SanRex SANARG 200AP User manual

SanRex
SANARG
200AP
AC/DC INVERTER
ARC WELDER
Operators
Manual
Version No: B Issue Date: JUN 12, 2019
Manual No: K00A0316900

Welcome to the SanRex Family Welding
Team!
Dear Welding Professional,
We would like to take this opportunity to thank you, and congratulate you on procuring a SanRex
Model 200AP AC/DC STICK Welding Machine.
Welding Professional, now that is a term that we do not take lightly. The welding machine that you
purchased is a full function, portable unit that was designed with the Welding Professional in mind.
The unit is suitable for use as a portable welder on the job site, to a unit utilized in an industrial
manufacturing setting. This unit will perform and is truly a welder for the Professional Welder. As
you review this manual, you will be provided with information regarding the use and functionality of
the unit. What you will not see is information or instruction on “how to weld”, as this appropriately
left to the vast array of Vocational, Trade and other institutions that provide instructional education
in welding.
This manual also contains sections that are dedicated solely to the safety of you and others in the
work area. It is highly recommended that this information be reviewed and that this manual be kept
in a secure but accessible location for reference of these import safety and well-being notices.
Remember, the number one requirement in performing any job is safety.
Sansha Electric of Osaka Japan and its “SanRex” brand name of products has specialized in the
power supply and power semiconductor manufacturing business for over 80 years. With over 55
years producing welding power supplies and over 30 years producing inverter based welding and
plasma cutting power supplies, you can be assured that you have purchased one of the best welding
machines on the market today.
The superior Arc Characteristics that you will experience is achieved through our dedication and
commitment to research and development as well as developing smart solutions for safe, reliable and
environmentally friendly welding machines.
We value long term relationships with our customers and strive to provide the most cost effective
solutions that support this philosophy.
We thank you for choosing SanRex equipment.
SanRex Family Welding Team

INTRODUCTION
PURPOSE OF THIS MANUAL
This manual has been prepared to present the safety, installation/operation and maintenance
instructions for the Welding Machine Model 200AP, an AC/DC Stick and TIG welding machine
manufactured by the Sansha Corporation of Osaka, Japan. The manual contains the information necessary for
the Professional Welder to correctly use and operate the 200AP. It is not the intent of this manual, and does
not, instruct or offer information on how to weld.
This operation manual includes an introduction followed by detailed information sections.
The information in this operating manual is generic to this model line of the welding machine and
must be supplemented with the application specific data, environment condition (location), electrical input
connections, limitations, and principal safety standards.
SECTION 1 - SAFETY REGULATIONS
AND REQUIREMENTS
This section contains the leading
particulars and descriptions of the welding
symbols, safety, warning instructions;
additional symbols for a complete
understanding and safe use of the
equipment are also included.
SECTION 2 –INTRODUCTION AND
DESCRIPTION
This section includes descriptions and
features of the product, V-A curves and the
block diagram of the product.
SECTION 3 - INSTALLATION
RECOMMENDATIONS
Describing the transportation, working
environment, electrical hook-up with
consideration for grounding and high
frequency interference. Also input power,
connections and specifications.
SECTION 4 –OPERATOR CONTROLS,
DIMENSIONS AND OUTLINE
Included in this section is a sequence of
operation, welding process selection,
welding model 200AP attributes and model
features, plus torch switch receptacle
specifications.
SECTION 5 –SET-UP FOR BASIC
STICK (SMAW) AND TIG
(GTAW) WELDING
This section shows the basic STICK and
TIG connection set-up from tank to work
piece.
SECTION 6 -SEQUENCE OF
OPERATION
This section describes the sequence to set-
up the machine to perform STICK, TIG
and HF-TIG welding operations.
SECTION 7 –VOLTAGE REDUCTION
DEVICE (VRD)
This section includes information in the
Voltage Reduction device that is built-in
to the unit. This device lowers the Open
Circuit Voltage in STICK welding. This
function is useful in applications where a
high OCV could be dangerous. The
200AP units are shipped from the factory
in the disabled state.
SECTION 8 –TROUBLESHOOTING
This section provides information on
Power Source problems and Power Source
Error Codes.
SECTION 9 –ROUTINE
MAINTENANCE
This section describes basic maintenance
for the welding power source.
SECTION 10 –PARTS LIST
This section contains the basic schematic,
exploded view and a listing of the spare
parts and order numbers.

