Fubag INMIG 200 Plus User manual

Omperator's anual
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 FUBAG welding machine.
1. Safety perationo
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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.
Each item listed below must be carefully checked before operation:
Make sure that there is no short circuit connection 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 over a long period or re-operation, which involves as follows:
Check the welding cable to see if it can continue to be used before it is worn out.
Replace the welder's input cable as soon as it is found to be 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 not work out or you may deem difficult to fix.
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Safety Check:
Omperator's anual
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2. Technical Specification
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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Description INMIG 200 Plus
Input voltage, V 220
Rated input current, А 36
Rated input capacitance, kVA 7,92
No-load voltage, V 65
Мin welding current MIG, А 30
Мax welding current MIG, А 200
Voltage at min welding current MIG, V 15,5
Voltage at max welding current MIG, V 24
Duty cycle at max welding current MIG, t=40°C, % 20
Welding current MIG at duty cycle 100%, t=40°C, А 89
Мin welding current ММА, А 20
Мax welding current ММА, А 170
Voltage at min welding current ММА, V 20,8
Voltage at max welding current ММА, V 26,8
Duty cycle at max welding current ММА, t=40°C, % 20
Welding current ММА at duty cycle 100%, t=40°C, А 76
Мin welding current TIG, А 15
Мax welding current TIG, А 200
Voltage at min welding current TIG, V 10,6
Voltage at max welding current TIG, V 18
Duty cycle at max welding current TIG, t=40°C, % 20
Welding current TIG at duty cycle 100%, t=40°C, А 89
Power factor 0,92
Insulation class H
Enclosure protection IP21S
Cooling type Fan cooled
Dimension (L W H ), mm 550х320х440
Weight, kg 15,4
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 operate and observe the whole working process
The highlighted characteristics of Inverter Welder:
- Featured with small volume and light weight, it widely used in upholstering field, repairing field and
fieldwork.
- Undercutfunction make arc-piloting more successful.
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The welder acquires 220V single phase industrial frequency DC power source through the power
switch and rectify through single phase rectifier bridge and then filtered through capacitor to get the
DC current. The 40 KHzAC 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 theAmp value under the same voltage.
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 the top 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 part is a radiator with power elements.
4. Welder’s Principle
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Rectifier Filter Inverter
Function
Drive
Protection
Inspect
Transformation
Modulate
Process
Control
High
Frequency
Rectifier
Trait
Control
Current
Adjustment
Sampling
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0,6 1,2 .
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- Unifying control in MIG welding, slow wire feeding, easy arc start.
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By various sound protection performance, it can keep the welding machine from overheating, over
voltage, under voltage, over current and so on
High working efficiency. Automatic Wire Feeding can realize high speed welding
No special requirements for the welding wire. Both solid and flux-cored wires are available. The
diameter of the wire is between at mm
Convenient connection mode. outer connection make it quick ,safe ,simple and reliable
Dual Pulse technology, could use 1,0 mm aluminum wire
TIG Lift-ARC welding, program control, easy arc start, torch anti-sticking
MMAfunction is also available.And it also can weld cellulosic electrode

5. orchT
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The torch is composed by torch stand, connecting cable and handle.
Torch stand is the interface of torch and wire feeding device.
Connecting cable: covered by nylon pipe the liner is loaded in the center of coreless cable. The inner
part of liner is the passage for wire feeding. The space between liner and coreless cable is the
passage for shielded gas. Coreless cable is the passage 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 with a sensitive switch on the handle to control the welding current.
Must cut off the power before assemble/disassemble torch or replace the components.
The nozzle must be replaced in time on the condition that welding quality was influenced when it
burned to some extent. The distributor of torch must be replaced when it ruined.
The cable of torch must be replaced when it worn out.
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Notice:
SWITCH HANDLE
STAND
GOOSENECK
SHUNT
CONTACT
TIP
CABLE
RUBBER LAYER
CONTROL CABLE
CORELESS CABLE
NYLON PIPE
WIRE
SPRING PIPE
NOZZLE
Environment to Which the Product Is Subject:
Requirement for Main Supply:
- The surrounding temperature range: when welding: -10 + 40 С;
During transport or in storage: -25 +55 С
- Relative humidity: when at 40 С: ≤50%, 20 С: ≤ 90%
- The dust, acid and erodible materials in the air can not exceed the amount required by the norm
(apart from the emissions from the welding process). No violent vibration at the job site.
- Keep from raining when it is used outdoor.
-Altitude no more than 1,000m.
- The oscillation of the supplied voltage should not exceed ±15% of the rated value.
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6. Sign & Pictures Illustration
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7. 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 humid place with the temperature range at -10 до 40 С.
- 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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IP21
Ground
Frequency
Power
Current
Insulation grade
XDuty cycle
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2
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Rated pen ircuit oltageoc v
Rated nput urrentic
Rated elding urrentwc
1
URated nput oltageiv
2
URated oadl voltage
SIGN NAME
Protection class
DC current
Power source
Welder’s tructures

