging to the local amenity tip
and place into the appropriate recycling bin.
Never dispose of electrical equipment or batteries in with
your domestic waste. If your supplier offers a disposal facili-
ty please use it or alternatively use a recognised re-cycling
agent. This will allow the recycling of raw materials and help
protect the environment.
1
Please read and fully understand the instructions in this manual
before operation. Keep this manual safe for future reference.
05721, 05725, 05741 & 05761
Weldmate
Arc Welder
T141P - T251P

2
31
Declaration of Conformity
We
SIP (Industrial Products) Ltd
Gelders Hall Road
Shepshed
Loughborough
Leicestershire
LE12 9NH
England
As the manufacturer's authorised representative within the EC
declare that the
Weldmate T211P Arc - SIP Part. No. 05721
Weldmate T251P Arc - SIP Part. No. 05725
Weldmate T141P Arc - SIP Part. No. 05741
Weldmate T161P Arc - SIP Part. No. 05761
Conforms to the requirements of the following directive(s), as indicated.
2006/95/EC Low Voltage Directive
2004/108/EC EMC Directive
89/686/EEC Personal Protective Equipment Directive
2008/35/EC RoHS Directive
Signed: …………………………………...
Mr P. Ippaso - Managing Director - SIP (Industrial Products) Ltd
Date: 02/06/2014.
And the relevant harmonised standard(s), including
DECLARATION OF CONFORMITY
EN 60794-1:2012
EN 60794-6:2011
EN 60794-10
EN 379:2003
EN 169:2002
EN 175: 1997

30
PARTS LIST WELDMATE T251P (05725)
Ref. No. Description Sip Part No.
1. Handle WE01-00057
2. Cover WE01-00069
3. Mains lead WE01-00059
4. Cable clamp WE01-00033
5. Rear panel WE01-00034
6. Fan motor WE01-00035
7. Axle WE01-00060
8. Wheel c/w cap WE01-00061
9. Insulation strip WE01-00036
10. Thermostat (transformer) WE01-00037
11. Shunt spindle fork WE01-00038
12. Clip WE01-00039
13. Transformer WE01-00070
14. Shunt WE01-00081
15. Indicator WE01-00042
16. Shunt bracket WE01-00043
17. Hand wheel c/w shaft WE01-00044
18. Chassis WE01-00071
19. Front foot WE01-00064
20. Earth return lead c/w earth clamp WE01-00072
21. Electrode holder lead c/w electrode holder WE01-00073
22. Rotary switch WE01-00067
23. Power indicator WE01-00075
24. Thermal overload indicator WE01-00077
25. Fault indicator WE01-00078
26. Plastic frame WE01-00051
27. Clear window WE01-00052
28. Handle cap WE01-00068
29. Thermostat (fault indicator) WE01-00076
30. Axle clip WE01-00074
N/A. Electrode 02715
N/A. Earth clamp 02735
3
CONTENTS
Page No. Description
4. Safety Symbols Used Throughout This Manual
4. Safety Instructions
11. Electrical Connection
13. Guarantee
13. Contents and Accessories
14. Technical Specification
15. Getting to Know Your Arc Welder
17. Assembly Instructions
18. Operating Instructions
20. Maintenance
21. Troubleshooting
22. Wiring Diagrams
23. Exploded Drawing 05741
24. Parts List 05741
25. Exploded Drawing 05761
26. Parts List 05761
27. Exploded Drawing 05721
28. Parts List 05721
29. Exploded Drawing 05725
30. Parts List 05725
31. Declaration of Conformity

