ARC 160 User manual

3. Plug the welding cable into the
output socket (+) and fasten it
8. Start welding
4. Connect with single phase 230V power
supply, and put the power switch in ON position
5. Switch on the mains switch
Warning! Operating the equipment incorrectly can cause serious injury and damage.
Do not use the machine until you have read "Safety Rules".
f 2
f
1
MODEL
No.
X
I
2
U
2
1～
100%60%
MADE NI
STAND AR D: G B1 5 57 9 .1 -2 0 04
20%
200A A 115 89A
1～(50/6 0 H z )
U
2
I
2
28V 4.6V 32.5 V2
U
1
=220V
～
230V I
1max
=48A I
1eff
=21.5A
U
0
=9V
ARC200
10A/20.4V
～
200A/28V
PROTECTION DEGREE:PI 21 INSULATIONDEGREE:F
E
L
N
E
NL
GN D
0
OF F
AC 2 20 V～23 0V
ON
GND/PE Earth
Wo r k p iece
Electrode holder
ARC Series Quick Instructions (This quick instruction is based on ARC200 model)
5. Switch on the mains switch
4. Connect with single phase 230V power
supply, and put the power switch in ON
position
----Stick Welding with cellulose electrode E6010 (II series) & acid electrode E6013
3. Plug the welding cable into the
output socket (-) and fasten it
f 2
f
1
MODEL
No.
X
I
2
U
2
1～
100%60%
MADE NI
STANDARD:GB15579.1-2004
20%
200A A 115 89A
1～(50/60Hz)
U
2
I
2
28V 4.6V 32.5V2
U
1
=220V
～
230V I
1max
=48A I
1eff
=21.5A
U
0
=9V
ARC200
10A/20.4V
～
200A/28V
PROTECTIONDEGREE:PI21 INSULATIONDEGREE:F
E
L
N
E
NL
GND
0
OF F
AC 22 0V～23 0V
ON
GN D/PE E arth
----SMAW welding with basic electrode: E7016 & E7018
1. Plug the ground cable into the
output socket (-) and fasten it
2. With the other end of ground
cable, establish a connection to
the work piece
6. Turn “Welding Current” knob to adjust the
welding current according to the size of
electrode
7. Turn “Arc Force” knob to adjust the
arc force according the size of electrode,
normally set in range 4-7
1. Plug the ground cable into the
output socket (+) and fasten it
2. With the other end of ground
cable, establish a connection to the
work piece
W o rkp i e c e
2
3
4
5
7
8
9
10
10
20
40
200
140
10
20
40
60
80
120
100
200
6
A
E
1
U
S
160
180
160
180
F
1
CURRENT(A)
6
A R C F O R C E
P O W E R P R O T E C T I O N
W o r k pi e c e
2
3
4
5
7
8
9
10
10
20
40
200
140
10
20
40
60
80
120
100
200
6
A
E
1
U
S
160
180
160
180
F
1
P R O T E C T I O N
A R C FO R C E C U R R E N T (A)
6
P O W E R

