CFC S2405 Flux Cored Wire Welding Machine

INSTRUCTION MANUAL

Inverter welding machine 120 A

Symbol explanations

Safety and warning information

• Only use the welding cables included in the scope of delivery.
• Do not position the device directly against the wall during operation and avoid covering it or sandwiching it between other devices. This will ensure adequate ventilation through the ventilation slots.
• Make sure that the device is properly connected to the mains voltage and avoid any strain on the mains cable.
• Before moving the unit, disconnect the mains plug from the socket outlet.
• Always switch off the device using the ON/OFF switch when it is not in operation.
• Place the electrode holder and hand torch on an insulated surface and do not remove the electrodes until they have cooled down for 15 minutes.
• Regularly check the condition of the welding cables, the electrode holder and the earth terminals.
  Wear on the insulation and live parts can give rise to hazards and impair the quality of welding.
• Arc welding creates sparks, molten metal parts and smoke. Therefore, please note: Remove all flammable substances and/or materials from the workplace and its immediate surroundings.
• Make sure that the workplace is adequately ventilated. Work with an extraction system or in well-ventilated areas. Avoid direct inhalation of the gases. Do not weld on containers, vessels or pipes that contain or have contained flammable liquids or gases.
• Avoid direct contact with the welding circuit, as the open-circuit voltage between the electrode pliers and earth terminal may be dangerous and there is a risk of electric shock.
• Do not store or use the device in a humid or wet environment, in rainy or snowy conditions. Please observe the IP21S protective provision.
• Protect your eyes using protective lenses designed for this purpose.
• Use welding gloves and dry protective clothing free of oil and grease to protect your skin from radiation from the electric arc.
• Do not use the welding power source to defrost pipes.
• Radiation from the electric arc can damage your eyes and result in burns to the skin.
• Arc welding creates sparks and drops of molten metal, whilst the welded workpiece will start to glow and remain relatively hot for a long time. Do not touch the workpiece with your bare hands.
• Always wear special welding gloves.
• Harmful vapours are released during arc welding. Take care not to inhale these if possible.
• Protect yourself against the dangerous effects of the arc, and make sure than anybody not involved in the work process is kept at least 2 metres away from the arc.
• During operation of the welding device, depending on the grid conditions at the connection point, there may be disruptions in the power supply to other consumers. When in doubt, contact your energy supply company.
• Other devices such as hearing aids, pacemakers, etc., may malfunction while the welding machine
  is in operation.

Sources of danger during arc welding

Arc welding is associated with a number of sources of danger. It is therefore particularly important for the welder to observe the following rules in order not to endanger himself and others and to avoid injury/damage to people and equipment.

• In accordance with national and local regulations, work on the mains voltage side, e.g. on cables,
  plugs, sockets, etc., should only be carried out by a qualified electrician.
• In the event of an accident, immediately disconnect the welding machine from the mains voltage.
• If electrical touch voltages occur, switch off the device immediately and have it checked by a qualified electrician.
• Make sure there are secure electrical contacts on the welding current side.
• When welding, wear insulating welding gloves on both hands to protect against electric shock, harmful radiation, glowing metal and spatter.
• Use sturdy, insulating footwear that also insulates in wet conditions. Low shoes are unsuitable as falling, glowing metal droplets can result in burns.
• Wear appropriate protective clothing and avoid synthetic materials.
• Do not stare into the arc without protection. Use a welding shield with protective glass in accordance with DIN regulations. The arc not only emits light and heat rays, but also invisible UV rays,
  which can lead to conjunctivitis and skin burns.
• Individuals in the vicinity of the arc must be alerted to the dangers and equipped with appropriate protective equipment. If necessary, erect protective walls.
• When welding, especially in confined spaces, make sure that there is a sufficient supply of fresh air, as smoke and harmful gases are generated.
• Avoid welding work on containers that contain or have contained gases, fuels, mineral oils or similar, as there is a risk of explosion due to residual materials.
• Adhere to special regulations in rooms where there is a risk of fire and explosion. Welded joints are subject to specific safety requirements and should only be worked on by especially trained and certified welders.
• ATTENTION! Always connect the earth terminal as close as possible to the welding point so that the welding current can travel the shortest possible distance from the electrode to the earth terminal.
• Never connect the earth terminal to the housing of the welding machine! Do not connect the earth terminal to earthed (grounded) parts far from the workpiece. Otherwise, the protective conductor system of the room in which you are welding could be damaged.
• Do not use the welding machine in the rain or in a damp environment.
• Always place the welding machine on a level surface.
• The output is rated at an ambient temperature of 20°C. Welding times may be reduced at higher temperatures.