4
When using your arc welder, basic safety precautions should always be followed to
reduce the risk of personal injury and / or damage to the arc welder.
Read all of these instructions before operating the arc welder and save this user man-
ual for future reference.
The arc welder should not be modified or used for any application other than that for
which it was designed.
This arc welder was designed to supply electric current for ARC welding.
If you are unsure of its relative applications do not hesitate to contact us and we will
be more than happy to advise you.
Before each use of the arc welder always check no parts are broken and that no parts
are missing.
Always operate the arc welder safely and correctly.
KNOW YOUR ARC WELDER: Read and understand the owner's manual and labels af-
fixed to the arc welder. Learn its applications and limitations, as well as the potential
hazards specific to it.
KEEP WORK AREA CLEAN AND WELL LIT: Cluttered work benches and dark areas invite
accidents. Floors must not be slippery due to oil, water or sawdust etc.
DO NOT USE THE ARC WELDER IN DANGEROUS ENVIRONMENTS: Do not use the arc
welder in damp or wet locations, or expose it to rain. Provide adequate space sur-
rounding the work area. Do not use in environments with a potentially explosive atmos-
phere.
KEEP CHILDREN AND UNTRAINED PERSONNEL AWAY FROM THE WORK AREA: All visitors
SAFETY SYMBOLS USED THROUGHOUT THIS MANUAL
SAFETY INSTRUCTIONS
IMPORTANT: Please read the following instructions carefully, failure to do
so could lead to serious personal injury and / or damage to the arc
welder.
Danger / Caution: Indicates risk of personal injury and/or the possibility of
damage.
Warning: Risk of electrical injury or damage!
Note: Supplementary information.
29
EXPLODED DRAWING WELDMATE T251P (05725)

28
PARTS LIST WELDMATE T211P (05721)
Ref. No. Description Sip Part No.
1. Handle WE01-00057
2. Cover WE01-00058
3. Mains lead WE01-00059
4. Cable clamp WE01-00033
5. Rear panel WE01-00034
6. Fan motor WE01-00035
7. Axle WE01-00060
8. Wheel c/w cap WE01-00061
9. Insulation strip WE01-00036
10. Thermostat (transformer) WE01-00037
11. Shunt spindle fork WE01-00038
12. Clip WE01-00039
13. Transformer WE01-00062
14. Shunt WE01-00081
15. Indicator WE01-00042
16. Shunt bracket WE01-00043
17. Hand wheel c/w shaft WE01-00044
18. Chassis WE01-00063
19. Front foot WE01-00064
20. Earth return lead c/w earth clamp WE01-00065
21. Electrode holder lead c/w electrode holder WE01-00066
22. Rotary switch WE01-00067
23. Power indicator WE01-00075
24. Thermal overload indicator WE01-00077
25. Fault indicator WE01-00078
26. Plastic frame WE01-00051
27. Clear window WE01-00052
28. Handle cap WE01-00068
29. Thermostat (fault indicator) WE01-00076
30. Axle clip WE01-00074
N/A. Electrode 02715
N/A. Earth clamp 02735
5
SAFETY INSTRUCTIONS….cont
should be kept at a safe distance from the work area.
STORE THE ARC WELDER SAFELY WHEN NOT IN USE: The arc welder should be stored in a
dry location and disconnected from the mains supply, and out of the reach of chil-
dren.
USE SAFETY CLOTHING / EQUIPMENT: Use a CE approved welding mask at all times with
the correct shade of filter lens. A fume extractor should be used particularly where
there is little or no ventilation.
PROTECT YOURSELF FROM ELECTRIC SHOCK: When working with the arc welder, avoid
contact with any earthed items (e.g. pipes, radiators, hobs and refrigerators, etc.). It is
advisable wherever possible to use an RCD (residual current device) at the mains
socket.
STAY ALERT: Always watch what you are doing and use common sense. Do not oper-
ate the arc welder when you are tired or under the influence of alcohol or drugs.
DISCONNECT THE ARC WELDER FROM THE MAINS SUPPLY: When not in use and before
servicing.
AVOID UNINTENTIONAL STRIKING: Make sure the switch is in the OFF position before
connecting the arc welder to the mains supply.
NEVER LEAVE THE ARC WELDER CONNECTED WHILST UNATTENDED: Turn the arc welder
off and disconnect it from the mains supply between jobs. Do not leave the arc weld-
er connected to the mains supply if no more welding is to be done.
DO NOT ABUSE THE MAINS LEAD: Never attempt to move the arc welder by the mains
lead or pull it to remove the plug from the mains socket. Keep the mains lead away
from heat, oil and sharp edges. If the mains lead is damaged, it must be replaced by
the manufacturer or its service agent or a similarly qualified person in order to avoid
unwanted hazards. All extension cables must be checked at regular intervals and re-
placed if damaged.
CHECK FOR DAMAGED PARTS: Before every use of the arc welder, any damage found
should be carefully checked to determine that it will operate correctly, safely and per-
form its intended function. Any damaged, split or missing parts that may affect its op-
eration should be correctly repaired or replaced by an authorised service centre un-
less otherwise indicated in this instruction manual.
KEEP ALL PANELS IN PLACE: Never operate the arc welder with any panels removed,
this is extremely dangerous.
MAINTAIN THE ARC WELDER WITH CARE: Keep the earth clamp and electrode holder
clean for the best and safest performance.
USE ONLY RECOMMENDED ACCESSORIES: Consult this user manual, your distributor or
SIP directly for recommended accessories. Follow the instructions that accompany the
accessories. The use of improper accessories may cause hazards and will invalidate
any warranty you may have.
SECURE THE WORK-PIECE: Always use welding clamps to secure the work piece. This
frees up both hands to operate the arc welder correctly.
DO NOT OVERREACH: Keep proper footing and balance at all times.
USE THE RIGHT TOOL: Do not use the arc welder to do a job for which it was not de-

