Operating Instructionsand Spare Parts Manual

MMA Welding Machine

Expressweld Inverter 200-E

Phase

www.askaynak.com.tr

General Safety Instruction 1 - 6

Genaral Specification 7 - 10 Description 7 Unpacking 7 Packing contents 7 Machine controls and operation 8 Installation 9 Extention cord 9 Welding operation 9 Troubleshooting 10 Maintanance 10 Storage 10 Transportage 10

Electrical Circuit Diagram 11

Spare Parts 12 - 13

Contents

Please read and save these instructions. Read through this owner’s manual carefully before using product. Protect yourself and others by observing all safety information, warnings, and cautions. Failure to comply with instructions could result in personal injury and/or damage to product or property. Please retain instructions for future reference.

General Safety Information

1.1 Welding Environment-Keeptheenvironmentyouwillbeweldinginfreefromflammablematerials.-Alwayskeepafireextinguisheraccessibletoyourweldingenvironment.-Alwayshaveaqualifiedpersoninstallandoperatethisequipment.- Make sure the area is clean, dry and ventilated. Do not operate the welder

in humid, wet or poorly ventilated areas.-Alwayshaveyourweldermaintainedbyaqualifiedtechnicianinaccordance

with local, state and national codes.- Always be aware of your work environment. Be sure to keep other people,

especially children, away from you while welding.- Keep harmful arc rays shielded from the view of others.- Mount the welder on a secure bench or cart that will keep the welder secure

and prevent it from tipping over or falling.

1.2 Welder’s Condition- Check ground cable, power cord and welding cable to be sure the insulation

is not damaged. Always replace or repair damaged components before using the welder.

- Check all components to ensure they are clean and in good operating condition before use.

1.3 Use of WelderDo not operate the welder if the output cable, electrode, MIG gun, wire or wire feed system is wet. Do not immerse them in water. These components and the welder must be completely dry before attempting to use them.

GENERAL SAFETY INSTRUCTION

GENERAL SAFETY INSTRUCTION

- Follow the instructions in this manual.-Keepwelderintheoffpositionwhennotinuse.- Connect ground lead as close to the area being welded as possible to

ensure a good ground.- Do not allow any body part to come in contact with the welding wire if you

are in contact with the material being welded, ground or electrode from another welder.

- Do not weld if you are in an awkward position. Always have a secure stance while welding to prevent accidents. Wear a safety harness if working above ground.

- Do not drape cables over or around your body.- Wear a full coverage helmet with appropriate shade (see ANSI Z87.1 safety

standard) and safety glasses while welding.- Wear proper gloves and protective clothing to prevent your skin from being

exposed to hot metals, UV and IR rays.- Do not overuse or overheat your welder. Allow proper cooling time between

duty cycles.-Keephandsandfingersawayfrommovingpartsandstayawayfromthe

drive rolls.- Do not point MIG gun at any body part of yourself or anyone else.- Always use this welder in the rated duty cycle to prevent excessive heat

and failure.

GENERAL SAFETY INSTRUCTION

Specific Areas of Danger, Caution or Warning

Electrical Shock

Electric arc welders can produce a shock that can cause injury or death. Touching electrically live parts can cause fatal shocks and severe burns. While welding, all metal components connected to the wire are electrically hot. Poor ground connections are a hazard, so secure the ground lead before welding.- Wear dry protective apparel: coat, shirt, gloves and insulated

footwear.- Insulate yourself from the work piece. Avoid contacting the

work piece or ground.- Do not attempt to repair or maintain the welder while the power

is on.- Inspect all cables and cords for any exposed wire and replace

immediately if found.- Use only recommended replacement cables and cords.- Always attach ground clamp to the work piece or work table as

close to the weld area as possible.- Do not touch the welding wire and the ground or grounded work

piece at the same time.- Do not use a welder to thaw frozen pipes.

Fumes and Gases- Fumes emitted from the welding process displace clean air and

can result in injury or death.- Do not breathe in fumes emitted by the welding process. Make

sure your breathing air is clean and safe.- Work only in a well-ventilated area or use a ventilation device to

remove welding fumes from the environment where you will be working.

