INSTRUCTIONAL MANUAL

PHANTOM 400

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 WARNING!!
Manual Metal Arc (MMA) and Tungsten Inert Gas (TIG) welding process could be dangerous to
the users, all the people working closer to the machine and the surrounding environment if the machine is
not used or handled in a proper way. All the relevant safety instructions need to be followed and safety
norms must be followed while using the machines. Welding process can damage the individual welder.
It can also create a lot of problems in the ambience. It emits light which can damage eyes, it
generates gas which is not good for health, and the current carrying conductors are live if they are kept
bare. Proper attention need to be paid to the following:

1. RELATED TO ELECTRICITY:

a) The welding equipment must be installed according to the safety regulations and standards and by a
trained and qualified person. Have installation, maintenance and repair work performed by
trained and qualified people only.
b) Avoid all contact with live components in the welding circuit and with electrodes and wires if you
have bare hands. Always dry welding gloves having holes.
c) Ensure that you are correctly and safely earthed.
d) Use a safe and working position.
e) Ensure that the welding machine is correctly positioned and is being maintained well. Work must stop
immediately in case of cable damage or insulation failure.
f) Repairs and maintenance must be performed by a trained and qualified person. While
repairing, make sure that the equipment's power connection is switched off.
2. RELATED TO LIGHT & HEAT EMISSIONS: I
a) Protect your eyes as even a short-term exposure can cause lasting damage to the eyes. Use a welding
helmet with suitable radiation protection glass.
b) Protect the body against the light from the arc as the skin may be damaged by welding radiation.
Use protective clothes covering all parts of the body.
c) The place of work should be screened, if possible and other persons in the area warned against the
light from the arc.
3. RELATED TO WELDING SMOKE & GAS:
Inhaling of the smoke and gases emitted during welding process is injurious to health. Ensure that
any exhaust systems are working properly and that there is sufficient ventilation.
a) Do not weld in locations near chlorinated hydrocarbon vapors coming from degreasing or spraying
operations.
4. RELATED TO FIRE HAZARD:
a) Radiation and sparks from the arc represent a fire hazard. As a precaution, combustible materials
must be removed from the place of welding.

b) Working clothing should also be secure against sparks from the arc.

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 NOISE:
The arc generates surface noise according to the welding task. In some cases, use of hearing aids is

necessary.

GENERAL DESCRIPTION:
The MMA/TIG welding machines from M/S. MIRAJ ELECTRICALS & MECHANICALS CO. Pvt.

Ltd. (MEMCO) type MEMCO INV is an ultra modern inverter controlled machine suitable for

MMA/TIG operations. The machine has been indigenously developed with the latest technology and with

high speed Insulated Gate Bi-polar Transistors (IGBT) as power devices. IGBTs are good for high power

and high frequency operations. The complete machine consists with primary rectifier bridge, high speed

inverter, inverter transformer, high speed rectifier and necessary output filter. Very high frequency of

operation has helped to make the machine very compact and weight of the machine is much less.

Necessary indications such as Mains ON, Fault, and Weld ON etc. have been taken to the front panel for

convenience of the user.

The MMA/TIG machines are light in weight, compact in size and designed to operate on three- phase

power supply as well as on single-phase connections. The machines are sturdy. The Machines are

supported on four wheels. High-frequency along with high-voltage TIG-ARC initiation systems

are also available in a modular form.

Being suitable for heavy duty industrial welding, the machine can be equipped with water cooling

unit. The purpose is to maintain the temperature of the torch well within its working limits.

The control panel comprises of a voltmeter, an ammeter, controls for various welding characteristics,

Indicating lamps to show faults as well as healthiness. The meters are connected through an on/off switch.

The schematic block diagram, machine diagram and the diagrams of all the PCBs are shown in further sections.

INSPECTION:
On receiving the inverters at your end, please check the packing for any damage. Inform the
supplier and/or the transporter for any dam0.5age immediately. After unpacking the unit, inspect the
machine to ensure that no damage has occurred during transport. Any loss or damage should be reported
to the suppliers branch office without any delay.
Carry out insulation resistance test before installing the machine.

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 SPARE PARTS:
The inverter based MMA/TIG welding machine does not have any discrete electronic

components. For achieving good reliability features, compactness and ease of handling,

the inverters are manufactured with modular sub-assemblies. It is advisable to change the

respective modular sub-assemblies for rectifying the inverter. Following are the

electronic sub-assemblies for MMA/TIG inverters:

1. Control Card: This card generates necessary 'gating' signals for the inverter. It generates LED
indications as well.

2. Power Card I: It accommodates the bridge rectifier, the inverter and the snubber circuit.
3. Power Card II: It accommodates the Diode rectifier.
4. Relay Card: It accommodates two 24V relays.
5. Front Panel (Card Dive Card): It indicates power supply.

Apart from the above mentioned modules, following are the spares that may be used

for repairing the inverter:

1. Fans: Type no: 8”, VBM make or equivalent.

2. MCB: 64Amp, C-Curve, 3-pole,

. 3. Potentiometer for Current Setting: 5 K/3 W, 19rnrn shaft, Pankaj Make

4. Meters : Digital Amp Meter & Voltmeter .

5. Control Transformer:0,230,415 V/ 0,9V 16-0-16 V

6. Choke Coil: 45 -90

 MAINTENANCE.