6
SAFETY INSTRUCTIONS….cont
signed.
DO NOT OPERATE THE ARC WELDER IN EXPLOSIVE ATMOSPHERES: Do not use the arc
welder in the presence of flammable liquids, gases, dust or other combustible
sources. Arc welding will create sparks which can ignite the dust or fumes.
DO NOT EXPOSE THE ARC WELDER TO RAIN OR USE IT IN WET CONDITIONS: Water enter-
ing the arc welder will greatly increase the risk of electric shock.
HAVE YOUR ARC WELDER REPAIRED BY A QUALIFIED PERSON: The arc welder is in ac-
cordance with the relevant safety requirements. Repairs should only be carried out by
qualified persons using original spare parts, otherwise this may result in considerable
danger to the user.
Stop operation immediately if you notice anything abnormal.
Always disconnect the plug from the mains supply before cleaning or servicing
etc.
Be alert at all times, especially during repetitive, monotonous operations; Don't
be lulled into a false sense of security.
Use of improper accessories may cause damage to the arc welder and sur-
rounding area as well as increasing the risk of injury.
Do not modify the arc welder to do tasks other than those intended.
To avoid injury, the work-piece should never be held with the bare hands; The
work-piece will become hot during normal welding operations, and stay hot for
a period after the weld is complete.
Appropriate personal protective equipment MUST be worn and MUST be de-
signed to protect against all hazards created. Severe permanent injury can re-
sult from using inappropriate or insufficient protective equipment - Eyes in par-
ticular are at risk.
The work should be clamped firmly whilst welding, If its loose it could result in
personal injury or damage to the machine or item that is being welded.
DO NOT attempt any repairs unless you are a competent electrician or engi-
neer.
Ensure that the machine is connected to the correct supply voltage and pro-
tected by a fuse or circuit breaker of the recommend rating.
Never allow the earth clamp and electrode holder to come into contact with
each other.
27
EXPLODED DRAWING WELDMATE T211P (05721)

