ARC 200CT User manual

ARC 200CT WELDING
MACHINE
USER MANUAL

Preface
This manual includes hardware description and operation introduction of the equipment. For your
and other people’s safety, please read the manual carefully.
Pay attention
Pay attention to the words after the signs below.
Sign
Description
The words after this sign means there is great potential danger, which
may cause major accident, damage or even death, if it is not followed.
The words after this sign means there is some potential danger, which
may cause hurt or property lose, if it is not followed.
The words after this sign means there is potential risk, which may
cause equipment fault or break, if it is not followed.
Version
Version YF-TAE-0060, A1, Released on 22th, Jan, 2018.
The contents of this manual are updated irregularity for updating of product. The manual is only
used as operation guide, except for other promises. No warranties of any kind, either express
or implied are made in relation to the description, information or suggestion or any other
contents of the manual.
The images shown here are indicative only. If there is inconsistency between the image and the
actual product, the actual product shall govern.

3
Content
SAFETY WARNING........................................................................................................................................... 4
MACHINE DESCRIPTION................................................................................................................................. 9
TECHNICAL PARAMETERS TABLE.............................................................................................................. 10
INSTALLATION INSTRUCTION...................................................................................................................... 11
OPERATION INSTRUCTION.......................................................................................................................... 12
PANEL FUNCTION INSTRUCTION................................................................................................................ 13
NOTES OR PREVENTIVE MEASURES......................................................................................................... 14
QUESTIONS TO BE RUN INTO DURING WELDING.................................................................................... 15
MAINTENANCE............................................................................................................................................... 16
TROUBLE SHOOTING AND FAULT FINDING............................................................................................... 17

4
SAFETY WARNING
The safety notes listed in this manual is to ensure correct use of the machine and to keep you and other
people from being hurt.
The design and manufacture of welding machine considers safety. Please refer to the safety warning
listed in the manual to avoid accidents.
Different damage would be caused by wrong operation of the equipment as follows. Please read the
user manual carefully to reduce such damage.
Sign
Description

Any contact of electric parts may cause fatal electric shock or burnt.

Gas and fumes are harmful to health.

Operation in narrow space may cause choke .

Spark and hot workpiece after welding may cause fire.

Bad connected cable may cause fire.

Incompletion connection of workpiece side circuit may cause fire.

Never weld on the case of tinder stuff, or it may cause explode.

Never weld airtight containers such as slot, pipe etc., or it may break.

Arc ray may cause eye inflammation or skin burnt.

Spark and residue will burn your eyes and skin.

Toppling over of the gas cylinder will cause body hurt.

Wrong use of the gas cylinder will lead to high-pressure gas eruption
and cause human hurt.

Never let fingers, hair, clothes or etc. near the moving parts such as
the fan.

The wire shoot out of the torch may stab eyes, face and other naked
parts.

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
The machine is portable, never lift it by any equipment.
Please follow the rules below to avoid heavy accidents.
Never use the equipment to do other things but welding.
Follow related regulations for the construction of the input-driven power source, choice of place,
usage of high-pressure gas, storage, configuration, safe-keeping of workpiece after welding and
disposal of waste, etc.
Nonessentials do not enter the welding area.
People using heart pacemaker is not allowed to get close to the welding machine or area without
doctor’s permission. The magnetism created by energizing the welding machine can have a bad
effect to the pacemaker.
Install, operation, check and maintain the equipment by profession personnel.
Understanding the contents of the user manual for safety.
Please follow the rules below to avoid electric shock。
Keep away from any electric parts.
Earth the machine and workpiece by professional personnel.
Cut off the power before installation or checking, and restart 5 minutes later. The capacitance is
chargeable device. Please ensure it has no voltage before start again even if the power source is cut
off.
Do not use wire with inadequate section surface or damage insulation sleeve or even exposed
conductor.
Do ensure well isolation of wire connection.
Never use the device when the enclosure is removed.
Never use broken or wet insulation gloves.
Use firenet when work at high position.
Check and maintain regularly, don’t use it until the broken parts are fixed well.
Turn off the power when not in used.
Follow the national or local related standard and regulations when using the AC welding machine at
narrow or high position.
Please follow the below notes to avoid fire and explode, etc.

