iBell Tools IBL M200-105 User manual

FLUX-CORED MAG / MMA
IBL M200-105
WELDING MACHINE
OPERATORS MANUAL

1

2
1. SAFETY PRECAUTIONS _______________________________
2. PRODUCT DESCRIPTION _____________________________
3. PRODUCT SPECIFICATIONS __________________________
4. PRODUCT OVERVIEW ________________________________
5. INSTALLATION ______________________________________
6. GENERAL OPERATION _______________________________
7. TROUBLESHOOTING _________________________________
TABLE OF CONTENTS
IBL M200-105
3
6
7
9
10
15
18

3
M200-105 Welding machine functions both as Gas-less Flux-cored
MAG (Metal Active Gas) and MMA (Manual Metal Arc) Machine.
Touching live electrical parts can cause fatal shocks or
severe burns. The electrode and work circuit is
electrically live whenever the output is on. Incorrectly
installed or improperly grounded equipment is a hazard.
▪Insulate yourself from work and ground using dry insulating
mats or covers, big enough to prevent any physical contact with
the work or ground.
▪Do not connect more than one electrode or work cable to any
single weld output terminal.
▪Always verify the supply ground –check and be sure that input
power cord-ground wire is properly connected to ground terminal
in disconnect box or that cord plug is connected to a properly
grounded receptacle outlet.
Welding produces fumes and gases. Breathing these fumes
and gases can be hazardous to your health. Keep your head
out of the fumes. Do not breathe the fumes.
▪Do not weld on coated metals, such as galvanized, lead, or
cadmium plated steel, unless the coating is removed from the
weld area, the area is well ventilated, and if necessary, while
wearing an air-supplied respirator.
SAFETY PRECAUTIONS: MMA & MAG WELDING
WARNING! Read all safety warnings, instructions, illustrations and
specifications provided with this machine. Failure to follow all
instructions listed below may result in electric shock, fire and/or
serious injury. Only qualified persons should install, operate,
maintain, and repair this unit.
ELECTRIC SHOCK
FUMES AND GASES
IBL M200-105

4
Arc rays from the welding process produce intense visible
and invisible (ultraviolet and infrared) rays that can burn
eyes and skin. Sparks fly off from the weld.
▪Wear a welding helmet fitted with a proper shade of filter to
protect your face and eyes when welding or watching.
▪Wear approved safety glasses with side shields under your helmet.
Accidental contact of electrode to metal objects can
cause sparks, explosion, overheating, or fire.
Hot parts can cause severe burns. Do not touch hot parts
bare handed. Allow cooling period before working on gun
or torch.
Overuse can cause overheating; Allow cooling period
and follow rated duty cycle. Reduce the current before
starting to weld again. Do not block or filter airflow.
Moving parts can cause injury. Keep away from moving
parts such as fans. Keep all doors, panels, covers, and
guards closed and securely in place.
High-frequency due to welding can cause interference,
it can interfere with radio navigation, safety services,
sensors computers, and communications equipment.
Electo-static discharge can damage printed circuit
boards. Put on grounded wrist strap before handling
boards or parts.
FURTHER CASES
ARC RAYS
IBL M200-105

5
Welding wire can cause injury; Do not press gun
trigger until instructed to do so. Do not point gun
toward any part of the body, other people, or any
metal when threading welding wire.
▪This welding machine is only for MMA and gas-less flux-cored
welding; This machine cannot connect to a spool gun which is
recommended for other materials.
▪Do not weld or heat Aluminium, as it requires shielding gas and
this machine is a gas-less welding machine. Likewise, do not weld
lead, zinc, cadmium, mercury, beryllium, cobalt, manganese,
copper, silver, barium, chromium, vanadium, nickel, or similar
metals without seeking professional advice and inspection of the
ventilation of the welding area. These metals produce extremely
toxic fumes which can cause discomfort, illness and death.
▪Do not, in any manner, come into physical contact with any part
of the welding current circuit, which includes:
i. Workpiece or any conductive material in contact with it.
ii. Ground clamp.
iii. Electrode or Welding Flux-cored Wire.
iv. Any metal parts on the electrode holder or MAG Gun.
▪All the equipment should be kept in good working condition,
inspected and, when defective, promptly repaired or withdrawn
from service.
▪Training should be sought out in the safe use of this
equipment, the processes and the emergencies.
IBL M200-105
WARNING! The product must be fully assembled before
operation! Do not use a product that is only partly
assembled or assembled with damaged parts! Follow the
assembly instructions step-by-step

