This document is an operator's manual for iBELL MMA (Manual Metal Arc) welding machines, specifically covering models IBL M200-89, IBL M200-77, IBL M220-76, IBL M220-78, IBL M250-103, and IBL M250-104. The manual provides essential information for safe installation, operation, maintenance, and troubleshooting of these welding machines.
Function Description
iBELL welding machines are designed for Manual Metal Arc Welding (MMA), a process where a consumable, flux-covered electrode and a ground clamp are used to create a short-circuit on the weld piece. An electric arc forms between the electrode and the workpiece, generating heat that melts both. As the electrode melts, the flux coating produces gas and slag, which protect the weld pool from air and other pollutants. The slag then cools and solidifies, protecting the weld seam. These machines utilize high-performance IGBT (Insulated Gate Bipolar Transistor) Technology, which provides power suitable for various welding processes.
Important Technical Specifications
The iBELL welding machines operate on a 220V±15% input power supply with a frequency of 50/60Hz.
Key specifications vary by model:
- Input Capacity (KVA): Ranges from 6.1 KVA (M200-89, M200-77) to 10.8 KVA (M250-103).
- Input Current (A): Ranges from 28A (M200-89, M200-77) to 49A (M250-103).
- No Load Voltage (V): Ranges from 45V to 48V.
- Current Range@100%: Varies from 20-140A (M200-89, M200-77, M250-103) to 30-220A (M250-104).
- Max Current (A): Ranges from 200A (M200-89, M200-77, M250-103) to 250A (M250-104).
- Efficiency (%): All models boast an 85% efficiency.
- Usable Electrodes (mm): All models can use electrodes from 1 to 4mm, with some (M220-76, M250-103, M250-104) extending to 1 to 5mm. The M220-78 model supports 1.6 to 4mm.
- Hot Start: Built-in on all models.
- Anti-Stick: Built-in on all models.
- ARC Force: Built-in on M200-89, M200-77, M220-78, and M250-103. Adjustable on M220-76 and M250-104.
- Power Boost: Available on M250-103.
- Advanced IGBT Technology: Present in all models.
- Voltage Compensation: Present in all models.
- VRD (Voltage Reduction Device): Built-in on all models, and adjustable on M220-78.
- Thermal Protection: Present in all models.
- Insulation Class: F for most models, H for M220-76 and M220-78.
- Protection Class: IP21S for all models.
- Cooling: All models feature a Smart Fan.
- Power Socket Amp Required: 32A for all models.
- Continuous Welding @100%: Ranges from 140A (M200-89, M200-77) to 220A (M250-104).
- Continuous Welding Electrode Gauge: Ranges from 6 (M250-104) to 10 (M200-89, M200-77).
- Maximum Electrode Cable Length (100% Efficiency): 20M for all models, with current proportionally reducing as cable length increases.
- Generator (KW) Required: Ranges from 5 KW (M200-89, M200-77) to 5.8 KW (M220-76, M250-103, M250-104, M220-78).
Usage Features
The iBELL welding machines are designed for user-friendly operation with several control and operational features:
- Current Adjusting Knob: A potentiometer used to set the output current during welding.
- Digital Display: Shows the present welding current before and during welding.
- Power Indicator (Green LED): Lights up when the machine is ON and ready for operation.
- Heat Indicator (LED): Illuminates when the machine overheats and disables output, typically due to exceeding the duty cycle. It turns OFF when components cool down, allowing normal operation to resume.
- QC Indicator (LED): Turns on when the machine is overheated/overloaded.
- Quick Connector Sockets (+ and -): For connecting the electrode holder and earth cable, respectively. Connections should be tightened clockwise.
- On-off Switch: Controls the power to the machine.
- Power Cord Anchorage: Secures the power cord.
- Smart Fan: A circuitry that activates only when cooling is required, reducing dirt intake and power consumption. It runs continuously during welding.
- Arc Force Regulator (M220-76 & M250-104): Temporarily increases output current when the arc is too short, improving simple position welding. It can be finely adjusted for optimal weld performance across various electrodes.
- Hot Start Regulator (M250-104): Provides excellent arc ignition without electrode sticking, preventing metallurgical defects.
- Anti-sticking (Inbuilt): Minimizes short-circuit current if the electrode sticks to the workpiece, making it easy to remove the electrode and preventing damage to the electrode gun and cable. It also acts as a safety device for the operator.
