Ter Welding Smart Welder MMA 140 User manual

USER'S MANUAL
MMA SERIES WELDING MACHINE
SMART WELDER MMA 140-160-170-
180-200

REVISION 2016-03-30

Preface
This ma ual i cludes hardware descriptio a d operatio i troductio of the MMA series equipme t. For
your a d other people’s safety, please read the ma ual carefully.
Pay attention
Pay attention to the words after the signs below.
Sign Description
The words after this sig mea s there is great pote tial da ger,
which may cause major accide t, damage or eve death, if it is ot
followed.
The words after this sig mea s there is some pote tial da ger,
which may cause hurt or property lose, if it is ot followed.
The words after this sig mea s there is pote tial risk, which may
cause equipme t fault or break, if it is ot followed.
Version
Versio YF-TAE-0013, A3, Released o 30th, 03, 2016.
The co te ts of this ma ual are updated irregularity for updati g of product. The ma ual is o ly used as
operatio guide, except for other promises. No warra ties of a y ki d, either express or implied are
made i relatio to the descriptio , i formatio or suggestio or a y other co te ts of the ma ual.
The images show here are i dicative o ly. If there is i co siste cy betwee the image a d the actual
product, the actual product shall gover .

Content
1 Safety war i g..................................................................................................................................4
2 Product.............................................................................................................................................8
2.1 Ge eral...................................................................................................................................8
2.2 Tech ical data.........................................................................................................................9
3 I stallatio .......................................................................................................................................11
4 Operatio ........................................................................................................................................13
4.1 Structure................................................................................................................................13
4.2 Operatio i structio .............................................................................................................15
4.3 Weldi g e viro me t a d safety...........................................................................................15
4.4 Weldi g problems a d resolutio ..........................................................................................16
5 Daily mai te a ce a d checki g...................................................................................................17
6 Trouble shooti g a d fault fi di g..................................................................................................19
Appe dix Circuit diagramⅠ.................................................................................................................20
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1. DECLARATION OF CONFORMIT
TER SRL - Via Leopardi, 13 - 36030 Caldogno (VI) Italy
declares that the machines descripted in this manual must be use solely for
professional purposes in an industrial environment and they are manufactured in
compliance with the instructions contained in the harmonized standard:
2014/35/EU (LDV) – 2014/30/EU (EMC) – 2002/95 (RoHs)
and with the instructions contained in the harmonized standard, if applicable:
EN 60974-1 EN 60974-2 EN 60974-3 EN 60974-5 EN 60974-7 EN 60974-10 EN 60974-12
Date 30/03/2016
Maurizio Terzo
Ge eral director
IN CASE OF AN TECHNICAL PROBLEM ASK FOR QUALIFIED
SERVICE ASSISTANCE
The equipment don’t compiles with EN/ IEC 61000-3-12.
The installer or the user must be sure that it can be connected to the public low voltage power line, if necessary, in consultation with the network
distributor.
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1 Safety warning
The safety otes listed i this ma ual is to e sure correct use of the machi e a d to keep you a d
other people from bei g hurt.
The desig a d ma ufacture of weldi g machi e co siders safety. Please refer to the safety
war i g listed i the ma ual to avoid accide ts.
Different damage would be caused by wrong operation of the equipment as follows. Please read the user
manual carefully to reduce such damage.
Sign Description
Any contact of electric parts may cause fatal electric shock or burnt.
Gas and fumes are harmful to health.
Operation in narrow space may cause choke .
Spark and hot workpiece after welding may cause fire.
Bad connected cable may cause fire.
Uncompleted connection of workpiece side circuit may cause fire.
Never weld on the case of tinder stuff, or it may cause explode.
Never weld airtight containers such as slot, pipe etc., or it may break.
Arc ray may cause eye inflammation or skin burnt.
Spark and residue will burn your eyes and skin.
Toppling over of the gas cylinder will cause body hurt.
Wrong use of the gas cylinder will lead to high-pressure gas eruption
and cause human hurt.
Never let fingers, hair, clothes or etc. near the moving parts such as
the fan.
The wire shoot out of the torch may stab eyes, face and other naked
parts.
Never stand in front of the swing equipment or under it, or it may fail
and cause injury.
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Please follow the rules below to avoid heavy accidents.
