manual_arc160

ARC INVERTER
INSTRUCTION MANUAL
Contents
Warning
3
General Description
4
Block Diagram
4
Main Parameters
5
Circuit Diagram
5
Installation and Operation
6
Caution
7
Maintenance
7
Spare Parts List
8
Troubleshooting
10
EC DECLARATION OF CONFORMITY
We hereby declare that the following machines:
ARC120 / ARC140 Dual Voltage / ARC160 / ARC200B
correspond to the following edicts and standards:
EMC Directives: 73/23/EEC and 89/336/EEC
European Standard: EN/IEC60974
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ARC Inverter Instruction Manual
Warning
Welding and cutting is dangerous to the operator, people in or near the working area, and the
surrounding environment. Therefore, the performance of welding and cutting must only be done
under the strict and comprehensive observation of all relevant safety regulations. Please read and
understand this instruction manual carefully before installation and operation.
•Switching function modes during welding could potentially damage the equipment.
•Disconnect the electrode-holder cable from the equipment before welding.
•A safety switch is necessary to prevent the equipment from electric-leakage.
•Use only high quality welding tools and equipment with this Inverter.
•Operators should be suitably trained to use this equipment.
Electric Shock
•Connect the earth cable according to standard regulation.
•Avoid any contact with live components of the welding circuit, electrodes
and wires with bare hands. The operator should wear suitable welding
gloves while using this machine.
•The operator should keep the work piece insulated from himself/
herself.
Smoke and Gas generated while welding or cutting
•Avoid breathing in smoke and gas from welding or cutting.
•Make sure the are you are working in a well ventilated area.
Arc light-emission
•Always wear a welding helmet and appropriate work clothes while
welding.
•Measures should also be taken to protect people in or near the area
you are working.
Fire hazard
•Sparks from welding may cause fire. Remove any flammable items from
the immediate area before welding.
•Have a fire extinguisher nearby.
Noise
•Surface noise is generated while welding and cutting. Use suitable
hearing protection.
Machine Fault
•Consult this instruction manual in the case of a fault.
•Contact your local dealer or supplier for further advice.
3
General Description
This welding machine is manufactured with advanced inverter technology. With power component
MOSFET and PWM technology, the inverter converts DC voltage, which is rectified from input
AC voltage, to high 100KHz frequency AC voltage; as a consequence, the voltage is transformed
and rectified. Therefore, it results in a smaller transformer and lighter inverter machine, which
increases welding performance by 30%. The high frequency oscillation, which enables the output
of high frequency DC, is employed in the arc-starting system. The features of this product are as
follows: stable current, reliable, fully portable, efficient and quiet in operation.
Warranty of maintenance for main components is one year. During the warranty period, all
maintenance is free of charge, not including any deliberate damage or alteration to this welding
equipment.
In the case of a fault with the inverter machine, only qualified electricians are authorized to carry
out repairs.
Block Diagram
INPUT
CONTROL
PWM
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ARC Inverter Instruction Manual
Main Parameters
ARC120
ARC140 DV
ARC160
ARC200B
Fuse Rating
13 amp
110 volt 15 amps
240 volt 13 amps
16 amps
20 amps
Generator
Friendly
+ / − 15%
+ / − 15%
+ / − 10%
+ / − 10%
Input Power
Voltage
AC 230 volt
(single phase)
110 / 230 volt
(single Phase)
AC 230 volt
(single phase)
AC 230 volt
(single phase)
Rate Input
Power Capacity
3.8 KVA
4.4 KVA
5.3 KVA
7 KVA
Input Voltage
Frequency
50 / 60 Hz
50 / 60 Hz
50 / 60 Hz
50 / 60 Hz
Output Current
Range
10 − 120 amps
10 − 140 amps
20 − 160 amps
20 − 200 amps
Duty Cycle
(25°C)
120 amps @ 60%
110 volt 100 amps @ 100%
240 volt 140 amps @ 60%
155 amps @ 60%
200 amps @ 60%
Weight
5 kg
6.4 kg
8 kg
10 kg
Overall
Dimensions
230 x 120 x 170 mm
290 x 132 x 216 mm
371 x 155 x 295 mm
425 x 205 x 355 mm
Protection
Class
Ip23
Ip23
Ip23
Ip23
Diameter
of Rod
1.6 mm − 3.2 mm
1.6 mm − 3.2 mm
1.6 mm − 4.0 mm
1.6 mm − 5.0 mm
Circuit Diagram (single phase input)
SNUBBER
CIRCUIT
MAIN SWITCH
DRIVE
MODULE
AC 220 volt
POWER
SUPPLY
PROTECT
CIRCUIT
CONTROL
MODULE
5
FEEDBACK
Installation and Operation
G
E
E
F
C
D
D
C
F
F
A
A
B
E
B
C
D
A
B
A : Mains Lead
A primary power supply cable is available for this welding equipment. Connect the power supply
cable with required voltage. Check whether the voltage value varies in the given range with a
multi-meter.
B : Connection of Output Cables
Two Dinze sockets are available for this welding equipment. Connect the plug to the socket on
the panel board. It is possibly damaging to both the plug and socket, if the plug and the socket
are incorrectly connected.
