iBell IBL M200-89 User manual

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1. SAFETY PRECAUTIONS ______________________________
2. PRODUCT OVERVIEW ________________________________
3. PRODUCT SPECIFICATIONS _________________________
4. SETUP _______________________________________________
5. CONTROLS AND OPERATIONAL FEATURES__________
6. GENERAL OPERATION _______________________________
7. TROUBLESHOOTING _________________________________
TABLE OF CONTENTS
MMA WELDING MACHINES
3
7
13
15
19
21
25

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Touching live electrical parts can cause fatal shocks or
severe burns. The electrode and work circuit is electrically
live whenever the output is on. The input power circuit
and machine circuits are also live when power is on.
Incorrectly installed or improperly grounded equipment is a hazard.
Do not touch live electrical parts. Wear dry, hole-free insulating
gloves and body protection.
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 use AC output in damp areas, if movement is confined,
or if there is a danger of falling. Use AC output ONLY if required
for the welding process.
Do not connect more than one electrode or work cable to any
single weld output terminal.
Disconnect input power or stop the machine before installing or
servicing this equipment.
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.
Frequently inspect input power cord for damage or bare wiring
–replace cord immediately if damaged –bare wiring can kill.
Do not touch electrode if you are in contact with the work,
ground, or another electrode from a different machine.
SAFETY PRECAUTIONS: ARC 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. Save all warnings and instructions for future
reference. Only qualified persons should install, operate, maintain,
and repair this unit.
ELECTRIC SHOCK
MMA WELDING MACHINES

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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.
If inside, ventilate the area and/or use exhaust at the arc to
remove welding fumes and gases. If ventilation is poor, use an
approved air-supplied respirator.
Work in a confined space only if it is well ventilated, or while
wearing an air-supplied respirator. Always have a trained watch-
person nearby. Welding fumes and gases can displace air and
lower the oxygen level causing injury or death. Be sure the
breathing air is safe.
Do not weld in locations near cleaning, or spraying operations.
The heat and rays of the arc can react with vapours to form highly
toxic and irritating gases.
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.
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.
Use protective screens or barriers to protect others from flash and
glare; warn others not to watch the arc.
Wear protective clothing made from durable, flame-resistant
material (leather and wool) and foot protection.
FUMES AND GASES
ARC RAYS
MMA WELDING MACHINES

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Welding on closed containers, such as tanks, drums, or
pipes, can cause them to blow up. Sparks can fly off from
the welding arc. The flying sparks, hot work-piece, and
hot equipment can cause fires and burns. Accidental contact of
electrode to metal objects can cause sparks, explosion,
overheating, or fire. Check and be sure the area is safe before
doing any welding.
Protect yourself and others from flying sparks and hot metal. Do
not weld where flying sparks can strike flammable material.
Remove all flammables within 35 feet (10.7 m) of the welding arc.
If this is not possible, tightly cover them with approved covers.
Be alert that welding sparks and hot materials from welding can
easily go through small cracks and openings to adjacent areas.
Watch for fire, and keep a fire extinguisher nearby.
Be aware that welding on a ceiling, floor, bulkhead, or partition
can cause fire on the hidden side. Do not weld on closed
containers such as tanks, drums, or pipes, unless they are
properly prepared by required safety Standards.
Connect work cable to the work as close to the welding area as
practical to prevent welding current from traveling long, possibly
unknown paths and causing electric shock and fire hazards.
Cylinders can explode if damaged; Shielding gas
cylinders contain gas under high pressure and damaged
cylinder can explode, so be sure to treat them carefully.
Keep cylinders away from any welding or other electrical circuits.
Never hang a welding torch over a gas cylinder.
Never allow a welding electrode to touch any cylinder. Never weld
on a pressurized cylinder –explosion will result.
Do not install or place unit on, over, or near
combustible surfaces or flammables. Do not overload
building wiring –be sure power supply system is properly
sized, rated, and protected to handle this unit.
EXPLOSION
MMA WELDING MACHINES