6. Turn “Welding Current” knob to
adjust the welding current according
to the size of electrode
7. Turn “Arc Force” knob to adjust the arc
force according the size of electrode,
normally set in range 4-7
2
3
4
5
7
8
9
10
10
20
40
200
140
10
20
40
60
80
120
100
200
6
A
E
1
U
S
160
180
160
180
F
1
P R O T E C T I O N
A R C FO RC E C U R R E N T (A)
6
POWER
2
3
4
5
7
8
9
10
10
20
40
200
140
10
20
40
60
80
120
100
200
6
A
E
1
U
S
160
180
160
180
F
1
CURRENT(A)
6
A R C FO R C E
POWER PROTECTION
Wo r
8. Start welding
Stick Amperage Table (SMAW-Shielded Metal Arc Welding)
ELECTRODE
TYPE
METAL THICKNESS
MilliMeters Inches
CURRENT
RANGE
6010
&
6011
6013
7014
2.4
3.2
4.0
4.8
5.6
6.4
1.6
2.0
2.4
3.2
4.0
4.8
5.6
6.4
2.4
3.2
4.0
4.8
5.6
6.4
3/32
1/8
5/32
3/16
7/32
1/4
1/16
5/64
3/32
1/8
5/32
3/16
7/32
1/4
3/32
1/8
5/32
3/16
7/32
1/4
40-85
75-125
110-165
140-210
160-250
210-315
20-45
35-60
40-90
80-130
105-180
150-230
210-300
250-350
80-125
110-165
150-210
200-275
255-340
330-415
ELECTRODE
TYPE
METAL THICKNESS
MilliMeters Inches
7018
7024
Ni-CI
308L
2.4
3.2
4.0
4.8
5.6
6.4
2.4
3.2
4.0
4.8
5.6
6.4
2.4
3.2
4.0
4.8
2.4
3.2
4.0
3/32
1/8
5/32
3/16
7/32
1/4
3/32
1/8
5/32
3/16
7/32
1/4
3/32
1/8
5/32
3/16
3/32
1/8
5/32
Note: All settings are approximate/welds should be tested to comply to your specifications.
Welding Standard
k piece
CURRENT
RANGE
65-100
110-165
150-220
200-275
260-340
320-400
100-145
140-190
180-250
230-305
275-365
335-430
50-70
65-85
100-140
130-175
40-80
75-115
105-160
Elect rode holder

1
Dear Customer
This instruction manual will help you get to know your new machine.
Read the manual carefully and you will soon be familiar with all the
many great features of your new product. Meanwhile, please
remember well safety rules and operate as instruction.
If you treat your product carefully, this definitely helps to prolong its
enduring quality and reliability–things which are both essential
prerequisites for getting outstanding results.
Production specification may change without advance notice.
The model you purchase is:
ARC160/200
ARC200II/250II
Please find corresponding models from the "Contents".
Important:
Please take special note of safety rules and operate as instruction in
case of damage and serious injury.

2
Safety Rules
“Danger” indicates an imminently hazardous situation which, if not
avoided, will result in death or serious injury.
“Warning!” indicates a possible hazardous situation which, if not
avoided, could result in death or serious injury. The possible hazards are
explained in the text.
“Caution” indicates a possible hazardous situation which, if not avoided,
may result in slight or moderate injury.
“Note!” indicates a situation which implies a risk of impaired welding
result and damage to the equipment.
Utilization for intended purpose only
•The machine may only be used for jobs as defined by the “Intended
purpose”.
•Utilization for any other purpose, or in any other manner, shall be
deemed to be “not in
accordance with the intended purpose”. The manufacturer shall not be
liable for any
damage resulting from such improper use.
Safety signs
•All the safety instructions and danger warnings on the machine must
be kept in legible condition, not removed, not be covered, pasted or
painted cover.
Safety inspection
•The owner/operator is obliged to perform safety inspection at regular
intervals.
•The manufacturer also recommends every 3-6 months for regular
maintenance of power sources.
Electric shock can kill
•Touching live electrical parts can cause fatal shocks or severe burns.
The electrode and work circuit is electrically live whenever the output is
on. The input power circuit and machine internal circuits are also live
when power is on. In MIG/MAG welding, the wire, drive rollers, wire
feed housing and all metal parts touching the welding wire are
electrically live. Incorrectly installed or improperly grounded equipment
is a hazard.
•Do not touch live electrical parts of the welding circuit, electrodes and
wires with your bare skin or wet clothing.
•The operator must wear dry hole-free insulating welding gloves and
body protection while performs the welding.
•Insulate yourself from work and ground using dry insulating protection
which is large enough to prevent you full area of physical contact with

