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02/2022

IM 240-i

Operation Manual REV 1.0

MIG-MAG Welding Inverter

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Summary of Contents for IM 240-i

Page 1: ...02 2022 IM 240 i Operation Manual REV 1 0 MIG MAG Welding Inverter ...

Page 2: ...PREPARATION 8 2 8 CONNECTING THE PRESSURE BOTTLE 8 2 9 CONNECTING THE RETURN CABLE 8 3 SAFETY AND FIRE INSTRUCTION 9 3 1 PROTECTION 9 3 2 REMOVING THE FIRE HAZARD 9 3 3 HANDLING THE PRESSURE BOTTLES 10 3 4 PROTECTION AGAINST ELECTRICAL ACCIDENTS 10 3 5 EXTRAORDINARY MENACE DURING WELDING 11 4 WELDING PROCESSES 12 4 1 MIG MAG WELDING 12 4 2 WELDING POSITIONS 15 5 OPERATION 16 5 1 TURNING THE DEVICE...

Page 3: ... MAINTENANCE 19 6 1 DISPOSAL OFT THE MACHINE 19 7 TECHNICAL DATA 20 8 AVERAGE CONSUMPTION VALUES FOR WELDING 21 8 1 AVERAGE WELDING WIRE CONSUMPTION FOR MIG MAG WELDING 21 8 2 AVERAGE SHIELDING GAS CONSUMPTION FOR MIG MAG WELDING 22 9 TROUBLESHOOTING 23 10 DISTRIBUTORS WORLDWIDE 25 11 EU DECLARATION OF CONFORMITY 26 ...

Page 4: ...nger resulted from welding and follow the safety and fire instructions see the Part 7 It is necessary to keep the device on a dry place to protect device against moisture It is not advisable to use the device on the open air during rain 2 SETUP 2 1 Setup conditions It s necessary to set the device for welding in protection atmosphere on a dry place with the sufficient area for cooling The device i...

Page 5: ... certified plug according national standard 230V Supply 110V Supply Net Wire color Net Wire color L Brown L1 Brown N Blue L2 Blue PE Yellow Green PE Yellow Green 2 4MIG MAG torch For torch connecting is used EURO Standard torch connector Please tighten the connector well to eliminate the conduction losses A loose connection can cause damage of the machine and torch Never use damaged torch Make sur...

Page 6: ...other metals a tube of wear resistant plastic for example Teflon is used Plastic guides have a lower friction coefficient than steel Material Wire diameter Liner material Liner color 0 6mm Steel spiral Fe 0 8mm or Teflon 1 0mm Inox 0 8mm Teflon 1 0mm AlMg AlSi 0 8mm Teflon 1 0mm CuSi3 0 8mm Teflon 1 0mm CuAl8 0 8mm Teflon 1 0mm Liner color Blue Art N 337139 Red Art N 337142 Black Art N 337147 Gree...

Page 7: ...sed welding wire Material Shape Diameter Article Number Fe Inox CuSi CuAl 0 6 0 8mm 0 8 1 0mm 337219 337220 AlMg AlSi 0 8 1 0mm xxx When the feeding wheel is set up you can see on the front side of the wheel the assigned welding wire diameter value is in mm Feeding rolls Fixing point Pressure adjustment ...

Page 8: ...der that the gas flows away from your body Screw a reduction valve on the pressure bottle Connect a hose to the MIG MAG welding device reduction valve The recommended gas flow is 8 15 liter minute in a room without draft If you use an adjustable reduction valve you can adjust a gas flow with a toggle nut with a liter scale The device must be turned on and gas check function activated the welding b...

Page 9: ...4647 standard depending on used current Do not look into an electric arc with unprotected eyes you can go blind or you can burn Invisible U V radiation causes a very painful eye conjunctiva inflammation without eyes protection which rises even after couple of hours Weld nearby the other persons which are able to help you fast in a case of emergency The persons or assistants present nearby an elect...

Page 10: ...nies 3 4 Protection against electrical accidents It s not allowed to carry the torch under armpit or to hold it in such way that a current could flow through human body The device must be switched off during the longer breaks When the welding is finished and before moving the device must be un plugged from the power supply It is necessary to cut immediately off the power supply in a case of accide...

Page 11: ... followed in this areas It s not allowed to weld in tanks for gas fuel oil paint etc even if they are empty for a long time The remnant of content could cause an explosion The welds exposed to an extraordinary strain must comply to strict safety regulations and can be welded only by trained and examined welders e g pressure tanks rails drawing devices for cars supporting structures ...

Page 12: ...ects the liquid metal under the arc from oxidation which would weaken the weld In metal active gas MAG welding either pure CO2 or a mixed gas of argon and small amounts of CO2 and O2 e g Corgon is used Depending on their composition the welding process penetration drop size splash losses can be actively influenced Metal inert gas welding MIG uses argon as a noble gas and more rarely also the expen...

Page 13: ...rt circuit current The current increase rate of the current source determines the type of droplet separation significantly After re ignition of the arc the voltage increases suddenly The welding current drops again and adjusts itself according to the position of the arc operating point on the current source characteristic The course of the instantaneous welding current is essentially determined by...