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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 to unit.
High-frequency due to welding can cause interference,
it can interfere with radio navigation, safety services,
sensors computers, and communications equipment.
Be sure all the equipment in the welding area is
electromagnetically compatible. To reduce possible interference,
keep weld cables as short as possible, close together, and down low,
such as on the floor. Locate welding operation 100 meters from any
sensitive electronic equipment.
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.
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.
Electo-static discharge can damage printed circuit
boards. Put on grounded wrist strap before handling
boards or parts. Use proper static-proof bags and boxes
to store, move, or ship PC boards.
FURTHER CASES
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PRODUCT OVERVIEW
1. Current adjusting knob
2. Power indicator
3. Heat Indicator
4. QC indicator
5. Digital Display
6. Quick connector socket:
welding machine output (+)
7. Quick connector socket:
welding machine output (-)
8. On-off Switch
9. Power cord anchorage
10. Smart Fan
IBL M200-89
MMA WELDING MACHINES

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IBL M200-77
1. Current adjusting knob
2. Power indicator
3. Heat Indicator
4. QC indicator
5. Digital Display
6. Quick connector socket:
welding machine output (+)
7. Quick connector socket:
welding machine output (-)
8. On-off Switch
9. Power cord anchorage
10. Smart Fan
MMA WELDING MACHINES

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IBL M220-76
1. Current adjusting knob
2. Arc Force Regulator
3. Power indicator
4. Heat Indicator
5. QC indicator
6. Digital Display
7. Quick connector socket:
welding machine output (+)
8. Quick connector socket:
welding machine output (-)
9. On-off Switch
10. Power cord anchorage
11. Smart Fan
MMA WELDING MACHINES

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IBL M220-78
1. Current adjusting knob
2. Digital Display
3. VRD Switch
4. LED Light
5. Quick connector socket: welding machine output (-)
6. Quick connector socket: welding machine output (+)
7. On-off Switch
8. Power cord anchorage
MMA WELDING MACHINES

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IBL M250-103
1. Current adjusting knob
2. Power indicator
3. Heat Indicator
4. QC indicator
5. Handle
6. Digital Display
7. Power boost button
8. Quick connector socket: welding
machine output (+)
9. Quick connector socket: welding
machine output (-)
10. On-off Switch
11. Power cord anchorage
12. Smart Fan
MMA WELDING MACHINES

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IBL M250-104
1. Current adjusting knob
2. Arc force regulator
3. Hot start regulator
4. Power indicator
5. Heat Indicator
6. QC indicator
7. Digital Display
8. Quick connector socket:
welding machine output (+)
9. Quick connector socket:
welding machine output (-)
10. On-off Switch
11. Power cord anchorage
12. Smart Fan
MMA WELDING MACHINES

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Model Number
IBL M200-
89
IBL M200-
77
IBL M220-
76
IBL M250-
103
IBL M250-
104
Input Power (V)
220V±15%
220V±15%
220V±15%
220V±15%
220V±15%
Supply Frequency
(Hz)
50/60Hz
50/60Hz
50/60Hz
50/60Hz
50/60Hz
Input Capacity
(KVA)
6.1
6.1
7.2
10.8
8.9
Input Current (A)
28
28
33
49
41
No Load Voltage (V)
48
45
45
45
45
Current Range@
100%
20-140
20-140
20-160
20-140(190)
30-220
Max Current(A)
200
200
220
200 (250)
250
Efficiency (%)
85%
85%
85%
85%
85%
Usable
electrodes(mm)
1 to 4
1 to 4
1 to 5
1 to 5
1 to 5
Hot Start
Built-in
Built-in
Built-in
Built-in
adjustable
Anti-Stick
Built-in
Built-in
Built-in
Built-in
Built-in
ARC Force
Built-in
Built-in
adjustable
Built-in
adjustable
Power Boost
X
X
X
Yes
X
Advanced IGBT
Technology
Yes
Yes
Yes
Yes
Yes
Voltage
Compensation
Yes
Yes
Yes
Yes
Yes
VRD
Built-in
Built-in
Built-in
Built-in
Built-in
Thermal Protection
Yes
Yes
Yes
Yes
Yes
Insulation class
F
F
H
F
F
Protection Class
IP21S
IP21S
IP21S
IP21S
IP21S
Cooling
Smart Fan**
Smart Fan **
Smart Fan**
Smart Fan **
Smart Fan**
Power Socket Amp
Required
32A
32A
32A
32A
32A
Continuous welding
@100%
140
140
160
140/190
220
Continuous welding
electrode gauge
10
10
8
8
6
Maximum electrode
cable length (100%
Efficiency)
20M***
20M***
20M***
20M***
20M***
Generator (KW)
Required
5
5
5.8
5.8
5.8
PRODUCT SPECIFICATIONS
** Smart Fan work only when cooling is required.
*** Current proportionally reduce when electrode cable length increases.
MMA WELDING MACHINES

