Jegs BLUEARC-200MSTI, Owner'S Manual

Page 1: ...OWNER S MANUAL THE IGBT SERIES OF MIG MAG ...

Page 2: ...e of welder 7 5 Installation 8 6 Welding settings quick reference chart 15 7 Range of welding current and voltage in CO2 welding 20 8 Welding parameters table 20 9 Caution 22 10 Maintenance 23 11 Daily checking 24 12 Connection diagram of the machine 27 13 Explosion drawing 28 ...

Page 3: ...f this machine The contents of this manual may be revised without prior notice This instruction manual is issued in January 2021 1 SAFETY Welding and cutting is dangerous to the operator people in or near the working area and the surrounding area if the machine is not correctly operated Therefore the performance of welding cutting must only be under the strict and comprehensive observance of all r...

Page 4: ...g piece insulated from himself herself Smoke and gas generated while welding or cutting is harmful to people s health Avoid breathing the smoke and gas generated while welding or cutting Keep the working area well ventilated Arc rays harmful to people s eyes and skin Wear welding helmet anti radiation glass and work clothes while the welding operation is performed Measures also should be taken to ...

Page 5: ... excellent welding bead shaping Welding voltage can be preset and the voltmeter displays the preset voltage value when not welding Both welding current and welding voltage can be observed at the same time Burn back time is adjustable Slow wire feeding during arc starting remove the melting ball after welding reliable arc starting Wire feeding part is separated from the welding machine wide welding...

Page 6: ... with LIFT TIG function contact type TIG torch with one output power cable and one air tube The use way of LIFT TIG is shown as below The output power cable connect with the negative output terminal and the air tube connect with the gas meter on the argon gas bottle There is a nut cover on the air tube which can connect with the gas meter The thread specification for the gas meter and the nut shou...

Page 7: ...igher duty cycles have been obtained All tests on duty cycles have been carried out at 40 with a 50 So in practical working conditions the duty cycles will be much greater than those stated above TYPE BLUEARC 200MSTI Power supply voltage V single phase 220V 15 Input current A 36 Power supply capacity KVA 8 Current adjustment range A 50 200 Output voltage V 15 24 Rated output current A 200 Rated ou...

Page 8: ... FORCE 5 MIG Torch Euro Style Connection Socket 6 Positive Welding Output Terminal 7 Negative Welding Output Terminal 8 Polar conversion line 9 rating label 10 power switch 11 welding gas inlet 12 power cable 13 Wire tension adjustment 14 Wire tension arm support roller 15 Wire input guide 16 Wire drive roller 17 Drive roller retainer 18 wire spool retainer 19 Spool brake adjustment 13 14 15 16 17...

Page 9: ...nt screw 19 using an allen wrench Clockwise to increase brake tension counter clockwise to decrease brake tension The spool brake tension should be set so that the spool can rotate freely but does not continue to rotate once the wire feed stops This may need to be adjusted as the wire is used up and the spool weight decreases 5 1 2 Loading wire feeder 5 1 2 1 release the wire feeder tension arm 14...

Page 10: ...ins power is switched off Warning The use of excessive feed tension will cause rapid and premature wear of the drive roller the support bearing and the drive motor 5 1 3 setup for gasless MIG welding operation 5 1 3 1 Connect the MIG Torch Euro Connector 21 to the torch socket on the front of the welder 5 Secure by firmly hand tightening the threaded collar on the MIG Torch Euro Connector clockwis...

Page 11: ...tle The gas supply system includes the gas bottle the air regulator and the gas hose the heater cable should be inserted into the socket of machine s back and use the hose clamp to tighten it to prevent leaking or air in so that the welding spot is protected Please note 1 Leakage of shielding gas affects the performance of arc welding 2 Avoid the sunshine on the gas cylinder to eliminate the possi...

Page 12: ... Because of the synergic digital programming both the voltage and the wire speed will adjust together 5 1 5 3 To adjust the voltage independently Rotate Left Knob 1 to adjust the welding voltage This will change and give the display screen as below Then use the Left knob 1 to adjust the welding voltage 5 5V from the standard synergic setting This will not change the wire speed It is recommended fo...

Page 13: ... display will change to show the actual welding voltage and welding current as pictured below 5 1 5 7 2T 4T function press the Right Button 4 2T 4T Selection Switch to move between 2T and 4T modes 4T operation means the trigger is pulled once to start welding and pulled again to stop This is useful for long weld joints 2T mode the trigger must be depressed and held during welding A quick note rega...

Page 14: ... 5 1 7 1 Connect Earth Lead Quick Connector 23 to the negative output welding terminal 7 5 1 7 2 Connect Earth Clamp 22 to the work piece Contact with workpiece must be strong contact with clean bare metal with no corrosion paint or scale at the contact point 5 1 7 3 Connect the ARC electrode holder lead optional to the positive welding output terminal Note some welding electrode types utilize dif...

