Weldability ARC200S User manual

INSTRUCTION MANUAL
WELDABILITY ARC200S MACHINE
PHONE : [phone]
Email: [e-mail]
Website: www.weldability-sif.com
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®

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IN STRUCT ION M ANU AL
WARNING: BEFORE USING THE MACHINE READ THE INSTRUCTION MANUAL CAREFULLY!
SECTION 1 : PRODUCT AND COMPANY IDENTIFICATION
PRODUCT NAME : Weldability ARC200S machine
SYNONYMS : Manual arc welding machine for coated electrodes.
PRODUCT CODES : TWX1A200S
SUPPLIER : Weldability | Sif
ADDRESS : Peters House, The Orbital Centre, Icknield Way, Letchworth Garden City,
Hertfordshire. SG6 1ET. UK.
CONTACT PHONE : [phone]
CONTACT FAX : [phone]
PRODUCT USE : MMA “stick” welding applications.
PREPARED BY : Technical Support Team, Weldability | Sif
SECTION 2 : GENERAL SAFETY CONSIDERATIONS FOR ARC
WELDING
•Avoid direct contact with the welding circuit: the no-load voltage supplied by the welding machine
can be dangerous under certain circumstances.
•When the welding cables are being connected, or checks and repairs are carried out, the welding
machine should be switched off and disconnected from the power supply outlet.
•Switch off the welding machine and disconnect it from the power supply outlet before replacing
consumable torch parts.
•Make the electrical connections and installation according to the safety rules and legislation in
force.
•Make sure that the power supply plug is correctly connected to the earth protected outlet.
•Do not use the welding machine in damp or wet places and do not weld in the rain.
•Do not use cables with worn insulation or loose connections.
•Do not weld on containers or piping that contains or has contained flammable liquid or gaseous
products.
•Do not operate on materials cleaned with chlorinated solvents or near such substances.
•Do not weld on containers under pressure.
•Remove all flammable materials (e.g. wood, paper, rags etc.) from the working area.
•Provide adequate ventilation or facilities for the removal of welding fumes near the arc; a systematic
approach is needed in evaluating the exposure limits for the welding fumes, which will depend on
their composition, concentration and the length of exposure itself.

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•Use adequate electrical insulation with regard to the electrode, the work piece and any (accessible)
earthed metal parts in the vicinity.
•This is normally achieved by wearing gloves, shoes, head coverings and clothing designed for this
purpose and by using insulating platforms or mats.
•Always protect your eyes using masks or helmets with a special welding filter glass.
•Use special fire-resistant protective clothing and do not allow the skin to be exposed to the
ultraviolet and infrared rays produced by the arc; other people in the vicinity of the arc should be
protected by shields of non-reflecting curtains.
•The electromagnetic fields generated by the welding process may interfere with the operation of
electrical and electronic equipment.
•Users of vital electrical or electronic devices (e.g. pace-makers, respirators etc.) should consult
a doctor before stopping in the vicinity of areas where this welding machine is used.
•Users of vital electrical or electronic devices should not use the welding machine.
SECTION 3 : OTHER RISK WARNINGS
OVERTURNING: Position the welding machine on a horizontal surface that is able to support
the weight to avoid the risk of overturning (e.g. inclined or uneven floors etc).
IMPROPER USE: It is hazardous to use the welding machine for any work other than that for
which it was designed (e.g. de-icing mains water pipes). Do not use the
handle to hang up the welding machine.
SECTION 4 : INTRODUCTION AND GENERAL DESCRIPTION
This apparatus is a power source for arc welding, made specifically for alternating current (AC) MMA welding with
coated electrodes.
Electrode holder clamp and cable
Return cable and earth clamp
STANDARD ACCESSORIES:
Wheels kit (in models on wheels)

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SECTION 5 : TECHNICAL DATA & PLATE DATA
The most important data regarding use and performance of the welding machine is summarised on the rating plate
and has the following meaning:
18 19
20 21
14
15
16
17
1
2
3
4
5
6
7
8
9
10
13
1111
12
22 23
24
Key
Section No Description
1 European norm regarding safety and the construction of arc welding machines
2 Symbol of the internal structure of the machine: frequency converter (inverter) – transformer – rectifier
3 Symbol of the welding current characteristics: drooping characteristic = constant current
4 Symbol of the welding procedure chosen: manual arc welding with stick electrode
5 Symbol of mains: alternative voltage – single phase
6 Thermal class of insulation. H=180C
7 Output current range
8 Case protection grade
9 Arc rod size
10 Open circuit volts
11 Output current
12 Serial number. Identification of machine (necessary for technical assistance, requests for parts and for
tracing product origin).
13 Mains frequency
14 & 15 Mains input voltage
16 & 17 Mains current
18 & 19 Fuse and rating
20 Do not use in wet conditions
21 Fan cooled
22 Dispose correctly or recycle
23 CE approved
24 Duty Cycle
IP21