Hazard due to electric shock:

An electric shock from a welding electrode can be fatal. Do not weld in rainy or snowy conditions.
Wear dry insulating gloves. Do not touch the electrode with your bare hands.
Do not wear wet or damaged gloves. Protect yourself from electrical shock by insulating against the workpiece. Do not open the machine housing.

Danger from welding fumes:

Inhalation of welding fumes can endanger your health. Do not put your head into the smoke. Use the equipment in open areas. Use ventilation to remove the smoke.

Danger from welding sparks:

Welding sparks can give rise to an explosion or a fire. Keep flammable materials away from the welding site. Do not weld next to flammable materials. Welding sparks can cause fires. Keep a fire extinguisher close by and an observer who can use it immediately. Do not perform welding on drums or any closed containers.

Dangers from welding sparks:

Arc rays can damage your eyes and damage your skin. Wear a hat and safety goggles. Wear hearing protection and a shirt with high collar. Wear a protective welding helmet and correctly sized filters.
Wear full body protection.

Exposure to electromagnetic fields:

Welding current generates electromagnetic fields. Do not use with medical implants. Never wrap the welding lines around your body. Keep the welding cables together.

Environment with an increased electrical hazard

• Observe the following safety instructions when welding in environments with an increased electrical hazard. Such environments with an increased electrical hazard can occur in the following
  situations: at workplaces where the work area is restricted, so that the welder is operating in a forced position (e.g. kneeling, sitting, lying) and is touching electrically conductive components;
• At workplaces that are fully or partially electrically conductive and where there is a high risk of preventable or accidental contact by the welder;
• In wet, humid or hot workplaces where humidity or perspiration significantly reduces the resistance of human skin and the insulating properties or protective equipment.
• A metal ladder or scaffolding can also create an environment with an increased electrical hazard.

Using the carrying strap

Welding must not be carried out when the flux-cored wire welding machine is being carried, for example using the carrying strap.

• This is to prevent the following risks: The risk of losing balance when connected cables are pulled.
• Increased risk of electric shock as the welder comes into contact with the earth when using a Class

I welding power source where the housing is earthed through its protective earth conductor.

Protective clothing

• Throughout the work process, the welder must be protected against radiation and burns on his entire body by appropriate clothing and face protection. The following steps should be observed:
  – Donn protective clothing before welding.
  – Wear welding gloves.
  – Use an open window or fan to ensure satisfactory air supply.
  – Wear safety glasses/helmet and a mouth guard.
• Wear welding gloves made of a suitable fabric (leather) on both hands. They must be in perfect condition.
• Suitable leather aprons must be worn to protect clothing from sparks and burns.

Protection against radiation and burns

• • A notice should be displayed at the workplace with the wording “Caution! Do not look into the flame!” to draw attention to the danger to your eyes. In addition, the workplaces should be screened off so that individuals in the vicinity are protected and unauthorised individuals are kept away from the welding work.

EMC equipment classification

In accordance with EN IEC 60974-10, this is a welding device with Class A electromagnetic compatibility.
This Class A equipment is not intended for use in residential areas where power is supplied from a public low-voltage power supply network. In such environments, problems may occur in ensuring electromagnetic compatibility due to both conducted and radiated interference.

