Arcoweld Arcostick MMA 160 Minespec User manual

CONTENTS

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: [phone]
F: + 61 8 9248 3166
93 Mulgul Road, MALAGA, WA 6090
PO Box 3087, MALAGA DC, WA 6945
Email- [email protected]m.au
Website- www.alloysteel.net

CONTENTS
II
CONTENTS
1 SAFETY ...................................................................................................................................................1
1.1 SIGNAL EXPLANATION ..................................................................................................................................1
1.2 ARC WELDING DAMAGE...............................................................................................................................1
1.3THE KNOWLEDGE OF ELECTRIC AND MAGNETIC FIELDS.......................................................................................5
2 SUMMARY..............................................................................................................................................6
2.1 BRIEF INTRODUCTION...................................................................................................................................6
2.2 WORKING PRINCIPLE ...................................................................................................................................7
2.3 VOLT-AMPERAGE CHARACTERISTIC .................................................................................................................7
3INSTALLATION & ADJUSTMENT ............................................................................................................. .8
3.1 PARAMETERS.......................................................................................................................................8
3.2 DUTY CYCLE &OVER HEAT ............................................................................................................................9
3.3 WELDING POLARITY CONNECTION WAY .............................................................................................................9
3.3.1 MMA ................................................................................................................................................. 9
3.3.2 (TIG) ...................................................................................................................................................10
4OPERATION CONTROL AND CONNECTORS...........................................................................................11
4.1 LAYOUT FOR FRONT &REAR PANEL...........................................................................................................11
4.3 WELDING OPERATION ................................................................................................................................13
4.3.1 Striking the arc .................................................................................................................................. 13
4.3.2 Manipulation of electrode ............................................................................................................... 14
4.4 WELDING PARAMETERS .............................................................................................................................14
4.4.1 Joint form in MMA .................................................................................................................... .......14
4.4.2 Electrode selection .......................................................................................................................... 14
4.5 ARC WELDING DEFECT AND PREVENTION METHOD .................................................................................... ..15
4.6 OPERATION ENVIRONMENT.......................................................................................................................16
4.7 OPERATION NOTICES ...............................................................................................................................16
5 MAINTENANCE & TROUBLESHOOTING..............................................................................................18
5.1 MAINTENANCE .......................................................................................................................................18
5.2 TROUBLESHOOTING .................................................................................................................................19
5.3 ELECTRICAL PRINCIPLE DRAWING ................................................................................................................21

SAFETY
1
1 SAFETY
1.1 Signal Explanation
The above icons mean warning! Danger! Injury exists from electric shock or running parts.
The corresponding notices are as follows.
1.2 Arc Welding Damage
The following signals and word explanations explain damage or injury that may occur when
welding. Please remind yourself and others to be aware.
Only persons who are authorised can install, debug, operate, maintain and repair the
equipment.
During the operation, only required persons should be present.
After shutting off the machine power, please maintain and examine the equipment according
to Part 5 due to 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 restricted spaces, and wet circumstances.
Never close the machine power before installation and adjustment.
Ensure you 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
2
Always be sure 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 fumes. 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.

SAFETY
3
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.
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
4
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 equipment.
Do not put your hands near the engine fan. Do not attempt to override the governor or idler by
pushing on the throttle control rods while the engine is running.
DO NOT adds fuel near an open flame welding arc or when the engine is
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
5
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:
Never coil the power cable around your body.
Make sure welding machine and power cable to be positioned a safe distance from the
operator.
Connect the work cable to the workpiece as close as possible to the area being welded.
Persons with heart-pacemakers should be away from the welding arc.

SUMMARY
6
2 Summary
2.1 Brief Introduction
Arcoweld MMA welders are general MMA arc welder which adopt the latest pulse width
modulation (PWM) technology and the insulated gate bipolar transistor (IGBT) power module. It
can change work frequency to medium frequency to replace the traditional hulking work
frequency transformer with the cabinet medium frequency transformer. Thus, it is characterized
with portable, small size, low consumption etc.
Arcoweld MMA’s excellent performances: 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. Should a problem
occur an 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.
Arcoweld MMA welders can also realize TIG operation. In 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 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.

SUMMARY
7
2.2 Working Principle
The working principle of Arcoweld MMA welders is shown in the following figure. Single phase
110V －220V±10%work frequency (50/60 Hz) AC is rectified into DC, then by PFC circuit,
DC(about 380V)is converted to medium frequency AC (about 20-40KHz) 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 technology to insure current output stably. Meanwhile,
the welding current parameter can be adjusted continuously and steplessly to meet with the
requirements of welding craft.
2.3 Volt-Amperage Characteristic
Arcoweld MMA welders have excellent volt-amperage characteristics, as displayed in 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）.

