Fubag INMIG 200 PLUS User manual

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WARNING! BEFORE USING THE WELDING MACHINE READ THE INSTRUCTION MANUAL CAREFULLY! FOR QUALIFIED AND SPECIALLY TRAINED PERSONS ONLY AFTER PROPER READING OF THIS MANUAL IS ALLOWED TO USE AND TO MAINTAINTHIS WELDING MACHINE.

The detailed description, safety rules and all required information necessary for proper operation and maintenance of FUBAG welding machine are provided below. Keep this instruction manual by machine and refer to it by any doubts concerning safety operation, maintenance storage and handling of FUBAG weldingmachine.

1. Safety perationo

It is highly recommended always to follow the safety rules. Wear protective clothes and

special means to avoid injuries to eyes and skins.

Use the welding mask or special protective glasses while working with the welding

machine. Only by viewing through the filter lens on the welding mask your eyes are secured by your operation.

Prevent the sparks and spatter from harming your body.

Under no circumstance allow any part of your body to touch the welder's output bipolarity

(torch and work piece).

Do not operate under water or more humid place.

Fumes and gases produced when welding are hazardous to health. Make sure to work in

places where there are exhaust or ventilation facilities to keep fumes or emissions away from the breathing zone.

Please remember to keep arc rays away from the other nearby people when welding. This

is only due to the interference from arc rays.

There will be high temperature when welding work piece, so please don't directly touch on it

No touching on the output connection or any other electrification parts while welding.

No touching on the electrification parts after turning on the power. Cut off the power supply

after operation or before leaving the welding site.

No welding in the dangerous site where easily get an electrical shock.

No welding for the container loaded inflammable or explosive materials.

Safe measures should be adoptted while operating in high place to avoid accident.

No entering the welding site for persons not concerned.

Welders possible have electromagnetism and frequency interference, so keep away people

with heart pace or the articles which can be interfered by electromagnetism and frequency.

WARNING. The welder voltage is always higher, so the safety precaution should be taken before repair to avoid accidental shock. Switch off the power supply before each type of maintenance work. The untrained people are not allowed to make maintenance of the machine.

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Check the connection of input and output cables and the earth (ground) connection, etc.

Maintenance should be conducted by the trained personnel.

The newly installed machine or the welder not in use for some time needs to be checked by

multimeter have the right insulation resistance between each winding and the case.

When the welder is used outdoors, it should be kept from rain or long exposure to the sun.

Check is needed from time to time to make sure the welding cable is in good condition if the

welding machine is in frequent use. Check at least once each month if the welder is in regular use. It is necessary to check when the welder is in mobile use.

If the welder is not in use either for a long time or temporarily, it should be kept dry and have

good ventilation to free it from moisture, erodible or toxic gas.

- The welder must be installed in the place where it can not be exposed to sun and rain. Also it

must be stored in less humid place with the temperature range at -10 +40 .

Dust removal is needed every year. Check the machine's fasteners, moving-iron, current

regulation screws, etc to make sure there are no loose connection problems.

The dust, acid and erodible dirt in the air at the job site can not exceed the amount required

by the norm (excluding the emission from the welder).

The welder must be installed in the place where it can not be exposed to sun and rain. Also it

must be stored in less humid place with the temperature.

There should be 50 cm space about for the welding machine to have good ventilation.

Make sure that there is no metal-like foreign body to enter the welding machine.

Electrode must be taken down from holder when no welding.

No violent vibration in the welder's surrounding area.

Make sure that there is no interference with the surrounding area at the installation site.

The welder should be installed on the horizontal surface and if it over 15°, there should be

added some anti-dump set.

Take measures to prevent wind while operating in the strong wind since the welder is gas

shielded. The wind speed is limited below 1 0 m/s, or the wind shield device must be loaded.

Safety Check:

Each item listed below mustbe carefully checked beforeoperation:

Make sure that there isno short circuit connection withwelder's both outputs.