6
M200-105 Welding machine functions both as Gas-less Flux-cored
MAG (Metal Active Gas) and MMA (Manual Metal Arc) Machine.
▪MAG with Flux cored arc welding uses heat generated by an
electric arc to fuse base metal in the weld joint area. This arc is
struck between the metallic workpiece and the continuously-fed
tubular cored consumable filler wire, with both the wire and the
metallic workpiece melting together to form a weld joint. This
welding works well with most carbon steels, cast iron, stainless
steel and hard facing /surfacing alloys. However, non-ferrous
exotic metals, like aluminium cannot be welded using this
welding technique.
▪In Manual Metal Arc Welding (MMA) with consumable, flux-
covered electrode and a ground clamp, a short-circuit is initially
made on the weld piece. An electric arc forms between electrode
and work-piece, which heats up enough to melt both. As the
electrode melts, the flux coating on the electrode develops gas
and slag, which help protect the weld pool. The gas keeps air and
other pollutants away, while slag forms on top of the weld pool to
protect the weld seam.
▪The machine uses a high performance IGBT Technology, which
is very useful as they give power that can be used for different
welding processes.
Hot Start provides excellent arc ignition without the electrode
sticking and avoiding any metallurgical default in the weld. Its
Anti-sticking feature minimizes the short circuit current in the
event of the electrode sticking to the work piece.
VRD (Voltage Reduction Device) in-built function provides an
additional measure of safety.
Arc force in-built improves the weld performance on the
specified size of electrodes to be used, making the job easier.
▪This machine has a Smart Fan circuitry inside, which work only
when cooling is required, and reduces the amount of dirt which
can be drawn inside thereby reducing power consumption.
PRODUCT DESCRIPTION
IBL M200-105

7
: 220V±15% ~50/60 Hz
: 4 kW
: 23.5 A
: 65 V
: 60%
: 0.73
: 85%
: 0.5 mm
: F
: 20-140A
: 40-140A
: 1.6 –3.2 mm
: 0.6/0.8/0.9 mm diameter
[1Kg] 100 mm length
Accessories:
▪3m-cable 16mm² 300A Electrode Holder
▪2m-cable 16mm² 300A Earth Clamp
▪3m MAG Torch
▪1 Kg Flux cored wire
Rated voltage
Rated Input Power
Rated input current
No-load voltage
Duty Cycle
Power Factor (CosΦ)
Efficiency
Min. welding thickness
Insulation Class
MMA Output current
MAG Output current
MMA Electrode size
MAG Flux cored wire
PRODUCT SPECIFICATIONS
** Smart Fan work only when cooling is required.
*** Current proportionally reduce when electrode cable length increases.
IBL M200-105

8
Current setting: The correct current, or amperage setting primarily
depends on the diameter and type of electrode selected. Select an
amperage based on the material thickness and welding position
(about 15 % less heat for overhead work compared to a flat weld).
According to the adjustment of current, the wire feed rate
for MAG torch also gets adjusted.
Length of arc: The correct arc length varies with each electrode and
application. As a good starting point, arc length should not exceed
the diameter of the metal portion of the electrode. Excessively long
arcs (too much voltage) produce spatter, low deposition rates,
undercuts and sometimes porosity. Length of arc is regulated by
holding electrode tip at a suitable distance from welding piece.
Angle of travel: Hold the rod perpendicular to the joint and tilt the
top of the electrode in the direction of travel approximately 5 to
15°. For welding vertical up, use a forehand technique and tilt the
top of the rod 15° away from the direction of travel.
Speed of travel: The proper travel speed produces a weld bead with
the desired contour (or crown), width and appearance. Slow travel
speeds produce a wide, convex bead with shallow penetration.
Excessively high travel speeds also decrease penetration, create a
narrow and/or highly crowned bead, and possibly undercuts.
Diameter of
welding rod (mm)
φ1.6
φ2.0
φ2.5
φ3.2
Welding current (A)
20-60
60-100
80-120
120-140
PARAMETERS
IBL M200-105

9
PRODUCT OVERVIEW
1. MMA/MAG Switch
2. Current Adjustment Knob
3. MAG Gun/Torch
4. (+) Electrode holder socket (MMA)
Earth clamp socket (MAG)
5. (-) Earth clamp socket (MMA)
IBL M200-105
3
1
2
4
5

10
▪Connect the welding tongs (grounding clamp and electrode
holder) correctly according to the figure. Firstly, make sure that
cable, welding tongs and quick plugs are connected reliably.
▪Connect the electrode holder in the quick socket with the
polarity of ‘+’, and then tighten it; suitable electrode is connected
to the holder.
▪Connect the grounding clamp into quick socket with the polarity
of ‘-’, tighten it by force; the grounding clamp connects to the
work-piece.
MMA ASSEMBLY
Work piece
WARNING! Make sure that welding cable and earth cable
connections are tight. If a connection is slack, it will result in
voltage drop that will cause the connection to heat.
INSTALLATION
Electrode holder
Earth clamp
IBL M200-105