- Do not weld on coated materials (galvanized, cadmium plated

GENERAL SAFETY INSTRUCTION

or containing zinc, mercury or barium). They will emit harmful fumes that are dangerous to breathe.

If necessary use a ventilator, respirator with air supply or remove the coating from the material in the weld area.

- The fumes emitted from some metals when heated are extremely toxic. Refer to the material safety data sheet for the manufacturer’s instructions.

- Do not weld near materials that will emit toxic fumes when heated. Vapors from cleaners, sprays and degreasers can be highly toxic when heated.

UV and IR Arc RaysThe welding arc produces ultraviolet (UV) and infrared (IR) rays that can cause injury to your eyes and skin. Do not look at the welding arc without proper eye protection.- Always use a helmet that covers your full face from the neck to

top of head and to the back of each ear.- Use a lens that meets ANSI standards and safety glasses. For

welders under 160 Amps output, use a shade 10 lens; for above 160 Amps, use a shade 12. Refer to the ANSI standard Z87.1 for more information.

- Cover all bare skin areas exposed to the arc with protective clothing and shoes. Flame-retardant cloth or leather shirts, coats, pants or coveralls are available for protection.

- Use screens or other barriers to protect other people from the arc rays emitted from your welding.

- Warn people in your welding area when you are going to strike an arc so theycan protect themselves.

Fire Hazards- Do not weld on containers or pipes that contain or have had flammable, gaseous or liquid combustibles in them. Weldingcreatessparksandheatthatcanigniteflammableandexplosivematerials.

GENERAL SAFETY INSTRUCTION

- Donotoperateanyelectricarcwelderinareaswhereflammableor explosive materials are present.

- Removeallflammablematerialswithin35feetoftheweldingarc.Ifremovalisnotpossible,tightlycoverthemwithfireproofcovers.

- Takeprecautionstoensurethatflyingsparksdonotcausefiresor explosions in hidden areas, cracks or areas you cannot see.

- Keepafireextinguishercloseinthecaseoffire.- Weargarments thatareoil-freewithnopocketsorcuffsthat

will collect sparks.- Do not have on your person any items that are combustible,

such as lighters or matches.- Keep work lead connected as close to the weld area as possible

to prevent any unknown, unintended paths of electrical current fromcausingelectricalshockandfirehazards.

- Wear protective apparel at all times: ANSI-approved safety glasses or shield, welder’s hat and ear plugs to keep sparks out of ears and hair.

Hot Materials Welded materials are hot and can cause severe burns if handled improperly.- Do not touch welded materials with bare hands.

Electromagnetic Field - Electromagneticfieldscaninterferewithvariouselectricaland

electronic devices such as pacemakers.- Consult your doctor before using any electric arc welder or

cutting device- Keep people with pacemakers away from your welding area

when welding.- Do not wrap cable around your body while welding.

GENERAL SAFETY INSTRUCTION

- Wrap MIG gun and ground cable together whenever possible.- Keep MIG gun and ground cables on the same side of your body.

Shielding Gas Cylinders Can Explode High pressure cylinders can explode if damaged, so treat them carefully.- Never expose cylinders to high heat, sparks, open flames,

mechanical shocks or arcs.- Do not touch cylinder with MIG gun.- Do not weld on the cylinder.- Always secure cylinder upright to a cart or stationary object.- Keep cylinders away from welding or electrical circuits.- Usetheproperregulators,gashoseandfittingsforthespecific

application.- Do not look into the valve when opening it.- Use protective cylinder cap whenever possible.

Proper Care, Maintenance and Repair- Always have power disconnected when working on internal

components.- Do not touch or handle PC board without being properly

grounded with a wrist strap. Put PC board in static proof bag to move or ship.

- Donotputhandsorfingersnearmovingpartssuchasdriverollsand fan.

DescriptionExpressweld Inverter 200-E is a DC type MMA welder. This unit uses 1~Phase 220 V, 50/60HZ AC power. 16 amp time delay fuse or circuit breaker isrecommended.

-MachinehasagoodweldingperformancewithAWS6013andAWS7018electrodes.

- Machine is designed to avoid water getting inside the machine. Protection degree is IP21S.

- Machine has a dropping (CC) welding characteristics.- Machine is equipped with voltage protection. It stops the operation at

overvoltage and low voltage conditions.