Table of Contents
1.0 SAFETY REGULATIONS AND REQUIREMENTS............................................................. 9
1.1 NOTES, CAUTIONS AND WARNING ANNOTATIONS................................................. 9
1.2 SAFETY RECOMMENDATIONS..................................................................................... 10
1.3 WELDING SYMBOLS ....................................................................................................... 11
1.3.1 SAFETY SYMBOL LEGEND..................................................................................... 11
1.3.2 GRAPHIC SYMBOL LEGEND .................................................................................. 15
1.4 SAFETY PRECAUTIONS................................................................................................. 16
1.5 SAFE OPERATION OF THE WELDER AND PERSONAL PROTECTION................... 17
1.5.1 IMPORTANT SAFETY PRECAUTIONS................................................................... 17
1.5.2 ELECTRIC SHOCK..................................................................................................... 18
1.5.3 GASES AND FUMES.................................................................................................. 19
1.5.4 FIRE AND EXPLOSIONS........................................................................................... 20
1.5.5 ARC WELDING RAYS, NOISE AND SPATTER OR SLAG................................... 21
1.5.6 GAS CYLINDERS....................................................................................................... 22
1.6 REFERENCE PUBLICATIONS......................................................................................... 23
2.0 INTRODUCTION AND DESCRIPTION.............................................................................. 25
2.1 GENERAL........................................................................................................................... 25
2.2 WELDING MACHINE DESCRIPTION............................................................................. 25
2.3 200AP POWER SOURCE FEATURES.............................................................................. 25
2.4 WELDING OUTPUT VOLTAGE AND AMPERAGE CURVES..................................... 27
2.4.1 200AP V/A OUTPUT CURVES.................................................................................. 27
2.5 FUNCTIONAL BLOCK DIAGRAM.................................................................................. 28
3.0 INSTALLATION RECOMMENDATIONS.......................................................................... 29
3.1 TRANSPORTATION METHODS...................................................................................... 29
3.2 ENVIRONMENT................................................................................................................. 30
3.3 MACHINE GROUNDING & HIGH FREQUENCY INTERFERENCE ........................... 30
3.3.1 GROUNDING .............................................................................................................. 30
3.3.2 HIGH FREQUENCY INTRODUCTION .................................................................... 30
3.3.3 HIGH FREQUENCY INTERFERENCE..................................................................... 31
3.4 LOCATION ......................................................................................................................... 32
3.5 ELECTRICAL INPUT CONNECTIONS & REQUIREMENTS ....................................... 32
3.5.1 INPUT POWER............................................................................................................ 32
3.5.2 FUSING........................................................................................................................ 33
3.5.3 ELECTRICAL INPUT CONNECTIONS.................................................................... 33
3.5.3.1 200AP Input Power Connections................................................................................... 34
3.6 SPECIFICATIONS.............................................................................................................. 36
3.6.1 INPUT/OUTPUT.......................................................................................................... 36
3.6.2 GENERAL.................................................................................................................... 37
3.7 DUTY CYCLE..................................................................................................................... 38
4.0 OPERATOR CONTROLS, DIMENSIONS & OUTLINE.................................................... 39
4.1 DIMENSIONS AND OUTLINE......................................................................................... 39
4.2 OPERATOR CONTROLS, LOCATION AND FUNCTIONALITY ................................. 39
4.3 14-PIN REMOTE CONTROL RECEPTACLE .................................................................. 42
4.4 PARAMETER DISPLAY PANEL...................................................................................... 43
4.5 FUNCTION SELECTION................................................................................................... 46
4.6 PARAMETER SELECTION............................................................................................... 47
5.0 SET-UP FOR BASIC STICK (SMAW) AND TIG (GTAW) WELDING............................ 48
6.0 SEQUENCE OF OPERATION.............................................................................................. 49