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No combustible in welding area.
Keep off combustible when welding.
Keep hot workpiece after welding away from flammable gas.
Do move away the combustible around when weld the dooryard, ground and wall,.
The wire connection of base metal should be as close to the welding place as possible.
Never weld those facilities with gas pipe or airtight slot.
Put fire extinguisher around the welding area to prevent fire.
The gas and fumes are harmful to health, please wear protective device
according to regulations.
Wear exhaust equipment and breathe preventive facilities to prevent gas poisoning or choke.
Use suggested part exhaust equipment and breathe preventive facilities to prevent hurt or poisoning
by gas and other powder, please.
To prevent oxygen-deficiency, air out the gas-filled room which isfull of CO2and argon on the bottom,
when operating on trunks, boilers, cabins, etc.
Please accept the supervisor’s inspection when operating in narrow space. Air the room and wear
breathe preventive facilities.
Never operate in degrease, washing or spray space.
Using breathe preventive facilities when weld shielded steel for it will cause poisonous dust and gas.
The arc, spark, residue and noise are harmful to health, please wear
protective appliance.
Eye protection against arc is recommended when welding or supervise welding.
Please wear preventive spectacles.
Welder’s gloves, welder’s goggles, long sleeve clothes, leather apron, and other standard protection
equipments must be worn for welding operation.
A screen to protect other people against the arc must be set in the welding place.
Please follow the notes below to avoid gas cylinder toppling over or broken.
Use the gas cylinder correctly.
Use the equipped or recommended gaseous regulator.
Read the manual of gaseous regulator carefully before using it, and pay attention to the safety notes.

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Fix the gas cylinder with appropriative holder and other relative parts.
Never put the cylinder under high temperature or sunshine environment.
Keep your face away from the gas cylinder exit when opening it.
Put on the gas shield when it is not used.
Never put the torch on the gas cylinder. The electrode can not meet the gas cylinder.
Any touch of the switch part will cause injury, please note the following.
Never use the machine when the enclosure is off.
Install, operate, check and maintain the machine by professional person.
Keep your fingers, hair, clothes etc. away from the switch parts such as the fan.
The wire end may deal damage, please note the following.
Never look into the electric conduction hole when checking the wire feeding is normal or not, , or the
shooting wire may stab your eyes and face.
Keep youreyes, face or other naked parts away from the end of torch when feeding the wire manually
or pressing the switch.
For better work efficiency and power source maintenance, please note the
following.
Precautions against toppling over.
Never use the welding equipment for pipe thawing.
Lift the power source from side when use the up-down forklift truck to avoid toppling over.
When using the crane for lift, tie the rope to the ears with an angle no more than φ15 to the vertical
direction.
When lifting the welding machine which equipped with gas cylinder and wire feeder, download them
from the power source and ensure the horizontal of the machine. Do fix the gas cylinder with belt or
chain when moving it to avoid body hurt.
Ensure fastness and insulation when lifting the wire feeder through the swing ring for welding.
Electromagnetic interference needing attention.
It may need extra preventive measures when the equipment is used in particular location.

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Before the installation, please estimate the potential electromagnetism problems of the environment
as follows.
a) Upper and lower parts of the welding equipments and other nearby power cable, control cable,
signal cable and phone cable.
b) Wireless electric as well as TV radiation and reception equipment.
c) Computer and other control equipments.
d) Safety-recognition equipment etc. Such as supervise of industrial equipments.
e) Health of people around. Such as personnel using the heart pacemaker or audiphone.
f) Equipments for adjustment and measurement.
g) Anti-disturb capability of other used equipments .Users should ensure these equipments and the
environment are compatible, which may need extra preventive measures.
h) Practical state of the welding and other activities.
Users should observe the following dos and don’ts to decrease radiation interference.
a) Connect the welding equipments to the power supply lines.
b) Maintain the welding equipments regularly.
c) The cable should be short enough to be close to each other and the ground.
d) Ensure the safety of all the welding metal parts and other parts nearby.
e) The workpiece should be well earth.
f) Shield or protect the other cable and equipments to decrease the effects of disturbances. The
welding equipments can be complete shielded in some special conditions.
Users are responsible for interference due to welding.

