Fubag WS 230 DC ES Welding Power Station User Manual

Operator’s Manua
Welding power station
WS 190 DC ES
WS 230 DC ES
www.fubag.ru

WARNING! BEFORE USING THE MACHINE READ THE INSTRUCTION MANUAL CAREFULLY!
Our generators FUBAG are designed to give safe anddependable service if operated according to instructions. Read and understand the manual before operating the generator FUBAG. Failure to do so could result in personal injury or equipment damage.

General safety

WARNING!
Exhaust gas contains poisonous carbon monoxide. Never run the generator in an enclosed area. Be sure to provide adequate ventilation. When installed in ventilated protection are to be observed.
WARNING!
The muffler becomes very hot during operation and remains hot for a while after stopping the engine.
Be careful not to touch the muffler while it is hot. Let the engine cool before storing the generator indoors. The engine exhaust system will be heated during operation and remain hot immediately after stopping the engine. To prevent scalding, pay attention to the warning marks attached to the generator.
WARNING!
Gasoline is extremely flammable and explosive under certain conditions. Refuel in a well ventilated area with the engine stopped. Keep away from cigarette. smoke and sparks when refueling the generator. Always refuel in a well- ventilated location. Wipe up spilled gasoline at once.
WARNING!
Connections for standby power to a building’s electrical system must be made by a qualified electrician and must comply with all applicable laws and electrical codes. Improper connections can allow electrical current from the generator to back feed into the utility lines. Such back feed may electrocute utility company workers or others who contact the lines during a power outage, and when utility power is restored, the generator may explode, bum or cause fires in the building’s electrical system.
WARNING!
– Always make a pre-operation inspection before you start the engine. You may prevent an accident or equipment damage.
– Place the generator atleast 5m away from buildings or other equipment during operation.
– Operate the generator on a level surface. If the generator is tiled, fuel spillage may result.
– Know how to stop the generator quickly and understand operation of all the controls.Never permit anyone to operate the generator without proper instructions.
– Keep children and pets away from the generator when it is in operation.
– Keep away from rotating parts while the generator is running.
– The generator is a potential source of electrical shocks when misused; do not operate with wet hands.
– Do not operate the generator in rain or snow and do not let it get wet.
– The power generator is a mains replacement that generates electrical power for supply to a mobile distribution system.
– The power generator must be operated outdoors within the prescribed voltage, output and rated speed limits (see type plate).
– The power generator must not be connected to other electrical supply systems or electric generation systems (e.g. other power generators).
– The power generator may not be used in environments where there is a risk of explosion.
– The power generator may not be used in environments where there is a risk of fire.
– The power generator must be operated in accordance with the conditions set out in the technical documentation.
– All improper use of the power generator including all uses not described in these instructions will constitute unauthorized incorrect usage for which the manufacturer is not legally liable.
– Operation in environments where there is a risk of explosion and fire.
– Operation in enclosed areas and under direct exposure to rain or snowfall.
– Operation without the requisite safety precautions and connected to existing supply network systems.
– Spraying with high-pressure cleaners or fire extinguishing equipment.
– Non-compliance with regular servicing requirements.
– Failure to carry out measurements and checks for early detection of defects.
– Know and apply the Prevention of Injury regulations and the safety instructions for the power generator.
– Understand and be able to practically implement the technical documentation.
– The operator must know the functions of, and be able to use, the components of the power generator.
– The operator must wear the appropriate personal safety equipment.
– The labelling on the electrical generator must be complete and maintained in a readable condition.
– Constructive changes may not be carried out on the electrical generator.
– The rated speed of the motor has been set during manufacture and may not be changed.
– The operating safety and correct functioning must be checked before and after each use.
– No naked flames, lights or spark-emitting appliances may be used within the hazard area of the power generator.
– Smoking within the hazard area of the power generator is strictly forbidden.
– During operation, the power generator must be protected from dirt and foreign matter.
– The power generator may only be transported when cold.
– The power generator may only be lifted using the carry handles intended for this purpose.
– The electrical safety must be checked before each operational use.
– The appliance may not be covered. The air intake may not be blocked or obstructed.
– When starting, the load may not be connected.
– Only certified and approved cables may be used for the wired network.
– The power drawn may not exceed the maximum rated power.
– The power generator may not be operated without the sound absorber.
– The power generator may not be operated without the air filter or with the air filter cover open.
– The generator’s tank may not be refilled during operating.
– The tank may not be refilled when the power generator is hot.
– The power generator may not be cleaned and serviced when in operation; when hot.
– Always remove spark plug connector prior to commencing servicing and repair work.
– The power generator must be shut down when not required for periods longer than 30 days.
– The power generator must be stored in a dry enclosed room.