26
PARTS LIST WELDMATE T161P (05761)
Ref. No. Description Sip Part No.
1. Handle WE01-00030
2. Cover WE01-00053
3. Mains lead WE01-00054
4. Cable clamp WE01-00033
5. Rear panel WE01-00034
6. Fan motor WE01-00035
7. Insulation strip WE01-00036
8. Thermostat (transformer) WE01-00037
9. Shunt spindle fork WE01-00038
10. Clip WE01-00039
11. Transformer WE01-00055
12. Shunt WE01-00041
13. Indicator WE01-00042
14. Shunt bracket WE01-00043
15. Hand wheel c/w shaft WE01-00044
16. Chassis WE01-00056
17. Earth return lead c/w earth clamp WE01-00046
18. Electrode holder lead c/w electrode holder WE01-00047
19. On/Off switch WE01-00048
20. Thermal overload indicator WE01-00079
21. Fault indicator WE01-00080
22. Plastic frame WE01-00051
23. Clear window WE01-00052
24. Thermostat (fault indicator) WE01-00076
N/A. Electrode holder 02700
N/A. Earth clamp 02735
7
SAFETY INSTRUCTIONS….cont
Keep your body and clothing dry. Never work in a damp area without ade-
quate insulation against electrical shock, stay on a dry duck board, or rubber
mat when dampness or sweat can not be avoided. Sweat, sea water or mois-
ture between the body and an electrically ’hot’ part or grounded metal reduces
the body surface electrical resistance enabling dangerous and possibly lethal
currents to flow through the body.
NEVER allow live metal parts to touch bare skin or any wet clothing, be sure
welding gloves are dry.
Before welding, check for continuity; Be sure the earth clamp is connected to
the work piece as close to the welding areas as possible. Grounds connected
to building frame work or other remote locations from the welding area reduce
efficiency and increase the potential electric shock hazard. Avoid the possibility
of the welding current passing through lifting chains, crane cables or various
electric paths.
Frequently inspect leads for wear, splits, cracks and any other damage. IMME-
DIATELY replace those with worn or damaged insulation to avoid a possibly le-
thal shock from bare leads.
All inflammable materials must be removed from the area.
Have a suitable fire extinguisher available close by.
Causes of fire and explosion are; combustibles reached by the arc, flame, fly-
ing sparks, hot slag or heated material, misuse of compressed gases and cylin-
ders and short circuits.
Flying sparks or falling slag can pass through cracks along pipes, through win-
dows or doors and through walls or floor openings and out of sight of the opera-
tor. Sparks and slag can fly up-to 10 metres.
Keep equipment clean and operable; Free of oil, grease and of metallic parti-
cles (in electrical parts) that can cause short circuits.
If combustibles are in the area. DO NOT weld , move the work if practical to an
area free of combustibles, avoid paint spray rooms, dip tanks, storage areas
and ventilators. If the work can not be moved, then move the combustibles at
least 10 metres away and out of the reach of sparks and heat or protect
against ignition with suitable and snug fitting, fire resistant covers or shields.
Walls touching combustibles on opposite sides should not be welded on, walls,
ceilings and the floor near the work area should be protected by heat resistant
covers or shields.
Openings (concealed or visible) in floors or walls within 10 metres may expose
combustibles to sparks.
Combustibles adjacent to walls, ceilings, roofs or metal partitions can be ignit-
ELECTRIC SHOCK
FIRE

8
SAFETY INSTRUCTIONS….cont
The electric welding arc must not be observed with the naked eye. Always use a
welding mask; Ensure the welding mask is fitted with the correct shade of filter
lens for the welding current level.
Welding gauntlet gloves should be worn to protect the hands from burns, non-
synthetic overalls with buttons at the neck and wrist, or similar clothing should be
worn. Greasy overalls should not be worn. Wear suitable protective footwear.
Always wear correctly rated protective clothing.
Avoid oily or greasy clothing, a spark may ignite them.
Hot metal such as electrode stubs and work pieces should never be handled
without gloves.
First aid facilities and a qualified first aid person should be available for each
shift unless medical facilities are close by for immediate treatment of flash burns
to the eyes and skin.
Flammable hair products should not be used by persons intending to weld.
Warn bystanders not to watch the arc and not to expose themselves to the
welding-arc rays or to hot metal.
Keep children away whilst welding, they may not be aware that looking at an
arc can cause serious eye damage.
Protect other nearby personnel from arc rays and hot sparks with a suitable non-
flammable partition.
GLARE AND BURNS
ed by radiant or conducted heat.
After the work is done, check that the area is free of sparks, glowing embers and
flames.
An empty container that has held combustibles, or that can produce flamma-
ble or toxic vapours when heated, must never be welded, unless the container
has first been cleaned. Consult HSE INDG214, HSG250 and CS15. HSE docu-
ment CS15 includes information on cleaning by thorough steam or solvent/
caustic cleaning followed by purging and inserting with nitrogen, carbon diox-
ide or water filling just below working level.
A container with unknown contents should be treated as if it contained combus-
tibles (see previous paragraph), DO NOT depend on sense of smell or sight to
determine if it is safe to weld.
Hollow items must be vented before welding as they can explode.
Explosive atmosphere; Never weld when the air may contain flammable dust,
gas or liquid vapours (such as petrol).
25
EXPLODED DRAWING WELDMATE T161P (05761)

