KICKING HORSE A100 User manual

OPERATION MANUAL
A100 Arc Welding Machine
Serial Number: _________________________________
Where Purchase: _________________________________
Date of purchased: _________________________________

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CONTENT
1.Safety ............................................................................................................................................ 2
2. Summary ..................................................................................................................................... 4
3. Electrical principle drawing ...................................................................................................... 5
4. Specifications .............................................................................................................................. 6
5. Operation control and connectors ............................................................................................ 6
6. Installation & Operation ............................................................................................................ 7
6.1Installation .................................................................................................................. 7
6.2Welding parameters ................................................................................................... 7
7. Safety precaution ........................................................................................................................ 8
7.1 Installation ......................................................................................................................... 8
7.2 Safety .................................................................................................................................. 8
8. Maintenance ................................................................................................................................ 8
9. Troubleshooting & Service ........................................................................................................ 9

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1. Safety
 Welding may damage your body or others, so please take protection measure
in operation
 Only ones who are trained professionally can install , debug, operate, maintain
and repair the equipment.
 Do not maintain and repair the machine when the machine is connected with power.
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.
 Ensure to install the equipment correctly and ground the work or metal to be welded to a
good electrical (earth) ground according the operation manual.
 Ensure to operate the equipment in safe position.
Fumes and gasses can be dangerous
 Welding may produce fumes and gases hazardous to health. Avoid breathing
these fumes and gases. When welding, keep your head out the fume.
 Using enough ventilation and/or exhaust at the arc to keep fumes and gases away from the
breathing zone.
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 not materials from welding can easily go through small cracks and openings to
adjacent areas.
Do not weld enclosed tanks or containers
 Prohibit to use welder to unfrozen.
 Have a fire extinguisher readily available.
Hot parts can lead to burn

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 Do not touch the hot parts.
 Please use the torch after cooling or use the welding blow lamp.
 The people with heart-pacemaker should be away from the welding arc.
Rotating parts may be dangerous
 Far away from rotating parts. (like fan)
 Keep the parts of machine in the safe position.

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2. Summary
A100 is a MMA arc welder which adopts the insulated gate bipolar transistor(IGBT) power
module.
It can change work frequency to medium frequency so as to replace the traditional hulking
work frequency transformer with the cabinet medium frequency transformer.
Thus, it is characterized with portable, small size, light weight, low consumption and noise
etc.
A100 has excellent performance: constant current output makes welding arc more stable; fast
dynamic response speed reduces the impact form the arc length fluctuation to the current.
There are also some automatic protection functions for under voltage, over current, over heat,
etc. inside the welders, when the problems listed before occurred, the alarm on the front panel
is light 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 of the welders.
A100 can be ignited easily, also with little splash and good weld bead.
A100is widely used in Petroleum, chemical, mechanical, shipbuilding, architecture, boiler,
pressure container, war industry and installation and so on. This machine has high duty cycle
even in the 40Ԩ, which can keep the continuous operation. The frame is Stability of the
machine, which can keep working under high temperature and corrosion environment.

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3. Electrical principle drawing

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4. Specifications
Models
Parameters A100
Power Supply Voltage (V) 1~110/120/130±10%
Frequency(HZ) 50/60
Rated input current（A） 44
Rated input power（KW） 3.3
Duty cycle (40Ԩ 10 min)
30% 100A
60% 70A
100% 55A
No Load Voltage(V) 85
Efficiency (%) ≥80%
Power Factor 0.65
Insulation class H
Protection class IP23
Cooling AF
Net Weight(Kg) 3.5
Dimensions(mm) 230x120x170
Electrode Diameter φ1.6~φ3.2
Electrode Type 6013,7018 etc.
5. Operation control and connectors
Front Panel (Figure A below)
(1) Positive output: Connect electrode holder.
(2) Negative output: Connect to earth clamp.
(3) Welding current adjustment knob: Turn this knob to adjust the output current.
(4) Power indicator: power indicator, power on light on.
(5) Alarm light: alarm indicator, lights that occurred over voltage, over current, or
overheating inside the machine, is protected.

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Rear panel (as shown in Figure B)
(6) Power cord.
(7) Power switch: control power.
(8) Fan.
Figure A Figure B
6. Installation & Operation
Electrical connection operation must be shut after power distribution box power switch!
The equipment protection level is IP23. Do not use in the rain!
6.1 Installation
(1) Welding machine should be installed in a stable position and with good ventilation. Avoid
direct sun outdoors or rain. Place at a distance of 12” (300mm) or more from walls or similar
that could restrict natural air flow for cooling. Avoid transport in invert or side position.
(2)Switch the ON/OFF Switch (located on the rear panel) to OFF.
(3) Connect electrode holder to positive connection and earth cable to negative connection. Insert
Electrode holder/earth clamp quick connector into receptacle and turn 90º clockwise.
(4)Connect the earth clamp to your work piece.
6.2 Welding parameters
Note: The following table applies to low-carbon steel, other materials, please refer to related
information.
Electrode diameter (mm) Recommended welding current(A)
1.0 20~60
1.6 44~84

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2.0 60~100
2.5 80~120
3.2 108~148
4.0 140~180
7. Safety precaution
7.1 Installation
(1) Welding environmental temperature should be between -10Ԩ to 40Ԩ.
(2) The air humidity of not more than 90%.
(3) Avoid environment containing dust or corrosive gas.
(4)Avoid sunlight or rain, do not let water into the welding machine.
(5)Avoid the strong wind environment.
7.2 Safety
Refer to the American National Standard Z49.1 entitled: SAFETY IN WELDING AND CUTTING.
ALL INSTALLATION, OPERATION, MAINTENANCE, AND REPAIR WORK MUST BE
PERFORMED BY QUALIFIED PERSONAL.
1. Welders must be equipped with welding mask, gloves and tie the sleeves and collar properly. Use
Table 6.4 to choose proper glass shade, also can reference to ANSI Z49.1 listed in Safety
Standards. There should be an arc shield around welding field to protect others from arc shock.
2. Do not weld near flammable, explosive materials or gases.
3. Keep finger, hair and clothing away from the rotating fan.
4. The power source must be grounded when welding.
5. When yellow protection light is enlightened during welding, it is indicating that the welder is
over current or over heat, and automatic protection will be triggered. Stop welding immediately
and wait until welder cool down.
6. Welding machine should not work in a flammable and toxic environment, avoid moisture, rain,
and do not directly expose to sun.
7. Do not switch off the welder during welding!
8. Periodically maintain the machine and clean the dust inside.
8. Maintenance
Periodic maintenance is necessary for keeping the machine work properly.
DISCONNECT POWER INPUT AND SWITCH OFF THE MAIN POWER SWITCH BEFORE
START OF MAINTENANCE.
Regular Check and Inspection 6 Month Routine Maintenance
 Replace unreadable labels.
 TIG-Clean spatter inside the nozzle when
continuously use the machine
 TIG-Check and change broken parts in the torch
 Blow out with dry clean pressure air or vacuum
inside machine, especially transformer coil and
power component.
 Check the electric connection of input/output bar
to avoid bad contact caused by loose or rusted