Fubag IRMIG 180, IRMIG 140, IRMIG 160 User Manual [ru]

MIG-MAG
Сварочный полуавтомат

MIG-MAG Welding machine

IRMIG 140
IRMIG 1 06
IRMIG 1 08

Operator's Manual

Инструкция по эксплуатации

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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
MAINTAIN THIS 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 FUBAGweldingmachine.

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 isalways 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.

,

O

C

Safety Check:

Each item listedbelowmustbe carefully checkedbefore operation:

-

Make sure thatthere is no short circuitconnection with welder'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 overa long period or re-operation,which involves as follows:

-

Check the weldingcable to see if itcan continue to be usedbefore it is worn out.

-

Replace the welder'sinput cable as soon asit is found to bebroken 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 cannot work out or youmay deem difficult to fix.

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2. Technical Specification

Item IRMIG140 IRMIG160 IRMIG180

Rated input voltage, V 220
Frequency, Hz 50
Rated input current, А 25 28 30
Rated input, kVA 5,5 6,2 6,6
Rated no-load voltage, V 52 52 52
MIG min welding current, А 30 30 30
MIG max welding current, А 140 160 180
MIG rated duty cycle, % 35 30 25
MIG welding current at 100%, А 83 88 90
Efficiency, % 85 85 85
Power factor 0,92 0,92 0,75
Insulation class H
Enclosure protection IP21S
Cooling type Fan cooled
Dimension (LхWхH), mm 570x300x370
Weight, kg 11 11 12

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

3. Description

MIG Series Inverter is designed to be used with the advanced IGBT (Insulated Gate Bipolar Tube)
and rapid recovery diode as its main control and transfer components and assisted with the
specially developed controlcircuit. The continuous wire can form welding seam metalafter melting
so as to connect the wok pieces each other. The melting electrode gas protects the welding district
easily, so it is easy to operate & observe the whole working process. Its characteristics are high
produce efficiency andeasy to carry outall-position welding.
The highlighted characteristicsof MIG Series Inverter:

Featured with smallvolume and light weight, itwidely used in upholstering field,repairing field and

­fieldwork.

High working efficiency.Automatic Wire Feedingcan realize high speed welding.

­No special requirementsfor the welding wire. Bothsolid and flux-cored wires areavailable. The

-

diameter of thewire is between 0 6 0,8 (1 0)

ndercutfunction make arc-pilotingmore successful.

-U

, - , mm.

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4. Welder’s Principle

The welder acquires 220V single phase industrial frequency DC power source through the power
switch andrectify through single phase rectifier bridge and then filtered through capacitor to get the
DC current.The 40 KHz AC current is got through the IGBT all-bridge inverter. Then this alternating
current, transformed by the intermediate frequency transformer and rectified by quick recovery
diode, outputs the stable direct current for the welder immediately after it has been filtered by the
reactor. 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 the Amp value underthe 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, abnormal indicator light, working indicator. The back side is
installed with power switch, gas valve connection , cooling fan, power source lead-in wire, breaker.
On thetop there is a handle for the 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 partis a radiator with powerelements.

Environment to Which the Product Is Subject:

- The surroundingtemperature range: when welding: -10 + 40 С;

During transport orin storage: -25 +55 С

- Relative humidity:when at 40 С: ≤50%, 20 С: ≤90%

ОО

О

when at

О

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

(apart from theemissions from the welding process).No violent vibration at thejob site.

- Keep fromraining when it is usedoutdoor.

-Altitude no more than1,000m.

Requirement for Main Supply:

- The oscillationof the supplied voltageshould not exceed ±10% ofthe rated value.

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5. orchT

The torch iscomposed by torch stand, connectingcable and handle.
Torch stand isthe interface of torch andwire feeding device.
Connecting cable: covered by nylon pipethe liner is loaded in the center ofcoreless cable. The inner
part of liner is the passage for wire feeding. The space between liner and coreless cable is the
passage for shieldedgas. Coreless cable is thepassage for current.
There is a gooseneck installed in the handle of the torch. In the back part of the torch there is a
connecting with the coreless cable and in the front part is a shunt. The shielded gas distributes via
the shunt and forms well-proportioned air current in the nozzle, and then spurt out in a form of air
hanging. Set witha sensitive switch on thehandle to control the weldingcurrent.

Notice:

Must cut offthe power before assemble/disassembletorch or replace the components.

-

The nozzle must be replaced in time on the condition that welding quality was influenced when it

-

burned to someextent. The distributor oftorch must be replaced whenit ruined.

The cable oftorch must be replaced whenit worn out.

-

NOZZLE

CONTACT
TIP

SHUNT

GOOSENECK

SWITCH HANDLE

RUBBER LAYER

CONTROL CABLE

CORELESS CABLE

NYLON PIPE

SPRING PIPE

WIRE

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6. Sign & Pictures Illustration

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SIGN

H

IP21

0

X

I

1

I

2

U

1

U

2

7. Installation

NAME

Current

Power

Frequency

Ground

Insulation grade

Protection class

DC current

Power source

Rated pen ircuit oltageoc v

Duty cycle

Rated nput urrentic

Rated elding urrentwc

Welder’s tructures

Rated nput oltageiv

Rated oadl voltage

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 humid place with the temperature range at -10 до 40 С.

О

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

Apparatus to exclude wind and smoke should be equipped if the inside aeration is not sound.

-

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POWER INPUT CABLE

GAS
FLOWMETER

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СО

2

GAS PIPE

TORCH

WORK
PIECE

TORCH SWITCH

GROUNDING
CABLE

Connection between Welderand Power Source

Connect the power source cable at the back board of the welder into the single phase 220 voltage
power network with breaker;380 voltagepower sources is strictlyprohibited tothe welder which will
severely damage thewelder, otherwise theuser should take theconsequences for it.

Notice:

The melting currentof the fuse is 1.2~1.5times of its rated current.

1-

phaze
power supply
220

V

Input connection Sketch

Circuit breaker, А ≥40 ≥45
Fuse (Rated current), А 30 40
Knife Switch, А 35 45
Power cord, мм

Item IR 140/160 IR 180/200

2

≥,25 ≥,25

The installation and connection of MIG Welding
Connection and installation of the wire feeder

- Select suitable wire according to welding technology. The wire diameter must be matched with
drive roll, wireguide pipe liner and contacttip.

Open the lid of wire reel on the wire feeder put “Wire Coil” into “Wire Reel” on the wire feeder.

-

Attention:

There is damping screw device in the “Wire Reel”(hex headscrew will be seen when open the lid).

-

Wire end underthe “Wire Reel”, opposite wirefeeder.

Pull the wirereel with hand when adjust. If resistance isover large, may adjust damping bolt: screw
clockwise will enlargethe value and vice versa.

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TORCH

WIRE

FEED
ROLLER

- 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
after switching on the power.)

Connection of the Connection Cable

Connect thecopper 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 tipwill burn
out.

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

-

the “+”, “-”in an opposite way, that’s thewire feed motor with“-“and the connecting cable with“+”.

Notice:

welder and workpiece.

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

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