Wido WD060115516 Maintenance and service guide

Welding Machine
160A/180A/200A/250A
WD060116018
WD060116020
WD060116025
WD060115516
MMA AC

WD060115516/WD060116018/WD060116020/WD060116025
Thank you for purchasing a WIDO product. We are confident that you will appreciate the quality of
the product and you will be entirely satisfied with your purchase. Please read carefully the user
safety and operating instruction on how to operate this product correctly within safety norms and
regulations.
2

3
WD060115516/WD060116018/WD060116020/WD060116025
L
N
220-240V
A
B
C
380-400V
380V 220V
A.C. WELDER
321
1
2
3
9
10
5 46
7

4
WD060115516/WD060116018/WD060116020/WD060116025
380V 220V
380V 220V
A.C. WELDER A.C. WELDER
x
8
45 6
987
121110
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160/180/200/250A MMA AC WELDING MACHINE ENG
COMPONENT LIST
1) Power cable
2) Current adjustment knob
3) Power switch
4) Power indicator light (only for WD060116018/WD060116020/WD060116025)
5) Overheat indicator light
6) Handle
7) Power control screw (only for WD060116018/WD060116020/WD060116025)
8) Current pointer
9) Electrode holder with cable
10) Ground clamp with cable
NORMAL ACCESSORIES
1) Protective mask: 1pc
2) Hammer brush: 1pc
We recommend that you purchase your accessories from the same store that sold you the welding
machine. Use good quality accessories marked with a well-known brand name. Choose the type
according to the work you intend to undertake. Refer to the accessory packaging for further details. Store
personnel can assist you and offer advice.
5

WELDING MACHINE SAFETY WARNINGS
Warning: Read all safety warnings and all instructions. Failure to follow the warnings and
instructions may result in electric shock, fire and/or serious injury.
Save all warnings and instructionsfor future reference.
Electric shock can kill.
Electric arc welders can produce a shock that can cause injury or death. Touching electrically live parts
can cause fatal shocks and severe burn. While welding, all metal components connected to the wise
are electrically live. Poor ground connections are a hazard, so secure the ground lead before welding.
●Wear dry protective apparel: coat, shirt, gloves and insulated footwear.
●Insulate yourself from the workpiece. Avoid contacting the workpiece or ground.
●Do not attempt to repair or maintain the welder whilethe power is on.
● Inspect all cables and cords for any exposed wire and replace immediately if found.
● Use only recommended replacement cables and cords.
● Always attach ground clamp to the workpiece or worktable as close to the weld area as possible.
●Do not touch the welding wire and the ground or grounded work piece at the same time.
●Do not use a weldertothaw frozen pipes.
● Turn off all equipment when welder not in use.
Fumes can be dangerous.
Fumes emitted from the welding process displace clean air and can result in injury or death.
●Do not breathe in fumes emitted by the welding process. Make sure your breathing air is clean
safe.
●Work only in a well- ventilated area or use a ventilation device to remove welding fumes from
environment where you will be working.
●Do not weld on coated materials (galvanized, cadmium plated or containing zinc,mercury or barium).
They will emit harmful fumes that are dangerous to breathe. If necessary use a ventilator, respirator
with air supply or remove the coating from the material in the weld area.
●The fumes emitted from some metals when heated are extremely toxic. Refer to the material
data sheet for the manufacturer’s instructions.
●Do not weld near materials that wil l emit toxic fumes when heated. Vapors from cleaners, sprays
anddegreasers can be highly toxic when heated.
Arc rays can burn eyes and skin.
The welding arc produces ultraviolet (UV) and infrared (IR) rays that can cause injury to your eyes and
skin. Do not look at the welding arc without proper eye protection.
● Always use a helmet that covers your full face from the neck to top of head and to the back of
each ear.
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160/180/200/250A MMA AC WELDING MACHINE ENG
and
the
safety

