Operation

& Safety manual

MMA

MMA

200CI

15-200Amps DC - Single Phase - 240V

Inverter DC Arc

Welder

Congratulations on the purchase of your new PlasmaPart product

We are delighted you have chosen us to provide you with high quality welding equipment and we will strive to provide you with the best aftermarket service in the industry. Your product is backed up by our comprehensive guarantee please take a moment to fill in your warranty details below which will help you if you have to contact us in the future.

Machine Type ……………………………………..

Invoice Number ……………………………………..

This manual has been written to instruct you in the correct and safe use of your PlasmaPart product please read and fully understand it before use.

Your understanding of the product is key to your safety, welding is hazardous, by taking the correct precautions you can minimise the inherent hazards associated with welding.

You have made the right choice in choosing a PlasmaPart product.

PlasmaPart are the welding and plasma cutting brand of choice for a huge range of users and supply a diverse range of industries and private individuals from aerospace & defence to boilermakers, our product performance, safety, backup, technical support, service and value lead the way in the welding and plasma cutting industry we hope you enjoy using your new product.

Important Safety Information

The following information is extremely important and must be observed, this section is in addition to specific hazard warnings that are mentioned throughout the manual where appropriate

The operation and routine maintenance of welding equipment can be extremely

dangerous and hazardous to your health and wellbeing.

The electric arc welding process produces strong electric and magnetic emissions which may cause improper or non-function of cardiac pacemakers, and other electrical health equipment & devices. Consult your doctor if you are in any doubt before using or being in close proximity of a working welder.

Electric Shock

Electric shock can injure or kill you, the electric arc welding process requires medium level voltages at high currents to create the high temperature welding arc. This can cause serious injury or death to you or others in the workplace if precautions are not taken.



Never touch any components or parts that are electrically live or hot

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Never change rods or parts of the torch when the machine is turned on

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Always ensure parts and consumables are replaced when they are worn or damaged

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Do not operate the machine in damp or wet conditions

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Ensure the machine is used in conjunction with an appropriate RCD

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Insulate yourself from the work piece and any other parts of the circuit using appropriate safety equipment such as gloves

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Read and follow all instructions in the operation manual, if you are unsure about any of them please contact us



The work piece should be earthed either direct to ground or to the earth terminal on the rear of the machine

Fire and Explosion

When welding there is a risk that sparks, slag, arc, conducted heat or a combination of these could cause flammable or potentially explosive materials to ignite or detonate.



Ensure that all combustible materials are removed from the affected area



Protect yourself and flammable materials that cannot be moved



Never weld a container or vessel that has held flammable or volatile substances

Hazardous gases & fumes

Gases produced during the welding process can be dangerous and may affect your health. Please take precautions to avoid inhaling them



Ensure your work area is well ventilated, or that you are wearing sufficient protective equipment to avoid inhaling the fumes



Keep your head out of the direct fume plume



All fumes produced during welding can be hazardous to health and should not be inhaled. Certain materials produce more toxic fumes and great care should be taken when cutting any material made from or containing any of the following:

Antimony

Arsenic

Beryllium

Cadmium

Chromium

Cobalt

Lead

Manganese

Mercury

Nickel

Selenium

Silver

Titanium

Vanadium

Zinc

Any coated, painted, dipped, galvanised or plated material

Residue from chlorinated solvents

If in doubt, consult the MSDS sheet for any material you are cutting or substance previously applied to it.

Welding Arc Ultraviolet Radiation

Welding arc radiation can burn your eyes and skin, without adequate protection your eyes and skin are at risk, if exposed your eyesight can be permanently damaged please ensure you are wearing adequate PPE.

The following should be treated as a guide as to the minimum shade numbers to use for eye protection while plasma cutting.

Process: Electric Arc Welding

Current used Minimum shade number

< 60amps

60-160amps

160-250amps

8

9

10

11 250-500amps

Declaration of Conformity

PlasmaPart 200A MMA CI Welder

Manufacturer:

ZHEJIANG ZHONGJIAN (ZOJAN) WELDING EQUIPMENT CO.,LTD

Address: South Of Jiulong Rd., Industrial City, Wenling, Zhejiang, China

Tel.:86-576-81667866

PlasmaPart Limited

Unit 1 Debdale Lane

Keyworth

Nottinghamshire

NG12 5HN

0844 822 80 40

The equipment described in this manual conforms to all applicable aspects and regulations of the Low Voltage Directive and to the national legislation for the enforcement of this directive.

