HT 120 IGBT User manual

Handheld 120
IGBT MMA
ARC Welder
USER GUIDE

Copyright © HValley Tools LLC 2Version A
Handheld 120 IGBT
MMA ARC Welder
User Guide
HValley Tools LLC
1065 Industrial Blvd
Southampton PA 18966
215-938-5060
HValleyTools.Com
[e-mail]

Copyright © HValley Tools LLC 3Version A
Handheld 120 IGBT
MMA ARC Welder
User Guide
TABLE OF CONTENTS
1. Precautions and Safe Use ........................................4
2. Operating / Working Environment ............................5
3. Safety Tips and Recommendations..........................6
4. Welding Fundamentals .............................................8
5. Parts List / Box Contents ..........................................9
6. Features and Functions..........................................10
7. Safety Face Shield Assembly .................................11
8. Setup and Operation ..............................................12
9. Operating your Welder............................................13
10. Common ARC Welder Electrodes ..........................14
11. Common Problems and Solutions ..........................15
12. Recommended Maintenance..................................16
13. Technical Specifications .........................................17
14. Notes Pages ...........................................................18

Copyright © HValley Tools LLC 4Version A
Handheld 120 IGBT
MMA ARC Welder
User Guide
PRECAUTIONS AND SAFE USE
Welding may result in injury to you and others, so please
implement proper protections and precautions when welding.
Electric shock-may result in serious injury or
even death!
Ensure devices are properly grounded.
Do not touch live parts with naked skin, wet
gloves or wet clothes.
Be sure you are insulated from the ground and
workpiece.
Confirm the safety of your working position.
Smoke may be harmful to your health!
Keep your head away from fumes and smoke
to avoid inhalation of waste gas while welding.
When welding, keep the working environment
well-ventilated with exhaust or ventilation
equipment.
Arc radiation may hurt your eyes and burn
your skin!
Use a proper welding mask and wear
protective clothing to protect your eyes and
body.
Ensure onlookers have a proper mask or
curtain to avoid injury.
Improper use and operation may result in fire
or explosion.
Welding sparks may cause fires, please
ensure there are no flammables near the
welding are and pay attention to fire safety.
Ensure there is a fire extinguisher nearby, and
make sure someone has been trained to
operate the fire extinguisher.
Do not weld in a closed unventilated container.
Do not use this machine for pipe thawing.
Hot workpieces can cause severe scalds or
burns.
Do not touch the workpiece(s) with bare
hands.
If continuously working, periodically cool the
welding torch to avoid overheating the tip.

Copyright © HValley Tools LLC 5Version A
Handheld 120 IGBT
MMA ARC Welder
User Guide
Excessive noise can be harmful to people’s
hearing.
Wear proper hearing protection when welding.
Ensure onlookers have a proper hearing
protection or distance to avoid injury.
Magnetic field can impair cardiac pacemaker
operation.
People with a cardiac pacemaker should
consult their physician prior to attempting to
use welding equipment.
Moving parts may injure your body.
Please keep away from moving parts (like
fan).
Each door, panel, cover, baffle plate, and
protective device the like should be closed and
located correctly.
Seek professional support with operating
issues.
When an issue arises with the installation and
operation or the unit, please refer to the
operating manual before attempting repairs.
If the issue persists, or you still cannot solve
the problem, please contact the dealer to
obtain professional support.
Working Environment
Prior to welding, properly inspect the work area for potential
hazards before starting any welding operations.
1) Welding should be carried out in a dry environment with
humidity below 90%.
2) The temperature of the work area should be between 14⁰F
and 104⁰F.
3) Avoid welding in sunlight and rain. Keep everything dry at
all times.
4) Avoid welding in dusty areas or environment with corrosive
chemical gas.
5) Arc welding should be operated in an environment without
strong airflow.
6) Weld in a well-ventilated area or use proper ventilation
systems to remove harmful fumes and gases.

