ADA INSTRUMENTS IronWeld 200, IronWeld 160, IronWeld 220, IronWeld 180 User Manual [ru]

IronWeld 160/180/200/220

Operating manual

DC Inverter Welder

IronWeld 160/180/200/220

Manufacturer: ADAINSTRUMENTS Address: WWW.ADAINSTRUMENTS.COM

IronWeld 160/180/200/220

Table of contents

1.Complete set . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

2. Application . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

3. Safety instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

4. Spesications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

5. Features and operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

6. Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

7. Maintenance andservice . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13Maintenance and service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

8. Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

9. Exceptions from responsibility . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

10. Appendix 1- «Certicate of acceptance and sale»

11. Appendix 2- «Warranty card»

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MEASUREMENT FOUNDATION

IronWeld 160/180/200/220

WARNING!

Please, read all instructins before operation. Failure to follow all instructions listed below may result in electric
shock, re and/or serious injury.

1. Complete set

- Hammer/brush

- Mask. When welding, the mask will protect your eyes and face.

- Electrode holder (with 2.5M welding cable)

- Earth clamp (with 1.5M earth cable)

2. Application

Inverter welder is used for welding with covered electrodes (ММА). It is designed wih Advanced Inverter
IGBT Technology. Models of welding inverter allow to perfect manual art-starting performance of welder.
These welders are specially designed for application in daily routine: for repair work when building a house,

for residential care and so on.

The equipment uses electrical arc between electrode and weld material as a heat source for melting of the
electrode and weld material. It is used in the welding of all kinds of elecctrodes: rutile, base contact, elec­trodes from stainless steel and other. The instrument is protected from overheating and it is used for work
with power 220V.
The main characteristics of this inverter instrument are:

- Small size and light weight. That’s why it’s easy to use it for repair work in eld condition.

- Perfect striking of an arc.

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MEASUREMENT FOUNDATION

IronWeld 160/180/200/220

- Availability of protection protects the instrument from overheating, overvoltage, voltage loss, overcurrent

and so on.

- Convenient connection. External plug makes connections safe, fast and reliable.

3. Safety instructions
WARNING. Welder is under voltage. Disconnect the plug from the power source before making any adjust-

ments, changing accessories, or storing power tools. Such preventive safety measures reduce the risk of
starting the power tool accidentally. Only specialists can work with he welder.

- Always follow safety instructions. Wear appropriate protective clothing, shoes and helmet to avoid dam­ages of eyes and skin.

- Always wear protective mask when operate the welder. Or use protective glasses with protective darken­ing glass.

- Try to avoid from arc ray, sparing and splattering.

- Do not expose power tools to rain or wet conditions. Water entering a power tool will increase the risk of
electric shock. When you operate outside, protect the instrument from rain and sun rays. Use the welder in
the place where there is no rain and direct sun rays.

- The welding fog and gas can make the worker uncomfortable, or hunted, especially in the limited land­scape, so do not breathe the fog and gas. Be sure of good ventiation.

- Be sure that the radiation of the arc doesn’t reach other people, that are near to the place of welding.

- Remember, that the temperature of welding surface increases. So ty not to touch to the welding parts. It
can cause burns.

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MEASUREMENT FOUNDATION

IronWeld 160/180/200/220

- It’s forbidden to touch electrode with bare hands. It’s forbidden to wear wet or damaged gloves or protec­tive clothes.

- Don’t touch the parts under voltage.

- It’s forbidden to touch electrode that is in contact with welding surface, ground or other electrode which is
connected to another welder.

- Never weld tanks that contain ammable and explosive materials.

- To avoid accidents when working at height, follow safety regulations.

- Be careful, there must be no bystanders on the working site.

- Welders radiate electromagnetic waves and make noises. So be sure that there are no people with cardiac
stimulator or other equipment that can be inuenced with electromagnetic waves and radio frequencies.

- Before operation check the connection of cables and earth. From time to time check the condition of weld­ing cable. If you use this instrument regularly, check it once per month.

- Only qualied specialists can do servicing.

- If you don’t use welder for a long time, store it in place wih good ventilation.

- Regularly clean welder from dust. Check holding elements. They must be tighten. Check ectromagnetic
system, current adjusting knob and so on.

- Dust in the air and also corrosive substances mustn’t exceed permissible levels.

- It’s necessary to provide access for air for the welder. There must be free space around welder, about 50

cm.

- Ensure that there are no metallic or foreign objects near the welder. They can get into the welder.

- Take out the electrode if you don’t use welder for a long time.

- Don’t place the welder on the vibrating surface.

- Ensure that there are no noises in the place of adjustment of welder.