Never use the equipme t to do other thi gs but weldi g.
Follow related regulatio s for the co structio of the i put-drive power source, choice of
place, usage of high-pressure gas, storage, co figuratio , safe-keepi g of workpiece after
weldi g a d disposal of waste, etc.
No esse tial do ot e ter the weldi g area.
People usi g heart pacemaker is ot allowed to get close to the weldi g machi e or area
without doctor’s permissio . The mag etism created by e ergizi g the weldi g machi e ca
have a bad effect to the pacemaker.
I stall, operatio , check a d mai tai the equipme t by professio perso el.
U dersta di g the co te ts of the user ma ual for safety.
Please follow the rules below to avoid electric shock。
Keep away from a y electric parts.
Earth the machi e a d workpiece by professio al perso el.
Cut off the power before i stallatio or checki g, a d restart 5 mi utes later. The capacita ce
is chargeable device. Please e sure it has o voltage before start agai eve if the power
source is cut off.
Do ot use wire with i adequate sectio surface or damage i sulatio sleeve or eve exposed
co ductor.
Do e sure well isolatio of wire co ectio .
Never use the device whe the e closure is removed.
Never use broke or wet i sulatio gloves.
Use fire et whe work at high positio .
Check a d mai tai regularly, do ’t use it u til the broke parts are fixed well.
Tur off the power whe ot i used.
Follow the atio al or local related sta dard a d regulatio s whe usi g the AC weldi g
machi e at arrow or high positio .
Please follow the below notes to avoid fire and explode, etc.
No combustible i weldi g area.
Keep off combustible whe weldi g.
Keep hot workpiece after weldi g away from flammable gas.
Do move away the combustible arou d whe weld the dooryard, grou d a d wall,.
The wire co ectio of base metal should be as close to the weldi g place as possible.
Never weld those facilities with gas pipe or airtight slot.
Put fire exti guisher arou d the weldi g area to preve t fire.
The gas and fumes are harmful to health, please wear protective device
according to regulations.
Wear exhaust equipme t a d breathe preve tive facilities to preve t gas poiso i g or choke.
Use suggested part exhaust equipme t a d breathe preve tive facilities to preve t hurt or
poiso i g by gas a d other powder, please.
To preve t oxyge -deficie cy, air out the gas-filled room which is full of CO2 a d argo o the
bottom, Whe operati g o tru ks, boilers, cabi s, etc.
Please accept the supervisor’s i spectio whe operati g i arrow space. Air the room a d
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wear breathe preve tive facilities.
Never operate i degrease, washi g or spray space.
Usi g breathe preve tive facilities whe weld shielded steel for it will cause poiso ous dust
a d gas.
The arc, spark, residue and noise are harmful to health, please wear
protective appliance.
Eye protectio agai st arc is recomme ded whe weldi g or supervise weldi g.
Please wear preve tive spectacles.
Welder’s gloves, welder’s goggles, lo g sleeve clothes, leather apro , a d other sta dard
protectio equipme ts must be wor for weldi g operatio .
A scree to protect other people agai st the arc must be set i the weldi g place.
Please follow the notes below to avoid gas cylinder toppling over or
broken.
Use the gas cyli der correctly.
Use the equipped or recomme ded gaseous regulator.
Read the ma ual of gaseous regulator carefully before usi g it, a d pay atte tio to the safety
otes.
Fix the gas cyli der with appropriate holder a d other relative parts.
Never put the cyli der u der high temperature or su shi e e viro me t.
Keep your face away from the gas cyli der exit whe ope i g it.
Put o the gas shield whe it is ot used.
Never put the torch o the gas cyli der. The electrode ca ot meet the gas cyli der.
Any touch of the switch part will cause injury, please note the following.
Never use the machi e whe the e closure is off.
I stall, operate, check a d mai tai the machi e by professio al perso .
Keep your fi gers, hair, clothes etc. away from the switch parts such as the fa .
The wire end may deal damage, please note the following.
Never look i to the electric co ductio hole whe checki g the wire feedi g is ormal or ot, ,
or the shooti g wire may stab your eyes a d face.
Keep your eyes, face or other aked parts away from the e d of torch whe feedi g the wire
ma ually or pressi g the switch.
For better work efficiency and power source maintenance, please note
the following.