Class A appliances are appliances that are suitable for use in all areas other than residential areas and those areas that are directly connected to a low-voltage supply network that (also) supplies residential buildings.

Make sure that there are no other mains, control, signalling or telecommunication cables in the vicinity of the device. Make sure that there is no one with a pacemaker or hearing aid in the area close to the device.
Check the safety of other devices in the same environment. In some cases, additional safety measures may be required.

! NOTE: Class A equipment is intended for use in an industrial environment. Due to the occurrence of performance-related as well as radiated disturbances, it may be difficult to ensure electromagnetic compatibility in other environments.

Even if the device meets the emission limits stipulated in the standard, such devices can still cause electromagnetic interference in sensitive systems and devices. The user is responsible for any faults
caused by the arc, and the user must take suitable protective measures.

The user must pay particular attention to the following:

• Other mains cables, control cables, signalling and telecommunication cables above, below and next to the arc welding equipment;
• Sound and TV broadcast stations and receivers;
• Computers and other control devices;
• Critical safety devices, e.g. protection for commercial facilities;
• The health of people in the vicinity, e.g. those using cardiac pacemakers or hearing aids;
•  Facilities for calibrating or measuring;
• The immunity to interference of other equipment in the vicinity. The user must ensure that other equipment, which is being used in the vicinity, is suitable for them. This may require additional protective measures;
• The time of day at which welding or other activities are being carried out.

The dimensions of the surrounding area being considered will depend on the type of construction of the building and the other activities taking place there.
In order to reduce possible interference, the following is recommended:

• Equip the mains connection, e.g. with a mains filter;
• Regular maintenance;
• The welding lines should be completely uncoiled and be as short and close together as possible and run close to the ground;
• If possible, devices and systems that are subject to interference should be removed from the work area or shielded.

Welding equipment should be connected to the public power supply in accordance with the manufacturer’s recommendations. In the event of interference, additional precautions may be necessary,
such as the use of filters. It is recommended that the power supply line is shielded by means of an electrically connected metal pipe so that good electrical contact between the sheathing and the housing of the welding power source is achieved.

The arc welding device should be serviced regularly according to the manufacturer’s recommendations.
All access and service doors and lids should be closed and well secured when the arc welding device is in operation. With the exception of the changes and settings specified in the manufacturer’s instructions, arc welding equipment should not be modified in any way. In particular, the spark gaps of arc ignition and stabilisation devices should be adjusted and maintained according to the manufacturer’s recommendations.

 

Important: read this instruction manual carefully to become familiar with the device before connecting it to the gas. Keep the instructions in a safe place so that you can read them again. Hand over the instructions when providing the device to third parties

KEEP OUT OF THE REACH OF CHILDREN!

Intended use

This welding device is suitable for arc welding without gas with self-protective flux-cored welding wire. It can be used with a variety of metals such as carbon steel, alloy steel, stainless steel and other stainless steels. With the included electrode holder, the device can also be used for electrode welding with stick electrodes. It features an indicator lamp, a thermal protection indicator and a cooling fan. It is also equipped with a carrying strap that enables the product to be lifted and moved in a safe manner. Exclusively for use by qualified personnel or persons  who are trained in the tasks to be completed and who are fully aware of the potential dangers of careless behavior.

Equipment

(1) Carrying strap
(2) Control lamp for operation (input voltage)
(3) Overheat control lamp (overload protection)
(4) Output voltage in amperes
(5) Rotary knob function (synergistic)
(6) Display for 0.8 mm flux-cored welding wire
(7) Display for 0.9 mm flux-cored welding wire
(8) MMA display

(9) Output ground terminal (-)
(10) Electrode holder output (+)
(11) Supply cable hand torch hose package
(12) Manual torch for arc welding with hose package
(13) Ground clamp MK 300 A
(14) Electrode holder EH 200 A
(15) Slag hammer
(16) Power cable
(17) Mains plug
(18) ON/OFF switch