11
Unlock the panel cover to see the inner compartment
for MAG Gasless usage to feed the flux cored wire.
MAG ASSEMBLY
Flux cored
Wire reel/spool
Panel
Unlock button
Drive roll (Two wire feed)
0.8/0.9 mm 0.6 mm
Pressure
arm
Roller
retainer
▪Set the wire reel in the spring holder and insert the snap pin.
▪Turn the adjustment knob of the pressure arm counter-clockwise
to loosen it.
I
II
Snap pin
Arm Knob
IBL M200-105

12
▪Lower the pressure arm so as to raise the roller retainer to feed
wire through the drive roll.
III
IV
V
VI
▪While turning the wire reel counter-clockwise, pass the end of
the wire through the guide tube.
▪Guide the wire to the correct roller groove (according to its size)
Push it through to the inlet tube of the torch.
▪Place the retainer back and Pull up the pressure arm back to
position and turn the knob clockwise.
NOTE: The placement of the reel should be such that the wire
comes off the spool, it will look like the illustration above. The
wire should unspool from the bottom, and the spool will
rotate in a counter-clockwise manner.
.
▪Wire from reel to the drive should relax with a slight curve after
feeding, it should not be a tight-line.
IBL M200-105

13
VII
VIII
▪For proper tension, align tops of the screw and nut together on
the knob of pressure arm.
The drive roll pressure should not be too much nor too less.
Too little pressure, the roll can slip and feed can be erratic.
Too much pressure can crush wire, causing wire feeding problems
and welder damage.
▪Connect the plug to power for inspection of proper wire feed.
MAG Gun/Torch
Trigger Switch
Wire
▪Pull the trigger on the MAG gun to feed wire through the gun
assembly. Let the panel be open (as of now) so that you can inspect
the wire feeding process.
▪Keep the gun straight. When feeding a new wire through the
liner, make sure the wire is cut cleanly (no burrs or angles) and
that at least 2cm from the end is straight (no curves).
Cut off the excess wire that extends past the end of the nozzle.
The nozzle can be loosened to see a vivid wire movement through
the contact tip.
IBL M200-105

14
NOTE: When the drive pressure is set correctly, there should
be no slippage between the wire and the drive roller. If
obstruction occurs along the feed path, the wire should then
slip on the drive roller. This can be checked by squeezing the
wire between two fingers with moderate force as it comes out of
the gun. If this stops the wire from feeding, increase pressure
until the wire feeds through your fingers without issue.
▪Check if the drive roll is slipping on the wire and increase
pressure on the pressure arm adjustment knob if necessary.
MAG Gun
MAG Connection:
▪For MAG, Connect the grounding clamp into quick socket with
the polarity of ‘+’(not like in the MMA) tighten it by force; the
grounding clamp connects to the work-piece.
Earth clamp
Work piece
IBL M200-105

15
The MMA/ MAG Switch (1) is used to switch between the two
welding operations: MMA and MAG Gasless welding.
▪Always fix earth cable clamp directly on the welding piece.
Turn the power switch to ‘ON’position. Cooling fan inside the
machine should begin to work once welding starts.
▪Clamp the welding rod on the electrode holder, the machine is in
the manual welding mode and in the standby state.
▪In accordance with the thickness of welding work-piece, diameter
of welding rod, working position and technology needs, make
sure suitable welding current with the adjustment knob (2).
(Check out the table on pg.no. 8 for electrode size-current criteria)
(If current is too high, intensified splashing occurs and if low, the melted
welding stick becomes fluid and drop transfer would not proceed smoothly)
For beginners, the first difficulty is priming the arc.
For best results proceed as follows:
▪Test the current intensity and the electrode on a piece of scrap
material. Hold the electrode approx. 2 cm above the start of the
joint. Touch the work-piece with the electrode and stroke it
repeatedly on-off the work-piece to start the arc.
▪Watch the arc only through the face shield and keep the arc
length approximately 1–1.5 times the diameter of the electrode.
Hold the electrode at an angle approximately 70° –80°.
▪Wait until the joint has cooled completely before removing the
slag. If you wish to continue welding a joint after taking a break,
the slag at the end of the joint must be removed first. Prime the
arc in the joint and melt the electrode at the point where the two
joints meet.
GENERAL OPERATION
NOTE: It is recommended that you try welding and rate of welding
current first on something else than the actual work piece. You can
start welding after having made the necessary selections.
MMA WELDING
IBL M200-105