Safety welding operation

– No work of power station in a mode “welding” and “generator” is forbidden. Before carrying out  of welding works disconnect all consumers from sockets.
– Itis highly recommended always to follow the safety rules. Wear protective clothes and special means to avoid injuries to eyes and skins.
– Use the welding mask or special protective glasses while working with the welding machine. Only by viewing through the filter lens on the welding mask your eyes are secured by your operation.
– Prevent the sparks and spatter from harming your body.
– Under no circumstance allow any part of your body to touch the welder’s output bipolarity (torch and work piece).
– Fumes and gases produced when welding are hazardous to health. Make sure to work in places where there are exhaust or ventilation facilities to keep fumes or emissions away from the breathing zone.
– Please remember to keep arc rays away from the other nearby people when welding. This is only due to the interference from arc rays.
– There will be high temperature when welding work piece, so please don’t directly touch on it
– No welding for the container loaded inflammable or explosive materials.
– Welders possible have electromagnetism and frequency interference, so keep away people with heart pace or the articles which can be interfered by electromagnetism and frequency.
– Taking welder power for pipe unfreezing device will be prohibited.
– Check is needed from time to time to make sure the welding cable is in good condition if the welding machine is in frequent use. Check at least once each month if the welder is in regular use. It is necessary to check when the welder is in mobile use.
– Electrode must be taken down from holder when no welding.

Description

1. Electric starting key
2. Voltmeter
3. Circuit breaker
4. Socket 220V
5. Fuel tank cap
6. Fuel gauge
7. Current regulation knob
8. Indicator lamp
9. Welder teminals| 10. Battery
11. Oil drain plug
12.Oil filler cap
13.Fuel valve
14.Chokw lever
15.Recoil starter
16.Air cleaner
17.Muffler
18.Spark plug
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Specifications

Welding specifications
Welding current type| DC
Welding current, A| 40-190| 50-230
Rated no-load voltage, V| 65| 65
Welding current of duty cycle 60%, A| 120| 150
Min. electrode diameter, mm| 1,6
Max. electrode diameter, mm| 4| 5

The manufacturer reserves himself the right to make the manual’s content or power generator function change without any preliminary notification of the users.

Putting the Power Generator into Operation

Operating conditions
Power stations provide steady work at ambient temperature from -15°C to +40°C, (gasoline and oil type should be picked up according to these conditions). Relative humidity <60%.
Generating set performance is reduced by approximately 4% for every additional 10°C and/or approximately 1% for every additional 100m in altitude.
Operator’s manual
Positioning the generating set for operation
Place the generating set on a flat, horizontal surface which is firm enough to prevent the set sinking down (under no circumstances should the set tilt any direction by more than 10°).
Earthing the generating set
To earth the generating set, use a 10 mm’ copper wire attached to the generating set earth connection and to an earthing rod of galvanised steel set in the ground to a depth of 1 metre. This also dissipates the static electricity that builds up in the electrical machines.
Checking the oil level
– Remove the dipstick/plug on the exhaust side by unscrewing it, and wipe the dipstick.
– Insert the dipstick into the filler neck without screwing it in. A second plug, without a dipstick, is available if necessary on the other side of the engine.
– Check the level and top up if necessary. If it is necessary:
– Using a funnel, fill the engine oil sump right up to the top of the filler opening.
– Screw the plug fully back onto the filler tube.
– Check that there are no leaks.
– Wipe off excess oil with a clean cloth.

Checking the fuel level

Check the fuel level and top up if necessary:
– See the fuel tank indicator.
– Fill the tank using a funnel, taking care notto spill petrol.
– Screw the cap back on to the fuel tank.
Only use clean fuel without any water. Do not overfill the tank (there should not be any fuel in the filler neck). When you have filled up, ensure that the tank cap is closed correctly.
Take care not to spill any fuel when filling the tank.
Before starting up the generating set, and if any fuel has been spilt, make sure that it has dried and that the vapours have cleared away.

Using the generator set

Elecrtic starting

1. Open the fuel tap by turning lever to the right.

2.  Move the choke knob to the closed position.
   Note: Do not use the choke when the engine is warm or when the atmospheric temperature is high.

3. Turn the engine switch to the START position and hold it there for 5 seconds or until the engine starts.

4. When the engine has started, gradually open the choke.

Recoll starting

1. Open the fuel tap by tuming lever to the right.

2. Move the choke knob to the closed position.
   Note: Do not use the choke when the engine is warm or when the atmospheric temperature is high.

