Arcoweld Arcostick MMA 130 User manual


CONGRATULATIONS!
THANK YOU FOR YOUR PURCHASE OF THIS
QUALITY ARCOWELD PRODUCT!
WELCOME TO THE ARCOWELD TEAM!
We look forward to supporting you with dependable service and
our extensive range of first-class products.
Our range can be viewed at -https://arcoweld.com.au/
For support please contact your Authorised distributor or Arcoweld
directly
T: + 61 8 9248 3188
F: + 61 8 9248 3166
93 Mulgul Road, MALAGA, WA6090
PO Box 3087, MALAGA DC, WA 6945
Email- [email protected]m.au
Website- www.alloysteel.net

CONTENT
II
CONTENTS
1 SAFETY ...................................................................................................................................................1
1.1 SIGNAL EXPLANATION ..............................................................................................................................2
1.2 ARC WELDING DAMAGE ...........................................................................................................................1
1.3 THE KNOWLEDGE OF ELECTRIC AND MAGNETIC FIELDS...................................................................................5
2 SUMMARY..............................................................................................................................................6
2.1 BRIEF INTRODUCTION...............................................................................................................................6
2.2 WORKING PRINCIPLE ...............................................................................................................................6
2.3VOLT-AMPERAGE CHARACTERISTIC .............................................................................................................7
3INSTALLATION & ADJUSTMENT ...............................................................................................................8
3.1 PARAMETERS ..........................................................................................................................................8
3.2DUTY CYCLE &OVER HEAT ........................................................................................................................8
3.3 WELDING POLARITY CONNECTION...............................................................................................................8
3.3.1 MMA (take TM-1600E for an example) .....................................................................................8
3.3.2 TIG (take TM-1600E foran example).........................................................................................9
4OPERATION CONTROL AND CONNECTORS...........................................................................................10
4.1LAYOUT FOR FRONT &REAR PANEL (EXAMPLE FOR TM-1600E) ...............................................................10/11
4.2 WELDING CURRENT ADJUSTMENT.............................................................................................................12
4.3 WELDING OPERATION ............................................................................................................................12
4.3.1 Striking thearc..........................................................................................................................12
4.3.2 Manipulation of electrode........................................................................................................13
4.4 WELDING PARAMETERS............................................................................................................................13
4.4.1 Joint form in MMA....................................................................................................................13
4.4.2 Electrode selection ...................................................................................................................13
4.5ARC WELDING DEFECT AND PREVENT METHOD..........................................................................................14
4.7 OPERATIONAL ENVIRONMENT.................................................................................................................15
4.8 OPERATIONAL NOTICES .......................................................................................................................16
5 MAINTENANCE & TROUBLESHOOTING .................................................................................................17
5.1 MAINTENANCE .....................................................................................................................................16
5.2 TROUBLESHOOTING ...............................................................................................................................18
5.3 ELECTRICAL PRINCIPLE DRAWING ..............................................................................................................21

SAFETY

1 SAFETY
1.1 Signal Explanation
The above signals mean warning! Running parts and electric shock can cause injury to yourself
or others. The corresponding notices are as follows. It is quite a safe operation after taking
several necessary protection measures.
1.2 Arc Welding Damage
The following points explain some of the dangers that could cause injury to yourself or
others. Please always show care.
Only authorised persons can install, debug, operate, maintain and repair the equipment.
During the operation, only persons relative to the welding operation should be present.
After shutting off the machine power, please maintain and examine the equipment according
to section 5 because of the DC voltage existing in the electrolytic capacitors.
ELECTRIC SHOCK CAN KILL.
Never touch electrical parts.
Wear dry, hole-free gloves and clothes to insulate yourself.
Insulate yourself from work and ground using dry insulation. Make certain the insulation is
large enough to cover your full area of physical contact with work and ground.
Take care when using the equipment in confined spaces, heights and wet circumstances.
Always isolate machine power before installation and adjustment.
Ensure to install the equipment correctly and ground the work or metal to be welded to a
good electrical (earth) ground according to the operation manual.
The electrode and work (or ground) circuits are electrically “hot” when the welder is on. Do
not touch these “hot” parts with your bare skin or wet clothing. Wear dry, hole-free gloves to
insulate hands.
In semiautomatic or automatic wire welding, the electrode, electrode reel, welding head,
nozzle or semiautomatic welding gun are also electrically “hot”.