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Other technical data, including the weight and voltage of each machine is listed in Tab. 1 below:
SECTION 6: DESCRIPTION OF THE WELDING MACHINE CONTROL, ADJUSTMENT AND
CONNECTION DEVICES
SECTION 7 : INSTALLATION
WARNING!
•CARRY OUT ALL INSTALLATION OPERATIONS AND ELECTRICAL CONNECTIONS WITH THE
WELDING MACHINE COMPLETELY SWITCHED OFF AND DISCONNECTED FROM THE POWER
SUPPLY OUTLET. THE ELECTRICAL CONNECTIONS MUST BE MADE ONLY AND EXCLUSIVELY BY
AUTHORISED OR QUALIFIED PERSONNEL.
Mains switch
Welding current adjustment
Graduated scale
Thermostat trigger light

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PREPARATION: Unpack the welding machine; assemble the separate parts contained in the package.
ASSEMBLING THE PROTECTIVE MASK
ASSEMBLING THE RETURN CABLE-CLAMP
ASSEMBLING THE WELDING CABLE-ELECTRODE HOLDER CLAMP

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WARNING! POSITION THE WELDING MACHINE ON A FLAT SURFACE WITH SUFFICIENT CARRYING
CAPACITY FOR ITS WEIGHT, TO PREVENT IT FROM TIPPING OR MOVING HAZARDOUSLY.
Before making any electrical connection, make sure the rating
data of the welding machine corresponds to the mains voltage
and frequency available at the place of installation.
CONNECTION TO THE MAIN
POWER SUPPLY:
The welding machine should only be connected to a power
supply system connected to earth.
PLUG AND OUTLET.
(FOR WELDING MACHINES WITHOUT A
PLUG) :
Connect a normalised plug (2P + E, 3P + E) having sufficient
capacity to the power cable and prepare a mains outlet fitted with
fuses or an automatic circuit-breaker; the special earth terminal
should be connected to the earth conductor (yellow-green) of the
power supply. Table 1 (TAB.1) shows the recommended
delayed fuse sizes in amps, chosen according to the max
nominal current supplied by the welding machine, and the
nominal voltage of the main power supply.
For welders with double voltage supply, it is necessary to set the blocking screw of the voltage-reverse switch in the
position corresponding to the voltage really available (see example below).
WARNING!
Failure to observe the above rules will make the (Class 1) safety system installed by the manufacturer
ineffective with consequent serious risks to persons (e.g. electric shock) and objects (e.g. fire).
CONNECTION OF THE WELDING CABLES
Table 1 (TAB. 1) gives the recommended values for the
welding cables depending on the maximum current supplied by
the welding machine.
WARNING! BEFORE MAKING CONNECTIONS MAKE SURE THE WELDING MACHINE IS SWITCHED OFF AND
DISCONNECTED FROM THE POWER SUPPLY OUTLET.
CONNECTING THE ELECTRODE-HOLDER
CLAMP WELDING CABLE
The electrode holder clamp (Fig F) is connected to the machine
via a direct cable or a cable via a terminal. In either case the
cable or terminal pole has the symbol:
CONNECTING THE WELDING CURRENT
RETURN CABLE
The welding current return clamp (Fig E) is connected to the
machine via a direct cable or a cable via a terminal. In either
case the cable or terminal pole has the symbol:
Mains voltage