Page 14: ...c Spray arc transfer time view The spray arc burns continuously without a short circuit interruption The material transfer from the wire electrode into the weld pool is fine droplet It is relatively high thermal energy introduced into the weld metal which is why heat affected zone and thus the workpiece distortion are greater than the short arc This type of arc is used to weld thicker sheets ...

Page 15: ...Operation manual IM 240 i Seite 15 4 2 Welding Positions ...

Page 16: ... Front panel IM b Amperage rating in Ampere window 200 200Amp c Firmware revision in Ampere window r1 1 major minor revision numbers 5 2 Operating Panel Filler wire material selection FeSg2 MIX Standard not alloyed steel shielding gas 82 Ar 18 CO2 FeSg2 CO2 Standard not alloyed steel shielding gas 100 CO2 AlMg Aluminium Magnesium shielding gas 100 Ar AlSi5 Aluminium 5 Silicium shielding gas 100 Ar...

Page 17: ...ure The welding power is to adjust just with one main rotary encoder By setup of material thickness in millimeters are automatically set all welding parameters 5 3 1 2 Arc length correction There is possible to adjust length of the welding arc By turning the encoder in any direction is display switching from Voltage mode to Arc length correction mode LED Active Arc length 0 Arc length 30 Arc lengt...

Page 18: ...elding voltage setup Set up the welding voltage in Volts by turning the encoder 5 3 2 3 Arc length correction There is possible to adjust length of the welding arc By turning the encoder in any direction is display switching from Voltage mode to Arc length correction mode LED Active Arc length 0 Arc length 30 Arc length 30 AMP VOLT VOLT ...

Page 19: ...aring up subsequently When the hole in the nozzle is too large it is necessary to change the nozzle The metal drops are embedding in the inner walls of the torch cover Take them out if necessary The separator is helpful and it is also a prevention against the firm caking of the drops You have to change the damaged cables at once 6 1 Disposal oft the machine Do not dispose of electrical equipment t...

Page 20: ... 24V 20 200V 16Amp 200Amp 24V 20 No load output voltage Uo 40 2V Efficiency 85 Idle power consumption in MIG mode 25W Power factor 0 75 Current adjustment range 20 200Amp Voltage adjustment range 10 35V 0 1V step Wire speed range 1 5 15 m min Wire feed roll diameter 37mm Wire spool diameter 300mm max 17kg max Thermal class H 180 C Temperature range 10 40 C operating temp 40 80 C storage temp Dimen...

Page 21: ...g h 3kg h 3 7kg h 12m min 2 7kg h 3 6kg h 4 4kg h CrNi welding wire Wire feed rate 0 6 mm Welding wire diameter 0 8 mm Welding wire diameter 1 0 mm Welding wire diameter 2m min 0 5kg h 0 6kg h 0 8kg h 3m min 0 7kg h 0 9kg h 1 1kg h 5m min 1 1kg h 1 5kg h 1 9kg h 7m min 1 6kg h 2 1kg h 2 7kg h 10m min 2 3kg h 3kg h 3 8kg h 12m min 2 7kg h 3 6kg h 4 6kg h Aluminium welding wire Wire feed rate 1 0 mm...

Page 22: ...kg h 5m min 1 2kg h 1 6kg h 2kg h 7m min 1 7kg h 2 2kg h 2 8kg h 10m min 2 4kg h 3 2kg h 4kg h 12m min 2 9kg h 3 8kg h 4 8kg h 8 2 Average shielding gas consumption for MIG MAG welding MIG MAG steel welding Welding wire diameter 0 6mm 0 8mm 1 0mm 1 2mm Average gas consumption 8 l min 9l min 10l min MIG MAG aluminium welding Welding wire diameter 0 6mm 0 8mm 1 0mm 1 2mm Average gas consumption 12l ...

Page 23: ...uch little wire adjust the wire feed regulator 3 The workpiece clamp is loose or transfer resistance is too high rust paint make a good contact between workpiece and clamp 4 The contact nozzle is worn up or the diameter is wrong change it 5 The gas flow is not correct adjust the gas flow 6 The workpiece is not clear in the welding area remove paint rust fat etc 7 Performance grade malfunction take...

Page 24: ...ange the contact nozzle if the wire is deformed lower the pressure on wire Device turns OFF and the Err t is displayed 1 Time of make is exceeded TM Let the device cool down and follow the instructions for TM according to device type The protective gas still flows 1 Magnetic valve is dirty and it is still open Disconnect the torch connector and connecting hose alternately flow a pressure air into ...

Page 25: ...al IM 240 i Seite 25 10 Distributors Worldwide Here you can find our worldwide distributors https www wielanderschill com service vertretungen weltweit https www wielanderschill com en service distributors worldwide ...

Page 26: ...IM 240 i Operation manual Seite 26 11 EU Declaration of Conformity ...

Page 27: ...Operation manual IM 240 i Seite 27 ...

Page 28: ...IM 240 i Operation manual Seite 28 ...

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