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Model Number
IBL M220-
78
Input Power (V)
220V±15%
Supply Frequency
(Hz)
50/60Hz
Input Capacity
(KVA)
7.2
Input Current (A)
33
No Load Voltage (V)
45
Current Range@
100%
20-160
Max Current(A)
220
Efficiency (%)
85%
Usable
electrodes(mm)
1.6 to 4
Hot Start
Built-in
Anti-Stick
Built-in
ARC Force
Built-in
Power Boost
X
Advanced IGBT
Technology
Yes
Voltage
Compensation
Yes
VRD
adjustable
Thermal Protection
Yes
Insulation class
H
Protection Class
IP21S
Cooling
___
Power Socket Amp
Required
32A
Continuous welding
@100%
160
Continuous welding
electrode gauge
8
Maximum electrode
cable length (100%
Efficiency)
20M***
Generator (KW)
Required
5.8
MMA WELDING MACHINES

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The equipment is packed in durable packages. Nevertheless,
always before using the equipment, make sure it is not damaged
during transportation/delivery.
Place the unit on horizontal, solid and clean surface. Shield it
from heavy rain and scorching sun. Make sure that cooling air
circulates freely.
Welding machines are among the most essential tools for a welding
professional. Welding machines generate heat that melts metal
parts, so that these parts can be joined.
In Manual Metal Arc Welding (MMA), 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 slag cools down and solidifies rapidly, protecting the weld area
after the gas has disappeared.
The machine uses a high performance IGBT Technology, which is
very useful as they give power that can be used for different
welding processes.
SETUP
UNPACKING AND ENSURING
WARNING! The product must be fully assembled before
operation! Do not use a product that is only partly assembled or
assembled with damaged parts! Do not connect the product to power
supply before it is completely assembled!
INTENDED USE
MMA WELDING MACHINES

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Make sure that the air vent of the machine is not covered and
clogged up to avoid failure of cooling system. All our welding
machines are equipped with VRD (Voltage Reduction Device)
Technology.
Connect the welding tongs (grounding clamp and electrode
holder) correctly according to the following figure. Firstly, make
sure that cable, welding tongs and quick plugs are connected
reliably.
Insert the quick plug that connects the electrode holder in the
quick socket with the polarity of “+”, and then tighten it by force
clockwise.
Insert the quick plug that connects the grounding clamp into
quick socket with the polarity of “-” on the panel of welding
machine, tighten it by force clockwise, the grounding clamp
connects to the work-piece.
Pay attention to the polarity of connection，if connected
improperly, unstable electric arc, large splash and sticky welding
rod may occur.
Connect the power plug to the corresponding voltage class of
distribution box according to the input voltage class of welding
machine, don’t connect the voltage by mistake. Make sure that
tolerance of supply voltage is within the allowable range.
INSTALLATION
Welding Machine
AC/DC Power
and controls
Electrode
Electrode
holder
Arc
Electrode cable
Work
Work clamp
Work cable
MMA WELDING MACHINES