Precautio s agai st toppli g over.
Never use the weldi g equipme t for pipe thawi g.
Lift the power source from side whe use the up-dow forklift truck to avoid toppli g over.
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Whe usi g the cra e for lift, tie the rope to the ears with a a gle o more tha φ15 to the
vertical directio .
Whe lifti g the weldi g machi e which equipped with gas cyli der a d wire feeder, dow load
them from the power source a d e sure the horizo tal of the machi e. Do fix the gas cyli der
with belt or chai whe movi g it to avoid body hurt.
E sure fast ess a d i sulatio whe lifti g the wire feeder through the swi g ri g for weldi g.
Electromag etic i terfere ce eedi g atte tio .
It may eed extra preve tive measures whe the equipme t is used i particular locatio .
Before the i stallatio , please estimate the pote tial electromag etism problems of the
e viro me t as follows.
a) Upper a d lower parts of the weldi g equipme ts a d other earby power cable, co trol
cable, sig al cable a d pho e cable.
b) Wireless electric as well as TV radiatio a d receptio equipme t.
c) Computer a d other co trol equipme ts.
d) Safety-recog itio equipme t etc. Such as supervise of i dustrial equipme ts.
e) Health of people arou d. Such as perso el usi g the heart pacemaker or audipho e.
f) Equipme ts for adjustme t a d measureme t.
g) A ti-disturb capability of other used equipme ts .Users should e sure these equipme ts
a d the e viro me t are compatible, which may eed extra preve tive measures.
h) Practical state of the weldi g a d other activities.
Users should observe the followi g dos a d do ’ts to decrease radiatio i terfere ce.
a) Co ect the weldi g equipme ts to the power supply li es.
b) Mai tai the weldi g equipme ts regularly.
c) The cable should be short e ough to be close to each other a d the grou d.
d) E sure the safety of all the weldi g metal parts a d other parts earby.
e) The workpiece should be well earth.
f) Shield or protect the other cable a d equipme ts to decrease the effects of disturba ces.
The weldi g equipme ts ca be complete shielded i some special co ditio s.
Users are respo sible for i terfere ce due to weldi g.
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2 Product
2.1 General
MMA series weldi g machi e applies the most adva ced i versio tech ology i the world.
The appeara ce of the i vert arc weldi g machi e comes after the i vert power theory a d
compo e ts. The pri ciple of the tech ology is to tra sform the power freque cy of 50Hz/60Hz i to
direct curre t a d i vert it i to high freque cy (33KHz) through high-power device IGBT, the
perform voltage-drop a d commutatio with the output high-power D.C power supply via full digital
Pulse Width Modulatio (PWM) co trol tech ology. Si ce the switch power i versio tech ology is
adopted, the weight a d volume decrease greatly while the co versio efficie cy i crease for more
tha 30%.
Our weldi g power source ca offer stro ger, more co ce trated a d more stable arc. Whe the
weldi g rod a d work piece get short circuit, its respo se will be quicker. It mea s that it is easy to
desig weldi g machi e with differe t dy amic characteristics, a d it ca eve adjust the
characteristics to make arc softer or harder.
U der MMA mode, the machi e has slope characteristic. The weldi g curre t, push curre t a d
heat arc i itiatio curre t is set by the same k ob sy chro ously, which makes good performa ce
of arc i itiatio , stable power output, weldi g shape a d i ter al quality.
MMA series weldi g machi e is widely used to weld differe t materials, such as carbo steel,
stai less steel, alloy steel, copper, o -ferrous metal, etc. It ca apply to differe t electrode,
i cludi g acid electrode, basic electrode a d cellulose electrode. Compared with the other
products, it has adva tages of light, ha dy, easy to i stallatio a d operatio , efficie t a d e ergy
savi g. The co versio rate is above 85%. It applies for higher levels weldi g, field work a d
i doors operatio .
Tha ks for purchasi g our products a d looki g forward to your precious advice, we will try our
best to perfect our products a d service.
The machine is mainly used in industrial fields. It will cause radion interference if used
indoors. Please take through precaution measures.