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MACHINE DESCRIPTION
The welding machine is a rectifier adopting the most advanced inverter technology.
The development of inverter gas-shielded welding equipment benefits from the development of the inverter
power supply theory and components. Inverter gas-shielded welding power source utilizes high-power
component to transfer 50/60Hz frequency up to 100KHz, then reduce the voltage and commutate, and output
high-power voltage via PWM technology. Because of the great reduce of the main transformer’s weight and
volume; the efficiency increases by 30%. The appearance of inverter welding equipment is considered to be
a revolution for welding industry.
The welding power source can offer stronger, more concentrated and more stable arc. When stick and work
piece get short, its response will be quicker. It means that it is easier to design into welding machine with
different dynamic characteristics, and it even can be adjusted for specialty to make arc softer or harder.
MMA welding machine has the following characteristics: effective, power saving, compact, stable arc, good
welding pool, high no-load voltage, and good capacity of force compensation and multi-use. It can weld
stainless steel, alloy steel, carbon steel, copper and other color metal. It can apply to electrode of different
specifications and materials, including acidity, alkalescence. It can apply in high altitude, the open air and
inside and outside decoration. Compared with the same products of home and abroad, it is compact in volume,
light in weight, easy to install and operate.
Thanks for purchasing our product and hope for your precious advice. We will dedicate to produce the best
products and offer the best service.
WARNING!
The machine is mainly used in industry. It will produce radio wave, so the worker should
make fully preparation for protection.

10
TECHNICAL PARAMETERS TABLE

11
INSTALLATION INSTRUCTION
The machine is equipped with power voltage compensation equipment.When the power voltage fluctuation is
between±15% of rated voltage, it still can work normally.
When the machine is used with long cables, in order to prevent voltage from going down, bigger section
cable is suggested. If the cable is too long, it may affect the performance of the power system. So cables of
configured length are suggested.
1. Make sure the intake of the machine is not blocked or covered to avoid malfunction of cooling system.
2. Put the fastening plug of the cable to fastening socket of “+” terminal at the front panel, fasten it
clockwise, and the earth clamp at the other terminal clamps the work piece.
3. Please pay attention to the connecting terminal, DC welding machine has two connecting ways: positive
connection and negative connection. Positive connection: holder connects with “-” terminal, while work
piece with the “+” terminal. Negative connection: work piece with the“-” terminal, holder with the “+”
terminal. Choose suitable way according to the working situation. If unsuitable choice is made, it will
cause unstable arc, more spatters and conglutination. If such problems occur, please change the polarity
of the fastening plug.
4. According to input voltage grade, connect power cable with power supply box of relevant voltage grade.
Make sure no mistake is made and make sure the voltage difference is among permission range. After
the above job, installation is finished and welding is available.
The images shown here are indicative only. The actual product may differ.
Earth clamp
Electrode holder
Workpiece
L1
L2
Ground cable

12
OPERATION INSTRUCTION
1. Turn on the power switch, the power led lights up.
2. Adjust knobs of welding current and arc-striking push, make welding function complies with demands.
3. Generally, welding current is adequate to welding electrode according with as following:
Specification
φ2.5
φ3.2
φ4.0
φ5.0
Current
50-90A
90-130A
140-210A
190-270A
WARNING！
Before connecting operation please make sure all the power is turned off. The right order
is to connect the welding cable and ground cable to the machine first, and make sure they
are firmly connected and then put the power plug to the power source.

13
PANEL FUNCTION INSTRUCTION
ARC 200CT/250CT FRONT PANEL ARC 200CT/250CT BACK PLANEL
NO.
Function
1
Current meter
2
Abnormal indicator
3
VRD indicator
4
Welding current adjusting knob
5
Power switch
The images shown here are indicative only. The actual product may differ.

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NOTES OR PREVENTIVE MEASURES
1. Environment
1）The machine should be operated in dry environments with humidity levels of max 90%.
2）Ambient temperature should be between -10 to 40 degrees centigrade.
3）Avoid welding in sunshine or drippings. Do not let water inter the machine.
4）Avoid welding in dust area or the environment with corrosive gas.
5）Avoid gas welding in the environment with strong airflow.
2. Safety norms
The welding machine is installed with protection circuit of over voltage, over current and over heat. When
voltage, output current and temperature of machine exceed the required standard, welding machine will
stop working automatically. However, overuse (such as over voltage) will still result in damage to the
welding machine. To avoid this, the user must pay attention to the following.
1）The working area is adequately ventilated！
The welding machine is powerful machine, when it is being operated, it generated by high currents,
and natural wind will not satisfy machine cool demands. So there is a fan in inner-machine to cool
down machine. Make sure the intake is not in block or covered, it is 0.3 meter from welding machine
to objects of environment. User should make sure the working area is adequately ventilated. It is
important for the performance and the longevity of the machine.
2）Do not over load！
The operator should remember to watch the max duty current (Response to the selected duty cycle).
Keep welding current is not exceed max duty cycle current. Over-load current will damage and burn
up machine.
3）No over voltage！
Power voltage can be found in diagram of main technical data. Automatic compensation circuit of
voltage will assure that welding current keeps in allowable range. If power voltage is exceeding
allowable range limited, it will damage to components of machine. The operator should understand
this situation and take preventive measures.
4）Ground the earth wire in the power supply cable.
5）If welding time is exceeded duty cycle limited, welding machine will stop working for protection.
Because machine is overheated, temperature control switch is on “ON’’ position and the indicator light
is red. In this situation, you don’t have to pull the plug, in order to let the fan cool the machine. When
the indicator light is off, and the temperature goes down to the standard range, it can weld again.

