IGBT BLUEARC 200STI User manual

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BLUEARC 200STI
OWNERS MANUAL
(Plastic Panel)
INVERTER IGBT DC PULSE TIG/MM WELDING MACHINE

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WARNING!
Read the instructions before installing and starting the device!
1. GENERAL REMARKS
Commissioning and operation of the device may only be carried out after thoroughly reading this Operator's
Manual.
Due to the constant technical development of the device, some of its functions may be modified and their
operation may differ in detail from the descriptions in the manual. This is not a device error, but the result of
progress and continuous modification work on the device.
Damage to the device caused by improper operation will void the warranty. Any modifications to the charger
are prohibited and will void the warranty.
2. SECURITY
Employees operating the device should have the necessary qualifications authorizing them to perform
welding work:
--should be authorized by an electric welder in the field of welding with coated electrodes and in gas shields,
--knowledge of health and safety principles when operating power equipment, such as welding equipment
and auxiliary equipment powered by electricity,
--be aware of health and safety rules for handling cylinders and compressed gas (argon) installations,
--Know the contents of this manual and use the device for its intended purpose.
WARNING
Welding may endanger the safety of the operator and other persons in the vicinity. Therefore, special
precautions should be taken when welding. Before welding, read the health and safety regulations at
the workplace.
During MMA and TIG electric welding, the following risks exist:
 ELECTRIC SHOCK

NEGATIVE IMPACT OF ARC LIGHT ON EYES AND SKIN OF A HUMAN
 STEAM AND GAS POISONING
 BURNS
 EXPLOSION AND FIRE HAZARDS
 NOISE
Prevention of electric shock:
 connect the device to a technically efficient electrical installation with adequate protection and zeroing
efficiency (additional protection against electric shock); other devices at the welder's workplace should be
checked and correctly connected to the network,
 install power cables with the device switched off,
 do not touch simultaneously the non-insulated parts of the electrode holder, electrode and workpiece,
including the device housing,
 do not use holders and power cables with damaged insulation,

in conditions of special risk of electric shock (work in environments with high humidity and closed
tanks), work with an assistant assisting the welder and ensuring safety, use clothing and gloves with
good insulating properties,
 if you notice any irregularities, please contact competent persons to remove them,
 Operation of the device with covers removed is forbidden.
Prevention of negative effects of the electric arc on human eyes and skin:

Wear protective clothing (gloves, apron, leather shoes),
 Use shields or protective helmets with a properly selected filter,
 Use protective curtains made of non-combustible material and choose the right colors for the walls that
absorb harmful radiation.
Prevention of poisoning by vapors and gases emitted during welding from electrode coating and
metal evaporation:
 Use ventilation equipment and extractors installed in positions with limited air exchange,

Blow out with fresh air when working in a confined space (tanks),

Use masks and respirators.

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Burn prevention:
 Use appropriate protective clothing and footwear to protect against burns from arc radiation and spatters,

Avoid staining clothing with grease and oil that can ignite it.
Explosion and fire prevention:

It is forbidden to operate the device and weld in rooms where there is a risk of explosion or fire,
 The welding station should be equipped with fire extinguishing equipment,

The welding station should be at a safe distance from flammable materials.
Prevention of negative effects of noise:
 Use ear plugs or other noise protection measures,

Warn of the danger of nearby people.
WARNING!
Do not use a power source for thawing frozen pipes.
Before starting the device:
 Check the condition of electrical and mechanical connections. Holders and cables with damaged
insulation must not be used. Inadequate insulation of the grips and current leads can cause electric
shock,
 Ensure proper working conditions, i.e. ensure proper temperature, humidity and ventilation at the
workplace. Protect against atmospheric precipitation outside enclosed rooms,
 Place the charger in a place that allows easy operation. Persons operating the welder should:
 have the authorization to electric welding with coated electrodes and the TIG method,
 know and comply with the health and safety regulations applicable to welding work,
 use proper, specialized protective equipment: gloves, apron, rubber boots, shield or welding
helmet with a properly selected filter,
 know the content of these operating instructions and use the welder for its intended purpose. Any repairs
to the device may only be carried out after disconnecting the plug from the power socket.
 When the device is connected to the network, no parts forming the welding current circuit may be touched
by bare hands or wet clothing.
 It is forbidden to remove the outer covers when the device is connected to the network.

