Inverter Fusion 315A Bedienungsanleitung

Instruction Manual

USER MANUAL * MIGSTAR

-1-

MIGSTAR SERIES

Instruction Manual

315A

250A

Instruction Manual

USER MANUAL * MIGSTAR

-2-

________________________________________________________________

CONTENTS

GUARANTEE……………………………………………………………………………3

INTRODUCTION………………………………………………………………………..3

Equipment Identification………………………………………………………..3

WARNING……………………………………………………………………………….3

SAFETY REGULATIONS……………………………………………………………...4

HAZARDS……………………………………………………………………………….4

Fire Prevention………………………………………………………………….4

Metal Fume Hazard…………………………………………………………….5

Positioning Power Source……………………………………………………..5

Electromagnetic Field………………………………………………………….6

INSTALLATION…………………………………………………………………………6

User’s Liability and Protection…………………………………………………6

TECHNICAL DATA…………………………………………………………………….7

MODE OF OPERATION……………………………………………………………….8

Shielding Gas Connection………………………………………………..……8

Welding Wire Connection………………………………………………………8

Fitting the Welding Wire………………………………………………………..8

WELDING TECHNIQUE……………………………………………………………….9

Influence of the Welding Position………………………………………….…10

WORKING ENVIRONMENT…………………………………………………………11

MAINTENANCE……………………………………………………………………12-13

TROUBLESHOOTING………………………………………………………………..13

WARRANTY………………………………………………………………………..14-15

Instruction Manual

USER MANUAL * MIGSTAR

-3-

GUARANTEE

We give our unreserved guarantee that the Inverter Welding and Cutting Power

Source series comply with IEC60974 international safety standard.

Maintenance for one year since the date of purchase.

INTRODUCTION

This manual has been written for professional welders and should be read

carefully before using your MIGSTAR welder.

The welding machines, type MIG STAR SERIES have been developed for thin

plate welding and car body repair.

The MIG STAR SERIES are designed to normal single—phase 220-240V 35A or

three-phase 380V 20A mains supply. The welding transformer has been

dimensioned to obtain optimum welding capacities, and for a working temperature

of 150°C.

Equipment Identification

The unit's identification number (specification or part number), model, and serial

number usually appear on a nameplate attached to the control panel. Make a

record of these numbers for future reference.

WARNING

These powerful machines provide exceptional performance for welding of mild

steel and stainless steel with high reliability and easy maintenance. Do not

attempt to set up, operate or service equipment if not qualified to do so.

Contact Inverter Fusion Ltd direct for technical assistance.

Welding is a source of radiation, noise, heat and fumes, therefore the protection

of the operator and any third persons must be guaranteed with suitable safety

precautions.

Never approach the arc or hot metal; failure to adhere to these regulations could

lead to serious health risks.

Instruction Manual

USER MANUAL * MIGSTAR

-4-

SAFETY REGULATIONS

1. Operate the welding power source only on power supply with a reliable

well-protected connection point.

2. Use the welder away from flammable material.

3. Use appropriate protective clothing for your hands, eyes and body.

4. Always wear safety glasses with side shield: be aware of others in your

work area.

5. Make sure the welding cables and the main power supply are in good

condition before carrying out your work.

6. Use the welding power source only in a dry indoor location. If outdoors, use

in a place of limited exposure to sunlight and rain. Never use welding

equipment near water. Ensure that the surrounding area, including any

objects therein and the equipment, is dry

7. Make sure objects do not obstruct the fan cooling system of the welding

power source. Always keep the welder well ventilated

HAZARDS

Fire prevention

1. Keep fire extinguishers, water and sand, within easy reach.

2. Never weld or cut closed containers or pipes.

3. Never weld or cut containers or pipes (even open) containing or which

have contained substances that could give rise to explosions, humidity or

heat sources.

Metal fume hazards

Welding fumes and gases may be hazardous if inhaled for long periods of time.