3. Move the engine switch to ON.

4. Pull the starter handle slowly until resistance is felt. Retum the handle to its original position and pull swiftly. Do not fully pull out the rope. After starting, allow the starter return to its original position while still holding the handle.

5. When the engine has started, gradually open the choke. If the engine has not started, repeat the procedure until the engine starts while gradually opening the choke.
   Warm up the engine without load for a few minutes.

Using electric power

1. Check the voltmeter display for proper voltage.
2. Check the amperage of the socket, and be sure not to take a current exceed the exceed the specified amperage. Be sure that the total wattage of all appliances does not exceed the rated output of the machine.
3. Turn off the switch(es) of the electrical auntie nce(s) before connecting to the machine.
4. Insert the plug(s) of the electrical appliance(s) into the receptacle.

Welding instructions
No work of power station in a mode “welding” and “generator” is forbidden. Before carrying out of welding works disconnect all consumers from sockets.

1. Check the welding cable, connect the welding cables to the welder’s DC terminals.
2. Start the engine, run at no load to warm up fully.
3. Set the current adjust knob to the proper current level.

Switching off

1. Take the plugs out of the sockets and allow the engine to run without any charge for 1 to 2 minutes.
2. Place the engine switch on “OFF” and the set will stop.
3. Close the fuel tap.

Oil sensor
The oil sensor detects the fall in oil in the crankcase and automatically stops the engine when the oil level falls down below the safety limit. If the engine does not start by usual starting procedures, check the oil level.
High altitude operation
At high altitude, the standard carburetor air-fuel mixture will be excessively rich. Performance will decrease, and fuel consumption will increase.
High altitude performance can be improved by installing a smaller diameter main fuel jet in the carburetor and readjusting the pilot screws. If you always operate the generator at altitudes higher than 1000 m above sea level, have your authorized dealer perform these carburetor modifications. Even with suitable carburetor jetting, engine horsepower will decrease approximately 3.5% for each 300 m increase in altitude. The affect of altitude on the horsepower will be greater than this if no carburetor modification is made. Operation of the generator at an altitude lower than the carburetor is jetted for may result in reduced performance,overheating,and serious engine damage caused by an excessively lean air/fuel mixture.

Preparation and maintenance in winter time Maintenance in winter time is considered to be the period when the temperature of the ambient air is fixed below +5°C. The low temperature of the ambient air hampers the engine start, negatively influences the operation of all its systems. To prepare the generator and provide its further no-failure operation it is necessary to make the following steps: – Use up all the old fuel completely, discharge the remaining one. – Clean the filter of the fuel valve. – Check the air filter. Change it if necessary. – Substitute the engine oil for the oil corresponding to the season. – Fill the fuel tank with the fuel to avoid ingress of water and its further freezing in the fuel tank and the carburetor. The generator is to be kept in a place at the temperature from +5°C and above in winter time. If the engine stops for more than 15 minutes during the operation at negative temperatures it is necessary to place the set into a warm place to prevent the condensate freezing in the breather pipe and the throttle before its start. It may cause the pressure boost in the crankcase housing and the gaskets break down. The monitoring of the set operation is to be carried out oftener than under usual operating conditions as they are considered to be rough.

 Maintenance

– The maintenance interval frequency and the operations to be carried out are outlined in the maintenance programme. – However, it should be added that it is the environment in which the generating set is operating which determines this programme. Accordingly, if the set is used in extreme conditions, shorter intervals between maintenance procedures should be adopted. These maintenance schedules apply only to generating sets running on fuel and oil, that conform to the specifications given in this booklet.

Daily| •Check the air cleaner
•Check oil level and refill to the upper level before starting the engine.
•Check all the points indicated in’ Putting the Generator into Operation”.
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50 hours (Weekly)| •Clean and wash air-cleaner element.
•More often if used in dirty or dusty environments.
•Change engine oil.(The initial oil change must be conducted atter the 25 hours operation.)
•Check spark plug, and clean and adjust if necessary.
•Check and clean the fuel shut-off valve.
100 hours| •Replace spark plug.
•Replace air-cleaner element.
•Decarbonize cylinder head, valves and piston.
•Check and replace carbon brushes.
300 hours or every year| •Inspect control panel components.
•Check rotor and stator.
3 years| •Replace engine mount rubber.
•Overhaul engine.
•Change fuel lines.

Renewing the motor oll
Initial oil change should performed after first 25 hours of use. Thereafter change oil every 50 hours. Before changing oil, check for a suitable way to dispose of the old oil. Do not pour it down into sewage drains, onto garden soil or into open streams.
Drain the oil when the engine is still warm, to ensure that drainage is rapid and complete.