Any modifications of the rectifier on your own are prohibited and may constitute a deterioration of safety
conditions.

All maintenance and repair works may only be carried out by authorized persons, observing the safety
conditions in force for electrical equipment.
 It is forbidden to use the welder in rooms at risk of explosion or fire! The welding station should be
equipped with fire extinguishing equipment.

After finishing work, disconnect the power cord from the device.
 The threats and general health and safety rules presented above do not cover the welder's safety issues,
as they do not take into account the specificity of the workplace. An important supplement to these is the
workplace
 OHS instructions as well as training and instructions given by supervisory staff.
3.GENERAL DESCRIPTION
The machine is used for manual welding of structural steels with coated electrodes (MMA method) and
quality steels, copper and its alloys with a non-fusible electrode in an inert gas shield (TIG method). The
device is intended for workshop and occasional production work. The welder has the possibility of welding
with pulse and regulation, time of current drop and gas outflow. The device works in 2T / 4T mode and has a
display indicating welding parameters. The set includes a TIG welding torch, electrode cable and ground
cable.
The machine is made in IGBT technology that allows a significant reduction in the weight and
dimensions of the welder and an increase in efficiency while reducing energy consumption.
The machine is used in closed or roofed rooms, not exposed to direct weather effects.
4. TECHNICAL SPECIFICATIONS
4.1 MACHINE
Model
BLUEARC 200STI
Power supply voltage
AC 230V ±10% 50Hz/60Hz
AC 110V ±10% 50Hz/60Hz
Max. Power consumption
MMA: 6.6 KVA, TIG: 4,6 KVA
MMA: 4,6 KVA, TIG: 3.0 KVA
Welding current / work cycle
MMA: 180 A / 60%
TIG: 200 A / 60%
MMA: 130 A / 60%
TIG: 140 A / 60%
No-load voltage
81 V
80 V
Power consumption
MMA: 29A, TIG 20 A
MMA: 42 A, TIG 28 A
Weight
7 kg
Dimension
430 x 175 x 320 mm
Protection Class
IP21S

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4.2 Parameter adjustment ranges
Model
BLUEARC 200STI
Power supply voltage
AC 230V ±10% 50Hz/60Hz
AC 110V ±10% 50Hz/60Hz
Current
MMA: 10-180 A TIG:10-200 A
MMA: 10-130 A TIG:10-140 A
Gas outflow(Post Gas)
0 – 15 s
Current drop(Down Slope)
0 – 10 s
Pulse frequency
1,2 Hz / 200 Hz
Work cycle
The work cycle is based on a 10-minute period. A 60% duty cycle means a 4-minute break is required after 6
minutes of operation. A 100% duty cycle means that the device can work continuously without interruptions.
Warning! Heating tests were carried out at ambient air temperature. The duty cycle at 40ºC was determined by
simulation.
Level of security
IP determines to what extent the device is resistant to the penetration of solid and water pollutants. IP23 means
that the device is designed to work indoors and is not suitable for use in the rain
5.CONNECTION TO THE POWER SUPPLY NETWORK
1. The machine should only be used in a single-phase, three-wire power supply system with
grounded neutral.
2. The machine is designed to work with 230V 50Hz mains protected with 25 A fuses with time
delay. The power supply should be stable, without voltage drops.
3. The machine is equipped with a power cord and plug. Before connecting the power supply,
make sure that the power switch (14) is in the OFF position.
5.1 PREPARING THE MACHINE FOR WORK
If the device is stored or transported in low temperatures, the device should be brought to the right
temperature before starting work !!!
5.1.1 Method MMA
The ends of the welding leads should be connected to the sockets (5) and (8) on the front panel so that the
correct pole for the electrode is on the electrode holder. The polarity of the welding cable connection depends
on the type of electrode used and is indicated on the electrode packaging (DCEN negative or DCEP positive).
The return hose clamp should be securely attached to the workpiece. Connect the device's plug to a 230V
50Hz power socket.
DCEP DCEN
5.1.1 Method TIG