Make sure that there is always sound output and input wire connection instead of exposing it

outside.

Regular check needs to be conducted by the qualified personnel after the welding machine has

been installed over a longperiod or re-operation, whichinvolves as follows:

Check the welding cable tosee if it cancontinue to be usedbefore it is wornout.

Replace the welder's inputcable as soon asit is found tobe broken or damaged.

Make sure whether there is enough power supply to make the welding machine work properly.

Any power source required to access the welding machine must be installed with some protective equipments.

Please do not hesitate to contact us for technical assistance whenever you come across the problems you can notwork out or youmay deem difficult to fix.

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2. Technical Specification2. Technical Specification

Rated input voltage, V 220 Frequency, Hz 50/60 Rated input current, А 35 Rated input, kVA 7,7 Rated no-load voltage, V 58 MIG min welding current, А 20 MIG max welding current, А 200 MIG output voltage at min welding current, V 15 MIG output voltage at max welding current, V 24 MIG rated duty cycle, % 20 MIG welding current at 100%, А 90 ММА min welding current, А 20 ММА max welding current, А 170 ММА output voltage at min welding current, V 20,8 ММА output voltage at max welding current, V 26,8 ММА rated duty dycle, % 20 ММА welding current at 100%, А 76 TIG min welding current, А 15 TIG max welding current, А 200 TIG output voltage at min welding current, V 10,6 TIG output voltage at max welding current, V 18 TIG rated duty cycle, % 20 TIG welding current at 100%, А 90 Efficiency, % 85 Power factor 0,92 Insulation class H Enclosure protection IP21S Cooling type Fan cooled Dimension (LхWхH), mm 550х320х440 Weight, kg 15,4

The manufacturer reserves himself the right to make the manual's content or welder's function change without any preliminary notification of the users.

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3. Description

This welding machine is designed to be used with the advanced IGBT and rapid recovery diode as its main control and transfer components and assisted with the specially developed control circuit. It is available to MIG (both CO gas-shielded welding and flux-cored welding) and stick welding. It uses arc between wire and work piece as heat source to melt wire and master material metal, and then sends shielded gas to welding site, which makes the melt pond and master material metal free from around air s erosion. The continuous wire can form welding seam metal after melting so as to

’ connect the wok pieces each other. The melting electrode gas protects the welding district easily, so it is easy to operateand observe the whole workingprocess The highlighted characteristics of Inverter Welder:

- Featured with small volumeand light weight, it widelyused in upholstering field,repairing field and fieldwork.

- Undercutfunction make arc-piloting moresuccessful.

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By various sound protection performance,it can keep the weldingmachine from overheating, over

voltage, under voltage, over currentand so on

High working efficiency. Automatic Wire Feeding can realize highspeed welding

- .

No special requirements for thewelding wire. Both solidand flux-cored wires areavailable. The

diameter of the wire isbetween at mm

Convenient connection mode. outerconnection make it quick,safe ,simple and reliable

- .

Dual pulse technology, could use10 mm aluminum wire

0,6 1,0 .

- Unifying control in MIGwelding, slow wire feeding,easy arc start.

TIG Lift-ARC welding, program control,easy arc start, torch anti-sticking

MMAfunction is also available.And it also can weld cellulosic electrode

4. ’Welder s Principle & Structures

The welder acquires 220 V single phase industrial frequency DC power source through the power switch SW 101 and rectify through single phase rectifier bridge B1 and then filtered through capacitor C1, C2, C3, C4 to get the DC current. The 20 KHzAC current is got through the IGBT (Q1, Q2, Q3, and Q4) all-bridge inverter. Then this alternating current, transformed by the intermediate frequency transformer and rectified by quick recovery diode ( D4, D5, D6, D7), outputs the stable direct current for the welder immediately after it has been filtered by the reactor L2. The wire feed speed can be stepless adjusted through the speed adjust knob. The welding current is easily influenced from the wire feed speed, usually the faster the wire feed speed the bigger theAmp value under the same voltage