1. Place an appropriate container under the drain plug, remove the dipstick/filler piug and the drain plug.
2. On completion, screw in and tighten the drain plug.
3. Fill the engine oil sump with the recommended cil, then check the level.
4. Reposition the dipstick/filler plug and tighten.
5. After filling, check that there are no oil leaks.
6. Wipe off any trace of oil with a clean cloth.

Cleaning the air filter

1. Remove the air filter cover, then remove the latter.
2. Remove the assembly consisting element, and separate them. Check carefully that the element are not tom or pierced. Replace them if they are damaged.
3. Wash the foam element in a solution of household cleaning product and warm water, then rinse thoroughly, or wash it in non-flammable solvent or solvent with a high flash point. Leave the elernent to dry fully. Soak the element in clean engine oil and remove the excess oil. The engine will smoke when it is started for the first time if too much oil temains in the foam.
4. Carry out refitting following the reverse procedure to that used for removal.

Checking the spark plug

1. Remove the spark plug cap and use a spark plug spanner to remove the spark plug.
2.  Visually inspect the spark plug and discard it if the electrodes are wor or if the insulation is split or chipped. tfit is to be re-used, clean the spark piug with a wire brush.
3.  Measure the electrode gap with a feeler gauge. The electrode gap should be from 0,7 to 0,8 mm. Check that the spark plug washer is in good condition and screw the spark plug in by hand, in order to avoid damaging the threads.
4.  After fitting the spark plug, tighten it with a spark plug spanner to secure the washer.
   Note: when fitting a new spark plug. tighten it by 1/2 tum after itis in place, in order to press the washer tightly. For the installation of an old spark plug. tighten it by a 1/8—1/4 tum after itis in place, in order to press the washer tightly.

Clianing fuel strainer

Dirt and water in the fuel are removed by the fuel strainer.

1. Remove the strainer cup and throw away water and dirt.
2. Clean the screens and strainer cup with gasoline.
3. Tightly fasten the cup to main body, making sure to avoid fuel leak.

Preparation for storage

Certain operations must be carried out on generating sets which are to remain unused for a long period of time, in order to keep them in good condition. Check that the storage area is not dusty or humid. Clean the exterior of the generating set and apply a rustproofing product.
– Drain fuel from fuel tank carefully. Gasoline left in the fuel tank will eventually deteriorate making engine-starting difficult.
– Loosen the drain screw on the bottom of the carburetor float chamber, and drain the fuel completely.
– Change engine oil.
– Check for loose bolts and screws, tighten them if necessary.
– Clean generator thoroughly with oiled cloth. Spray with preservative if available.
– Pull starter handle until resistance is felt, leaving handle in that position.
– Store generator in a well ventilated, low humidity area.

Trouble Shooting

When welder engine fails to start after several attempts, or if no electricity is available at the outpul socket, check the following chart. If your welder still fails to start or have no electricity, contact you’ nearest welder dealer for further information or corrective procedures.
When Engine Fails to Start:

Check if choke lever is in its proper position| | Set the choke lever to “CLOSE” position.
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Check if fuel cock is open.| If closed. opon fuel cock.
Check fuel level.| If empty. refill fuel tank making sure not to overfill
Check to make sure generator is not connected to an appliance.| If connected, turn off the power switch on the connected appliance and unplug.
Check spark plug for loose spark plug cap.| | If loose. push spark plug cap back into place.
Check spark plug for contamination.| Remove spark plug and clean electrodes.

When No Electricity Is Generated at Receptacle:

Check to make sure no-fuse breaker is in the ON Position.| | After making sure that the total wattage of the electrical appliance is within permissible limits and there are no defects in the appliance, turn the circuit breaker to the”ON’position. If breaker, continue to actuate, consult your nearest servicing dealer.
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Check DC terminals for loose connections.| Secure connections if necessary.
Check the appliance or equipment have any defects .| | Replace or repair it.

Wiring diagram

 Warranty

Warranty refer to defects of materials and components and do not refer to components subject to natural wear and maintenance work. Only machines cleaned from dust and dirt in original factory packing fully completed, provided with instruction manual, warranty card with fixed sales date with a shop stamp factory serial number and originals of sales and ware receipt issued by salesman are subjects of warranty. Within the warranty period the service center eliminate free of charge all detected production defects. The manufacturer disclaims warranty and legal responsibilities if nonobservance of the instruction manual by user, unqualified disassembling repair or maintenance of the machine as well does not bear responsibility for caused injury to persons or damages.

info@fubag.ru
www.fubag.ru

References

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