UnpackingRemove cartons, bags or Styrofoam containing the welder and accessories. After unpacking unit, inspect carefully for any damage that may have occurred during transit. Check for loose, missing, or damaged parts. Shipping damage claimmustbefiledwithcarrier.

Packing contents

GENERAL SPECIFICATION

InputInput Voltage Input Power Frequency

220 V ± % 10 ~ 1 Ph 8,36kVA@maximumoutput 50/60Hertz(Hz)

Duty Cycle (10 minutes period) Output Current (Amp.) Output Voltag (Volt.)

% 16 180 A 27,2 V

% 60 95A 23,8V

Height Width Length Weight

290 mm 150mm 380mm 6,5kg

Phisical Properties

Welding Current Range Maximum Open Circuit Voltage

30-180A 68 V DC

Output Range

Welding Current - Output Rating

Operating Temperature : Between - 10°C and + 40°C

Power Factor (cos j) : 0.70

Fuse Size and Type : 16 Amp. (delayed)

• DC Inverter Arc Welder 1 unit• Welding cable with electrode holder 1pc

• Grounding cable with earth clamp 1pc• Operator’s Manual 1set

Machine controls and operation

1- WELDING MODE SELECTION MMA or LIFT TIG welding mode can be selected from this knob.

2- POWER INDICATOR When the machine is turned on, the power indicator will be on.

3-ALARMINDICATOR When the thermal indicator is on, it shows the machine is overloaded and

theinternaltemperatureistoohigh.Weldoutputwillturnoffautomaticallybut the fan will still be working. When the internal temperature is decreased, theoverloadlightwillturnoffandthemachinewillbereadytoweld.

4- WELDING CURRENT ADJUSTMENT This knob is used for adjusting welding current.

5-WELDINGCABLECONNECTORS Connect the cables to appropriate sockets.

6- POWER SWITCH In the “OFF” position no power is being supplied. In the “ON” position power

is supplied to the main transformer and control circuit.

7- POWER CORD The power cord is included with a 16 A receptacle.

GENERAL SPECIFICATION

6

7

2

3

4

5

1

InstallationExpressweld Inverter 200-E is a Class A arc welder.The class A equipment is not intended for use in residential locations where the electrical power is provided by the public low voltage supply system.High voltage danger from power source! Consult a qualified electrician forproper installation of receptacle. This welder must be grounded while in use to protect the operator from electrical shock.Do not remove grounding connection or alter the plug in any way. Do not use any adapters between the welder’s power cord and the power source receptacle. Make sure the POWER switch is OFF when connecting your welder’s powercord toaproperlygrounded220VAC,50/60Hz,singlephase,16ampfuse protected power source.

Extension cordDuring normal use an extension cord is not necessary. It is strongly recommended that an extension cord should not be used because of the voltage drop they produce. This drop in voltage can affect the performance of thewelder adsafety requirements. The adequate cord size can change according to the length. Please contact to an authorized electrical technician for proper size of extrension cord.

Welding operation1- Insert electrode to electrode holder.2- Plug the machine to adequate single phase power supply.3-Performthementionedcontrolsbeforestartingoperation:

3.1-Makesuremachineissafelygrounded.

3.2-SelecttheweldingmodeasMMAorLiftTIG.

3.3-Make sure that electrode holder, earth clamp or torch connections are donesecurely.

Note: This machine doesn’t include a tig welding torch

3.4-CheckthepolarityoftheweldingcableaccordingtotheelectrodetypeinMMAwelding. Lift TIG welding is mostly done in DC- polarity.

3.5-IfLiftTIGweldingisselected,connectthegashosetothegasregulatoronthegas cylinder.

3.6-Check the enviroment for any unsafe conditions. Don’t start welding untilenviroment is totally safe.

GENERAL SPECIFICATION

GENERAL SPECIFICATION

4- Switch on the machine.5-SettheweldingcurrentRecommended welding current for rutile and basic electrodes:2,5mm:70-140A 3,2mm:100-140A

Troubleshooting

MaintananceClean dust, dirt, grease, etc. from your welder. Every six months, or as necessary, remove the cover panel from the welder and air-blow any dust and dirt that may have accumulated inside the welder. Replace power cord, ground cable, ground or electrode clamp if damaged. Avoid water or any liquid getting inside the machine.