Rectifier

Filter

Inverter

Function

Drive

Protection

Inspect

Transformation

Modulate

Process

Control

High

Frequency

Rectifier

Trait

Control

Current

Adjustment

Sampling

MIG series use the movable carton like structures: The upper part in the front is equipped with a welding current regulation knob, power indicator light (green), abnormal indicator light (yellow), working indicator (red) while the lower part is furnished with the torch quick connector and quick

“-” connector. The back side is installed with power switch, gas valve connection , cooling fan, power source lead-in wire, breaker. On the top there is a handle forthe convenient of easy transport. When you open the cover, there is one primary transformer, one piece of printed circuit board. The bottom part is supplied with output reactor, primary transformer and etc. Installed in the middle part is a radiator with power elements

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Environment to Whichthe Product Is Subject:

- -10 + 4 С;

The surrounding temperature range: whenwelding 0

During transport or instorage

Relative humidity:

when at when at

The dust, acid and erodible materials in the air can not exceed the amount required by the norm

: -25 +55 С

40 С: 50%;

20 С: 90%;

≤ ≤

(apart from the emissions fromthe welding process).

No violent vibration at thejob site.

- 1000

Altitude no more than m

Требованияк электропитанию:

- The oscillation of thesupplied voltage should notexceed of the rated value

±15%

5. Sign & Pictures Illustration

SIGN

А V

IP21S

Х I

Current

(А)

Voltage V

()

Rated frequency Hz

ARC welder

MIG welder

TIG welder

Ground

Hinsulation grade

Case protection class

DC current

Single phases AC power source

Rated Open Circuit Voltage

Duty Cycle

Rated Input Current

Rated Welding Current

Single phase stillness transducer-transformer-rectifier

Rated Input Voltage

Rated Load Voltage

Descending

+ electrode

“”

electrode

“-”

Rated Input Power

()

NAME

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6 Installation.

Welder s Placement

The dust, acid and erosible dirt in the air at the job site can not exceed the amount required by the

norm.

The welder must be installed in the place where it can not be exposed to sun and rain. Also it must

be stored in less humidplace with the temperature rangeat 0

There should be 50 cmspace about for thewelding machine to havegood ventilation.

Apparatus to exclude wind andsmoke should be equippedif the inside aerationis not sound

- .

-10 до 4 С.

Connection between Welderand Power Source

Connect the power source cable at the back board of the welder into the single phase 220 or 115v voltage power network with breaker 380 voltage power sources is strictly prohibited to the welder which will severely damage thewelder,otherwise the user should take the consequences for it

Notice’:

The melting current of thefuse is 1,2~1,5 times ofits rated current

;

power ON/OFF

power input V220

Input connection Sketch

Circuit breaker, А ≥35 Fuse (Rated current), А 35 Knife Switch, А 40 Power cord, мм

Item Value

≥,25

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Connection of theWelding Cable

It is available to MIG (both CO gas-shielded welding and flux-cored welding) and stick welding. It uses arc between wire and work piece as heat source to melt wire and master material metal, and then sends shielded gas to welding site, which makes the melt pond and master material metal free from around air s erosion

’

The installation andconnection of MIGWelding

Connection and installationof the wire feeder

Select suitable wire according to welding technology. The wire diameter must be matched with

drive roll, wire guide pipeliner and contact tip

Open the lid of wire reel on the wire feeder

put Wire Coil into Wire Reel on the wire

“”“ ” feeder. Attention: Wire end under the Wire Reel , oppositewire feeder

”.

There is damping screw device in the Wire

-“

Reel (hex head screw will be seen when

”

“

open the lid). Pull the wire reel with hand when adjust. If resistance is over large, may adjust damping bolt: screw clockwise will enlarge the value andvice versa

Lead wire into Wire Guide Pipe of wire

-“ ”

feeder, align wire with roll groove through

Drive Roll , re-lead Socket Tip and press

“”“ ”

Drive Roll . (If more welding wire is needed,

“” it will be done afterswitching on the power.)