INSTALLATION AND ADJUSTMENT
8
3 Installation & Adjustment
3.1 Parameters
Models
Parameters
160 PFC
Input power Single phase 98V-165V，50/60Hz Single phase 177V-265V，50/60Hz
TIG MMA TIG MMA
Rated input current（A）21.3 34.7 14.4 22.3
Rated input power（KW）2.2 3.8 3.1 4.7
Power factor 0.99 0.99
Welding current range（A）10～125 10～160
Max no-load voltage(V) 55(80)
Efficiency ≥80％≥80％
Duty cycle （40℃，10
minutes），see 3.2）
35% 125A
60% 95A
100% 100A
60% 125A
100% 90A
40% 160A
60% 125A
100% 90A
Protection class IP23
Insulation class F
Dimensions of Machine
（
L×W×H
）（
mm
）
365×140×230
Weight（Kg）8
Note: T
he above parameters are subject to change with the improvement of machines.

INSTALLATION AND ADJUSTMENT
9
3.2 Duty cycle & Over heating
Duty cycle, which is defined as the proportion of the time that a machine can work continuously
within a certain time (10 minutes). The rated duty cycle means the proportion of the time that a
machine can work continuously within 10 minutes when it outputs the rated welding current.
If the welder is overheating, the IGBT over-heat protection unit inside will output an instruction
to cut output welding current and light up the over-heat pilot lamp on the front panel. At this
time, the machine should be relaxed for 15 minutes to cool the fan. When operating the machine
again, the welding output current or the duty cycle should be reduced.
3.3 Welding polarity connection
3.3.1 MMA
Choosing the connection of DCEN or DCEP is based on the electrode type. Different electrodes require
different polarity. Please refer to the electrode manual.

INSTALLATION AND ADJUSTMENT
10
3.3.2 TIG
Steps of starting arc
Striking arc of TIG operation：when tungsten electrode touches the workpiece，the short-circuit
current is only 28A . After generating arc, current can rise to the pre set welding current.If the
tungsten electrode touches the workpiece when welding, the current will drop to 5A within 2s,
which can reduce the tungsten spoilage, prolong the using life of the tungsten electrode，and
prevent tungsten clipping.
●
With TIG operation, the shielded gas is inputted to the welding
gun directly, and the method of lifting arc is lifting the electrode..

OPERATION CONTROLAND CONNECTORS

MMA160 MINESPEC OPERATION
The layout of the Front Panel
2. MMA/Lift Tig Switch
1. AmpDisplay
5. Volt Display
6. Over Current Light
7. High Temperature Light
8. VRD Light
3. Amperage Adjustment
9. Positive Polarity Output
4. Negative Polarity Output

OPERATION CONTROLAND CONNECTORS

MMA160 MINESPEC OPERATION
The layout of the Back Panel
10. Primary Power Lead
11. Machine On/Off Switch

OPERATION CONTROLAND CONNECTORS
13
4.2 Welding current adjustment
Welding current range is 5～160A。
Arcoweld series welders have the function of welding current pre-setting.
Before welding/adjusting welding current, the welding current display will show the
amperage. It provides convenience to set parameters and adjust accurately.
4.3 Welding operation
4.3.1 Striking the arc
Striking arc: take the electrode upright to touch the workpiece, after forming a short
circuit, quickly lift about 2~4 mm, and arc will be ignited. This method is difficult to
master but with practice is quite effective.
electrode
workpiece
electrode electrode
workpiece workpiece
Take the electrode upright The Electrode touch the workpiece Lift up for about 2-4mm
upright
up
touch
2～4mm
Lifting arc: take the electrode and scratch it on the workpiece for striking the arc.
Lift the arc from within the weld groove.

OPERATION CONTROLAND CONNECTORS
14
4.3.2 Manipulation of electrode
In MMA welding, there are three motions
of electrode: the electrode moving to the
molten pool along axes; the electrode swing
right and left; the electrode moving along the
weld path in a forward’s direction.
The operator can choose the manipulation of electrode based on welding joint shape,
welding position, electrode spec, welding current and operation skill, etc.
The details please refer to《Welding Dictionary》P69, Volume 1 of Edition 2.
4.4 Welding parameters
4.4.1 Joint form in MMA
In MMA welding, the common basic joint form: butt joint, lap joint, corner joint & T
joint.
4.4.2 Electrode selection
The electrode diameter selection is based on the workpiece thickness, welding
position, joint form, welding layer, etc. Please refer to the following table.
The welding current reference for different electrode diameter
Electrode
diameter/mm 1.6 2.0 2.5 3.2
Welding current/A 25～40 40～60 50～80 100～130
The relation between the welding current(I)’ factor(K) & electrode diameter(d) (I＝K×d: Carbon electrode)
butt joint lap jointcorner joint T joint
electrode
workpiece
weld
1
2
3
2
1-electrode moving; 2-the electrode swing right & left; 3-the electrode move along weld