- VRD (Voltage Reduction Device) (Inbuilt): An additional safety measure, especially in high-risk electrical shock environments (wet, humid, sweaty conditions). It reduces the welding power source's open circuit voltage (OCV).
- Power Boost Button (M250-103): Increases output current by up to 40% for using 4 or 5 mm electrodes.
- Multi Metal Capability (M220-78): Allows welding of Zinc, Carbon steel, Copper, Iron, and Aluminium.
General Operation Guidelines:
- Unpacking and Setup: Ensure the equipment is undamaged during transport. Place the unit on a horizontal, solid, and clean surface, shielded from rain and sun, ensuring free air circulation. The product must be fully assembled before operation and connected to the correct voltage class of the distribution box.
- Connections: Connect welding tongs (grounding clamp and electrode holder) correctly. The electrode holder connects to the "+" quick socket, and the grounding clamp to the "-" quick socket. Ensure all connections are tight to prevent voltage drop and overheating.
- Power On: Turn the power switch to "ON." The cooling fan should start, and the power LED will light up.
- Electrode and Workpiece: Clamp the welding rod on the electrode holder. Fix the earth cable clamp directly on the welding piece, ensuring a clean contact surface free of paint and rust.
- Current Selection: Select suitable welding current based on workpiece thickness, electrode diameter, welding position, and technology needs. Too high current can cause splashing and poor weld formation; too low current can cause sticking and uneven drop transfer.
- Priming the Arc (for beginners): Test current intensity on scrap material. Hold the electrode 2 cm above the joint, touch the workpiece, and stroke it repeatedly to start the arc. Remove with a firm lateral jerk.
- Arc Length: Maintain arc length at approximately 1-1.5 times the electrode diameter. Incorrect arc length affects welding current and voltage, leading to spatter, low deposition rates, undercuts, or porosity.
- Angle of Travel: Hold the rod perpendicular to the joint, tilting the top 5-15° in the direction of travel. For vertical up welding, tilt the rod 15° away from the direction of travel.
- Speed of Travel: Adjust travel speed to produce a weld bead with the desired contour and appearance. Keep the arc within the leading one-third of the weld pool. Slow speeds result in wide, convex beads with shallow penetration; high speeds lead to narrow, crowned beads and undercuts.
- Manipulation: Develop a unique style. For thinner materials (1/4 inch or less), straight-ahead travel is often sufficient. For wider beads on thicker materials, manipulate the electrode in overlapping circles or a Z-shaped, semi-circle, or stutter-step pattern. Limit side-to-side motion to 2.5 times the electrode core diameter.
- Slag Removal: Wait until the joint has cooled completely before removing slag. If continuing welding after a break, remove slag from the end of the previous weld first.
Maintenance Features
All maintenance work must be performed with the power plug disconnected.
- Dust Removal: Regularly remove dust from the welding machine using dry compressed air, especially in heavy fume and polluted environments (at least once a month). Ensure compressed air pressure is appropriate to avoid damaging internal components.
- Moisture Prevention: Prevent water or moisture from entering the machine. If it does, dry it immediately and measure insulation resistance before use.
- Storage: Store the equipment and accessories out of children's reach in a dark, dry place at temperatures between 5°C and 30°C, preferably in its original packaging.
- Routine Checks: Regularly inspect and maintain the power control switch, grounding device, welding electrode holder, coupling device, and set screws.
- Insulation Resistance: Measure the welder's insulation resistance periodically.
- Repairs: All repairs should be carried out by qualified personnel using original spare parts to ensure safety.
Troubleshooting:
The manual provides a troubleshooting guide for common issues, emphasizing that these operations should be performed by qualified electricians.
- Meter doesn't display, fan doesn't work, no welding output: Check if the power switch is OFF, if the power source connection to the input cable is working, and if the input voltage is 3 phase.
- Meter is normal, fan is working, no welding output: Check for broken or damaged output terminal connectors or a damaged control board.
- QC indicator is ON, fan is working, meter is normal: Indicates potential damage to IGBT, rectifier of quick recovery, control board, or a fault in the feedback circuit.
- Too much spatter: Output terminal polarity connection might be wrong; change the polarity.
- Erratic welding output current or out of control of potentiometer: Potentiometer might be damaged, or connectors (especially plugs) have poor contact.
- Power switch doesn't work: Power switch is broken, three-phase rectifier bridge is broken (replace it), or there is a short circuit inside the machine.
Environmental Responsibility:
The manual also includes a directive for responsible disposal of electrical products, encouraging recycling and not disposing of them with household waste.
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