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MEASUREMENT FOUNDATION

IronWeld 160/180/200/220

4. Spesications

Environmental conditions:

a) temperature range
During welding : -10 °C ~ +40 °C
During transportation and storage : -25 °C ~ +55 °C

b) humidity
at +40 °C <50%
at +20 °C <90%
c)

dust, acid and dirt in the air of work area also mustn’t exceed permissible levels (except of emission from weld-

er).
d) height above sea level no more than 1000 m.
e) angle of slope during operation mustn’t exceed 15 °.
f) noise level during operation mustn’t exceed 75 dB

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MEASUREMENT FOUNDATION

IronWeld 160/180/200/220

Parameter

Input voltage 230V 230V 230V 230V

Frequency 50/60Hz 50/60Hz 50/60Hz 50/60Hz

Phase Single Single Single Single

Max input power 4.6 KVA 5.3 KVA 6.2 KVA 7.1 KVA

Max No-load voltage 68 V 68 V 68 V 68 V
Current range 10-160 A 10-180 A 10-200 A 10-220 A

Duty cycle 60% 60% 60% 60%
Insulation grade F F F F

Electrode diameter 2.0-4.0 mm 2.0-4.0 mm 2.0-5.0 mm 2.0-5.0 mm

Dimensions (L×W×H) 38х22х30 cm 38х22х30 cm 38х22х30 cm 38х22х30 cm

IronWeld 160 IronWeld 180 IronWeld 200 IronWeld 220

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Model

MEASUREMENT FOUNDATION

IronWeld 160/180/200/220

5. Features and operation

There is power indicator, indicator of thermoprotection and adjusting knob of current strength on the upper
part of the instrument. There are plugs for connection of welding cables with electrode holders and clamp
on the bottom. Power switch is located on the back panel.

1

6

2

3

4

5

1. Power indicator

2. Indicator of thermopro-

tection.

7

3. Adjusting knob of cur­rent strength.

4. Plug for connection of
earth clamp.

5. Plug for connection
of cable with electrode
holder.

6. Input of cable con­nection to the electricity

supply.

7. Power switch.

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MEASUREMENT FOUNDATION

IronWeld 160/180/200/220

WARNING: Indicator of thermoprotection will light after long period of operation. That means that inner tem-

perature exceeds permitted value. In that case stop work and let the instrument cool down. You can continue
operation when the indicator is switched off.

Installing of welder

Do not expose your welder to rain or direct sunlight. You must provide good ventilation. The distunce above
welder must be no less than 50 cm. In case of poor inner ventilation, set the equipment to get rid of smoke
and protect from wind.

Connection of power suply

Connect electric cable to single-phase net of power supply 220V with switch.
It’s forbidden to use voltage 380V. As it can damage the tool and operator.
When connecting welder to the electric network under voltage 220V and with frequency 50 Hz, it’s necessary
to provide protection of the socket. It’s important for connection with automatic switch or 25 A fuse.

WARNING: Use socket with ground connection to connect the tool.

Connection of cables with electrode holders and earth clamp

Connection of welding cable. Connect bayonet plug of welding cable to the output connection on the front
panel with marking «+» and turn clockwise.

Electrode holder is used for electrode clamp

Connection of earth cable. Connect bayonet plug of welding cable to the output connection on the front panel
and turn clockwise. Earth clamp is used for connection of welding material to the chain of welding current.

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MEASUREMENT FOUNDATION

IronWeld 160/180/200/220

Cleanup of welding material befor welding

Metal must be cleaned of rust, oil dust, water, paint and so on. Clean the metal at distance 10-20 mm from
the joint.

Welding

Adjustment before welding.
Adjust current according to the thickness of welding detail and diameter of welding electrode.
Take electrode holder, set the electrode, touch welding material with electrode in order to get arc.

Electrode replacement

Stop welding when the length of electrode decreases up to 1-2 cm. Press the handle of electrode holder.
After that, set new electrode and release handle.

WARNING: Electrode warms till the high temperature. Please, follow safety precautions to avoid burns.

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MEASUREMENT FOUNDATION

IronWeld 160/180/200/220

6. Troubleshooting

TROUBLE REASON SHOOTING

Indicator of thermoprotection
lights

Adjustment of current doesn’t
work

Electrode holder and weld­ing cable heat up to the high

temperature

Overheating protection because

of poor ventilation.
Environment temperature is too

high.

Usage of tool beyond its duty

cycle.

Adjustment of current is broken.

Socket is dirty with oxides. Clean the sockets.

Distance between holder and
cable is big.

Improve the conditions of

ventilation.

Reduce the temperature. The
indicator will switch off.

Replace the adjustment of

current.

Disconnect electrode holder
and clean up cable of the place

of contact.

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MEASUREMENT FOUNDATION