OPERATION CONTROLAND CONNECTORS
15
Electrode
diameter/mm
1.6 2～2.5 3.2
Factor/K 20～25 25～30 30～40
Notice: the above parameters originate from《Welding Dictionary》P66～P67, Volume
1 of Edition 2.
Electrode should be dry in accordance to user manual before using. For reducing
hydrogen of the molten pool and welding seam and avoiding blowholes and cold
cracking.
In the welding process, the arc must not be too long; otherwise, it will cause
unstable arc burning, large spatter, light penetration, undercut, blowhole, etc.
If the arc is too short, it will cause electrode to stick.
In MMA welding the arc length is usually equal to 0.5~1.0 time of the electrode
diameter. The basic electrode’s arc length is not beyond the electrode diameter,
it’s better to choose the short arc welding; the electrode’s arc length is equal to
the electrode diameter.
4.5 Arc Welding Defects and Prevention Methods
Defect name
Caused reasons
Prevent methods
Weld doesn’t
meet the
requirement
The groove angle is not correct.
The root face and assembly gap are not equal
Welding technics parameters are
unreasonable
The welder’s operation skill is low.
Choose the proper groove angle & assembly
gap, improve the assembly quality
Choose the proper welding parameters
Improve the operation skill of welders
Undercut
Over current
Arc length is too long
The electrode angle is wrong
Manipulation of electrode is not correct
Choose the proper welding current & speed
The arc should be kept short.
The electrode angle should be correct.
Manipulation of electrode should be correct
Incomplete
penetration
The groove angle or gap is too small, the root
face is too big
Welding parameters are not suitable, or the
assembly is not good
The welder’s operation skill is low.
Correctly choose and process the groove size
Correct assembly and ensure clearance
Choosing the suitable welding current & speed
Improve the operation skill of welders
Incomplete
fusion
The welding thermal input is too low
The arc direction is lean
There is rust & dust on the side of groove
The slag between the layers is not cleared well
Choose the correct welding parameters
Clean the weld area.
Clean slag from between runs.
Overlap The temperature of molten pool is too high
The liquid metal cools slowly.
Choose parameters based on the welding
position
Control the molten hole size
Crater The crater time is too short
Over current in the welding of thin plate
In the crater, electrode should be kept for a
short time at the end of the weld.
Ensure correct welding amperage.

OPERATION CONTROLAND CONNECTORS
16
Blowhole
There is some dust like oil, rust or water on the
work piece surface and groove
The coating of electrode is damped & is not
drying
Under current or over speed in the welding
The arc is too long or lean burning, the molten
pool protection is not good
Over current with the coating of electrode
falling off and losing protection
Manipulation of electrode is not correct.
Clear out the dust around groove for about 20～
30mm
Strictly dry the electrode according to manual
Choose correct parameters and use short arc
operation
Welding operation in the field should have
anti-wind protection
Don’t use an invalid electrode
Inclusion &
slag inclusion
Slag removal is difficult.
Under current or over speed in the welding
Welding operation is not correct.
The welding material can not match the work
piece.
The groove design & processing are not
correct.
Choose an electrode with good slag
detachability
Clean slag from within each pass. Choose
correct welding parameters
Adjust the electrode angle and manipulation
Hot crack
In the process of solidification, inter crystal
segregation is caused. At the same time, with
the effect of welding stress, the hot crack is
formed.
Strictly control the percentage of S and P in
welding material.
Adjust the structure of welding material.
Adopt the basic electrode.
Cold crack
Three reasons will cause cold crack:
The structure turned from the marten site
The residual stress caused by high restraint
intensity
The residual hydrogen in welding gap.
Adopt low hydrogen type basic electrode.
Bake under guidelines before use.
Remove the feculence before use, reduce the
percentage of hydrogen
Adopt appropriate parameters and heat input
After welding, do dehydrogenation at once.
4.6 Operational Environment
● Height above sea level is below 1000m.
● Operation temperature range:-100C～+400C.
● Relative humidity is below 90 %(+200C).
●Machine should be situated level. Maximum angle does not exceed 150.
● Protect the machine against heavy rain or in hot circumstances against direct
sunshine.
● The content of dust, acid, corrosive gas in the surrounding air or substance cannot
exceed normal standards.
● Take care that there is enough ventilation during welding. There is at least 30cm free
distance between the machine and wall.
4.7 Operational Notices
●Read 1 carefully before attempting to use this equipment.
●Connect the ground wire to the machine directly

OPERATION CONTROLAND CONNECTORS
17
●Do not touch the output electrode with any part of your body.
●Before operation ensure only required persons are present. Do not watch the arc
with unprotected eyes.
●Ensure good ventilation of the machine to improve duty ratio.
●Turn off the engine when the operation finished to economize energy sources.
●When power switch shuts off protectively because of failure do not restart it until
problem is resolved. Otherwise, the problem may be extended.
●In case of problems, contact your local dealer or Authorized repair agent