3
the work or ground.
•Connect the primary input cable according to rules. Disconnect input
power or stop machine before installing or maintenance.
•If welding must be performed under electrically hazardous conditions
as follow: in damp locations or wearing wet clothing; on metal
structures such as floors, gratings, or scaffolds; when in cramped
positions such as sitting, kneeling, or lying; or in occasion when there is
a high risk of unavoidable or accidental contact with the work piece or
ground. Must use additional safety precautions: semiautomatic DC
constant voltage (wire) welder, DC manual (Stick) welder and AC
welder with reduced open-load voltage.
•Maintain the electrode holder, ground clamp, welding cable and
welding machine in good, safe operating condition. Replace damaged
part immediately.
Electric and magnetic fields (EMF)may be dangerous
•If electromagnetic interference is found to be occurring, the operator is
obliged to examine any possible electromagnetic problems that may
occur on equipment as follow:
-mains, signal and data-transmission leads
-IT and telecoms equipment
-measurement and calibration devices
-Wearers of pacemakers
•Measures for minimizing or preventing EMC problems:
-Mains supply
If electromagnetic interference still occurs, despite the fact that the mains
connection in accordance with the regulations, take additional measures
-Welding cables
Keep these as short as possible
Connect the work cable to the work piece as close as possible to the area
being welded.
Lay term well away from other cables.
Do not place your body between your electrode and work cables.
-Equipotential bonding
-Workpiece grounding (earthing)
-Shielding
Shield the entire welding equipment and other equipment nearby.
ARC rays can burn.
•Visible and invisible rays can burn eyes and skin.
•Wear an approved welding helmet or suitable clothing made from
durable flame-resistant material (leather, heavy cotton, or wool) to
protect your eyes and skin from arc rays and sparks when welding or
watching.
•Use protective screens or barriers to protect other nearby personnel
with suitable, non-flammable screening and/or warn them not to watch
the arc nor expose themselves to the arc rays or to hot spatter or

4
material.
Fumes and gases can be dangerous
•Welding may produce fumes and gases, breathing these fumes and
gases can be hazardous to your health.
•When welding, keep your head out of the fume. If inside, ventilate the
area at the arc to keep fumes and gases away from the breathing zone.
If ventilation is not good, wear an approved air-supplied respirator.
•Work in a confined space only if it is well ventilated, or while wearing an
air-supplied respirator.
•Welding fumes and gases can displace air and lower the oxygen level
causing injury or death. Always use enough ventilation, especially in
confined areas, to insure breathing air is safe.
Welding and cutting sparks can cause fire or explosion.
•When not welding, make sure the electrode circuit is not touching the
work or ground. Accidental contact can cause sparks, explosion,
overheating, or fire. Make sure the area is safe before doing any
welding.
•Welding and cutting on closed containers, such as tanks, drums, or
containers, can cause them to blow up. Make sure proper steps have
been taken.
•When pressure gas is used at the work site, special precautions are
required to prevent hazardous situations.
•Connect work cable to the work as close to the welding zone as
practical to prevent welding current from passing too long and creating
fire hazards or overheat.
•Wear oil-free protective garments such as leather gloves, heavy shirt,
cuffless trousers, high shoes, and a cap. Wear ear plugs when welding
out of position or in confined places. Always wear safety glasses with
side shields when in a welding area.
•Be attention that welding sparks and hot materials from welding can
easily go through small cracks and openings to adjacent areas and
start a fire. Remove fire hazardous from the welding area, if not
possible, cover them thoroughly. Do not weld where flying sparks can
strike flammable material and where the atmosphere may contain
flammable dust, gas, or liquid vapors (such as gasoline).
•Protect yourself and others from flying sparks and hot metal. Remove
any combustibles from operator before perform any welding.
•Keep a fire extinguisher readily available.
•Empty containers, tanks, drums, or pipes which have combustibles
before perform welding.
•Remove stick electrode from electrode holder or cut off welding wire at
contact tip when not in use.
Apply correct fuses or circuit breakers. Do not oversize or bypass them.