StorageStore in a clean dry facility free from corrosive gas, excess dust and high humidity.

TransportageWhen transporting or storing the welder after use, it is recommended to repack the product as it was received for protection. Cleaning is required before the

Trouble Possible Error Solution

Voltage is too high/lowSwitchoffpowersourcecheckthe mains supply.

Yellow indicator is on

OverheatWait until the machine cools down. It will recover when the temperature is low enough.

Cooling fan is not workingFan is broken Contact to service.

There is no electricity. Check the connections, cables.

Machine doesn’t weld.

Welding current is improper. Set the welding current in accordance with the electrode diameter.

Connections are poor. Check all the connections and tighten if loose.

ELECTRICAL CIRCUIT DIAGRAM

12

12

SW1 L1

C7

AC1

AC2

12

34B1

220V

~240

VA

CC8

C17

C16

YM

1

AC1

AC2

C4

D11

R17

G

C E

T1

G

C E

T4

6 7

45 12

ZBY

Q1

EART

H

+ 1- 2O 3

G 4

HE1

22

3R9C2

3R12

C10

C1 C11

L2

C3 C12

R7 R13

R15

R14

R8 R11

TR1

35 4 1

2J1

21 3

4

D1

21 3

4

D2

21 3

4D

6

21 3

4D

8

VCC

R16

G

C E

T2G

C E

T3

G

C E

T5 G

C E

T6

R3R2

R1

R18

R19

R20G1

E1

G2E2

G1

G2

E1

E2

OHT1

GND

+24V

CS1

CS2

V+V-

-15V+15V

IFB

MM

A

IP-1

O.C

OHT2

VCC

SGND

J1+

OHT

FAN

O.C

1

VCC-1

CA

RiA

RC-

W Z

KB

G1

G2

E1E2

12CN2

1 2

3

FAN FAN1

+ -

NTC

1

VC

C

D3

D5

D4

D9

D10

D7

123

CN4

123

CN5

12

CN3

C5

C6 C13

AC1

AC2

+3

-4

Z2

+15V

1 2 3 4 5 6 7 82CN

1

CA

RiA

RC-

W M

B

NTC

2

1234

CN20

1

12345678

CN6

IFB

AC1

AC2

+3

-4

Z1

C14

3R10

product as it was received for protection. Cleaning is required before storage and you must seal the plastic bag in the box for storage.

SPARE PARTS

No ASKAYNAK PART NUMBER DESCRIPTION Qty

1 8220505134 Handle 1

2 821101010709 Case 1

3 8220751710 Amorphous magnetic ring and base 1

4 8220733630 IGBT 4

5 821105020469 Main PCB 1

6 8220505132 Front Plastic panel 1

7 8220711016 Pontetiometer Knob 1

8 8220429003 Waterproof cap 1

9 821208010517 Welding cable with electrode holder 1

10 821208020489 Grounding cable with earth clamp 1

11 8220757972 Quick connector 2

12 821105070095 Small PCB 1

13 821101052902 Outputfixboard 1

14 8220725952 Medium frequency transformer 1

15 8220512121 Right wind screen 1

16 821101041336 Bottom 1

17 821207023730 NTC resistance-II 1

18 8220743917 Fast recovery radiator 1

19 8220512122 Left wind screen 1

20 8220743918 IGBT radiator 2

21 821207023701 NTC resistance-I 1

22 821207022713 FAN 1

23 8220505133 Rear plastic panel 1

24 821207012612 Power cord 1

25 8220780001 Switch 1

26 8220737563 Singlerectifierbridge 2

SPARE PARTS

MANUFACTURER;Kaynak Tekniği Sanayi ve Ticaret A.Ş.TOSBOtomotivYanSanayiİhtisasOrganizeSanayiBölgesi2.Cadde,No:5,Şekerpınar41420Çayırova-KOCAELİ-TURKEYTel: (+90.262) 679 78 00 Fax: (+90.262) 679 77 00

info@askaynak.com.trwww.askaynak.com.tr MADE IN CHINA