(19) Maintenance flap
(20) Burner nozzle
(21) Contact nozzle
(22) Adjusting screw
(23) Pressure feed unit
(24) Coil holder
(25) Feed roller holder
(26) Feed roller
(27) Wire entry
(28) Cable assembly bracket

Delivery

• 1 Flux-cored wire welding machine with hand torch and hose package
• 1 burner nozzle (pre-assembled)
• 2 contact tips (1 x 0.9 mm pre-assembled;
• 1 x 0.8 mm)
• 1 Electrode holder EH 200 A
• 1 Ground clamp MK 300 A
• 1 Carrying strap
• 1 Slag hammer with wire brush
• 1 User manual

Technical specifications

MMA

• Mains connection: 230 V ~ 50-60 Hz (AC)
• Max. welding current and the corresponding rated operating voltage: 15 A / 20.4 V to 120 A / 24.8 V
• Rated value of mains voltage: U1: 230 V
• Maximum rated value of mains current: I1max: 23 A
• Maximum effective input current: I1eff: 7.3 A
• Rated value of open-circuit voltage: U0: 86 V
• Protection class: IP21S
• Weldable material thickness: max. 4.0 mm

Flux-cored welding wire

• Mains connection: 230 V ~ 50-60 Hz (AC)
• Max. welding current and the corresponding rated operating voltage: 30 A / 15.5 V to 120 A / 20 V
• Rated value of mains voltage: U1: 230 V
• Maximum rated value of mains current: I1max: 19.5 A
• Maximum effective input current: I1eff: 6.2 A
• Rated value of open-circuit voltage: U0: 86 V
• Protection class: IP21S
• Weldable material thickness: max. 4.0 mm
• Welding wire drum max: approx. 1,000 g
• Welding wire diameter max.: 0.9 mm
• Hose package length 2.5 m
• Electrode type and diameter range Contact tip 0.8 mm or 0.9 mm
• Rated current 100 % 38 A; 60 % 49 A; 10 % 120 A

Before commissioning

Remove the machine and accessories from the packaging and check them for damage (e.g. transport damage).

• Attach the carrying strap (1) to the machine

Insert flux-cored welding wire

Note: Depending on the application, different welding wires are required.
The feed roller, welding nozzle and wire cross section must always correspond.
The device is suitable for wire spools up to a maximum of 1,000 g.

• The manual torch for arc welding with hose package is already pre-assembled and ready for use.
• Unlock and open the wire feeder cover by pushing the latch up.
• Unlock the coil unit by pressing the coil holder (24) and turning it counter-clockwise (see symbol).
• Pull the spool holder (24) and washer off the shaft.
• Place the wire spool on the shaft. Ensure that the wire spool is unwound on the side of the wire bushing. Only use wire coils (27) from the company CFH.
• Put the washer and the spool holder (24) back on and lock them by pressing and turning them clockwise (see symbol).
• Loosen the adjustment screw (22) of the pressure feed unit (23) and swing it upwards.
• Turn the pressure roller (23) to the side.
• Loosen the feed roller holder (25) by turning it counter-clockwise and pull it upwards.
• Check the top of the feed roll (26) to see if the appropriate wire size is indicated. If necessary, the feed roller must be turned around. The flux-cored welding wire must be in the upper groove!
• Replace the feed roller holder (25) and screw it clockwise.
• Take the end of the flux-cored welding wire and shorten the wire end with a wire cutter or a side cutter to remove the damaged bent end of the wire.
  Note: The flux-cored welding wire must be kept tight at all times to avoid loosening and unrolling!
• Push the flux-cored welding wire through the wire gland (27). Pass the flux-cored welding wire along the feed roller (26), and then slide it into the wire receptacle (28).
• Then swing the pressure roller unit (23) in the direction of the feed roller (26).
• Hook in the adjusting screw (22) and set the back pressure using the adjusting screw (22). The flux-cored welding wire must sit firmly between the pressure roller (23) and the feed roller (26) in the upper guide without being crushed.
• Switch the device on using the ON/OFF switch (18). The fan noise signals that the device is ready for operation.
• Press the rotary knob function (5) to switch between the different modes for flux-cored welding wire and MMA.
• Press the torch button to activate the wire feed and transport the flux-cored wire into the hose package. The process is complete when the wire comes out of the front of the burner (20).
• Before changing the flux-cored wire, pull the old flux-cored wire forward from the contact tip (21) using pliers. When inserting a new wire spool, ensure that there is no flux-cored wire left in the hose assembly.