5
Cylinder can explode if damaged.
•Pressure gas cylinders contain gas under high pressure. If damaged, a
cylinder can explode. Since gas cylinders are normally part of the
welding process, be sure to treat them carefully.
•Cylinders should be located away from areas where they may be
struck or subjected to physical damage. Use proper equipment,
procedures, and sufficient number of persons to lift and move
cylinders.
•Always install cylinders in an upright position by securing to a
stationary support or cylinder rack to prevent falling over or tipping.
•Keep a safe distance from arc welding or cutting operations and any
other source of heat, sparks, or flame.
•No touching cylinder by welding electrode, electrode holder or any
other electrically “hot” parts. Do not drape welding cables or welding
torches over a gas cylinder.
•Use only correct compressed gas cylinders, regulators, hoses, and
fittings designed for the process used; maintain them and associated
parts in good condition.
•Use only compressed gas cylinders containing the correct shielding
gas for the and properly operating regulators designed for the gas and
pressure used. All hoses, fittings, etc. should be suitable for the
application and maintained in good condition.
•Open the cylinder valve slowly and keep your head and face away from
the cylinder valve outlet.
Valve protection caps should be kept in place over valve expect when the
cylinder is in use or connected for use.
Hot parts can burn
•Do not touch hot parts with bare hand or skin.
•Ensure equipment is cooled down before perform any work.
•If touching hot parts is needed, use proper tools and/or wear heavy,
insulated welding gloves and clothing to prevent burns.
Flying metal or dirt can injure eyes
•When welding, chipping, wire brushing, and grinding can cause sparks
and flying metal. It can hurt your eyes.
•Remember wear appropriate safety glasses with side shields when in
welding zone, even under your welding helmet.
Noise can damage hearing
•Noise from some processes or equipment can damage hearing.
Remember wear approved ear protection to protect ears if noise level is
high.
Moving parts can injure
•Stay away from moving parts such as fans.
•Stay away from pinch points such as drive rolls.
•Keep all doors, panels, covers, and guards closed and securely in
place.

6
•Have only qualified persons remove doors, panels, covers, or guards
for servicing and maintenance.
•Reinstall doors, panels, covers, or guards when servicing and
maintenance is finished and before reconnecting input power.
Overuse can cause overheating
•Use machine follow duty cycle. Reduce current or reduce duty cycle
before starting to weld again.
•Allow cooling period.
Do not block or filter airflow to unit.
Safety markings
Equipment with CE-markings meets the basic requirements of the
Low-Voltage and Electromagnetic Compatibility Guideline (e.g. relevant
product standards according to EN 60974).
Safety markings
Equipment with CCC markings meets the requirements of
implementations rules for China compulsory certification （e.g. relevant
product standards according to GB/T 15579）.
Safety markings
CSA marked equipment meets the requirements of the North American
market safety certification implementation rules (e.g. relevant product
standards according to CAN/CSA-E60974,ANSI/IEC 60974)

7
Contents
1-GENERAL REMARKS........................................................................................... 8
1-1 Power source features......................................................................................... 8
1-2 Functional principle...............................................................................................8
1-3 Output characteristics.......................................................................................... 9
1-4 Duty cycle...............................................................................................................9
1-5 Applications......................................................................................................... 10
1-6 Warning label...................................................................................................... 10
2-VERSIONS BRIEFS..............................................................................................10
3-BEFORE COMMISSIONING............................................................................... 11
3-1 Utilization for intended purpose only............................................................... 11
3-2 Machine installation rules.................................................................................. 11
3-3 Power source connection.................................................................................. 11
3-4 Welding cables instruction................................................................................ 12
4-ARC series.............................................................................................................13
4-1 System components...........................................................................................13
4-2 Basic equipments for welding...........................................................................13
4-3 Control panel....................................................................................................... 14
4-4 Interface............................................................................................................... 15
4-5 Installation............................................................................................................16
4-6 welding process installation.............................................................................. 18
4-7 Technical data.....................................................................................................19
4-8 Dimension............................................................................................................ 20
4-9 Disassembly and reassembly...........................................................................20
5-TROUBLE SHOOTING........................................................................................ 24
6-CARE AND MAINTENANCE.............................................................................. 25

8
1-GENERAL REMARKS
ARC series welding machine is suitable for DC MMA, lift TIG process, which can weld carbon
steel, stainless steel, copper etc. Because of the ideal static characteristic and dynamic
characteristics, machines highlights are as follows.
1-1 Power source features
Highlights as follows:
- Single phase 220/230V power supply, portable design
- Rapid adjustment adapting to changes in the load, stable arc length, excellent
constant-current characteristics
- Low spatter
- Easily arc ignition
- High penetration power, pretty weld formation
- Reliable and durable with patented technology
- ARC II series can weld cellulose electrodes
1-2 Functional principle
This welding machine applies HF inverter technology. Single phase input power is rectified,
filtered, converted to AC by inverter, reduced by transformer, rectified by rectifier. Then output
adjustable DC current. This process greatly improves the welding machine’s dynamic
response ability and efficiency, decrease size and weight of transformer and electric reactor,
realize energy saving and consumption reduction.
Fig.1-2-1: Schematic diagram
Transformer
Output
AC220/ 230V
50/60Hz
Control
Circuit
Rectifier &
Filter
Inverter
1-phase
Rectifier