●Use a lens and safety glasses. For welders under 160 A output,use a shade 10 lens; for above 160 A,
use a shade 12 lens.
● Cover all bare skin areas exposed to the arc with protective clothing and shoes. Flame- retardant
cloth or leather shirts, coats, pants or coveralls are available for protection.
● Use screens or other barriers to protect other people from the arc rays emitted from your welding.
●Warn people in your welding area when you are going to strike an arc so they can protect
themselves.
Welding can cause fire or explosion.
Do not weld on containers or pipes that contain or have had flammable, gaseous or liquid combustibles
in them. Welding creates sparks and heat that can ignite flammable and explosive materials.
●Do not operate any electric arc welder in areas where flammable or explosive materials are present.
●Remove all flammable materials within 10m of the welding arc. If removal is not possible, tightly
cover them with fireproof covers.
●Take precautions to ensure that flying sparks do not cause fires or explosions in hidden areas,cracks
or areas you cannot see.
●Keep a fire extinguisher close in the case of fire.
●Wear garments that are oil-free with no pockets or cuffs that will collect sparks.
●Do not have on your person any items that are combustible, such as lighters or matches.
●Keep work lead connectedas close tothe weld area as possible to prevent any unknown,unintended
paths of electrical current from causing electrical shock and fire hazards.
●To prevent any unintended arcs, cut wire back to 6mm stick out after welding.
● Remove stick electrode from holder or cut off welding wire at contact tip when not in use.
Hot materials can cause severe burns.
Welded materials are hot and can cause severe burns if handled improperly.
●Do not touch hot welding materials with bare hands.
●Do not touchgunnozzle after welding until it has had time to cool down.
Flying metal can injure eyes.
Welding creates hot sparks that can cause injury. Chipping slag off welds creates flying debris.
●Wear protective apparel at all times: Approved safety glasses or shield, welder’s hat and ear plugs
keep sparks out of ears and hair.
Magnetic fields can affect pacemakers.
Electromagnetic fields can interfere with various electrical and electronic devices such as pacemakers.
●Consult your doctor before using any electric arc welder or cutting device .
●Keep people with pacemakers away from your welding area when welding.
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160/180/200/250A MMA AC WELDING MACHINE ENG
to

●Do not wrap cable around your body while welding.
Noise can damage hearing.
Noise from some processes or equipment can damage hearing.
● Wear approved ear protection if noise level is high.
Extension cables
Using extension cables is not recommended. The use of extension cables will cause voltage to drop.
If an extension cable must be used, be sure it is:
A 3-wire extension cable that has a 3-blade grounding plug, and a 3-slot receptacle that will accept
the plug on the product.
In good condition.
The section of the cable should be bigger to reduce the lower of the cable voltage.
GROUNDING INSTRUCTIONS
This welding machine should be grounded while in use to protect the operator from electric shock. The
welding machine is equipped with a three-core cable and grounding type plug to fit the proper
grounding type receptacle. The green and yellow conductor in the cable is the grounding wire. Never
connect the green and yellow wire to a live terminal.
IMPORTANT NOTE
Be sure the supply is the same as the voltage and frequency given on the rating plate.
Remove the main plug from socket before carrying out any adjustment or servicing.
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160/180/200/250A MMA AC WELDING MACHINE ENG
Max distance is less than 5m
●
●
●
●

SYMBOLS
To reduce the risk of injury, user must read instruction manual
Warning
Electrical shock risk
Breathing risk
Wear protective mask
Fire or explosion risk
Burns risk
Wear eye protection
Wear ear protection
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160/180/200/250A MMA AC WELDING MACHINE ENG
Waste electrical products should not be disposed of with household waste. Please recycle
where facilities exist. Check with your Local Authority or retailer for recycling advice
Keep dry