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2.2 Technical data
Type
Item MMA140 MMA 160
Power voltage (V) 1 phase
230V15%
1 phase
230V15%
Freque cy (Hz) 50/60 50/60
Rated i put curre t (A) 23.5 28
Output curre t adjustme t (A) 15-140 15-160
Output voltage (V) 20.6-25.6 20.6-26.4
No-load voltage(V) 92 92
Duty cycle (%)/ 40℃20 20
Power factor 0.73 0.73
Efficie cy (%) 85 85
I sulatio grade F F
Housi g protectio grade IP21 IP21
Weight (kg) 3.5 3.5
Overall dime sio (mm) 288*123*220 288*123*220
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Type
Item MMA 170 MMA 180 MMA 200
Power voltage (V) 1 phase
230V15%
1 phase
230V15%
1 phase
230V15%
Freque cy (Hz) 50/60 50/60 50/60
Rated i put curre t (A) 31 31 34
Output curre t adjustme t (A) 20-170 20-180 20-200
Output voltage (V) 20.8-26.8 20.8-27.2 20.8-28
No-load voltage(V) 62 63 63
Power factor 20 20 20
Duty cycle (%)/ 40℃0.73 0.73 0.73
Efficie cy (%) 85 85 85
I sulatio grade F F F
Housi g protectio grade IP21 IP21 IP21
Weight (kg) 5.0 5.0 5.0
Overall dime sio (mm) 320*123*220 320*123*220 320*123*220
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3 Installation
The weldi g equipme t is equipped with power voltage compe satio device. It keeps the machi e
work ormally whe power voltage fluctuati g ±15% of rated voltage.
Whe usi g lo g cable, i order to reduce voltage drop, big sectio cable is suggested. If the cable
is too lo g, it will affect the performa ce of arci g a d other system fu ctio , it is suggested to use
the recomme d le gth.
Make sure the i take of the machi e is ot covered or blocked to avoid the malfu ctio of the
cooli g system.
Use grou d cable whose sectio o less tha 6mm2 to co ect the housi g a d earth. The
method is to co ect the grou ded i terface i the back to the earth device, or make sure the
earth e d of power i terface has bee reliably a d i depe de tly grou ded. Both ways ca be
used together for better security.
Installation Procedures
a) Make sure cable with electrode holder a d quick plug co ected well. Co ect the quick plug
to the socket “-” of the machi e, a d faste it clockwise tightly.
b) Co ect the quick plug at o e e d of the cable i to the socket “+” of the machi e, a d faste it
clockwise, the other e d clamps the workpiece.
c) Please pay atte tio to the co ecti g termi al, DC weldi g machi e has two co ecti g
ways: positive co ectio a d egative co ectio . Positive co ectio : holder co ects with
“-” termi al, while work piece with the “+” termi al. Negative co ectio : work piece with the“-”
termi al, holder with the “+” termi al. Choose suitable way accordi g to the worki g situatio .
If u suitable choice is made, it will cause u stable arc, more spatters a d co gluti atio . If
such problems occur, please cha ge the polarity of the faste ed plug. It should adopt egative
co ectio whe weldi g with alkali e electrode, while positive co ectio whe weldi g with
acid electrode.
This procedure shall be operated by electrician!
Co ect proper power cable to the distributio box with correspo di g capacity accordi g to the
i put voltage a d curre t (See tech ical parameter table). Do ot co ect to the i appropriate
voltage a d make sure that the differe ce of power supply is withi permitted ra ge.
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The MMA series products has two different structures, metal case and matal and plastic
case. Following with these two kinds of Installation diagrams.
Metal case
Metal and plastic case
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Power Supply
( 1 phase~AC230V)
Earth clamp
Electrode holder
Workpiece
Power Supply
( 1 phase~AC230V)
Earth clamp
Electrode holder
Workpiece

4 Operation
4.1 Panel layout
Front Panel Layout
a) Metal case
b) Metal a d plastic case
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Back Panel
a) Metal case
MMA 140/160
MMA 170/180/200
15

b) Metal a d plastic case
The images show here are i dicative o ly. The actual product may differ.
4.2 Operation instruction
Tur o the power switch, the power i dicator would light o , a d the fa starts ru i g.
Set the weldi g curre t accordi g to the weldi g requireme t.
Generally, welding current is adequate to welding electrode according with as following.