9
1-3 Output characteristics
Fig.1-3-1: Output characteristics
1-4 Duty cycle
Duty cycle is percentage of 10 minutes that a machine can weld at rated load without
overheating. If overheats, thermostat(s) will open, output stops. Wait for fifteen minutes for
the machine to cool down. Reduce amperage or duty cycle before welding.
Note! Exceeding duty cycle can damage the machine and greatly reduce its
lifespan.
Fig.1-4-1: Duty cycle

10
1-5 Applications
The TIG series can weld most of the metal materials like carbon steel, stainless steel, etc.
The power source is designed for the following recommend areas:
Boiler and pressure vessel fabrication
Chemical industry
Power generation
Pipe line
Automotive manufacture
Machinery manufacture
1-6 Warning label
The warning label is affixed on the top of machine.
Fig. 1-6-1: Warning label
2-VERSIONS BRIEFS
Professional welding of special materials requires special welding parameters. Different
models of the power sources are matched to different weldings.
ARC series
This series use the MOSFET tube as inverter device, the inverter frequency is as high as
100KHZ. This series welding machines is suitable for STICK and TIG welding.
ARC II series can weld cellulose electrodes.

11
3-BEFORE COMMISSIONING
Warning! Operating the equipment incorrectly can cause serious injury and
damage. Do not use the functions described here until you have read and
completely understood “safety rules”.
3-1 Utilization for intended purpose only
The power source may only be used for STICK and TIG. Utilization for other purposes, or in
any other manner, shall be deemed to be "not in accordance with the intended purpose". The
manufacturer shall not be liable for any damage resulting from such improper use.Operate,
inspect and maintain should follow all the instructions given in this manual.
3-2 Machine installation rules
According to test, protection degree of this power source is IP21S. However, the internal key
components must be protected from direct soaking.
Warning! A machine that topples over or falls from its stand can cause injury.
Place equipment on an even, firm floor in such a way that it stands firmly.
The venting duct is very important for safety protections. When choosing the machine location,
make sure it is possible for the cooling air to freely enter and exit through the louvers on the
front and back of machine. Any electro conductive metallic dust like drillings must not be
allowed to get sucked into the machine.
3-3 Power source connection
- The power source is designed to run on the voltage given on the nameplate.
- The mains cables and plugs must be mounted in accordance with the relevant technical
standards.
- The power supply sockets that come with power source are designed to use strictly
according to the marked voltages.

12
Note!Inadequately dimensioned electrical installations can lead to serious damage.
The mains lead, and its fuse protection, must be dimensioned in accordance with
the local power supply. The technical data shown on the nameplate shall apply.
3-4 Welding cables instruction
When welding, please pay attention to the followings:
a. The welding cables should be kept as short as possible;
b. If extended cable is used, please do as shown in Fig. 3-4-1.
Wrong
Coil the excess ground cable and welding cable
in same direction respectively.
Correct
Straighten the ground cable and welding cable
and make them close to each other.
Bundle the ground cable and welding cable
together, running the wires close to the ground.
Correct
When the excess cables are only be used by
rolling up, coil the cables to two windings in
reverse direction and overlap them.
The number of turns for A is same as the
number for B.
Handle the welding cable and ground cable
according to above-mentioned method.
Fig. 3-4-1: Welding cables instruction

13
4-ARC series
4-1 System components
ARC series welding machine can be equipped with many different accessories and can be
used in different special sites with different configurations.
Fig. 4-1-1: System components
4-2 Basic equipments for welding
Only be equipped with the necessary accessories, can the power source ARC series operate
well. The following is the needed accessories list.
STICK welding
-Power source
-Ground cable
-Electrode holder
-Electrode
TIG welding
-Power source
-Ground cable
-TIG torch with gas valve switch
-Gas regulator, gas hose, gas cylinder (to supply the machine with shielding gas)
-Welding wire