Copyright © HValley Tools LLC 6Version A
Handheld 120 IGBT
MMA ARC Welder
User Guide
Safety Tips and Recommendations
This unit is equipped with an over-current/over-voltage/over-
heating protection circuit. When the supplied voltage, output
current or inner temperature exceeds these limits, the unit will
stop automatically. Please check those conditions prior to
restarting. WARNING: excessive use of the unit with these
conditions will lead to welder damage.
1. Ventilation
1.1. This welder will create powerful electrical currents that
require the unit to have constant cooling.
1.2. The internal fans are critical to ensuring proper and
effective cooling of the machine.
1.3. The operator must ensure that the louvers are
uncovered and unblocked for proper airflow.
1.4. The minimum distance between the unit and nearby
objects should be 76 inches.
1.5. Good ventilation is of critical importance for optimum
performance and longer lifespan of the unit.
2. Overload Operation
2.1. Remember to operate the welder within the allowable
duty cycle (refer to the corresponding duty cycle).
2.2. Ensure that the welding current does not exceed the
max load current.
2.3. Overload could obviously shorten the machine's
lifespan, or even damage the machine.
3. Exceeding Recommended Voltage
3.1. Verify the power supply voltage range of the unit, please
refer to “Technical Parameters” table.
3.2. This unit is equipped with automatic voltage
compensation, which enables it to maintain a voltage
range within the allowable supply ranges.
3.3. Power supply voltage that exceeds the recommended
levels may lead to damaging the components of the unit.

Copyright © HValley Tools LLC 7Version A
Handheld 120 IGBT
MMA ARC Welder
User Guide
Safety Tips and Recommendations
4. Fault/Halt Indicator
4.1. A sudden halt may occur and the red indicator on the
front panel is lit.
4.2. The welder has exceeded the standard duty cycle which
triggers temperature alert due to overheating.
4.3. Should this occur, halt the welding operations and allow
the unit to cool down. Do not turn off the power and keep
the cooling fan operating to reduce the unit temperature.
4.4. Welding can be resumed after the unit temperature falls
back to the standard operating range and the red
indicator is off.

Copyright © HValley Tools LLC 8Version A
Handheld 120 IGBT
MMA ARC Welder
User Guide
Welding Fundamentals
Welding is a relatively simple process for bonding two pieces of
metal together. As an example, soldering two wires together is
the same concept. To connect the wires, we use heat to melt
solder onto the wires to create the connection and a permanent
bond and circuit.
The welding process utilizes a very strong electrical current that
creates enormous heat that literally melts the two pieces
together, and a consumable rod (ARC Welder) or wire (MIG
Welder) is melted into the joint and creates a strong metallic
bond between the two pieces.
The Handheld 120 is the latest evolution, if not revolution in
welder design utilizing IGBT (Insulated-Gate Bipolar Transistor)
technology that reduces the power demands while generating
sufficient energy to create welds.
The handheld design is clean, simple and easy to use. As with
any ARC welder (Stick Welder) a consumable electrode
conducts current to the pieces, as well as the bonding material to
create the weld. This type of welder is perhaps the easiest to
use, as it is somewhat of a point-and-shoot type of welder
suitable for hobbyists and even professionals.
There is a slight learning curve and experimentation as to the
welding voltage and the electrode type (charts are provided at
the end of this document). We recommend starting with an E-
6013 general purpose welding rod which is ideal for most
shallow welding needs.
The Handheld 120 will work with nearly all generally available
electrodes; however, some electrodes may require reversed
polarities and the larger diameter / demand electrodes may
exceed the holder capacity and power delivery of this unit.

Copyright © HValley Tools LLC 9Version A
Handheld 120 IGBT
MMA ARC Welder
User Guide
WHAT IS IN THE BOX / PARTSLIST
The Handheld 120 is a clean, simple and easy to use design.
NOTE: The Safety Face Shield is shown assembled and
consists of three parts.
1
Welding Face Shield
2
Handheld Welding Unit
3
Transport Carry Case
4
Welding Sticks (Electrodes)
5
Cleaning Brush
6
Grounding Clamp
1
2
3
4
5
6

Copyright © HValley Tools LLC 10 Version A
Handheld 120 IGBT
MMA ARC Welder
User Guide
FEATURES AND FUNCTIONS
1
Power Switch
2
Welder Activation Button
3
Welding Stick / Electrode
4
Welding Chuck
5
Electrode Release / Replacement
Button
6
Power Indicator
7
Alert Indicator
8
Current Adjustment Knob
9
All-in-One Ground Clamp
10
Power Connector and Cable

Copyright © HValley Tools LLC 11 Version A
Handheld 120 IGBT
MMA ARC Welder
User Guide
SAFETY FACE SHIELD ASSEMBLY
Proper eye and face protection is required and essential! Here are the
steps to assemble the basic handheld safety face shield.

Copyright © HValley Tools LLC 12 Version A
Handheld 120 IGBT
MMA ARC Welder
User Guide
SETUP AND OPERATION
The picture above illustrates how the handheld welder and
cables are connected for proper operation. The
connections outlined below are for “Basic Operation”.
1. Verify that the Power Switch is in the OFF position.
2. Connect the power plug to a power outlet.
3. Press the electrode release button and insert the
electrode.
4. Connect the Grounding Clamp Cord to the workpiece.
At this point, you are ready to begin welding. Ensure your
workspace is safe and you have the proper safety clothing,
eye protection and equipment ready.