1. Install a natural or forced-air ventilation system in the work area.

2. Use forced-air ventilation system when welding lead, beryllium, cadmium,

zinc, zinc-coated or painted materials and wear a protective mask.

Instruction Manual

USER MANUAL * MIGSTAR

-5-

3. Beware of gas leaks. Shield gases such as argon are denser than air, and

when used in confined spaces will replace it.

4. Store gas cylinders in a well-ventilated area.

5. Close the main valve when gas cylinder is not in use.

6. Irritation of the eyes, nose and throat are symptoms of inadequate

ventilation. Take immediate steps to improve ventilation. Do not continue

welding if symptoms persist.

Positioning & transporting the power source

1. The operator must have unobstructed access to controls and equipment

connections.

2. Do not position equipment in confined, closed spaces. Ventilation of the

power sources is extremely important. Avoid dusty or dirty locations, where

dust or other debris could be aspirated by the system.

3. Equipment (including connecting leads) must not obstruct corridors or work

activities of other personnel.

4. Position the power source securely to avoid falling or overturning

5. Bear in mind the risk of falling of equipment situated in overhead positions.

6. The power source handle or suitable sized nylon webbing may carry the

machine.

7. Always disconnect the power source and accessories from main supply

before lifting or handling operations.

8. Do not drag, pull or lift equipment by the cable

Electromagnetic Field

Before installing welding equipment the user should make an assessment of

potential electromagnetic problems in the surrounding area. The following shall be

taken into account:

1. Other supply cables, control cables, signalling and telephone cables;

above, below and adjacent to the welding equipment, radio and television

transmitters and receivers, computer and other control equipment.

2. The health of the people around, e.g. the use of pacemakers and hearing

aids.

Instruction Manual

USER MANUAL * MIGSTAR

-6-

3. The time of day that welding or other activities are to be carried out.

4. The size of the surrounding area to be considered will depend on the

structure of the building.

INSTALLATION

•Connect the ground lead as near as possible to the operating area. Earth

connections to structural parts of the building or to other places distant

from the operating area will reduce their effectiveness and increase the

danger of electric shock.

•Avoid all the direct contact between the skin or wet garments with live

metal parts. Check that gloves and protections are dry!

•Always wear gloves and rubber soled shoes when working in wet areas or

standing on metal surfaces.

•Always turn off equipment when not being used or in the event of power

failure. Accidental earth discharge may cause overheating and tire

hazards. Do not leave the machine unattended when it is turn on.

User's Liability and Protection

1. No modifications of the parts of this machine should be carried out.

2. Wear ear protectors; welding operations are often noisy and may disturb

other persons in the work area.

3. Position a fire-resistant screen or curtain around the welding area to

protect persons in the vicinity from rays, sparks and slag.

4. Compressed gas cylinders are potentially dangerous; consult the supplier

for correct handling procedures. Always protect cylinders from direct

sunlight flames, sudden temperature changes and low temperatures

TECHNICAL DATA

Instruction Manual

USER MANUAL * MIGSTAR

-7-

DATA WELDING MACHINE

250 315

Mains Supply Single Phase 50Hz / 60Hz 3 - Phase 50Hz / 60Hz

Voltage 230V AC 380V AC

Maximum Input Current 35 Amps 20 Amps

Fuse 35 Amp (Slow) 25 Amp (Slow)

Cable Cross Section 4 ~ 10mm

Permissible Loading

Duty Cycle Loading

20% 250A / 25V --

30% 189A / 23.5V --

60% 140A / 21V 315A / 29.8V

100% 100A / 19V 244A / 26.2V

Output Control

Voltage Adjustment 6 Steps 30 Steps

Open Circuit Voltage 24 ~ 45V DC 18 ~ 38 V DC

Maximum Welding

Output 250A / 25V 315A / 29.8V

Minimum Welding

Output 50A / 16.5V 70A / 17.5V

Filler Wire Dimensions 0.6 ~ 1.0 Ø mm 0.8 ~ 1.2 Ø mm

Wire Feed Speed 1 ~ 18m / min

Timer

(Spot or Stitch Welding) 0 ~ 5 sec

Static Characteristics Flat (Constant Voltage)