14
4-3 Control panel
The functions on the control panels are all arranged in a very logical way.
Note! Some described parameters in this manual may be slightly different from
the power source, some identification may be slightly different from power source
identification, but the manner of working is the same.
Warning! Operating the equipment incorrectly can cause serious injury and
damage. Do not use the functions described here until you have read and
completely understood all content of this manual.
Fig. 4-3-1: Control panel
Fig. 4-3-2: Control panel

15
1. Power on indicator
Green color, will light up if the machine is switched on AC230V power supply; light off if there’
s some problems with power supply.
2.Protection on indicator
Yellow color, will light off if the machine operates properly; lights up if the power source
overheats or has some other fault, and machine will stop working automatically. Keep the
machine power on and fan running until the indicator lights off, then wait 20 minutes before
start welding.
3.Welding current adjustment knob
Used for adjusting current value. Adjust welding current according to work piece thickness,
groove shapes, welding position, electrode diameter, etc. Welding current decides welding
seam penetration and wire melt speed.
4.Arc force current adjustment knob
Used for adjusting the arc force current. During welding, improper operation or droplet
transfer may cause short circuit between the electrode and work piece. To reduce this
problem, when the arc voltage is low, increase the arc force can let the droplet transfer into
molten pool as soon as possible, which will reduce the short circuit rate and improve anti-stick
function.
5.MMA/TIG switch(optional)
Used for switching between MMA and TIG;
Switch is on “MMA” position, welding machine is on DC STICK working mode;
Switch is on “TIG ” position, welding machine is on TIG working mode.
4-4 Interface
Fig. 4-4-1: interface

16
1. Welding cable quick socket (-)
On MMA mode, used for connecting the work piece.
On TIG mode, used for connecting the torch.
On MMA mode,When welding with 6010 electrode,used for connecting the electrode holder.
2.Welding cable quick socket (+)
On TIG mode, used for connecting the work piece.
On MMA mode , used for connecting the electrode holder.
On MMA mode,When welding with 6010 electrode,used for connecting the work piece.
3.Fan
Cool down the hot components inside welding machine
4.Power cord
The mixed-colored wire must be firmly grounded; the rest wires connect to 1- phase AC
220/230V ~50/60Hz power supply.
5.Main switch
Switch for 220/230V single-phase AC power.Turn on this switch (on the position:“ON”), then
the Power on indicator lights up, and the fan runs.
4-5 Installation
Warning! An electric shock can be fatal. If the machine is plugged into the mains
electricity supply during installation, there is high risk of very serious injury and
damage. Do not use the functions described here until you have read and
completely understood “safety rules” in the beginning.Only carry out work on the
machine when
- the mains switch is on turn-off position,
- the machine is unplugged from the mains.
● Installation environment requirements
1. It should be placed indoors without direct sunlight, rainproof, low humidity and less dust.
The ambient air temperature range is -10℃~+40℃.
2. The inclination to the ground should not exceed 10°.
3. There should be no wind in the welding station, if any, it should be covered.
4. The welding machine is more than 20cm away from the wall, and the distance between the
welding machine is more than 10cm.
5. When using water-cooled welding torch, pay attention to anti-freezing.
●Power supply and cable requirement
Please note the size of fuse and circuit breaker in the table below are for reference only.

17
Table.4-5-1:Power supply and cable requirement
Note! Welding machine must be taken special design if it is powered by generator, Please
contact with manufacturer if you have such needs.
●Connections of power cord and distribution box
Warning! -Avoid hot-line work
- Operating by professional electrician
- Avoid connecting two power sources to one breaker
- Please refer to Table 4-5-1 to check if standard of input voltage, breaker and input
cable is suitable
Fig. 4-5-1: Connections of power cord and distribution box
Model
160
200
250
Power supply
1- phase AC220/230V, 50/60Hz
Electricity grid min.
power (KVA)
Power grid
12
12
16
Generator
18
18
25
Input protection(A)
Fuse
60
60
60
Circuit breaker
60
60
60
Cable size (mm²)
Power cord
2.5
2.5
2.5
Welding cable
16
16
25
Protective GND
wire
2.5
2.5
2.5