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the control plug of the clamp should be placed in the socket (6), and the gas connector plug in the socket of the
quick coupler (7). The gas pipe from the regulator should be connected and secured to the gas connector (16)
located on the back of the housing. Connect the positive pole of the source (5) with the workpiece using a cable
with a clamp. Connect the device's plug to a 230V 50Hz power socket.
6 DESCRIPTION OF SWITCH FUNCTIONS AND KNOBS
6.1 Front and rear panel
1).Power supply LED 2).Thermal protection diode
3).Remote foot pedal and machine switch 4).Post gas adjustment knob
5).Control mode switch (two-stroke / four-stroke) 6).Display
7).Pulse frequency switch 8).Welding current adjustment knob
9).MMA/TIG switch 10).Down slope adjustment knob
11).Negative polarization socket 12).Shielding gas connection
13).Remote socket 14).Control socket
15).Positive polarity socket Fan 16).Power cord
17).Power on/off 18). Fan 19).Shielding gas cap
6.2 Control panel
Diode
The LED lights up when the device is turned on.
Diode
Overheat protection - the power source is equipped with a thermal automatic overload switch. When the
welder's temperature is too high, the protection disconnects the welding current and the LED lights up. After
the temperature drops, the circuit breaker will reset automatically.
Display of welding parameters
The display shows the welding current in amperes.
Welding method selection switch
The switch is used to select the welding method. MMA - welding with covered electrode (MMA), TIG -
welding with tungsten electrode in shielding gases.
Pulse frequency switch
Switch active only during TIG welding. Used to control the operation of the pulse:
pulseless welding pulse frequency welding 1.2 Hz
pulse frequency welding 200 Hz
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1
4
5
6
7
9
10
16
17
18
19
12
13
14
15
2
3
8

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Source mode selector switch (two-stroke / four-stroke)
The switch is only active for TIG welding. In the two-touch mode, pressing the switch on the handle of the
handle will turn on the ionizer and ignite the arc. Welding is carried out with the switch pressed. Releasing
the switch will end welding. In the four-stroke mode, pressing the switch in the handle of the handle will turn
on the ionizer and ignite the arc then release the switch and weld with the switch released. Pressing the
switch again will end welding.
DOWN SLOPE knob - current fall time Time of welding current decrease until arc extinguishing.
Adjustment range: 0 - 10s.
POST GAS knob - gas post-flow time
Time from quenching the arc to closing the gas valve to shield the solidifying weld pool from air and to cool the
tungsten electrode. Too short an afterflow time can result in weld oxidation.
Adjustment range: 0 - 15s.
7.WELDING
7.1 Arc initiation and coated electrode (MMA) welding
Initiation of the arc when welding with coated electrodes involves touching the electrode to the workpiece, short
rubbing and tearing. In the event of arc initiation with electrodes whose coating forms a non-conductive slag
after solidification, the electrode tip should be pre-cleaned by hitting the hard surface several times until
metallic contact with the welded material is achieved. To end welding, detach the electrode from the workpiece.
7.2. Welding in shielding gases (TIG method).
The machine is equipped with an ionizer enabling contactless ignition of the arc. To ignite the arc in two-stroke
mode, bring the electrode closer to the welded material at a distance of 2 millimeters and press the button on
the torch handle to turn on the ionizer. After correct arc initiation, welding should be carried out with the button
pressed. By releasing the handle button, the current drop phase begins and the welding process ends.
To ignite the arc in four-stroke mode, bring the electrode closer to the welded material at a distance of 2
millimeters and press the button on the torch handle to turn on the ionizer. After the arc has ignited correctly,
the button can be released and welding can be carried out with the button released. To end welding, press and
release the handle button again.
8. BEFORE CALLING FOR THE SERVICE
In the event of a malfunction of the machine, before sending the welder to the service, check the list of basic
failures and try to remove them yourself.
Any repairs to the device may only be carried out after disconnecting the plug from the power socket.
Warning! The device is not sealed and the user can remove the welder's housing to remove minor failures.
symptoms
Removal methods
The control panel does not
light up, the fan does not
work, no output voltage
1. Make sure the switch is in the ON position
2. Check the protection and voltage in the network
3. Remove the cover and check the connection of all electrical plugs
inside the device
The control panel lights up, the
fan does not work, no output
voltage.
1. Check that the device has not been connected to a higher voltage
network. If so, connect to 230V and switch on again
2. The supply voltage is unstable and switches on the overvoltage
protection. Turn off the device for 2-3 minutes and turn it on again
3. Briefly turning on and off the switch turned on the overvoltage
protection. Switch the device off for 2 minutes and switch it on again
4. There is other damage that requires repair by an authorized service
center
The control panel lights up,
the fan is running, arc
ignition problems
1. Check TIG torch, replace consumable parts if worn.
The control panel lights up,
the fan runs, the welder does
not ignite the arc
1. Check the terminals and the correct electrical conductivity of
the electrode and ground wire
2. Check the connection of the TIG torch to the device, make
sure that the pins in the socket are not broken off or are not
jamming.
3. Unscrew the handle of the TIG torch and check that the switch
in the torch is OK