160/180/200/250A MMA AC WELDING MACHINE ENG
TECHNICAL DATA
Note: For welding machine specifications refer to the nameplate on your welding machine.
Model WD060115516 WD060116018 WD060116020 WD060116025
Input voltage 220-240V AC 220-240V AC
380/400V AC
220-240V AC
380/400V AC
220-240V AC
380/400V AC
Frequency 50/60Hz 50/60Hz 50/60Hz 50/60Hz
Input capacity 8KVA 9.6KVA 11.2KVA 14KVA
No-load voltage48V 48V48V48V
Output range 55-160A 60-180A 60-200A 60-250A
Duty cycle 10%@160A10%@180A10%@200A10%@250A
Electrode diameter Ф2.0 -4.0mm Ф2.0 - 4.0mm Ф2.0 - 4.0mm Ф2.0 -5.0mm
Protection class IP21S IP21S IP21S IP21S
Insulation class H H H H
Machine weight 18.8Kg 21.5Kg 23Kg 23.5Kg
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160/180/200/250A MMA AC WELDING MACHINE ENG
OPERATING INSTRUCTIONS
Note: Before using the welding machine, read the instruction manual carefully.
1. Intended use
This welding machine is made with traditional technology. It is intended for use for welding steel, stainless
steel.
2. Working environment
Under comparative dry environment, the environment temperature should be between -100C and +400C,
avoid working in the sun or rain, avoid working in the environment where there is much dust or corrosive
gas.
3.Power requirements
This welding machine is designed to operate on a properly grounded 220-240V or 380-400V (only for
WD060116018, WD060116020, WD060116025) 50Hz or 60 Hz, single-phase alternating current power
source. It is recommended that an electrician verify the actual voltage at the receptacle.
Warning:If the actual power source voltage is less than 198V / 342V (only for WD060116018,
WD060116020, WD060116025) or greater than 253V / 440V (only for WD060116018, WD060116020,
WD060116025). Do not operate this welding machine.
4. Installation
Note: Only qualified persons should install, use or service this equipment. Protect yourself and others
from possible serious injury or death.
1) Connection of the power cable
a) This welding machine must be grounded while in use to protect the operator from electrical shock.
Make sure the power switch is off then connect your welding machine’s power cable to a properly
grounded.
Warning:The green and yellow conductor in the cable is the grounding wire. Never connect the
green and yellow wire to a live terminal.
b) When you connect the cable of welding machine to 230V power source, brown wire must be
connected to live line terminal, and blue wire must be connected to zero line terminal (See Fig 1).
c) When you connect the cable of welding machine to 380V power source, brown and blue wire must be
connected to arbitrary two phase line terminal (only for WD060116018, WD060116020, WD060116025)
(See Fig 2).
c) Use multimeter to check whether the voltage value varies in the given range.
2) Connection of output cable
a) Attach the work clamp to the workpiece, as close as possible to the area being welded. Clean with a
wire brush where necessary to ensure the connection is as clean as possible.
b) If the workpiece is too far away from the welding machine (Max distance is less than 5m), and the
secondary cable is too long, the section of the cable should be bigger to reduce the lower of the cable
voltage.
3) Checking
a) Whether the welding machine is connected to standard to earth.
b) Whether the power control screw is be adjusted to correct position.
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160/180/200/250A MMA AC WELDING MACHINE ENG
c) Whether all the connections are well-connected, especially that between the ground clamp and the
workpiece.
d) Whether the output of the electrode holder and earth cable is short-circuited.
e) If you choose the circuit protector, the leaking electricity should be less than 30mA.
f) The welding splash may cause fire, so make sure there is no flammable materials nearby.
5. Operating the welding machine
1) Switching on and off
a) To start the welding machine, press the upside of the power switch (only for WD060115516) or turn
the power switch to “230V” position (See Fig 3). The power switch (only for WD060115516) or power
indicator light on the front panel is lit and fan begins to spin whenthe switch is turned on.
b) If the cable of your welding machine (only for WD060116018, WD060116020, WD060116025) be
connected to 380V power source, you must adjust the power control screw to the other side of switch
knob (See Fig 4).
c) To start the welding machine, turn the power switch to “380V” position (See Fig 5). The power
indicator light on the front panel is lit and fan begins to spin whenthe switch is turned on.
d) To switch off the welding machine, press the underside of the power switch (only for WD060115516)
or turn the power switch to “0” symbol position.
Warning: your welding machine will be damaged if the switch be turn to wrong voltage
position.
2) Adjusting welding current
An appropriate current must be set by turning the welding current adjustment knob located on the front
panel of the welding machine. Clockwise rotation raises the welding current, counterclockwise rotation
reduces the welding current (See Fig 6).
Note: The most difficult aspect of the arc welding process, particularly for beginners, we strongly
recommend that you practice on some pieces of scrap metal to get the feel of the operation, before you
start on an actual welding job.
3)Holding the electrode
The best way to grip the electrode holder is the way that feels most comfortable to you. Position the
electrode to the workpiece when striking the initial arc it may be necessary to hold the electrode
perpendicular to the workpiece. Once the arc is started the angle of the electrode in relation to the
workpiece should be between 600and 800degrees. This will allow for good penetration, with minimal
spatter.
4) Striking the arc
Warning: Exposure to a welding arc is extremely harmful to the eyes and skin! Prolonged
exposure to the welding arc can cause blindness and burns. Never strike an arc or begin welding
until you are adequately protected. Wear flame-proof welding gloves, a heavy long sleeved shirt,
trousers without cuffs, high topped shoes, and a welding mask.
Scratch the workpiece with the end of electrode to start arc and then raise it quickly about X gap
(X=50%-100% diameter of electrode) between the rod andthe workpiece (See Fig 7).
Note: It is important that the gap be maintained during the welding process and it should be neither too
wide or too narrow. If too narrow, the rod will stick to the workpiece. If too wide, the arc will be
extinguished. It needs much practice to maintain the gap. The beginners may usually get sticker or arc
extinguishing. When the rod is stuck to the workpiece, gently rock it back and forth to make them
separate. A good arc is accompanied by a crisp, cracking sound. The sound is similar to that made by
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160/180/200/250A MMA AC WELDING MACHINE ENG
eggs frying. To lay a weld bead, only 2 movements are required, downward and in the direction the weld
is to be laid (See Fig 8).
5) Types of weld bead
The following paragraphs discuss the most commonly used arc welding beads.
a) The stringer bead formed by traveling with the electrode in a straight line while keeping the electrode
centered over the weld joint (See Fig 9).
b) The weave bead used when you want to deposit metal over a wider space than would be possible with