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These welding machines consist of a drooping specification, and are suitable for welding with alternating current
using coated electrodes (E 43 R type) based on t
he diameters given on the data plate.
To switch on the welding machine operate the main switch (Fig. B-1).
The intensity of the supplied welding current can be adjusted continuously, by means of a manually operated
magnetic shunt (Fig. B-2).
CHECK THE WELDING MACHINE MODEL
N.B. In the case of a welding machine with switch, current adjustment should be carried out with the main switch (Fig.
B-1) in the O position (off).
The value of the current setting, (I2) can be read in Amps on the graduated scale (Fig. B-4) on the top or side panel
of machines where it is provided.
THERMOSTATIC
PROTECTION
This welder is automatically protected from thermic overheating (thermostat
automatic re-start). When the windings reach performance temperature, the
protection cuts off the supply circuit, igniting the yellow lamp on the front panel (B-5).
After a few minutes cooling the protection will reopen the supply line and turn off the
yellow lamp. The welder is ready for further use.
WELDING
Use electrodes suitable for working in alternating current. The welding current must
be regulated according to the diameter of the electrode in use and the type of the
joint to be carried out: see below the currents corresponding to various electrode
diameters:
ø Electrode (mm) Welding current (A)
min max
1.6 25 50
2 40 80
2.5 60 110
3.2 80 160
4 120 200
The user must consider that, according to the electrode diameter, higher current values must be used for flat welding,
whereas for vertical or overhead welds lower current values are necessary.
In addition to being determined by the selected current intensity, the mechanical characteristics of the welded joint is
determined by the other welding parameters i.e. arc length, working rate and position, electrode diameter and quality
(to store the electrodes correctly keep them dry and protected by suitable packaging or containers).
Holding the mask IN FRONT OF THE FACE, strike the electrode tip on the work
piece as if you were striking a match. This is the correct strike-up method.
WARNING: DO NOT HIT THE ELECTRODE ON THE WORK PIECE, THIS COULD
DAMAGE THE ELECTRODE AND MAKE STRIKE-UP DIFFICULT.
As soon as the arc is ignited, try to maintain a distance from the work piece equal to
the diameter of the electrode in use. Keep this distance as constant as possible for
the duration of the weld. Remember that the angle of the electrode as it advances
should be of 20-30 degrees (Fig.H).
WELDING PROCEDURE
At the end of the weld bead, bring the end of the electrode backward, in order to fill
the weld crater, quickly lift the electrode from the weld pool to extinguish the arc.
SECTION 8 : WELDING: DESCRIPTION OF THE PROCEDURE

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CHARACTERISTICS OF THE WELD BEAD
SECTION 9 : MAINTENANCE
WARNING! BEFORE CARRYING OUT MAINTENANCE OPERATIONS MAKE SURE THE WELDING MACHINE
IS SWITCHED OFF AND DISCONNECTED FROM THE MAIN POWER SUPPLY.
EXTRAORDINARY MAINTENANCE:
EXTRAORDINARY MAINTENANCE OPERATIONS SHOULD BE CARRIED OUT ONLY AND EXCLUSIVELY BY
SKILLED OR AUTHORISED ELECTRICAL-MECHANICAL TECHNICIANS.
WARNING! BEFORE REMOVING THE WELDING MACHINE PANELS AND WORKING INSIDE THE MACHINE
MAKE SURE THE WELDING MACHINE IS SWITCHED OFF AND DISCONNECTED FROM THE MAIN POWER
SUPPLY. IF CHECKS ARE MADE INSIDE THE WELDING MACHINE WHILE IT IS LIVE, THIS MAY CAUSE
SERIOUS ELECTRIC SHOCK DUE TO DIRECT CONTACT WITH LIVE PARTS AND/OR INJURY DUE TO
DIRECT CONTACT WITH MOVING PARTS.
Inspect the welding machine regularly, with a frequency depending on use and the dustiness of the environment, and
remove the dust deposited on the transformer, using a jet of dry compressed air (max. 10 bar).
At the same time make sure the electrical connections are tight and check the wiring for damage to the insulation.
At the end of these operations re-assemble the panels of the welding machine and screw the fastening screws right
down.
Never, ever carry out welding operations while the welding machine is open

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SECTION 10 : CIRCUIT DIAGRAM
Weldability ARC2
00
S

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SECTION 11 : REPLACEMENT PARTS
7
7
7
710
29
28
25
24
21
21
20
20
21
18
17
22 19
17
23
17
17
16
16 15
15
14
14
13
13
1
3
4
7
2
8
9
5
7
7
6
6
7
7
6
10
11
37
37
21
21
38
36
36
35
30
36
26
31
32
41
4
34
33
42
13 13
13
13
12
40 40
40
40
39
For further information, contact Weldability | Sif technical support on 0870 330 7757 or email [e-mail]
Doc Ref: SIF/MANUAL/ARC200S REV: 7.04.10
Weldability ARC200S
TWX1A200S__ (#)