Physical Properties

Dimensions

(L X W X H) mm 870 X 310 X 650 950 X 380 X 730

Weight 75kg 100kg

Temperature Class F 150°C

Degree Of Protection IP21S

MODE OF OPERATION

Instruction Manual

USER MANUAL * MIGSTAR

-8-

•When the trigger at the welding handle is activated, the contactor will

couple voltage to the welding transformer, which will give a secondary

voltage decided by the position of the voltage switch.

•In the rectifier this AC voltage transformed into a DC voltage, which is

applied between welding, torch and return cable.

•At the same time the flow of protection gas and the wire feed motor are

started.

•The number of revolutions is decided by the adjustment button.

•When you lift your finger from the trigger the motor will stop and after a

short delay the contactor and the welding current are interrupted. This

delay has the effect that the welding wire will burn back a little from the

molten pool and thus does not stick to the pool.

•The electronic control can be set to the functions “continuous”, “spot” and

"stitch”.

Spot - the welding will stop after a delay that can be set by the button welding

time. Using this function you are sure of a uniform stitch welding.

Stitch - the wire feed motor will stop with stitch that can be set by the button

welding time and pause time. When you put pauses into the welding, the average

heat volume added is reduced to prevent a burning through on difficult welding

tasks.

Shielding Gas Connection

The shielding gas bottle is mounted on the machine and the regulator on the

bottle. lf the regulator is equipped with a flow meter, the flow rate is adjusted on 5-

15 litres / min.

Welding Hose Connection

The welding hose is put through the hole in the front plate and into switch on the

wire feed console. Keep the inlet nozzle as close to the wire feed roller as

possible without letting them touch each other.

Fitting the Welding Wire

Turn the tension spring aside and tip it up. Check that the wire feed roller, the wire

guide liner and the contact tip correspond to the wire diameter; the wire feed roller

is designed for one dimension. The following guide shows the recommended wire:

WIRE DIAMETER (FE.WIRE) WIRE GUIDE LINER INT. DIAMETER

Dia 0.6MM

Dia 1.0MM

Dia 1.0 –(–1.5)MM

WIRE DIAMETER (AL.WIRE)

Dia 0.8MM

Dia 1.0MM

Dia 1.5MM

Aluminium Wire

When using aluminium wire use a special guide liner where the internal liner goes

the way through the inlet nozzle. This prevents the aluminium wire from being

Instruction Manual

USER MANUAL * MIGSTAR

-9-

damaged. The reel of wire is put on the hub, and the wire is put through the wire

feed unit and some into the hose. As the wire guide liner is prone to burrs at the

point of the wire, it is important to straighten out the first 10-15cm. Unscrew

contact nozzle. Tip up the level. Set the wire speed at 6, press the start button,

the wire runs through the hose. When the wire is through the hose, stop the

machine and mount the contact nozzle. The pressure of the lever is adjusted to

allow the wire feed roller just to slide on the wire when this is stopped at the

contact nozzle.

WELDING TECHNIQUE

The setting up of a MIGSTAR SERIES welding machine demands some practice

from the welder, the machine having two control points that have to meet; the wire

feed speed and the welding voltage. The welding current is determined by the

wire feed speed, and it should correspond to the work piece. The current will

increase by wire speed, resulting in a shorter arc. Less wire speed will reduce the

current and lengthen the arc. Increasing the welding voltage hardly alters the

current intensity, but lengthens the arc. By decreasing the voltage a shorten arc is

obtained with little change in current intensity. When using CO2 as shielding gas,

increase the voltage by about 5 volts per 100 Amp. When changing the wire

diameters, different control settings are required. A thinner wire needs more

speed to acquire the same strength. A satisfactory weld cannot be obtained if

extreme values are exceeded. If the feed speed is too high for the welding

voltage, blockage will occur in the torch as the wire dips into the molten pool and

does not melt. Welding in these conditions normally gives faults due to lack of

fusion. If however, the welding voltage is too high, large drops will form on the end

of the wire, causing spatter. The correct setting of Voltage and speed can be seen

in an even and calm arc.