a stringer bead. It is made by weaving from side to side while moving with the electrode. It is best to
hesitate momentarily at each side before weaving back the other way (See Fig 10).
6) Welding position
a) Flat position it is easiest of the welding positions and is most commonly used. It is best if you can weld
in the flat position if at all possible as good results are easier to achieve (See Fig 11).
b) The horizontal position it is performed very much the same as the flat weld except that the angle is
different such that the electrode, and therefore the arc force, is directed more toward the metal above the
weld joint. This more direct angle helps prevent the weld puddle from running downward while still
allowing slow enough travel speed to achieve good penetration. A good starting point for your electrode
angle is about 30 degrees down from being perpendicular to the work piece (See Fig 12).
7) Judgethe good weld bead
When the trick of establishing and holding an arc has been learned, the next step is learning how to run a
good bead. The first attempts in practice will probably fall short of acceptable weld beads. Too long of an
arc will be held or the travel speed will vary from slow to fast (See Fig 13).
A. Weld speed is too fast.
B. Weld speed is too slow.
C. Arc is too long.
D. Ideal weld.
Note: A solid weld bead requires that the electrode be moved slowly and steadily along the weld seam.
Moving the electrode rapidly or erratically will prevent proper fusion or create a lumpy, uneven bead.
Warning: Electric shock can kill! To prevent electric shock, do not perform any welding while
standing, kneeling, or lying directly on the grounded workpiece.
8) Finish the bead
As the coating on the outside of the electrode burns off, it forms an envelope of protective gases around
the weld. This prevents air from reaching the molten metal and creating an undesirable chemical reaction.
The burning coating, however, forms slag. The slag formation appears as an accumulation of dirty metal
scale on the finished weld. Slag should be removed by using a chipping hammer.
Warning: Peening the slag from a weld joint causes small chips of metal to fly through the air!
Metallic chips flying through the air can cause eye injury or injury to other parts of the head,
hands or exposed portions of the body. Wear goggles or safety glasses with side shields and
protect the hands and other exposed parts of the body with protective garments, or if possible,
work with a shield between the body and the work piece.
The intense heat produced at the arc sets up strains in the metal joined by welding. Peening the weld not
only removes the scale left behind in the welding but relieves the internal strains developed by the
heating and cooling process.
9) Allowed duty cycle
Strictly work in conformity with the required duty cycle. If work under over duty cycle, the welding machine
may suddenly stop working, and the amber overheat indicator light is lit. That's the inner thermal parts
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160/180/200/250A MMA AC WELDING MACHINE ENG
work because of over-loading. Under this circumstance,no need to turn off the power switch, leave the
fan work to lower the temperature.
MAINTENANCE
Warning: Remove the plug from the socket before carrying out any adjustment, servicing or
maintenance.
1.Never use water or chemical cleaners to clean your welding machine. Only wipe clean with a dry cloth.
2.Under normal working conditions removing the covers and cleaning your welding machine with dry
compressed air at reduced pressure every six months will be quite sufficient. Cleaning at more frequent
intervals is advisable if the welding machine is operating in a dusty and dirty environment.
3.Always try to avoid getting particles of metal inside the welding machine since they could cause short
circuits.
4. Always store your welding machine in a dry place.
5. Check all cables periodically. They must be in good condition and not cracked. If the cable is damaged,
it must be replaced by the manufacturer, its service agent or similarly qualified persons in order to avoid a
hazard.
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160/180/200/250A MMA AC WELDING MACHINE ENG
TROUBLESHOOTING
Problem Possible Cause Solution
Unit does not power up Unit is not plugged in Plug in socket
Input power circuit breaker not
on
Reset input power circuit breaker
The main power switch is not
working
Replace main power switch
Can not create an arc Workpiece is painted or rusty Remove all paint and rust
Ground clamp is connected
where there is paint or rust
Remove all paint and rust so
ground clamp is connected to
bare metal
Ground clamp is not electrically
connected to the workpiece
Make certain the ground clamp is
connected to the workpiece
Amperage too low for electrode Consult the electrode packaging
for correct amperage settings.
Protection indicator lightis
on
The internal temperature is too
high.
Leave power on and let the fan
cool the unit. Output will continue
when the unit has cooled.
Electrode holder or ground
cable getting hot. Output
connections getting hot.
Weld cable connections loose Check to make certain weld
cables are tight.
Weld cable connections have
corroded.
Clean weld connections and
reinstall.
Poor welding performance,
excessive spatter
Damp electrode Use fresh and dry electrodes.
Electrode sticks The electrode is kept in contact
with the workpiece for too long
while striking an arc
This will take practice. Keep
trying.
Welding bead is too thin The welding travel speed is too
fast
Reduce the welding travel
speed. Maybe incorporate a
slight weave over the joint.
Welding bead is too thick The welding travel speed is too
slow
Increase the welding travel
speed.
ENVIRONMENT PROTECTION
Waste electrical products should not be disposed of with household wase. Please recycle
where facilities exist. Check with your Local Authority or retailer for recycling advice.
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160/180/200/250A MMA AC WELDING MACHINE ENG
EXPLOSIVE VIEW OF WD060115516
16
07
02
03
14
08
09
10
05
04
11
06
13
12
19
15
16
17
18
20
23
21
22
24
28
27
25
26
38
34
35
33
36
37
01
30
29
32
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160/180/200/250A MMA AC WELDING MACHINE ENG
PART LIST OF WD060115516
NO
DESCRIPTION
Q’TY
NO
DESCRIPTION
Q’TY
1 Bottom foot 2 20 Nut 4
2
Screw
2
21
Front support
1
3 Electrode holder with cable 1 22 Screw 2
4
Ground clamp with cable
1
23
Moving iron
2
5 Fairlead 3 24 Jump ring 1
6
Cable grip
3
25
Latch
2
7 Switch knob cover 1 26 Thermal protector 1
8
Nut
1
27
Main transformer
1
9 Spring washer 1 28 Current pointer 1
10
Current adjustment knob
1
29
Wheel axle cover
2
11 Current adjustment lead screw 1 30 Wheel axle circlip 2
12
Cable and plug
1
31
Wheel
2
13 Power switch 1 32 Wheel axle 1
14
Overheat indicator
1
33
Screw
16
15 Base plate 1 34 Housing 1
16
Screw
4
35
Current window
1
17 Washer 8 36 Bolt 2
18
Transformer support
2
37
handle
1
19 Spring washer 4 38 Fan 1
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160/180/200/250A MMA AC WELDING MACHINE ENG
EXPLOSIVE VIEW OF WD060116018/WD060116020/WD060116025
18
2
8
4
3
6
5
7
13
12
10
11
28
30
35
31
29
34
33
41
37
32
36
40
39
38
24 25
19
1
9
14
15
16
17
18 26
27
45
46
47
52
53
48
49
50
51
23
22
21
20
44
43
42
55
54
56
57
58

