Hyundai MMA-160 User manual

DC INVERTER MMA WELDER
MMA-160
User Manual
For Your Safety
Read and understand this manual
before use. Keep this manual for future
reference.
EN

HYUNDAI
01 MMA-160
MMA-160
We are still constantly improving this welder, therefore, some parts of this welder may be changed in order to
achieve the better quality, but the main functions and operations will not be alternated and changed.
Your understanding would be greatly appreciated.

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02 MMA-160
Safety ............................................................................................................................................................
General Description .....................................................................................................................................
Main Parameters ..........................................................................................................................................
Electric Block Diagram ..............................................................................................................................
Operation Control and Description .............................................................................................................
Installation Debugging and Operation ........................................................................................................
Caution .........................................................................................................................................................
Maintenance .................................................................................................................................................
Troubleshooting ............................................................................................................................................
Exploded Drawing ........................................................................................................................................
3
5
6
7
8
9
10
11
12
13
Table of Contents

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Welding is dangerous, and may cause damage to you and others, so take good protection when welding. For
details, please refer to the operator safety guidelines in conformity with the accident prevention requirements
of the manufacturer.
Professional training is needed before operating the machine.
● Use labor protection welding supplies authorized by national security supervision department.
● The operator must be qualified personnel with a valid “metal welding (OFC) operations” operation certificate.
● Cut off power before maintenance or repair.
Electric shock—may lead to serious injury or even death.
● Install earth device according to the application criteria.
● Never touch the live parts when skin bore or wearing wet gloves/clothes.
● Make sure that you are insulated from the ground and work piece.
● Make sure that your working position is safe.
Smoke& gas—may be harmful to health.
● Keep the head away from smoke and gas to avoid inhalation of exhaust gas from welding.
● Keep the working environment in good ventilation with exhaust or ventilation equipment when welding.
Arc radiation—may damage eyes or burn skin.
● Wear suitable welding masks and protective clothing to protect your eyes and body.
● Use suitable masks or screens to protect spectators from harm.
Improper operation may cause fire or explosion.
●
Welding sparks may result in a fire, so please make sure no combustible materials nearby and pay attention
to fire hazard.
● Have a fire extinguisher nearby, and have a trained person to use it.
● Airtight container welding is forbidden
●
Must not use the machines for other purposes except welding, such as pipe thawing, battery charging,
heating.
1. Safety

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Hot work piece may cause severe scalding.
● Do not contact hot work piece with bare hands.
● Cooling is needed during continuous use of the welding torch.
Magnetic fields affect cardiac pacemaker.
● Pacemaker users should be away from the welding spot before medical consultation.
Moving parts may lead to personal injury.
● Keep yourself away from moving parts such as fan.
● All doors, panels, covers and other protective devices should be closed during operation.
Please seek professional help when encountering machine failure.
● Consult the relevant contents of this manual if you encounter any difficulties in installation and operation.
●
Contact the service center of your supplier to seek professional help if you still cannot fully understand after
reading the manual or still cannot solve the problem according to the manual.

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Advanced DC inverter technology
● High inverter frequency greatly reduces the volume and weight of the welder.
●
Great reduction in magnetic and resistance loss obviously enhances the welding efficiency and energy saving effect.
● Switching frequency is beyond audio range, which almost eliminates noise pollution.
Leading control mode
●
Advanced control technology meets various welding applications and greatly improves the welding performance.
● It can be widely used in acid and basic electrode welding.
● Easy arc starting, less spatter, stable current and good shaping.
Features of MMA series
●
Efficiency, energy saving, portable, stable arc, high no-load voltage, and with good compensation of arc
force, are able to meet various welding requirements in field work.
2. General Description

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3. Main Parameters
Technical parameters table:
Model MMA-160
Rated Input Voltage (V) 1P AC 230V, 50Hz
Rated Input Power (KVA) 6.8
Rated Input Current (A) 31
Rated Output Current & Voltage 160A/26.4V
Output Current (A) 20~160
No-load Voltage (V) 65±5
Rated Duty Cycle (%) 40
Efficiency (%) 85
Power Factor (cosø) 0.73
Protection Class IP21S
Insulation Class F

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4. Electric Block Diagram

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5. Operation Control and Description