The equipment described in this manual conforms to all applicable aspects and regulations of the EMC directive and to the national legislation for the enforcement of this directive.

PlasmaPart machines are the result of extensive and continuous product development. Our manufacturing process is two-part and once the base units arrive at our facilities they are completed to our specification in the UK. Each machine is individually tested and verified before completion, ensuring the product is safe for use when used in accordance with these instructions.

PlasmaPart are committed to continual development and improvement of our products, if you have any comments, concerns, or suggestions please do not hesitate to contact us.

Statement of warranty:

PlasmaPart Limited hereby warrants to the original purchaser that new PlasmaPart machines sold are free from material defects and defective workmanship, should any failure arise within a period of five (5) years from the invoice date and the machine has been treated in accordance with the guidelines stated in this manual, PlasmaPart Limited will collect the machine, return it to working condition or replace it at our discretion and redeliver it to you as quickly a possible – typically within 48 hours.

This warranty is in lieu of any warranty of merchantability or fitness for a particular purpose.

Warranty period: 5 years parts and labour on power source

1 year parts and labour on leads and clamps

This warranty is conditional on you retaining the original packaging or being able to pack the machine so it can be transported safely by our delivery partner. If the machine is damaged in transit from you to us in the event of a warranty claim, you may be charged some of the repair costs if the machine has not been packaged adequately.

The warranty explicitly excludes:



Rods, Consumables, electrodes, nozzles, swirl rings, o-rings, fuses and filters



Equipment that has been modified, improperly used or installed, misused or improperly operated according to the guidelines in this manual

Limitation of liability:

We shall not be liable or responsible for any injury, illness, accident, misfortune, loss of profit, loss of earnings, loss of life however caused as a result of buying and/or using or misusing the product(s). In no event shall PlasmaPart be liable or responsible to you or any third party for any personal, mental, physical injury or illness, consequential, direct, indirect, special or contingent damages arising from the use, misuse or failure of the product(s) sold or advice given. Our cumulative liability on account of a claimed defect in any product supplied by PlasmaPart or any damages of whatsoever type caused by the use or misuse of the products(s) shall in no event exceed the purchase price paid by you.

Power Source Specifications MMA 200 CI

Supply Voltage

Supply Frequency

1-ph AC 220±15% V

50~60 Hz

Power requirement (at 200A) 4.8 KVA (Max)

Rated input current (at 200A) 16 A (Max)

No-load voltage

Output current range

90 V

20-200 A

Output voltage range 15-40 V

Duty cycle @ 185 Amps Output 100%

Efficiency

Arc striking model

Cos φ (η)

95%

Scratch (Hot)

0.93

Setup, Operation & Connections

Once unpacked please take a moment to identify the various inputs, outputs and controls on your new PlasmaPart system – key to its operation are:



Mains Input

In this case a 16A 240V plug is pre-wired to your machine, under certain circumstances you may use your PlasmaPart system whilst connected to a 13amp

240V supply, you must however not use the system with a welding amperage of over

100amps whilst connected to a 13amp standard 3 pin plug, any higher than this and the unit will draw more than 13amps input current and the 13amp fuse will fail.

Furthermore if you connect your machine to an extension lead ensure that the conductor size is adequate for the length of lead and current draw of the machine, in this case at least 4mm

2 should be used. If you are in any doubt please consult a qualified electrician. Always protect yourself and others by using your machine with an appropriately sized RCD or residual current device.

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On / Off switch - this turns the machine on and off

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O.C light – this is a general fault light, it will illuminate if the input voltage to the machine falls below the required level, the machine develops an electronic fault, the machine overheats, check your power connection, and failing this, call us and we will help you.

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Output current control – this is an infinitely variable rotational knob, which adjusts from minimum (fully anti-clockwise) to maximum (fully clockwise) it is linear in function and with the knob set halfway between the two extremes the output will be set at the machines mid-point output and so on.



Work piece clamp connection - this is an industry standard Dinze connector and is used to connect the work piece clamp to.

Turn the machine off before changing rods or adjusting the rod holder. Wear appropriate safety equipment at all times. Do not allow contact from the operator with the work piece whilst a cut is made – use suitable gloves.

Thank you again for your purchase and we hope your PlasmaPart welding system gives you

many trouble free years of operation

If you need to get in touch for advice, to purchase spares, for warranty support, service or for any other reason you can contact us here

PlasmaPart Limited

Unit 1 Debdale Lane

Keyworth

Nottinghamshire

NG12 5HN

0844 822 80 40

0844 822 80 48 [email protected] www

.P

lasmaPart.com