160/180/200/250A MMA AC WELDING MACHINE ENG
PART LIST OF WD060116018/WD060116020/WD060116025
NO
DESCRIPTION
Q’TY
NO
DESCRIPTION
Q’TY
1 Electrode holder with cable 1 30 Screw 2
2
Cable grip
3
31
Screw
4
3 Fairlead 3 32 Washer 8
4
Ground clamp with cable
1
33
Transformer support
2
5 Current adjustment knob cover 1 34 Spring washer 4
6
Nut
1
35
Nut
4
7 Spring washer 1 36 Front support 1
8
Washer
1
37
Screw
2
9 Current adjustment knob 1 38 Moving iron 2
10
Current adjustment lead screw
1
39
Current pointer
1
11 Overheat indicator 1 40 Jump ring 2
12
Nut
2
41
Main transformer
1
13 Power indicator 1 42 Thermal protector 1
14
Cable
1
43
Latch
1
15 Screw 1 44 Wheel axle cover 2
16
Switch knob
1
45
Wheel axle circlip
2
17 Switch knob fixer 1 46 Wheel 2
18
Screw
2
47
Wheel axle
1
19 Locking plate 1 48 Screw 16
20
Switch
1
49
Screw
2
21 Capacitor 1 50 Washer 2
22
Grounding terminal
1
51
Bottom foot
2
23 Tooth washer 5 52 Grounding terminal 2
24
Spring washer
5
53
Housing
1
25 Screw 5 54 Current window 1
26
Base plate
1
55
Nut
2
27 Fan 1 56 Bolt 2
28
Washer
2
57
Handle
1
29 Spring washer 2 58 Cover of handle 2
19

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