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Warning
Please install the machine strictly according to the following steps.
The protection class of this machine is IP21S, so avoid using it in rain.
Before using, please make sure the input voltage is in voltage range (200V-240V). Otherwise, the machine will
be damaged.
● The electrode holder and earth clamp are easily connected to the machine by inserting the quick connector
and rotating it clockwise. Always ensure a correct connection and pay attention to the connection polarity.
● This welder has the function of DCEP(straight polarity) and DCEN(reverse polarity). DCEN means the weld-
ers electrode holder can be connected in the “-” output terminal while the earth clamp is connected to the
“+” output terminal. However, we recommend you to use the DCEP. If DCEN is connected,
it will cause an unstable arc, spatter, and the electrode to stick. If these symptoms occur,
change the polarity.
● Turn on the machine with power switch located on the rear of the machine.
●
Set output power control switch according to the type
and size of electrode.
Remark: this table is mainly for low-carbon steel electrode.
Please consult with the supplier if operator welds other material of electrode.
6. Installation Debugging and Operation
Welding parameters table (for reference only)
Electrode dia. (mm) Recommended welding current (A) Recommended welding voltage (V)
1.0 20~60 20.8~22.4
1.6 44~84 21.76~23.36
2.0 60~100 22.4~24.0
2.5 80~120 23.2~24.8
3.2 108~130 23.32~24.92
4.0 160~210 24.6~27.2
5.0 260~270 26.4~29.2
6.0 260~300 26.4~32.2

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7.1 Working environment
1) The product shall be operated under dry environment with normal humidity under 90%.
2) The temperature of working environment should be between -10°C and 40°C.
3) Avoid welding in the open air unless sheltered from sunlight and rain. Keep it dry anytime and do not place
it on wet ground or in puddles.
4) Avoid welding in dusty area or environment with corrosive chemical gas.
5) Gas shielded arc welding should be operated in environment without strong airflow.
6) The welder shall be placed horizontally, on the slope of ground which does not exceed 15°.
7.2 Safety tips
Over-current/over-voltage/over-heating protection circuit is installed in this machine. If the input voltage or the
output current is too high or machine inside temperature over heating inside, the machine will stop automati-
cally. However, excessive use (e.g. too high voltage) of machine may also damage machine, so please note:
1) Ventilation
High current passes when welding is carried out, thus natural ventilation cannot satisfy the machine’s
cooling requirement. Maintain good ventilation through the louvers of the machine. The minimum distance
between the machine and any other objects in or near the working area should be 30cm. Good ventilation
is of critical importance for the normal performance and lifespan of the machine.
2) Welding operation is forbidden while the machine is overload.
Remember to observe the max load current at any moment (refer to the corresponding duty cycle). Make
sure that the welding current should not exceed the max load current. Overload could obviously shorten
the machine’s lifespan, or even damage the machine.
3) Over-voltage is forbidden.
Regarding the power supply voltage range of the machine, please refer to “Main Parameters” table. This
machine is of automatic voltage compensation, which enables the maintaining of the voltage range within
the given range. In case that the input voltage exceeds the stipulated value, it would possibly damage the
components of the machine.
4) Make sure earth connected before operation
There is a grounding screw on the back of machine with a grounding sign beside. Before using, make sure
earth connected well to prevent the operator from getting electric shock or electricity leak.
5) Operation over max duty cycle
When using the machine over max duty cycle, inside overheating circuit causes the temperature switch to
be open-circuit, which finally prevents the product from working on. This can be judged from the yellow
light LED on face panel. Under this circumstance, no need to pull off the plug from the power and keep
power on to let the fan cool down the machine. When the yellow LED turns off, welding can be continued.
6) Carrying the machine
When moving the welder, be careful not to be hurt by the machine. When lifting the welder with other equip-
ment like forklift, do not put yourself under it to avoid being hit if the welder drops.
7. Caution