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Connection between Welder and Power Source
High voltage danger from power source! Consult a qualified electrician for proper
installation of receptacle at the power source. This welder must be grounded while in use to
protect the operator from electrical shock. If you are not sure if your outlet is properly
grounded, have it checked by a qualified electrician. Do not cut off the grounding prong or
alter the plug in any way and do not use any adapters between the welder's power cord and
the power source receptacle. Make sure the POWER switch is OFF before connecting your
welder's power cord to a properly grounded 220VAC.
Connect the power source cable at the back board of the welder into the single phase 220 voltage
power network with breaker; 380 voltage power sources is strictly prohibited to the welder which will
severely damage the welder, otherwise the user should take the consequences for it.
The melting current of the fuse is 1.2~1.5 times of its rated current.Notice:
1-
220
phaze
power supply
V
Input connection Sketch
Item
Circuit breaker, А ≥
Fuse (Rated current), А
40
Knife Switch, А
Power cord, мм2≥,25
I 200NMIG
TORCH SWITCH
WORK
PIECE
TORCH
GROUNDING
CABLE
POWER INPUT CABLE
GAS
FLOWMETER
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GAS PIPE
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The installation and connection of MIG Welding
1. Connection and installation of the wire feeder
2. Connection between Welder and Torch
3. Connection of the Connection Cable
The installation and connection of Welding
Connection of welder and welding cable
Connection of welder and grounding cable
- Select suitable wire according to welding
technology. The wire diameter must be
matched with drive roll, wire guide pipe liner
and contact tip.
Open the lid of wire reel on the wire feeder put
“Wire Coil” into “Wire Reel” on the wire feeder.
Wire end under the “Wire Reel”,
opposite wire 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 and vice 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 after switching on the power.)
- Insert the connector of torch into “Torch Access Hole” on the front panel of the welder and rotate
the screw cap firmly.
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 “+”, “-” in an opposite way, that’s the wire feed motor with “-“and the connecting cable with “+”.
Do not use steel plate or the materials alike which are ill conductor to connect between
welder and work piece.
Connect the quick connector of welding cable to the output on front panel, and deasil turn down.
The electrode holder is used for clamp the electrode
Connect the quick connector of grounding cable to the output on the front panel, and deasil turn
down. The earth clamp is used for clamp the work piece
Do not use steel plate or the materials alike which are ill conductor to connect between
welder and work piece.
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Attention:
Notice:
Notice:
MMA
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FRONT
PANEL
TORCH
WIRE
EARTH CABLE
FEED ROLLER

8. Operation
ATTENTION: The protection class of MIG Series is IP21S. It is forbidden to put in a finger or
insert a round bar less than 12.5 mm (metal bar in particular) into the welder. No heavy force can be
employed on the welder.
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1.
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14. MIG;
ArcForce ММА;
SPOT
15. E
16. C
Control panel
VRD
digital display
MMA & TIG
lectrical inductor
urrent indicator
Mig torch connector
Welding cable connector
4. Specification
Gas input connector
Power Switch
Power Cord
Power Indicator
Protection indicator
indicator
Welding current
ire speed
Welding current
Welding
Welding
s
table
W adjust knob in MIG
adjust knob in
voltage digital display
voltage adjust knob in
adjust knob in welding
time adjust knob in
adjust knob
1
2
3
5
4
6
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8 9 10 11 12 13 14 15
222220191816 17
17. W indicatorire speed
18. W
19.
20.
21. W
22. M /S
eld function button
Torch mode button
Gas mode button
ire dianeter button
anual yn selection button

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Attention:
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elect protect gas by button , and the indicators at the left part of button will indicate the selection
gas
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. It can continue using after the protection indicator light is off
The power source should be switched off after 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 be put in the job site to prevent the arc will hurt other people
Inflammable or explosive materials are prohibited to access the job site
Each connection of the welder should be connected correctly and creditably
Wire, groove and surrounding 10-20 mm site must be cleaned, no existing rust, greasy dirt, water
and paint etc
Debugging before welding
Install the torch, gas and welding wire, and then turn on the power switch. The power indicator is on
and fan works
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Work Piece cleaning Before Welding
MIG welding steps
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Turn on the gas regulator of gas tank,
the gas pressure is shown on the meter
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knob 14
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knob 14 .
Turn the gas control counterclockwise.
Press the welding voltage the
display shows «GAS ON»
With gear, adjust the gas supply in
accordance with the specifications. To
stop the flow of gas press the welding
voltage again, the display
shows «GAS OFF»
If the welding procedure requires work
mode spot welding (SPOT), you must
configure during this operation. To do
this, press and hold the welding voltage
up until appears «SPtADJ»
Rotate the welding voltage, the desired
setting time duration welding one point.
knob 14 АV
АV
АV
АV