Sua ionMig 200 PFC Operation Manual

ionMig 200 PFC

INVERTER IBGT – MIG WELDING MACHINE

OPERATION MANUAL

IMPORTANT: Read this Owner’s Manual Completely before attempting to use this equipment. Save this manual and keep it handy for quick reference. Pay particular attention to the safety instructions we have provided for your protection. Contact your distributor if you do not fully understand this manual.

ionMig 200 PFC

CONTENT

1. Safety.............................................................................................................................................. 3

1.1 Signal Explanation.......................................................................................................................3

1.2 Arc Welding Damage...................................................................................................................5

1.3 The knowledge of Electric and Magnetic Fields........................................................................5

2. Overview.........................................................................................................................................6

2.1 Brief Introduction......................................................................................................................... 6

2.2 Working Principle ........................................................................................................................ 7

3.1 Parameters ................................................................................................................................. 10

3.2 Duty cycle and Over-heat...........................................................................................................11

3.3 Equipment Connection.............................................................................................................. 12

3.4 Maintenance of MIG Gun mechanism ...................................................................................... 13

3.4.1 Dissection graphics for the MIG GUN ................................................................................... 13

3.4.2 The parts list for the MIG GUN............................................................................................... 14

3.4.3 The operation for the MIG GUN ............................................................................................. 14

4. Operation......................................................................................................................................16

4.1 Layout for the front and rear panel .......................................................................................... 16

4.2 Welding operation...................................................................................................................... 18

4.2.1 MIG mode operation:..............................................................................................................18

4.2.2 TIG mode operation:............................................................................................................... 21

4.2.3 MMA mode operation: ............................................................................................................22

4.3 Welding parameters................................................................................................................... 22

4 .4 Operation environment.............................................................................................................22

5 Maintenance & Troubleshooting..................................................................................................23

5.1 Maintenance............................................................................................................................... 23

5.2 Troubleshooting......................................................................................................................... 25

5.3 Electrical schematic drawing.................................................................................................... 27

ionMig 200 PFC

1. Safety

1.1 Signal Explanation

Welding is dangerous, and may cause damage to you and others, so take good protection when welding. For details, please refer to the operator safety guidelines in conformity with the accident prevention requirements of the manufacturer.

Professional training is needed before operating the machine.

·Use labor protection welding supplies authorized by national security supervision department.

·The operator must be special personnel with a valid "metal welding (OFC) operations" operation certificate.

·Cut off power before maintenance or repair.

Electric shock—may lead to serious injury or even death.

·Install ground device according to the application criteria.

·Never touch the live parts when skin bared or wearing wet gloves/clothes.

·Make sure that you are insulated from the ground and workpiece.

·Make sure that your working position is safe.

Smoke& gas—may be harmful to health.

·Keep the head away smoke and gas to avoid inhalation of exhaust gas from welding.

·Keep the working environment in good ventilation with exhaust or ventilation equipment when welding.

Arc radiation—may damage eyes or burn skin.

·Wear Suitable welding masks and protective clothing to protect your eyes and body.

·Use suitable masks or screens to protect spectators from harm.

ionMig 200 PFC

Improper operation may cause fire or explosion.

·Welding sparks may result in a fire, so please make sure no combustible materials nearby and pay attention to fire safety.

·Have a fire extinguisher nearby, and have a trained person to use it.

·Airtight container welding is forbidden

·Pipe thaw with this machine is forbidden.

Hot workpiece may cause severe scalding.

·Don’t contact hot workpiece with bare hands.

·Cooling is needed during continuous use of the welding torch.

Magnetic fields affect cardiac pacemaker.

·Pacemaker users should be away from the welding spot before medical consultation.

Moving parts may lead to personal injury.

·Keep yourself away from moving parts such as fan.

·All doors, panels, covers and other protective devices should be closed and in place.

Machine fault—seek professional help when encountering any difficulties.

·Consult the relevant contents of this manual If you encounter any difficulties in installation and operation.