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Warning
● This machine will produce electric and magnetic fields, so the operator should ensure proper protection and
screening while using it.
● Earth leakage-circuit breaker should be used with this machine.
● During operation, DO NOT pull out or insert any plugs or cables. It can lead to fatal danger and cause dam-
age to the machine.
● Before connecting cables, make sure the power is off. (The correct way is to connect the cables to the ma-
chine first, and make sure they are firmly tightened and then connect the power plug to the power source.)
● Before maintenance and checking, power must be turned off,
● Before opening the cover, disconnect the ma chine from power source.
1) Remove dust with dry and clean compressed air regularly. If the welding machine is operated in polluted
area with smoke and dust, the machine needs to be cleaned regularly.
2) Pressure of compressed air must not be higher than 5 bars in order to prevent damage to small compo-
nents inside the machine.
3) Check inside the welding machine regularly and make sure the output terminals are connected tightly and
connectors are not damaged. If burnt, loose or damaged, please tighten or replace them if necessary.
4) Avoid water and steam entering into the machine. If the welding machine gets wet, please dry inside of the
machine and check the insulation status.
5) If the machine will not be used for long time, it should be put into a box or covered and stored in cool and
dry area.
Correct Disposal of this product
This marking indicates that this product should not be disposed with other household wastes throughout the
EU. To prevent possible harm to the environment or human health from uncontrolled waste disposal, recycle
it responsibly to promote the sustainable reuse of material resources. To return your used device, please use
the return and collection systems or contact the retailer where the product was purchased. They can take this
product for environmental safe recycling.
8. Maintenance

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If the machine still fails to work after maintenance and troubleshooting, please contact and
consult with local distributor or after-sale service center.
Warning
Experimentation and careless maintenance may lead to more problems to the machine. This will make pro-
fessional diagnosis and repair more difficult. When the machine is open, there may be exposed connections
containing life-threatening voltages. Any direct or indirect touch will cause electric shock, and severe electric
shock will lead to death.
Notes: only attempt to repair this machine if you have knowledge and understanding of electronic compo-
nents and the danger of high voltage electricity.
9. Troubleshooting
Common Malfunction Analysis and Solution:
Malfunction Cause and Solution
Power indicator is not lit, fan does not work and no welding output
1. Make sure if power switch is working.
2. Check if connection from power switch to power board is in good
condition.
3. Check if the plug you are using is working.
4. Check if input voltage is correct.
5. Control board might be faulty.
Power indicator is lit, fan works, no welding output
1. Check if all cables are connected properly.
2. Output connectors are disconnected or damaged.
3. Control circuit might be faulty.
QC(Quality Control) LED is on continuously or when striking an arc
1. The machine can be in over-heat protection. Wait for 15 minutes
2. The machine can be in over-current protection. Turn off the machine
for 30 seconds and then switch on again. If QC LED is still on and not
working. there is a fault on the board.
3. IGBT on control board might be faulty.
4. Fast recovery diodes or transformer might be faulty.
Output current is not stable
1. Input voltage is not stable.
2. There is harmful interference from input voltage or other equipment.
3. Check if there is any loose contact inside the machine. If any, please
reconnect.

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10. Exploded Drawing
1. Handle
2. Top cover
3. Pillar
4. Insulation board
5. Radiator
6. Capacitance
7. Relay
8. Main PCB
9. Main transformer
10. Copper connector
MMA-160
11. Base
12. Digital display
13. Potentiometer knob
14. Plastic panel
15. Quick connector
16. Fan
17. ON/OFF Switch
18. Power cable
19. Digital PCB
List of parts typically replaced due to wear
8. Main PCB
13. Potentiometer Knob
15. Quick connector
16. Fan
19. Digital PCB
19

DC Inverter MMA Welder HYUNDAI
EC
Declaration of
Conformity
HYUNDAI Corporation
25, Yulgok-ro 2-gil, Jongno-gu, Seoul 03143 Korea
Declare that the product detailed below :
DC INVERTER MMA WELDER
MODEL : MMA-160
Satisfies the requirements of the Council Directives :
EC-Low voltage directive 2014/35/EU
EC Directive of Electromagnetic Compatibility 2014/30/EU
RoHS Directive 2011/65/EU
and conform with the norms :
EN 60974-1 : 2012
EN 60974-10 : 2014
IEC 62321 : 2008
2018
We :
Date : 2018.04.23
General Manager
Yoonsung Lee
Project Manager
Donghoon Park

HYUNDAI Corporation
25, Yulgok-ro 2-gil, Jongno-gu,
Seoul 03143, Korea,
Post Code : 03143
82 2 390 1114
www.hyundaicorp.com
Copyright HYUNDAI Corporation All rights reserved.
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