After proper installation of the machine, the machine can be used. For a better life of the
machine, a basic maintenance procedure should be followed. Since the working environment of the machine is
used, is very dusty, it is a good practice to clean the machine by removing top cover, using an air blower daily.

If the machine is maintained properly according to the above mentioned procedure it will improve the life of
the machine which in-turn will benefit the user. In the further sections of this manual, the schematic block
diagram of the machine is given.

The front and back view of the machine and the related information is also given on further pages.
The outline of the control card, front panel and relay card along with the position of the different connectors and
their functions is given thereafter
SCHEMATIC BLOCK DIAGRAM.
 B

FRONT VIEW OF THE MACHINE.

1. 3-Phase supply switch-board. (To be prepared by the customer.)

2. Local/Remote mode selection switch.
3. MMA/TIG mode selection switch.
4. Remote Socket.
5. Output Ampere setting knob.
A and B: Weld terminals for MMA /TIG (Lift Arc) welding.

.
 BACK VIEW OF THE MACHINE.

6. Machine input supply cable.

7. Machine’s On/Off MCB.
 CONTROL-CARD CONNECTIONS.

CN1: 4-PIN CONNECTOR TO PULSE TRANSFORMER.

CN2: 4-PIN CONNECTOR TO RELAY CARD.

CN3: 16-0-16V SUPPLY FROM CONTROL TRANSFORMER.

CN4: 230V SUPPLY FROM CONTROL TRANSFORMER. (Only for machines with

gas valve.)

CN5: 3-PIN CONNECTOR TO FEED-BACK CIRCUIT ON DIODE SIDE.

CN6: 5-PIN CONNECTOR TO FRONT-PANEL.

CN7: 2-PIN CONNECTOR TO H.F. CARD. (Only for machines with H.F. unit.)

CN8: 4-PIN CONNECTOR WITH 2-PINS EACH, TO C.T. AND THERMAL-

SWITCH.

IC1-IC5: Important IC of the control card. (Check-points and their corresponding voltages
given in further section.

FRONT PANEL DIVE CARD CONNECTIONS.

 CN10: 3-PIN CONNECTOR TO CURRENT VARIATION POT.

CN11: 2-PIN CONNECTOR TO TIG/ARC MODE SWITCH.

CN12: 5-PIN CONNECTOR TO CONTROL CARD.

RELAY CARD CONNECTIONS.

CN18: 4-PIN CONECTOR FROM CONTROL CARD. K1, K2: RELAYS.R1, R2:
RESISTORS ACROSS K1 AND K2. S1, S2: SUPPLY FROM M.C.B.
 100

90
MMA
80

70
TIG
60
VOLTAGE

50

40

30

20

10

0
0 10 50 65 100 150 200 300 370 400
CURRENT

MACHINE’S OUTPUT CHARACTERISTICS.

 STEPS FOR TROUBLESHOOTING.
DEFECT.
The machine does not work
when supply is switched ON,
Mains LED is off and fans do
not rotate.
Fans rotate but Mains
indication is Off.
Mains indication is on but
fans do not rotate.
Machine does not get ON.
MCB trips regularly.
Limited welding current.
Erratic welding current.
No gas flow.
Power source not getting
switched ON.
POSSIBLE CAUSE. REMEDY.
Mains OFF, defective fuses/MCB, Check mains, then MCB
Faulty cable, loose connections. and at last Fuses.
Repair the unit once
fault has been
recognized.
Defective LED/Defective control Check and repair.
transformer or control power
supply is off.
Defective fan connection or 415V Check and repair.
supply absent,
a) Thermal switch faulty. Check and repair.
b) Output shorted.
c) Control Card failure. Consult dealer or
factory.
Rectifier failure, internal short Check and repair/
circuit, transformer failure or MCB consult supplier.
faulty.
Low supply voltage, long welding Use higher gauge
cable, fault in controller. welding cable/ replace
control card and try
again.
Loose welding connections, Choke Check and repair,
faulty, Fault in controller, One of replace choke coil or
the three phases is out. replace control-card
and try.
Solenoid valve defective, relay Check and replace.
defective, check connections in
control-card PCB as well.
Connection through remote cable Check and replace.
to control PCB is absent.
Thermal switch faulty.
 CHECK-POINTS OF IMPORTANT Integrated Circuits (I C) ON CONTROL CARD.

The placement of the important Ics on the control card is shown in the control-card diagram. The voltages at important pins is
given below for these I Cs.

IC1 IC2 IC3 IC4

Pin Voltage Pin Voltage Pin Voltage Pin Voltage
Number Number Number Number
4 -12.2 V 9 277 1 -12.2 V 1 -12.2 V
mV
6 40.9 mV 13 11.4 V 4 12 V 4 12 V
7 12.1 V 15 12 V 7 10.7 V 7 -608 mV
16 5.20 V 8 -12.1 V 8 10.9 V
11 -12.4 V 11 -12.2 V
14 7.42 V 14 10.8 V
(Varies
with
variation
of
ampere
knob.)

IC5
Pin Voltage
Number
1 -12.2 V
4 -12.2 V
7 10.8 V
8 12. V
 .
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Ground Floor, Saki Vihar Road,
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Chembur,Mumbai – 400 071 Mumbai – 400 072
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