Page 15: ...act with clean bare metal with no corrosion paint or scale at the contact point 5 1 8 3 Connect the TIG torch power lead to the negative welding output terminal 7 1 8 4 Connect the gas supply to the TIG torch 5 1 8 5 Turn the machine on at the Mains Power Switch 10 5 1 8 6 Press the Left button 2 to mode section and select the mode by Left knob 1 and press the Left knob 1 to confirm the LIFT TIG s...

Page 16: ...15 6 Welding settings quick reference chart ...

Page 17: ... obtained from an externally supplied welding grade shielding gas or welding grade shielding gas mixture The process is normally applied semi automatically however and fairly thick steels and some non ferrous metals in all positions FLUX CORED ARC WELDING FCAW This is an electric arc welding process which fuses together the parts to be welded by heating them with wan arc between a continuous flux ...

Page 18: ...ing seam is viewed at all times Always wear the welding helmet with proper filter lenses and use the proper safety equipment CAUTION Do not pull the welding gun back when the arc is established This will create excessive wire extension stick out and make a very poor weld The electrode wire is not energized until the gun trigger switch is depressed The wire may therefore be placed on the seam or jo...

Page 19: ...ble Variables These control the process after preselected variables have been found They control the penetration bead width bead height arc stability deposition rate and weld soundness They are Arc Voltage Welding current wire feed speed Travel speed Secondary Adjustable Variables These variables cause changes in primary adjustable variables which in turn cause the desired change in the bead forma...

Page 20: ... decreasing voltage a shorter arc is obtained with a little change in current level When changing to a different electrode wire diameter different control settings are required A thinner electrode wire needs more Wire speed to achieve the same current level A satisfactory weld cannot be obtained if the Wire speed and Voltage settings are not adjusted to suit the electrode wire diameter and the dim...

Page 21: ...ection efficiency than external angel welding For the main parameter refer to the following figure Option of C02 flow volume Welding mode Thin wire C02 welding Thick wire C02 welding Thick wire big current C02 welding C02 L min 5 15 15 25 25 50 8 WELDING PARAMETERS TABLE The option of the welding current and welding voltage directly influences the welding stability welding quality and productivity...

Page 22: ... 20 19 69 23 62 10 15 0 079 0 118 0 138 0 040 0 047 100 130 19 20 19 69 23 62 10 20 0 091 0 098 0 118 0 040 0 047 120 140 19 21 19 69 23 62 10 20 0 126 0 118 0 158 0 040 0 047 130 170 19 21 17 72 21 65 10 20 0 178 0 158 0 178 0 047 190 230 22 24 17 72 21 65 10 20 Parameter for fillet welding in the vertical position Please refer to the following figure Plate thickness t in Corn size I in Wire φ in...

Page 23: ...se will still lead to machine damage so please note 1 Ventilation High current passes when welding is carried out thus natural ventilation cannot satisfy the welding machine s cooling requirement Maintain good ventilation of the louvers of this welding machine The minimum distance between this welding machine and any other objects in or near the working area should be 30cm Good ventilation is of c...

Page 24: ...witched on 5 Clear the dust at regular intervals with clean and dry compressed air if the working condition is with heavy smoke and air pollution the welding machine should be cleaned daily 6 The compressed air should be reduced to the required pressure lest the little parts in the welding machine be damaged 7 To avoid water and rain if there is dry it in time and check the insulation with mega me...

Page 25: ...and check task of this welding equipment in case of machine fault 11 1 Power supply Part Check Remarks Control panel 1 Operation replacement and installation of Switch 2 Switch on the power and check if the power indicator is on Fan 1 Check if the fan is functioning and the sound generated is normal If the fan does not work or the sound is abnormal do inner check Power supply 1 Switch on the power...

Page 26: ...nd wire feed tube possibly leads to the unstable arc Replace it them if necessary 2 Make sure that there is no bending or elongation of wire feed tube Bending and elongation of wire feed tube possibly leads to the unstable wire feed and arc Replace it if necessary 3 Make sure that there is no dust or spatter accumulated inside the wire feed tube which makes the wire feed tub blocked If there is du...

Page 27: ...e arc 2 Check if the wire groove is blocked Replace it if necessary Pressure adjusting wheel 1 Check if the pressure adjusting wheel can rotate smoothly and it s physically complete Unstable rotation or physically incompleteness of the wheel possibly leads to unstable wire feeding and arc 11 4 Cables Part Check Remarks Torch cable 1 Check if the cable of torch is twisted The twisted torch cable le...

Page 28: ...27 12 CONNECTION DIAGRAM OF THE MACHINE ...

Page 29: ... 26 rectifier bridge 8 wire feeder motor 27 block plate 9 wire feeder support 28 main board 10 hinge 29 radiator 11 front control board 30 clapboard 12 front panel 31 radiator 13 upper plastic panel 32 fan 14 knob 33 fan support 15 downward plastic panel 34 solenoid valve 16 2 pin aviation plug 35 wire buckle 17 35 50 quick connector 36 power switch 18 base plate 37 downward plastic panel 19 insul...

Page 30: ...roceed 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 an...