SAFETY

Ensure the work cable makes a good electrical connection with the metal being welded.
The connection should be as close as possible to the area being welded.
Maintain the electrode holder, work clamp, welding cable and welding machine in good, safe
operating condition. Replace damaged insulation.
Never dip the electrode in water for cooling.
Never simultaneously touch electrically “hot” parts of electrode holders connected to two
welders because voltage between the two can be the total of the open circuit voltage of both
welders.
When working above floor level, use a safety belt to protect yourself from a fall should you
get a shock.
FUMES AND GASES CAN BE DANGEROUS.
Welding may produce fumes and gases hazardous to health. Avoid breathing these fumes
and gases. When welding, keep your head out of the fume. Use enough ventilation and/or
exhaust at the arc to keep fumes and gases away from the breathing zone. When welding with
electrodes which require special ventilation such as stainless or hard facing or on lead or
cadmium plated steel and other metals or coatings which produce highly toxic fumes, keep
exposure as low as possible and below Threshold Limit Values using local exhaust or mechanical
ventilation. In confined spaces or in some circumstances, outdoors, a respirator may be required.
Additional precautions are also required when welding on galvanized steel.
Do not weld in locations near chlorinated hydrocarbon vapors coming from degreasing,
cleaning or spraying operations. The heat and rays of the arc can react with solvent vapors to
form phosgene, a highly toxic gas, and other irritating products.
Shielding gases used for arc welding can displace air and cause injury or death. Always use
enough ventilation, especially in confined areas, to ensure breathing air is safe.
Read and understand the manufacturer’s instructions for this equipment and the consumables
to be used, including the material safety data sheet and follow your employer’s safety practices.
ARC RAYS CAN BURN.
Use a shield with the proper filter and cover plates to protect your eyes from sparks and the
rays of the arc when welding or observing open arc welding.
Use suitable clothing made from durable flame-resistant material to protect your skin and that
of your helpers from the arc rays.

SAFETY
3
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 metal.

SAFETY

SELF-PROTECTION
Keep all equipment safety guards, covers and devices in position and in good repair. Keep
hands, hair, clothing and tools away from V-belts, gears, fans and all other moving parts when
starting, operating or repairing welding equipment.
Do not put your hands near the engine fans. Do not attempt to override the governor or idler
by pushing on the throttle control rods while an engine is running.
DO NOT add fuel near an open flame welding arc or when engines are
running. Stop the engine and allow it to cool before refueling to prevent spilled fuel from
vaporizing on contact with hot engine parts and igniting. Do not spill fuel when filling tank. If fuel
is spilled, wipe it up and do not start engine until fumes have been eliminated.
WELDING SPARKS can cause fire or explosion.
Remove fire hazards from the welding area. If this is not possible, cover them to prevent the
welding sparks from starting a fire. Remember that welding sparks and hot materials from
welding can easily go through small cracks and openings to adjacent areas. Avoid welding near
hydraulic lines. Have a fire extinguisher readily available.
Where compressed gases are to be used at the job site, special precautions should be used to
prevent hazardous situation.
When not welding, make certain no part of the electrode circuit is touching the work or ground.
Accidental contact can cause overheating and create a fire hazard.
Do not heat, cut or weld tanks, drums or containers until the proper steps have been taken to
ensure that such procedures will not cause flammable or toxic vapors from substances inside.
They can cause an explosion even though they have been “cleaned”.
Vent hollow castings or containers before heating, cutting or welding. They may explode.
Sparks and spatter are thrown from the welding arc. Wear oil free protective garments such as
leather gloves, heavy shirt, cuff less trousers, high shoes and a cap over your hair. Wear ear plugs
when welding out of position or in confined places. Always wear safety glasses with side shields
when in a welding area.
Connect the work cable to the work as close to the welding area as practical. Work cables
connected to the building framework or other locations away from the welding area increase the