Electrode welding (MMA)

• Alternatively you can also use the device for electrode welding. To do this, connect the electrode holder (14) and the ground clamp (13) to the corresponding connections on the welding machine.
• Place an electrode in the electrode holder clamp (14).

Welding polarities

Flux-cored welding wire operation
! The earth cable from the earth terminal (13) must be connected to the positive pole (+) at the front of the device!

Supply cable hand torch hose package (-) | Ground terminal (+)

Electrode welding (MMA)

Starting-up

First select the welding mode using the rotary control, which must be pressed. You can switch between different functions and wire diame-ters by pressing the rotary knob. For flux-cored welding wire operation, select the 0.8 mm or 0.9 mm function according to the cored wire inserted. If you want to use the device for welding with stick electrodes, select MMA mode.

Flux-cored welding wire

• Make sure that the ON/OFF switch (18) is set to the “O” (“OFF”) position and that the mains plug (17) is not plugged into the socket.
• Connect the supply cable from the hand torch or hose package (11) to the corresponding output (9) on the device (marked with “-”)
• Then connect the earth terminal (13) to the corresponding output (10) on the device (marked with “+”).
  IMPORTANT: The ground cable must be connected to the positive (+) terminal on the front of the device!
• Wear appropriate protective clothing according to the specifications and prepare your workplace.
• Connect the earth terminal (13) to the workpiece.
• Install the filler wire and follow the instructions in “Before commissioning”.
• To operate the welding machine, insert the mains plug (17) into the mains socket and switch it on by turning the ON/OFF switch (18) to the “I” (“ON”) position.
• The LED input voltage display (2) on the front panel of the machine will light up and signal that the machine is ready for operation.
• Adjust the welding current using the rotary knob (5). You can read the set Amp number on the LCD displays.

Electrode welding (MMA)

• Make sure that the ON/OFF switch (18) is set to the “O” (“OFF”) position and that the mains plug (17) is not plugged into the socket.
• Connect the welding cables according to their polarity and to the specifications of the electrode manufacturer.
• To do this, connect the connection of the ground terminal (13) to the corresponding output (9) on the device (marked with “-”).
• Connect the connection of the electrode holder (14) to the corresponding output (10) on the device (marked with “+”).
• Wear appropriate protective clothing according to the specifications and prepare your workplace.
• Connect the earth terminal (13) to the workpiece.
• Clamp the electrode into the electrode holder (14).
• To operate the welding machine, insert the mains plug (17) into the mains socket and switch it on by turning the ON/OFF switch (18) to the “I” (“ON”) position.
• The LED input voltage display (2) on the front panel of the machine will light up and signal that the machine is ready for operation.
• Adjust the welding current using the rotary knob (5) depending on the electrode used. You can read the set Amp number on the LCD displays.

NOTE: Refer to the following table for the recommended welding current to be set depending on the electrode diameter.

MMA

Electrode	Welding current
1.5 mm	30 – 50 A
2.0 mm	50 – 60 A
2.5 mm	55 – 85 A
3.2 mm	90 – 140 A

For optimum welding results, it is important to set the current correctly. Too high a current leads to rapid burning of the electrode and a large weld pool that is difficult to control, whilst too low a current will result in a small, irregular weld pool.

