Genesis 200 MIX AC/DC

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Overview

Function Description
Important Technical Specifications
Usage Features
Maintenance Features

The BLUEARC GENESIS 200 MIX AC/DC Welding Machine is a versatile inverter-based welding device designed for both manual metal arc (MMA) and gas tungsten arc welding (GTAW), commonly known as TIG welding. It utilizes advanced PWM technology (pulse width modulation) and IGBT modules (bipolar transistors with an insulated gate) to provide stable and efficient welding performance. The device is capable of performing AC/DC TIG welding, including MIX TIG, and MMA welding, making it suitable for a wide range of materials and applications.

Function Description:

The BLUEARC GENESIS 200 MIX AC/DC offers multiple welding modes and adjustable parameters to cater to various welding needs.

MMA Mode: This mode is used for manual welding by direct current and alternating current using Manual Metal Arc (MMA) electrodes. It provides features like Hot Start and Arc Force.
- Hot Start & Arc Force: These features adjust the dynamics of the MMA welding arc. Hot Start shortens the arc length, increasing current to prevent sticking. Arc Force increases current to ensure deeper penetration and prevent short-circuiting, especially with long arc lengths and high melting rate electrodes.
TIG Mode (Lift TIG and HF TIG): This mode is for Gas Tungsten Arc Welding (GTAW).
- DC TIG: Suitable for welding most metals except aluminum, magnesium, and their alloys.
- AC TIG: Generally suitable for acid electrodes and for reducing arc blow. Specifically used for welding aluminum, magnesium, and their alloys.
- MIX TIG: This mode combines AC and DC output, offering a balance between penetration and arc concentration. It is particularly suitable for aluminum, magnesium, and their alloys, aiming to minimize tungsten loss and achieve deep penetration with a neat corrugated weld. The MIX frequency and MIX ratio are adjustable to control weld corrugation and penetration depth.
Pulse Welding: The device supports pulse welding, which allows for precise control of heat input, making it ideal for welding thin plates and materials prone to deformation. Pulse frequency and duty cycle are adjustable.
2T/4T/SPOT Operation: These modes define the torch trigger behavior.
- 2T (Two-Touch): Press and hold the trigger to start welding; release to stop.
- 4T (Four-Touch): Press and release to start, press and release again to stop. This mode is useful for longer welds, reducing operator fatigue.
- SPOT: Used for spot welding, where welding time is limited to a set duration. It's particularly effective for thin plates and materials sensitive to heat input.
Remote Control: The device supports remote amperage control via a foot pedal or digital welding torch, allowing for adjustments without returning to the machine.
VRD (Voltage Reduction Device): This safety feature reduces the open circuit voltage to less than 15V when the machine is idle, minimizing the risk of electric shock, especially in damp or enclosed environments.

Important Technical Specifications:

Input Voltage (V): 1220V-240V+1110-120V
Frequency (Hz): 50/60
Power Capacity (KVA): 7.1
Max Input Current (A): 43
No-load Voltage (V): 74V (230V), 70V (110V)
Rated Duty Cycle (%): 60
TIG/MMA Current range (A): 5~200 / 20~180
ARC Force Current range (%): 0-100
Hot Start range (%): 0-100
DC Pulse MMA:
- Base Current (%): 10-100
- Pulse Frequency (Hz): 0.2-500
- Duty Cycle (%): 5-95 (>200Hz Duty 50%)
AC MMA Frequency (Hz): 20~250 (Duty 50%)
Sync AC/DC MMA Electrode Dia (mm): 1.6, 2.0, 2.5, 3.2, 4.0
- Offset Current (A): ±20A
Pulse TIG Frequency (Hz): 0.2-500
Pulse TIG Duty (%): 5-95 (>200Hz Duty 50%)
Sync TIG Offset Current (A): ±35A
Base Current (%): 10-100
Initial / Final Current (%): 10-100
Up / Down Slope Time (S): 0.0-15.0
Pre / Post Flow Time (S): 0.1~15.0 / 0.5~15.0
Spot / Dead (Interval) Time (S): 0.1~15.0 / 0.0~15.0
TIG Tungsten Dia (mm): 1.0, 1.6, 2.0, 2.4, 3.2
AC TIG:
- Frequency (Hz): 20~250
- Balance (%): Sync Set ±10% Adjust
MIX TIG:
- Frequency (Hz): 0.5-20
- Ratio: 5-95
Efficiency (%): 85
Power Factor: 0.93
Protection Class (S): IP23
Insulation Class: F
Dimension (mm): 400150230
Weight (Kgs): 10

Usage Features:

User-Friendly Interface: The front panel features a digital display and intuitive controls for setting welding parameters. Dedicated buttons for MODE, POLAR, PULSE, OPER, MEMORY, and SYNC simplify operation.
Parameter Adjustment: Users can adjust various parameters such as current, time, pulse frequency, duty cycle, upslope/downslope time, pre/post flow time, AC balance, and MIX TIG frequency/ratio.
Memory Function: The device allows saving and loading up to 10 sets of welding parameters (CH0-CH9), which is convenient for frequently used settings.
SYNC Function: This feature automatically adjusts welding current values based on the selected electrode diameter, simplifying setup for MMA welding. Manual adjustment is also available for fine-tuning.
Error Codes: The display shows error codes (E01, E02, E03, E06) to indicate specific issues like overcurrent, overheating, temperature sensor failure, or undervoltage, aiding in troubleshooting.
Factory Reset: Welding parameters can be restored to their default factory settings by pressing and holding specific buttons.
Connectivity: The machine includes negative and positive polarization sockets, a gas connector, a remote socket, and a ground terminal.
Portability: With a weight of 10 kg and compact dimensions, the device is relatively portable.

Maintenance Features:

Regular Cleaning: The device should be kept clean and free from dust and metal filings to prevent electrical short circuits and damage. Periodic cleaning with compressed air is recommended.
Consumable Replacement: Regularly replace consumable parts such as contact tips, nozzles, liners (MIG), collets, cups, back caps, torch bodies (TIG), drive rolls, contactors, and electrode holders.
Electrical Connection Checks: Periodically inspect external connections, wires, and electric cables. A general review of electrical connections should be done at least every six months, focusing on protection against electric shock, insulation condition, security system status, and cooling system operation.
Environmental Considerations: The device should be operated in an atmosphere free from corrosive ingredients and high levels of dust. Avoid high humidity and condensation. If used outdoors, it should be placed under a roof to protect it from adverse weather.
Storage and Transport: Store the device at -10 °C to +40 °C with relative humidity up to 80%, free from corrosive fumes and dust. During transport, the packaged device should be secured against shifting.
Troubleshooting Guide: The manual provides a comprehensive troubleshooting guide for common issues, including solutions for control panel problems, unsatisfactory weld quality, and arc ignition issues.
Warranty: The device comes with a 1-year limited warranty covering solenoid valves, PC boards, controls, gas valves, drive motors, and drive systems, including parts and labor performed by authorized repair centers. Normal wear items are not covered.