SAFETY

possibility of the welding current passing through lifting chains, crane cables or other alternate
circuits. This can create fire hazards or overheat lifting chains or cables until they fail.
Rotating parts may be dangerous.
Use only compressed gas cylinders containing the correct shielding gas for the process used
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.
Always keep cylinders in an upright position securely chained to an undercarriage or fixed
support.
Cylinders should be located:
-Away from areas where they may be struck or subjected to physical damage.
-Asafe distance from arc welding or cutting operations and any other source of heat, sparks,
or flame.
Never allow the electrode, electrode holder or any other electrically “hot” parts to touch a
cylinder.
Keep your head and face away from the cylinder valve outlet when opening the cylinder valve.
Valve protection caps should always be in place and hand tight except when the cylinder is in
use or connected for use.
1.3 The knowledge of Electric and Magnetic Fields
Electric current flowing through any conductor causes localized Electric and Magnetic Fields
(EMF). The discuss on the effect of EMF is ongoing all the world. Up to now, no material
evidences show that EMF may have effects on health. However, the research on damage of EMF
is still ongoing. Before any conclusion, we should minimize exposure to EMF as few as possible.
In order to minimize EMF, we should use the following procedures:
Route the electrode and work cables together – Secure them with tape when possible.
All cables should be put away and far from the operator.
Never coil the power cable around your body.
Make sure welding machine and power cable is as far away from the operator as possible
according to the actual circumstances.
Connect the work cable to the workpiece as close as possible to the area being welded.
Persons with heart-pacemaker should be away from the welding arc.

SUMMARY
6
2 Summary
2.1 Brief Introduction
Arcostick welders are general MMA arc welder which adopts the latest pulse width modulation
(PWM) technology and the insulated gate bipolar transistor (IGBT) power module.
Arcostick series welders have excellent performance: constant current output makes welding arc
more stable; fast dynamic response speed reduces the impact from the arc length fluctuation to
the current; accurate stepless current adjustment and pre-setting function. There are also some
automatic protection functions for under voltage, over current, overheat, etc. inside the welders.
Should these problems occur the alarm on the front panel will light up and at the same time the
output current will be cut off. It can self-protect and prolong the using life and greatly improved
the reliability and practicability of the welders.
Arcostick series welders can also realize TIG operation. In MMA operation, if the electrode
touches workpiece over two seconds, the welding current will drop to the minimum current
automatically to protect the electrode. In TIG operation, the minimum current will be outputted
firstly until the arc is ignited by the lifting method, the output current will rise to the preset value,
which can protect the electrode. At the same time, the arc force and hot start will be provided
with MMA operation.
MMA——Manual Metal Arc welding;
PWM——Pulse-Width Modulation;
IGBT——Insulation Gate Bipolar Transistor;
TIG——Tungsten Inert Gas welding.
2.2 Working Principle
The working principle of Arcostick series welders is shown as the following figure. Single phase
220V±10% work frequency (50/60 Hz) AC is rectified into DC, then is converted to medium
frequency AC (about 20KHz) by inverter device (IGBT module), after reducing voltage by medium
transformer (the main transformer) and rectified by medium frequency rectifier (fast recovery
diodes) and is outputted by inductance filtering. The circuit adopts current feedback control

SUMMARY
7
technology to insure current output stably. Meanwhile, the welding current parameter can be
adjusted continuously to meet with the requirements of welding craft.
Rectify Inverter
Medium
frequency
transformer
Medium
frequency
rectify
Hall device
Current positive-
feedback control
Single phase,
AC DC AC DC
220V±10%(50/60
HZ)
AC DC
2.3 Volt-Ampere Characteristic
Arcostick welders have excellent volt-ampere characteristic as per the following graph. In MMA
welding, the relation between the rated loading voltage U2and welding current I2 is as follows:
When I2 ≤600A，U2＝20＋0.04 I2（V）； When I2＞600A，U2＝44（V）.
64
44
20
0600 I
2
（A）
U
2
（V）
Working
point
Volt-ampere characteristic The relation of the rated loading
voltage&welding current