Influence of the welding position

The position of the torch and the work piece is important for quality and

appearance of the seam.

Instruction Manual

USER MANUAL * MIGSTAR

-10-

The diagrams below show some of the many possibilities and indicate

schematically the importance of these positions. In practice it is best to use all

combinations of welding positions, torch directions and positions of the work

piece.

Together with the figures, the diagram below may help when an estimation of

separate factors for welding quality.

The terms drawing weld and thrusting weld mean:

Drawing weld: torch sloped in direction of weld.

Thrusting weld: torch sloped away from direction of weld.

Thrusting weld Drawing Weld

Width of seam Wider Narrower

Upper bead Smaller Larger

Penetration Decrease Increase

Tendency to lack of fusion Greater Lesser

Push Weld Pulling Weld

WORKING ENVIRONMENT

1. Shielding

Measures should be taken to shield the supply cable of permanently

installed welding equipment, in metallic conduct or equivalent. Shielding

Push Weld

Sloping Downwards

Pull Weld

Sloping Downwards

Pull Weld

Sloping Upwards

Dieses Handbuch passt für folgende Modelle

Inhaltsverzeichnis

Andere Inverter Fusion Schweißsystem Handbücher

Inverter Fusion

Inverter Fusion FUSION 151 HF Bedienungsanleitung

Inverter Fusion

Inverter Fusion TIG160P Bedienungsanleitung

Inverter Fusion

Inverter Fusion PLASMA CUT 40 Bedienungsanleitung

Inverter Fusion

Inverter Fusion i-tech mig350 Bedienungsanleitung

Inverter Fusion

Inverter Fusion i-TECH MIG150 Bedienungsanleitung

Inverter Fusion

Inverter Fusion MMA 250 Bedienungsanleitung

Inverter Fusion

Inverter Fusion i-TECH AC/DC 250 Bedienungsanleitung

Inverter Fusion

Inverter Fusion i-TECH CUT6 Bedienungsanleitung

Inverter Fusion

Inverter Fusion i-TECH MIG250 Bedienungsanleitung

Beliebte Schweißsystem Handbücher anderer Marken

Berner

Berner PLASMACUT 54 Bedienungsanleitung

Pro Spot

Pro Spot PR-155 Bedienungsanleitung

Forney

Forney 210 Bedienungsanleitung

Thermal Arc

Thermal Arc 400S Bedienungsanleitung

Lincoln Electric

Lincoln Electric HANDYMIG 170I Bedienungsanleitung

GYS

GYS PROTIG 201 AC/DC Bedienungsanleitung

TAFA

TAFA 30*8B35 Bedienungsanleitung

Lincoln Electric

Lincoln Electric INVERTEC V350-PRO CE Bedienungsanleitung

ESAB

ESAB Buddy Arc 145 Bedienungsanleitung

CIGWELD

CIGWELD 636804 Kurzanleitung

Red-D-Arc

Red-D-Arc DC-400 Bedienungsanleitung

Hobart Welding Products

Hobart Welding Products Spool Gun DP 3035-10 Bedienungsanleitung

Elettro

Elettro HI-MIG 3000 SYNERGIC Bedienungsanleitung

WIA

WIA Weldmatic 270 CP132-2 Bedienungsanleitung

Sonics

Sonics H520T Bedienungsanleitung

Miller

Miller Big Blue 400D Bedienungsanleitung

NewArc

NewArc RT2000 Kurzanleitung

Hypertherm

Hypertherm powermax1000 Bedienungsanleitung