Specificatio φ2.5 φ3.2 φ4.0 φ5.0
Curre t 70-100A 110-140A 170-220A 230-280A
4.3 Welding environment and safety
Working surrounding
a) Weldi g should be carried out i dry surrou di gs. The air humidity level should ot be higher
tha 90%.
b) The temperature should be betwee -10C to 40C.
c) Do ’t use the weldi g machi es i su shi e or rai . Keep it off water.
d) Do 't use the machi es i the places of dust or corrosive air.
e) MIG weldi g should ot be carried out i places with quick air flow.
Safety norms
Protectio circuit of over-voltage, over-curre t a d over-heat circuits are desig ed i the
weldi g machi es. It will stop worki g automatically whe the i put voltage, output curre t or
i ter al temperature exceed the rated value. But if the machi es are excessively used, such
as with i put voltage higher tha the rated, the machi e might be damage. Please pay close
atte tio to the followi g matters.
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a) Keep good ventilation!！
The weldi g machi es work with high weldi g curre t. Nature air flow ca ’t reach the
requireme t of heat dissipatio . So the fa s are i stalled as cooli g system to e sure stable
performa ce.
Make sure the ve tilatio wi dows are ot covered or blocked. The dista ce betwee the
machi es a d thi gs arou d should ot be less tha 0.3m. Good ve tilatio is good for
weldi g performa ce a d operatio al life.
b) Never over load!
Check the maximum rated curre t (accordi g to the Duty Cycle chose ). Make sure the
weldi g curre t is ever higher tha the rated value. Over curre t ru i g will obviously
shorte the operatio life, eve damage the machi e .
c) Never over voltage!
The I put Voltage could be fou d i Technical data diagram. The auto-compe satio
fu ctio will keep the weldi g curre t i the rated ra ge. If the i put voltage exceed the
permissible value, the machi e would be damaged. Users should take protective measures i
adva ce to avoid it.
d) Make sure earth connected before operation.
O the rear pa el of weldi g machi e, a screw for earth co ecti g would be fou d. It must be
grou d co ected with cable whose sectio is bigger tha 6mm2 before operatio , to avoid
accide ts caused by static or electricity leak.
4.4 Welding problems and resolution
The phe ome o listed below may happe due to releva t accessories used, weldi g
material, surrou di gs a d power supply. Pleas improve surrou di gs a d avoid these
problems..
Arc starting difficulty. Arc interruption happens easily.
a) Exami e whether grou di g wire clamp co tacts with the work pieces well.
b) Exami e whether each joi t has improper co tact.
The output current fails to reach rated value.
The deviatio of power voltage from rated value may cause that the output curre t does o
accord with adjusted value. Whe the power voltage is lower tha rated value, the maximum
output curre t may be lower tha rated value.
The current can not keep stable during operation.
This situatio may relate to the followi g factors:
a) The voltage of electric power etwork cha ges;
b) Serious i terfere ce from electric power etwork or other electric facilities.
Gas vent in welds.
a) Exami e whether the gas supply circuit has leakage.
b) Exami e whether there is su dries such as oil, dirt, rust, pai t etc. o the surface.
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5 Daily maintenance and checking
Daily maintenance
a) Remove dust regularly with dry compressed air. If the weldi g machi e is used i surrou di gs
with heavy smoke a d polluted air, it is ecessary to remove dust at least o e time o e mo th.
b) The pressure of compressed air shall fall to required level to preve t damage to small
compo e ts i the machi e.
c) Exami e i side electric joi ts a d e sure perfect co tact (Especially plugs a d sockets).
Faste the loosi g joi ts. I case of oxidatio , remove oxide film with sa d paper a d co ect
agai .
d) Preve t water from e teri g i to the machi e a d preve t the machi e from getti g moist. If
a y, blow a d dry. Measure the i sulatio with megohmmeter to make sure it is qualified to
use.
e) If the weldi g machi e is ot used for a lo g time, pack the machi e i origi al package a d
store i dry surrou di gs.
f) Every time the wire feeder operates for 300hours, gri d the electrical carbo brush a d clear
up the armature commutator. Ri se speed reducer, apply 2# Molybde um Disulfide lubrica t
to the turbi e, whirlpool rod a d beari g.
All the maintenance and testing must be carried out when the power supply is totally cut
off. Please make sure the power is off before opening the closure.
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