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The control panel lights up, the
fan runs, the LED lights up
1. The device has been overheated. Wait a few minutes. After the
diode goes out, continue welding.
Unsatisfactory weld quality
when MMA welding, the
electrode sticks to the
material being welded
1. Check the polarity of the welding cable connection
2. Check that the electrode is not wet. Replace the electrode.
3. The welder is powered by a power generator or by a long
extension cord with too small cable cross section. Connect the
device directly to the mains
Unsatisfactory weld
quality for TIG welding
1. Replace consumable parts. Change the tungsten electrode or gas
cylinder for higher quality materials
2. Check that the shielding gas flows with the right intensity
3. Check gas supply hose, improve hose connection with fittings and
condition of quick couplings
4. Check the bench gear reducer.
9. OPERATING INSTRUCTIONS
The machine should be operated in an atmosphere free of corrosive components and high dustiness. Do not
place the device in dusty places, near working grinders, etc. Dusting and contamination with metal chips of
control boards, wires and connections inside the device may lead to electric short circuit and, as a
consequence, damage to the welder.
Avoid operating in environments with high humidity, especially in situations of dew on metal components.
In the event of dew on metal parts, e.g. after placing a cool device in a warm room, wait until the dew has
disappeared. It is recommended to place the welding machine under a roof to protect against adverse weather
conditions when using the welder outdoors.
The machine should be used in the following conditions:
- changes in the effective value of the supply voltage not more than 10%
- ambient temperature from –10 ° C to + 40 ° C
- atmospheric pressure 860 to 1060 hPa
- relative atmospheric humidity not more than 80%
- altitude up to 1000m
10. MAINTENANCE INSTRUCTIONS
As part of daily service, keep the welding machine clean, check the condition of external connections and the
condition of electric wires and cables.
Replace consumable parts regularly.
Periodically clean the inside of the machine by blowing compressed air to remove dust and metal filings from
the control boards as well as the wiring and electrical connections.
A general inspection and condition of the electrical connections should be carried out at least once every six
months, in particular:
-status of electric shock protection
- insulation condition
- security system status
- proper functioning of the cooling system
Damage resulting from operating the welding machine in improper conditions and failure to comply
with maintenance instructions are not covered by warranty repairs.
STORAGE AND TRANSPORT INSTRUCTIONS
The device should be stored at -10 °C to + 40 °C and relative humidity up to 80% free of corrosive fumes
and dust. Packaged equipment should be transported using covered means of transport. During transport,
the packed device must be secured against slipping and positioned correctly.

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IGBT Equipment Warranty
Welding Material Sales
Effective Jan 1, 2019
Limited Warranty
This warranty applies to the original purchaser and is subject to the terms and conditions listed below.
This Limited Warranty is for new equipment sold after the above date, providing coverage for defects in
material and workmanship at the time it is shipped from the factory.
Limited to the warranty periods listed below, Welding Material Sales will repair or replace the item
under warranty that fails due to defects in material and workmanship. Welding Material Sales, Inc. must
be notified within 30 days of the failure, so as to provide instructions on how to proceed with the repair
of your welder and warranty claim processing. Warranty period begins at the time the welder is
purchased from an authorized Welding Material Sales, Inc. distributor and/or retailer. Proof of purchase
will be required for Welding Material Sales to proceed with any and all warranty claims, no exceptions.
Warranty Periods
Limited Warranty is divided into two categories: No warranty and 1 year.
No Warranty
Normal wear items including but not limited to MIG gun parts (contact tips, nozzle, adapter, liner), TIG
torch parts (collet, cup, back cap, torch body) drive roll, contactor, and electrode holder are not covered
under warranty.
1 Year
Solenoid valve, PC board, controls, gas valve, drive motor, and drive system. Parts and labor
performed by authorized repair center with original equipment repair parts. Call 888-905-6737 for a
repair center near you.