Copyright © HValley Tools LLC 13 Version A
Handheld 120 IGBT
MMA ARC Welder
User Guide
OPERATING YOUR WELDER
To begin your welding project!
1. For basic welding parameters, please refer to the table
below. Preset the welding current according to the type and
size of the electrode (see recommendations below) and turn
the Current Adjustment Knob to the recommended welding
current position.
2. Press the Welding Main Power Switch to the ON position.
3. The unit will “spin up” and verify that the Aert Indicator is not
lit.
4. Pull the Welder Activation Button (Trigger) and make contact
with the electrode to your piece and begin welding.
5. Ensure you are following all the Safety Procedures and
Precautions outlined above before proceeding.
6. Enjoy your welding!
Welding Parameters Table
NOTE: This table is suitable for mild steel welding. For other
materials, consult related materials and welding process charts
for reference.
If you experience issues while using your Handheld 120 Welder,
please review the Common Problems and Solutions Section.
If any conditions persist, please contact product support for
assistance, [e-mail] or
Electrode Diameter
(mm)
Recommend
Welding Current (A)
Recommended
Welding Voltage (V)
1.6
30~70
21.2~22.8
2.0
40~90
21.6~23.6
2.5
50~100
22~24
3.2
70~150
22.8~26
4.0
140~180
25.6~27.2
5.0
160~200
26.4~28

Copyright © HValley Tools LLC 14 Version A
Handheld 120 IGBT
MMA ARC Welder
User Guide
COMMON ARC WELDER
ELECTRODES

Copyright © HValley Tools LLC 15 Version A
Handheld 120 IGBT
MMA ARC Welder
User Guide
Common Problems and Solutions
Problem
Causes and Solutions
Arc striking is difficult and
pauses easily
1) Use a different electrode.
2) Verify that the electrode is
a high-quality tungsten
electrode.
3) Electrode may have been
exposed to moisture.
4) If extension cords are
being used, they are not of
sufficient heavy gauge.
Output current not up to the
rated value.
1) Verify the input power
supply meets the input
demands for the unit.
2) Variances in low power
will impact units
performance.
Current is not stabilizing
while being operated.
1) Unstable input power
supply is affecting the unit.
2) Check if other equipment
is running on the input
power supply circuit and
reducing or interfering with
power levels.
Excessive spattering
1) Too much current for the
stick diameter being used.
2) Polarity for the selected
electrode is incorrect.
Reversing the polarity may
correct the excessive
spattering.

Copyright © HValley Tools LLC 16 Version A
Handheld 120 IGBT
MMA ARC Welder
User Guide
Recommended Maintenance
1) Clean and blow the unit out periodically with dry and clean
compressed air. Perform this operation more frequently in
environments with heavy dust and smoke. 60-80 PSI
should be sufficient and avoid excess pressure to avoid
damaging the small parts inside the unit.
2) Check that all cables and connectors are in good condition.
If there is any oxidization on the connectors, carefully
remove it with fine steel wool or a high grit sandpaper and
then reconnect.
3) Store your welder in its original box and in a dry location if it
is not going to be used for a long period of time.

Copyright © HValley Tools LLC 17 Version A
Handheld 120 IGBT
MMA ARC Welder
User Guide
Technical Specifications
Specification
Unit of
Measure
Model
Handheld 120
Rated input voltage
V
AC110 ± 10%
Frequency
Hz
50/60
Rated input power
KVA
4.6
No-load voltage
V
57
Welding current range
(MMA)
A
20-120
V
20.8-24.8
Rated duty cycle
%
20
No-load voltage
V
57
No-load loss
W
10
Overall efficiency
%
85
Power factor
COSφ
0.76
Insulation Grade
F
Protection grade
IP21
Size
Inch
9.8 x 3.93 x 9.8
Weight
LB
3.96
Applicable electrode
Inches
1/16 – 1/8
MM
1.6 – 3.2

Copyright © HValley Tools LLC 18 Version A
Handheld 120 IGBT
MMA ARC Welder
User Guide
NOTES

Copyright © HValley Tools LLC 19 Version A
Handheld 120 IGBT
MMA ARC Welder
User Guide
NOTES

HValley Tools LLC
1065 Industrial Blvd
Southampton PA 18966
215-938-5060
HValleyTools.Com
[e-mail]