6.1 STICK WELDING............................................................................................................... 51
6.1.1 STICK SEQUENCE WITH VOLTAGE REDUCTION DEVICE DISABLED......... 52
6.1.2 STICK SEQUENCE WITH VOLTAGE REDUCTION DEVICE ENABLED ......... 52
6.2 AC OR DC HF TIG WELDING.......................................................................................... 53
6.3 LIFT TIG SEQUENCE........................................................................................................ 54
6.3.1 STANDARD MODE.................................................................................................... 54
6.3.2 SLOPE MODE.............................................................................................................. 54
6.3.3 REPEAT MODE........................................................................................................... 54
6.4 HF TIG SEQUENCE........................................................................................................... 55
6.4.1 STANDARD MODE.................................................................................................... 55
6.4.2 SLOPE MODE.............................................................................................................. 55
6.4.3 REPEAT MODE........................................................................................................... 55
6.4.4 SPOT MODE................................................................................................................ 56
7.0 VOLTAGE REDUCTION DEVICE (VRD).......................................................................... 57
7.1 VRD SPECIFICATIONS..................................................................................................... 57
7.2 SWITCHING VRD ON/Off................................................................................................. 57
8.0 TROUBLE SHOOTING......................................................................................................... 61
8.1 POWER SOURCE PROBLEMS......................................................................................... 61
8.2 POWER SOURCE ERROR CODES................................................................................... 63
9.0 ROUTINE MAINTENANCE................................................................................................. 67
9.1 OPENING THE ENCLOSURE........................................................................................... 68
10.0 PARTS LIST 200AP.............................................................................................................. 71
10.1 INTERCONNECT DIAGRAM 200AP ........................................................................... 80
10.2 EXPLODED VIEW 200AP.............................................................................................. 82
APPENDIX A: 200AP QUICK SET-UP GUIDE............................................................................. 85

9
SECTION 1- SAFETY REGULATIONS AND REQUIREMENTS
1.0 SAFETY REGULATIONS AND REQUIREMENTS
Throughout this manual, notes, cautions, danger, attention and warnings are used to highlight
important information. These highlights are categorized as follows:
1.1 NOTES, CAUTIONS AND WARNING ANNOTATIONS
NOTE: An operation, procedure, or background information which requires additional
emphasis or is helpful in efficient operation of the system.
CAUTION: A procedure which, if not properly followed, may cause damage to the equipment.
WARNING: A procedure which, if not properly followed, may cause injury to the operator or
others in the operating.
DANGER: Procedures, which if not properly followed, may lead to death or serious injury.
Please read this operating manual thoroughly before utilizing the equipment.
Wherever welding equipment is used, safety is always our concern.
PROTECT yourself and others.

10
1.2 SAFETY RECOMMENDATIONS
For the purpose of safety, it is recommended that this weldingequipment be installed, maintained,
inspected, and repaired by appropriable qualified person or persons who are well familiarized
with welding equipment..
As for safety training, it is recommended to avail yourselves of various seminars and
qualifying examinations for welding engineers and welding technicians sponsored by the
Welding Society, the Welding Engineering Society, and the headquarters or branch offices
of societies or associations concerned.
For the purpose of safety, it is recommended that this welding equipment should be operated by
persons who have enough knowledge and skill to understand all safety precautions and
instructions in the Operating Manual and to be able handle the equipment safely.
After reading this Operating Manual, please store it carefully with guarantee where it will be
made accessible to all personnel dealing with the equipment
.
Please call your local distributors, business offices, or service agents if you have any
questions