The electrode holder cable should be connected to the negative terminal, while the work piece
should be connected to the positive terminal.
•Positive connection electrode holder to “–”,while work piece to “+”
•Negative connection work piece to “–”, while electrode holder to “+”.
It is necessary to increase the diameter of cable in order to maintain and improve the performance
of voltage output.
C : On / Off Switch
While the power supply switch is on, the built-in fan works and current meter displays the current
value.
D : Welding Current Output Setting
According to practical demand, set the parameters of current output by the operation of welding
current knob and arc-leading pulse knob.
E : O.C. Light
When the pilot lamp is lit, the machine is in a temporary shut down mode to prevent damage
from over heating. The machine will automatically restart when the internal temperature has
dropped to a safe operational level.
F : TIG / MMA Switch
Select between TIG and MMA welding process.
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ARC Inverter Instruction Manual
G : Arc Force Knob (Arc200B only)
Arc Force knob is available for the improvement of arc-starting, especially in case of low current
input.
Caution
1. Working Environment
1.1 The location in which this welding equipment is installed should be free from dust, corrosive
chemical gas, flammable gas or materials.
1.2 Avoid the operation of welding in the open air unless the working area sheltered from the
elements. The ambient temperature of the working environment should be maintained within
–10°C to +40°C.
1.3 Allow a distance of at least 300mm (12”) between this machine and any walls.
1.4 Make sure the area you are working in is well ventilated.
2. Safety Tips
2.1 Ventilation: Good ventilation is of critical importance for the performance and service life of
this inverter welding machine. Maintain a minimum distance of 30cm (12”) between the inverter
machine and any other objects in or near the working area.
2.2 Do not operate this machine when the O.C. Light is lit.
A sudden halt may occur while the welding operation is carried out while this welding machine is
of over-load status. Under this circumstance, it is unnecessary to restart this welding equipment.
Keep the built-in fan working to bring down the temperature inside this welding equipment.
2.3 This welding equipment uses automatic voltage compensation, which enables the
maintaining of the voltage range within the given range. In case the voltage of input power
supply current exceeds the stipulated value, it is possibly damaging to the components of this
welding equipment.
2.4 An earth terminal is available for this welding equipment. Connect with the earth cable to
avoid static and electric shock.
2.5 DO NOT contact the output terminal when the welding operation is performed. An electric
shock will occur.
Maintenance
Exposure to extremely dusty, damp, or corrosive air is damaging to this machine. In order to
prevent any possible failure or fault of the inverter, clean any dust at regular intervals with
compressed air.
Please note: Proper maintenance should be carried out by a skilled and qualified technician on
a regular basis. Any attempts by an unauthorised or unskilled individual to remove the outer
casing, or conduct repairs or modifications to the machine will void the warranty.
7
Spare Parts List
Part Number
Description
ARC120
A
Front Panel
B
Cover
C
Carrying Strap / Handle
D
Dial
E
Dinze Socket
F
On / Off Switch
G
Power Cable
H
Internal Fan
I
Bottom PCB
J
Heat Sink
K
Center PCB
L
Rubber Feet
M
Top PCB
ARC140 DV
ARC160
ARC200B
ARC120
C
F
G
M
B
D
H
E
A
L
8
K
J
ARC Inverter Instruction Manual
ARC140
ARC160
ARC200B
9
Troubleshooting
Please note: In the event of a fault with this inverter welding machine, only qualified technicians
are authorised to undertake repairs.
Fault Symptoms
Reason
No output from machine, O.C. Light not lit, internal fan
not working
1. Possible failure of voltage input. Consult an authorised
technician.
2. Possible failure of power supply. Check plug and power
cable for damage.
No output from machine, O.C. Light not lit, internal fan
not working, machine suddenly halts operation
1. Possible failure of power supply. Check plug and power
cable for damage.
2. The machine is in temporary shut down mode due to
over heating. Wait a few minutes for machine to cool
down and it will automatically re-start.
3. Power supply input is faulty. Check plug and power
cable for damage.
4. The machine is in temporary shut down mode due to
constantly being switched on and off. Unplug the machine
and wait 5 minutes before re-starting.
5. 24 volt relay board may be defective. Consult an
authorised technician for a replacement.
6. The top PCB is not receiving power. Consult an
authorised technician.
No output from machine, O.C. Light not lit, internal fan
is working
1. Possible loose connection in machine. Consult an
authorised technician.
2. Possible failure of Control Module / Drive Circuit /
Drive Module. Consult an authorised technician for a
replacement if necessary.
3. Possible failure of MOSFET / Transformers / Rectifier
Diode / Internal connections. Consult an authorised
technician for a replacement if necessary.
No output from machine, O.C. Light is lit
1. The machine is in temporary shut down mode due to
over heating. Wait a few minutes for machine to cool
down and it will automatically re-start.
2. The machine is in temporary shut down mode due to
excess current.
3. Possible function failure of inverter machine. Unplug the
machine and perform the following checks:
a) If the fault indicator is on MOSFET the top PCB is
possibly faulty.
b) If the fault indicator is off there could be damage to
center PCB / possible damage to secondary rectifier of
transformer.
c) Possible damage to feedback circuit.
Consult an authorised technician.
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ARC Inverter Instruction Manual
Notes
11