24
PARTS LIST WELDMATE T141P (05741)
Ref. No. Description Sip Part No.
1. Handle WE01-00030
2. Cover WE01-00031
3. Mains lead WE01-00032
4. Cable clamp WE01-00033
5. Rear panel WE01-00034
6. Fan motor WE01-00035
7. Insulation strip WE01-00036
8. Thermostat (transformer) WE01-00037
9. Shunt spindle fork WE01-00038
10. Clip WE01-00039
11. Transformer WE01-00040
12. Shunt WE01-00041
13. Indicator WE01-00042
14. Shunt bracket WE01-00043
15. Hand wheel c/w shaft WE01-00044
16. Chassis WE01-00045
17. Earth return lead c/w earth clamp WE01-00046
18. Electrode holder lead c/w electrode holder WE01-00047
19. On/Off switch WE01-00048
20. Thermal overload indicator WE01-00049
21. Fault indicator WE01-00050
22. Plastic frame WE01-00051
23. Clear window WE01-00052
24. Thermostat (fault indicator) WE01-00076
N/A. Electrode holder 02700
N/A. Earth clamp 02735
9
SAFETY INSTRUCTIONS….cont
Ventilation must be adequate to remove the smoke and fumes during welding
(see the relevant safety standard for acceptable levels).
Toxic gases may be given off when welding, especially if zinc or cadmium
coated materials are involved, welding should be carried out in a well ventilat-
ed area and the operator should always be alert to fume build-up.
Areas with little or no ventilation should always use a fume extractor.
Vapours of chlorinated solvents can form the toxic gas phosgene when ex-
posed to U.V radiation from an electric arc. All solvents, degreasers and poten-
tial sources of these vapours must be removed from the arc area.
Severe discomfort, illness or death can result from fumes, vapours, heat, oxygen
enrichment or depletion that welding (or cutting) may produce. This will be pre-
vented by adequate ventilation or using a fume extractor. NEVER ventilate with
oxygen.
Lead, cadmium, zinc, mercury, beryllium bearing and similar materials when
welded may produce harmful concentrations of toxic fumes. Adequate ventila-
tion must be provided for every person in the area. The operator should also
wear an air supplied respirator, for beryllium both must be used.
Metals coated with or containing materials that emit toxic fumes should not be
heated unless coating is removed from the work surface. The area should be
well ventilated or the operator should wear an air supplied respirator.
Work in a confined space only while it is being ventilated and if necessary whilst
wearing an air supplied respirator.
Gas leaks in a confined space should be avoided, leaking gas in large quanti-
ties can change oxygen concentration dangerously. DO NOT bring gas cylin-
ders into a confined space.
Leaving a confined space you must shut off the gas supply at the source to
prevent possible accumulation of gases in the space if down stream valves are
left open. Check to be sure that the space is safe before re entering it.
Vapours from chlorinated solvents can be decomposed by the heat of the arc
(or flame) to form phosgene a highly toxic gas and other lung and eye-irritating
products. The ultra violet (radiant) energy of the arc can also decompose tri-
chloroethylene and perchlorethylene vapours to form phosgene. DO NOT WELD
or cut where solvent vapours can be drawn into the welding atmosphere, or
where the radiant energy can penetrate to atmospheres containing even mi-
nute amounts of trichloroethylene or perchlorethylene.
VENTILATION

10
SAFETY INSTRUCTIONS….cont
Some metals and metal composites have the potential to be highly
toxic; always wear a face mask .
When using the arc welder always ensure the operator as well as
those in the area use a welding mask with the correct shade filter
lens.
CAUTION: The warnings and cautions mentioned in this user manual can not
cover all possible conditions and situations that may occur. It must be under-
stood by the operator that common sense and caution are factors which can-
not be built into this product, but must be applied.
23
EXPLODED DRAWING WELDMATE T141P (05741)