·Contact the service center of your supplier to seek professional help If you still cannot fully understand after reading the manual or still cannot solve the problem according to the manual.

ionMig 200 PFC

1.2 Arc Welding Damage

 The following signals and word explanations are to some damages for your body or others

happening on the welding operation. While seeing these, please remind of yourself or others to be dangerous.

 Only ones who are trained professionally can install, debug, operate, maintain and repair the

equipment.

 During the operation, non-concerned people should be lift, especially for children.  After shut off the machine power, please maintain and examine the equipment according to §5

because of the DC voltage existing in the electrolytic capacitors.

1.3 The knowledge of Electric and Magnetic Fields

 Electric current flowing through any conductor causes localized Electric and Magnetic Fields  (EMF). The discussion on the effect of EMF is ongoing all the world. Up to now, no material

evidences show that EMF may have effects on health. However, the research on damage of EMF is still ongoing. Before any conclusion, we should minimize exposure to EMF as few as possible.

 In order to minimize EMF, we should use the following procedures:

o Route the electrode and work cables together – Secure them with tape when possible. o All cables should be put away and far from the operator. o Never coil the power cable around your body. o Make sure welding machine and power cable to be far away from the operator as far as

possible according to the actual circumstance.

o Connect the work cable to the workpiece as close as possible to the area being welded.

 The people with heart-pacemaker should be away from the welding area.

ionMig 200 PFC

2. Overview

2.1 Brief Introduction

MIG SERIES arc welding machine adopts the latest pulse width modulation (PWM) technology and insulated gate bipolar transistor (IGBT) power module, which can change work frequency to medium frequency so as to replace the traditional hulking work frequency transformer with the cabinet medium frequency transformer. Thus, it is characterized with portable, small size, light weight, low consumption and etc.

MIG SERIES arc welding machine uses Mix gas as shielded gas to realize gas shielded welding, active gas（Ar+O2、Ar+CO2） as shielded gas to realize MAG welding and inactive gas（Ar）as shielded gas to realize MIG welding.

MIG SERIESarc welding machine has automatic protection functions with intelligent to over-voltage, over-current and over-heat. If any one of the above problems happens, the alarm lamp on the front panel will be lighted and output current will be shut off automatically to protect itself and prolong the equipment using life.

MIG SERIES Features:

1. Digital control system, real-time display the welding parameters;

2. High performance multifunction power source (MMA/MIG/MAG);

3. Waveform control, stable welding arc;

4. IGBT technology, low power dissipation;

5. Rated duty circle is 40 % (40℃).

MULTIMIG 160/200 has another feature: Synergic control of the welding current and voltage.

MIG SERIES arc welding machine is suitable for all positions welding for various plates made of stainless steel, carbon steel, alloyed steel, copper, titanium, etc, which is also applied to pipe

ionMig 200 PFC

installment, mold mend, petrochemical, architecture decoration, car repair, bicycle, handicraft and common manufacture.

MAG--Metal Active Gas Welding

MIG--Metal Insert Gas Welding

2.2 Working Principle

The working principle of MIG SERIES arc welding machine is shown as the following figure.

Single-phase 220V work frequency AC is rectified into DC（350V）, then is converted to medium frequency AC (about 40KHz) by inverter device (IGBT), after reducing voltage by medium transformer (the main transformer) and rectifying by medium frequency rectifier (fast recovery diodes), and is outputted by inductance filtering. The circuit adopts current feedback control technology to insure current output stably when MMA or TIG. And adopts voltage feedback control technology to insure voltage output stably when MIG. Meanwhile, the welding current parameter can be adjusted continuously and infinitely to meet with the requirements of welding craft.

Current sensor

ionMig 200 PFC

2.3 Volt-Ampere Characteristic

MIG SERIES welding machine has an excellent volt-ampere characteristic, whose graph is shown as the following figure. The relation between the rated loading voltage U2and welding current I2is as follows: U2=14+0.05I2(V)

0 600

Io（A）

Uo（V）

Working point

Volt-ampere characteristic

The relation between the rated loading

voltage and welding current

ionMig 200 PFC

2.4 Principles of welding

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Sua ionMig 200 PFC Operation Manual

Specifications and Main Features

Frequently Asked Questions

User Manual