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QUESTIONS TO BE RUN INTO DURING WELDING
Fittings, welding materials,environment factor, supply powersmaybe have something to do with welding. User
must try to improve welding environment.
A. Arc-striking is difficult and easy to pause
1. Make sure quality of electrode is high.
2. If the electrode is not dried, it will cause unstable arc, welding defect increases and the quality is down.
3. If use extra-long cable, the output voltage will decrease, so please shorten the cable
B. Output current not to rated value
When power voltage departs from the rated value, it will make the output current not matched with rated
value; when voltage is lower than rated value, the max output may lower than rated value.
C. Current is not stabilizing when machine is being operated
It has something with factors as following:
1. Electric wire net voltage has been changed.
2. There is harmful interference from electric wire net or other equipment
D. Too much spatter
1. Maybe current is too big and stick’s diameter is too small.
2. Output terminal polarity connection is wrong, it should apply the opposite polarity at the normal technics,
which means that the stick should be connected with the negative polarity of power source, and work
piece should be connected with the positive polarity. So please change the polarity.

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MAINTENANCE
1. Remove dust by dry and clean compressed air regularly, if welding machine is operating in environment
where is polluted with smokes and pollution air, the machine need remove dust every month.
2. Pressure of compressed air must be within the reasonable range in order to prevent damaging to small
components of inner-machine.
3. Check internal circuit of welding machine regularly and make sure the circuit connections are connected
correctly and tightly (especially plug-in connector and components). If scale and rust are found, please
clean it, and connect again tightly.
4. Prevent water and steam from entering into the machine. If that happens, please blow it dry and check
insulation of machine.
5. If welding machine will not be used for long time, it must be put into the packing box and stored in dry and
clean environment.

17
TROUBLE SHOOTING AND FAULT FINDING
Notes: The following operations must be performed by qualified electricians with valid certifications.
Before maintenance, please contact with us for professional suggestion.
Faults symptom and solutions
Faults symptom
Solutions
Power indicator is not lit,
fan is not working, no
welding output.
A.
B.
Make sure power switch is close.
Make sure the electric wire net connecting to input cable is working
alright.
Power indicator is lit, fan
doesn’t work, no welding
output.
A.
B.
Input cable is possibly connected to 380V power, which causes over
voltage protection circuit is starting. Connect input cable to 220V power,
then restart the machine.
Erratic 220V power supply (input cable is too thin and long) or input
cable is connected to electricity network would start overload voltage
protection circuit. Increase section of input cable or tighten input
contact. Turn off machine for 2-3 min and restart it.
C.
Turn on and off power switch continuously would start overload voltage
protection circuit. Turn off machine for 2-3 min and restart it.
D.
Cables are loosed between power switch and power source board,
tighten them again.
Erratic welding output
current or out of control of
potentiometer.
A.
B.
1K potentiometer is damaged, replace it.
Terminal of output is broken circuit or poor connect.
Fan is working and
abnormal indicator is not
lit, no welding output.
A.
B.
C.
D.
Check if components are poor connects.
Check if connector of output terminal is break circuit and poor connect.
Check voltage between power source board (VH-07) is about DC
308V. If green indicator is not lit in assistant power of the board,
please connect with seller or our company and replace it.
E.
If there is some question in control circuit, please connect with seller or
our company.
Fan is working and
abnormal indicator is lit,
no welding output.
A.
B.
C.
Overload current protection may start, please turn off machine first, then
restart it after abnormal indicator is off.
Overheat protection may start, it will become normal in 2-3min.
Inverter circuit may go wrong. Please disconnect the power supply plug
of the main transformer on the board (near fan VH-07), then restart the
machine.
1）If abnormal indicator is still lit, that means some fieldistors on the
board are damaged. Check and replace them.
2）If abnormal indicator is off:
a.Maybe transformer of middle board is damaged, measure
primary inductance value and Q value of main transformer by
inductance bridge.
b.Primary value is parallel circuit, L=1.2-2.0mH, Q>40 If
inductance value and Q value is low, replace it.
c. Maybe some of secondary rectifier tube of transformer is broken,
check and replace rectifier tube.
D.
Maybe feedback circuit is in fault.