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Current setting: The correct current, or amperage setting primarily
depends on the diameter and type of electrode selected. The side of
the electrode box usually indicates operating ranges. Select an
amperage based on the material thickness, welding position (about
15 percent less heat for overhead work compared to a flat weld) and
observation of the finished weld.
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.
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. Adjust travel
speed so that the arc stays within the leading one-third of the weld
pool. 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.
Manipulation: Each welder manipulates or weaves the electrode in a
unique style. Develop your own style by observing others,
practicing and creating a method that produces good results for
you. Note that on material 1/4 inch and thinner, weaving the rod
typically creates a bead that is wider than necessary. In many
instances, plain, straight-ahead travel works fine. To create a wider
bead on thicker material, manipulate the electrode from side to side
creating a continuous series of partially overlapping circles, or in a
PARAMETERS
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Z-shaped, semi-circle or stutter-step pattern. Limit side-to-side
motion to two and a half times the diameter of the electrode core.
To cover a wider area, make multiple passes or stringer beads.
When welding vertical up, focus on welding the sides of the joint
and the middle will take care of itself.
Diameter of welding rod and Welding current
Diameter of
welding rod
(mm)
φ1.6
φ2.0
φ2.5
φ3.2
φ4.0
φ5.0
φ5.8
Welding
current (A)
40
55
80
115
160
190-
260
250-
300
Thickness of steel plate and Diameter of welding rod
Thickness of
steel plate (mm)
1-2
2-5
5-10
Over 10
Diameter of
welding rod
(mm)
1-2.5
2.5-4
3.2-5.8
4-8
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.
Arc is lit by scratching the welding piece with electrode. Length of
arc is regulated by holding electrode tip at a suitable distance
from welding piece. Suitable arc length is usually about half the
diameter of the electrode wire.
MMA WELDING MACHINES

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When the machine is turned ON, an auto-test is executed and power
LED (GREEN) lights up and display will ON. The Machine is ready to
operate when the Front Control Panel lights up the Power LED ON.
The below listed parts are labelled in the product overview.
Apart from two or three, all other parts are common to each
machine.
Current adjusting knob:
Potentiometer is used to set the output current during welding.
Arc Force Regulator (For M220-76 & M250-104):
Arc force is a temporary increase of the output current during
welding when the arc is too short. It also enhances simple position
welding, making the job easier. In order to produce an outstanding
weld performance on a variety of electrodes, the Arc Force can be
finely adjusted with a simple knob.
Hot start Regulator (For M250-104):
Hot Start provides excellent arc ignition without the electrode
sticking and avoiding any metallurgical default in the weld.
Anti-sticking (INBUILT):
This electronic device minimizes the short circuit current in the
event of the electrode sticking to the work piece. If a short circuit
does occur, it will be easy to remove the electrode from the work
piece and the electrode gun and cable will remain undamaged. It
also serves as a safety device in protecting the operator.
Multi metal capability (For M220-78):
This feature allows the machine to weld Zinc, Carbon steel, Copper,
Iron and Aluminium. This feature is achieved only by M220-78.
CONTROLS AND OPERATIONAL FEATURES
MMA WELDING MACHINES

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Power ON/OFF LED:
This LED lights up when the machine is ON.
Heat LED:
This indicator will turn on when the machine is overheated and the
output has been disabled. This normally occurs when the duty cycle
of the machine has been exceeded. Leave the machine ON to allow
the internal components to cool. When the indicator turns OFF,
normal operation is again possible.
QC LED:
This turns on when the machine is overheated/overloaded.
Digital Display:
The meter displays the present welding current before welding and
the actual welding current during welding.
Quick connector socket: welding machine output (+):
Connect the electrode holder to this socket.
Quick connector socket: welding machine output (-):
Connect earth cable to this socket.
Power boost button (For M250-103):
Button to increase the output current up to 40% for using 4 or 5 mm
electrodes.
Smart Fan:
This machine has a Smart Fan circuitry inside, which work only
when cooling is required. This feature reduces the amount of dirt
which can be drawn inside the machine and reduces power
consumption. The fan will continue to run whenever the machine is
welding.
VRD (INBUILT):
VRD (Voltage Reduction Device) provides an additional measure of
safety, especially when working in an environment with a higher
risk of electrical shock such as wet areas and hot, humid, sweaty
conditions. VRD reduces the welding power source’s open circuit
voltage (OCV).
MMA WELDING MACHINES