16
Welding current of this machine is directly proportional to the
Wire feed speed. Increasing/decreasing the welding current
increases/decreases the wire feed speed to the gun respectively.
This also matches the voltage with its semi auto-voltage switching.
▪Ensure the ground clamp has a good connection to the workpiece
and is connected on clean, bare metal.
▪Place the MAG gun (3) on the joint you want to weld. The distance
between the gun and the workpiece should be about 6mm-12mm
Lower your face shield and press the gun trigger to start the arc.
When the arc has struck, move the nozzle along the joint. Pull the
trigger while in contact with the workpiece. The machine does
not arc unless the trigger is pulled.
▪The gun should bisect the angle of the two workpieces, to form
the weld work angle. The torch in relation to its movement is
torch angle.
For an angle joint, the angle between
the weld gun and the workpiece should
be around 45°.
For a butt joint, the angle between the
weld gun and the workpiece should be
around 90°.
The torch can be pulled or pushed, can be moved in a straight line
(stringer bead), or in small overlapping arcs (weave pattern)
MAG WELDING
45°
90°
Weave pattern
Stringer
A weave is better for thicker materials that
require more heat.
A stringer is best for very thin material that
cannot take much heat.
IBL M200-105

17
Store the equipment and accessories out of children’s reach in a
dark and dry place at above freezing temperature. The ideal storage
temperature is between 5°C and 30°C. Store the electric machine in
its original packaging.
All the maintenance work must be conducted under the
condition of complete power failure; please make sure that power
plug is pulled out.
▪Regularly remove the dust on the welding machine with dry
compressed air. When use it in heavy fume and polluted air, do
this job at least once a month. Compressed air should drop down
to the required pressure to prevent damaging the small parts and
units in machine.
▪Avoid water or moist getting into welding machine, or else, blow
the welding machine to dry immediately, then measure the
insulation with insulation resistance meter, it can only be used
when the measuring result is accepted.
▪In the event that the welding machine is not used for long-term, it
should be placed into the original package and stored in dry
place.
▪Any improper or incorrect operation may cause the welder’s
failure and damage. Routine maintenance on power control
switch, grounding device, welding electrode holder, coupling
device and set screws should be performed on a regular basis.
▪Measure the welder’s insulation resistance with insulation
resistance meter.
STORAGE
MAINTENANCE
NOTE: Repairing welding equipment should be carried out by a
qualified person using original spare parts. This ensures the safety
of the device as well as yourself.
IBL M200-105

18
The following operations must be performed by qualified technicians.
Before maintenance, please contact with us for professional suggestion.
Problem
Solution
1. Meter doesn’t
display, fan
doesn’t work, no
welding output.
1.1 Make sure power switch is OFF.
1.2 Make sure the power source connecting
to input cable is working alright.
2. Meter is normal,
fan is working, no
welding output.
2.1 Check if connector of output terminal is
broken or damaged.
2.2 Check if the control board is damaged
(Connect with our customer service).
3. QC indicator is
ON, fan is
working, meter is
normal.
3.1 IGBT is damaged.
3.2 Rectifier of quick recovery is damaged.
3.3 Control board is broken.
3.4 The feedback circuit is in fault.
4. Too much spatter
4.1 Output terminal polarity connection is
wrong. So please change the polarity
5. Erratic welding
output current or
out of control of
potentiometer.
5.1 The potentiometer is damaged.
5.2 Check that all kinds of connectors are in
poor contact, especially plugs.
6. Power switch
doesn’t work
6.1 Power switch is broken.
6.2 Rectifier bridge is broken, Replace it.
6.3 Check if there is any short circuit of
inner-machine.
TROUBLESHOOTING
MMA WELDING
IBL M200-105

19
Problem
Possible Cause
Solution
1. Wire feeds,
but no arc
1.1 Poor grounding/
ground connection.
1.2 Trigger not pulled
while wire is in
contact with work.
1.1 Check connection/
Tighten ground cable.
1.2 Press the trigger
while in contact
with the workpiece.
2. Arc works, but
not feeding
wire
2.1 Insufficient or
excessive pressure
on the drive roller.
2.2 Wire reel/spool is
empty.
2.1 Adjust the drive
pressure.
(See page no.13)
2.2 Check if wire is in
place and replace if
necessary.
3. No arc or wire
feed.
3.1 Exceeded duty
cycle (>60%);
[Thermal protector
engaged]
3.2 Insufficient air
flow/ Overheat.
3.3 Circuit breaker
has been tripped.
3.1 Allow it to cool at
least 10 minutes
with machine ON.
3.2 Check the vents on all
sides of the machine
for any obstacles.
3.3 Make sure circuit
breaker is reset.
4. Poor quality
welds.
4.1 Gun moved over
workpiece too
quickly/too slowly.
4.2 Insufficient
amperage.
4.1 Move the gun in a
standard manner.
4.2 Enhance the welding
current.
MAG WELDING
IBL M200-105