CAUTION: The ground terminal (13) and the electrode holder (14) must not be brought into direct contact.

CAUTION: The device features overheating protection. When triggered, the yellow light (3) will come on and welding will temporarily be impossible. The device will continue to operate whilst the fan is cooling down. As soon as the device is ready for operation again, the yellow indicator lamp (3) will automatically go out and welding can be continued.

CAUTION: Take care not to rub the electrode against the workpiece. This can damage the workpiece and make it more difficult to ignite the arc. After igniting the arc, maintain the correct distance to the workpiece. The distance should correspond to the diameter of the electrode used. During welding, keep this distance as accurate and constant as possible.
The angle between the electrode and the working direction should be between 20° and 30°.

CAUTION: The welding clamp and welding electrode should be placed on the insulated bracket after the welding operation. Removal of the molten slag is only possible after the electrode has completely cooled down. To re-weld the interrupted weld seam, the molten slag must first be removed at the welding position.

CAUTION:

• Arc radiation can cause eye inflammation and skin burns.
• Splashing and molten slag can cause eye injury and burns.
• Wear tinted eye protection goggles or a protective mask.
  The eye protection goggles and protective mask must comply with safety standards.

Switching off

After the welding process, place the electrode holder and welding electrode on the insulated surface. Then switch off the power and disconnect the power plug (17) to ensure safety.

Storage and transport

Before storing or transporting the welding machine and accessories, make sure these have cooled down completely. Make sure that the machine is stable and secured during transport to prevent damage.

Maintaining and cleaning

! NOTE: The welding machine must be serviced and overhauled regularly to ensure proper functioning and compliance with safety requirements. Only rely on qualified electricians for repairs and maintenance work. Improper and incorrect operation can lead to failures and damage to the machine.

• Before cleaning the welding machine, disconnect the mains cable (17) from the mains socket so that the device is safely disconnected from the electrical circuit.
• Clean the machine and its accessories regularly from the outside. Remove dirt and dust using air, cotton wool or a brush.
  ! NOTE: The following maintenance work may only be performed by qualified personnel.
• The regulator, earthing device and internal cables should be serviced regularly.
• Check the welding machine’s insulation resistance at regular intervals. To do this, use the appropriate measuring device.
• In the event of a defect or if machine parts are to be replaced, please contact the appropriate personnel.

Disposal & Environmental Information

The packaging is made from environmentally friendly materials that you can dispose of at local recycling stations

Do not dispose of power tools in domestic waste!

Dispose of the packing in an environmentally friendly manner. Observe the labelling on the various packaging materials and
separate them if necessary. The packaging materials are marked with abbreviations (a) and (b) with the following meaning:
1–7: plastics, 20–22: paper and cardboard, 80–98: composites

You can find out how to dispose of obsolete devices from your local authority or town council.

Guarantee

Always keep the original receipt in a safe place. This document is needed as proof of purchase. Contact us via e-mail at: info@cfh-gmbh.de if you have a guarantee claim. We will contact you immediately.
We reserve the right to make technical and visual changes.

Specifications:

• Input Voltage: 230 V ~ 50-60 Hz
• Output Current Range: 15 A to 120 A
• Output Voltage Range: 20.4 V to 24.8 V
• Electrode Diameter Range: Up to 4.0 mm
• Protection Class: IP21S

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FAQ:

Q: What is the maximum output current of the inverter welding machine?

A: The inverter welding machine has a maximum output current of 120 A.

Q: How should I clean the welding machine?

A: Clean the external surfaces of the machine using a soft, dry cloth. Avoid using abrasive materials or solvents for cleaning.

Documents / Resources

CFC S2405 Flux Cored Wire Welding Machine [pdf] Instruction Manual 52884, BA, S2405, S2405 Flux Cored Wire Welding Machine, S2405, Flux Cored Wire Welding Machine, Cored Wire Welding Machine, Wire Welding Machine, Welding Machine

References

• User Manual