Connection between Welderand Torch

Insert the connector of torch into TorchAccess Hole on the front panel of the welder androtate the

-“” screw cap firmly

Connection of theConnection Cable

Connect the copper tip of the earth clamp which thread through the wire access hole on the panel

with of the connecting tip . The connecting cable must be reliable, or the connecting tip will burn

“-“ “ ”

out

In order to reach sound performance when welding with flux-cord wire, it s available that connect

-’ the inan opposite way, that s the wire feed motor with andthe connecting cable with

“+”, “-” ’ “-“ “+”.

Notice

welder and work piece

Do not use steel plate or the materials alike which are ill conductor to connect between

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The installation andConnection of weldingММА

Connection of welderand welding cable

Connect the quick connector of welding cable tothe output on front panel, and deasilturn down. The electrode holder is usedfor clamp the electrode

Connection of welderand grounding cable

Connect the quick connector of grounding cable to the output on the front panel, and deasil turn down. The earthclamp is used forclamp the work piece

Notice

welder and work piece

Do not use steel plate or the materials alike which are ill conductor to connect between

7. Operation

ATTENTION::

finger or insert a round bar less than 12.5 mm (metal bar in particular) into the welder. No heavy force can be employed onthe welder

The protection class of INMIG Inverter Welder is IP21S. It is forbidden to put in a

Protection indicator

Power indicator

Current display

Wire feeding voltage knob

Welding method switch

2T/4T/SPOT change

Voltage display

Voltage adjustment

9. Electron reactance

10.

Welding material

11.

Wire diameter

12.

Euro torch socket

13.

Output socket

14.

Gas input

15.

Power switch

16.

Cable holder

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Attention:

The protection indicator light will be on after a long time operation, it shows that the inner

-‘ ’ temperature is over the permitted data, then the machine should be stopped using for some time to let it cool down. Itcan continue using after the protection indicatorlight is off

The power source should beswitched offafter the operation or while temporarily leaving job site

- . Welders should dress canvas work cloth and wear welding mask to prevent the hurt from arc and

thermal radiation

Light separating screen should beput in the jobsite to prevent thearc will hurt otherpeople

- . Inflammable or explosive materialsare prohibited to accessthe job site

-. Each connection of the weldershould be connected correctlyand creditably

- .

Work Piece cleaningBefore Welding

Wire, groove and surrounding 10-20 mm site must be cleaned, no existing rust, greasy dirt, water and paint etc

MIG welding steps

Debugging before welding

а)

Install the torch, gas and welding wire, and then turnon the power switch. The power indicatoris on

and fan works

- When showing “Gas CH-” release the

knob, and turning the knob, you can choose the protection gas.

‘’.

- Turn the gas regulator anticlockwise, loose the wire roller, press down the torch switch, and then

adjust the gas flow tomeet the technics requirement, andthen repress the wireroller.

Сhosen СО

Сhosen СО +Ar

For acknowledgement press a

regulator

, on display «-- --».

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Turn on the gas regulator of gas tank,

the gas pressure is shownon the meter

- When showing “Gas On-”, release the

knob, gas valve will open and supply the gas

When showing “Gas OFF”,release the

knob, gas valve will close

When showing “SPt ADJ”, release the

knob, and turning the knob, you can adjust the spot welding time as you need

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АV

-Establish demanded value

- Press the torch switchtill the wire extends tothe nozzle.

- When wire feeding, makethe cable straight.

- When wire feeding, make sure the wire is located on the wire roller groove reliably and the feeding

speed should be smooth. If the wire feeding speed is not smooth, please adjust the tension of the wire roller

- When using MIG wire, the V groovewire roller should beused.

АV

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