Page 1
HandyArc 132i DV,
142i, 162i
Instruction manual
0463 764 001 GB 20201214
Page 2
TABLE OF CONTENTS
1 SAFETY
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1.1 Meaning of symbols
1.2 Safety precautions
1.3 User responsibility
1.4 California proposition 65 warning
2 INTRODUCTION
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2.1 HandyArc Inverter
2.2 Packing
3 TECHNICAL DATA
4 INSTALLATION
4.1 Receiving
4.2 Environment
4.3 Workplace
4.4 Ventilation
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4.5 Power grid requirements
4.6 Electromagnetic compatibility
5 OPERATION
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5.1 Welding with coated electrode / SMAW
5.2 Control panel and connectors
5.3 Resources
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5.4 Welding with coated electrodes (SMAW)
6 MAINTENANCE
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6.1 Preventive maintenance
6.2 Corrective maintenance
7 TROUBLESHOOTING
8 ELECTRICAL SCHEME
9 DIMENSIONS
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10 ORDERING SPARE PARTS
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1 SAFETY
1 SAFETY
1.1 Meaning of symbols
As used throughout this manual: Means Attention! Be Alert!
DANGER!
Means immediate hazards which, if not avoided, will result in immediate, serious
personal injury or loss of life.
WARNING!
Means potential hazards which could result in personal injury or loss of life.
CAUTION!
Means hazards which could result in minor personal injury.
WARNING!
Before use, read and understand the instruction manual and
follow all labels, employer´s safety practices and Safety Data
Sheets (SDSs).
1.2 Safety precautions
WARNING!
These Safety Precautions are for your protection. They summarise precautionary
information from the references listed in Additional Safety Information section. Before
performing any installation or operating procedures, be sure to read and follow the safety
precautions listed below as well as all other manuals, material safety data sheets, labels,
etc. Failure to observe Safety Precautions can result in injury or death.
PROTECT YOURSELF AND OTHERS
Some welding, cutting and gouging processes are noisy and require ear
protection. The arc, like the sun, emits ultraviolet (UV) and other radiation
and can injure skin and eyes. Hot metal can cause burns. Training in the
proper use of the processes and equipment is essential to prevent accidents.
Therefore:
1. Wear a welding helmet fitted with a proper shade of filter to protect your face and
eyes when welding or watching.
2. Always wear safety glasses with side shields in any work area, even if welding
helmets face shields and goggles are also required.
3. Use a face shield fitted with the correct filter and cover plates to protect your eyes,
face, neck and ears from sparks and rays of the arc when operating or observing
operations. Warn bystanders not to watch the arc and not to expose themselves to
the rays of the electric-arc or hot metal.
4. Wear flameproof gauntlet type gloves, heavy long-sleeve shirt, cuff less trousers,
high-topped shoes and a welding helmet or cap for protection, to protect against arc
rays and hot sparks or hot metal. A flameproof apron may also be desirable as
protection against radiated heat and sparks.
5. Hot sparks or metal can lodge in rolled up sleeves, trouser cuffs, or pockets. Sleeves
and collars should be kept buttoned and open pockets eliminated from the front of
clothing.
6. Protect other personnel from arc rays and hot sparks with a suitable non-flammable
partition or curtains.
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1 SAFETY
7. Use goggles over safety glasses when chipping slag or grinding. Chipped slag may
be hot and can fly far. Bystanders should also wear goggles over safety glasses.
FIRES AND EXPLOSIONS
Heat from flames and arcs can start fires. Hot slag or sparks can also cause
fires and explosions. Therefore:
1. Protect yourself and others from flying sparks and hot metal.
2. Remove all combustible materials well away from the work area or cover the materials
with a protective non-flammable covering. Combustible materials include wood, cloth,
sawdust, liquid and gas fuels, solvents, paints and coatings paper, etc.
3. Hot sparks or hot metal can fall through cracks or crevices in floors or wall openings
and cause a hidden smoldering fire or fires on the floor below. Make certain that such
openings are protected from hot sparks and metal.
4. Do not weld, cut or perform other hot work until the work piece has been completely
cleaned so that there are no substances on the work piece which might produce
flammable or toxic vapors. Do not do hot work on closed containers, they may
explode.
5. Have fire extinguishing equipment handy for instant use, such as a garden hose,
water pail, sand bucket, or portable fire extinguisher. Be sure you are trained in its
use.
6. Do not use equipment beyond its ratings. For example, an overloaded welding cable
can overheat and create a fire hazard.
7. After completing operations, inspect the work area to make certain there are no hot
sparks or hot metal which could cause a later fire. Use fire watchers when necessary.
ELECTRICAL SHOCK
Contact with live electrical parts and ground can cause severe injury or
death. DO NOT use AC welding current in damp areas, if movement is
confined, or if there is danger of falling. Therefore:
1. Be sure the power source frame (chassis) is connected to the ground system of the
input power.
2. Connect the workpiece to a good electrical ground.
3. Connect the work cable to the workpiece. A poor or missing connection can expose
you or others to a fatal shock.
4. Use well-maintained equipment. Replace worn or damaged cables.
5. Keep everything dry, including clothing, work area, cables, torch/electrode holder and
power source.
6. Make sure that all parts of your body are insulated from both the work piece and from
the ground.
7. Do not stand directly on metal or the earth while working in tight quarters or a damp
area; stand on dry boards or an insulating platform and wear rubber-soled shoes.
8. Put on dry, hole-free gloves before turning on the power.
9. Turn off the power before removing your gloves.
10.Refer to ANSI/ASC Standard Z49.1 for specific grounding recommendations. Do not
mistake the work lead for a ground cable.
ELECTRIC AND MAGNETIC FIELDS
May be dangerous. Electric current flowing through any conductor causes
localized Electric and Magnetic Fields (EMF). Welding and cutting current
creates EMF around welding cables and welding machines. Therefore:
1. Welders having pacemakers should consult their physician before welding. EMF may
interfere with some pacemakers.
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1 SAFETY
2. Exposure to EMF may have other health effects which are unknown.
3. Welders should use the following procedures to minimise exposure to EMF:
1. Route the electrode and work cables together. Secure them with tape
when possible.
2. Never coil the torch or work cable around your body.
3. Do not place your body between the torch and work cables. Route
cables on the same side of your body.
4. Connect the work cable to the workpiece as close as possible to the
area being welded.
5. Keep welding power source and cables as far away from your body as
possible.
FUMES AND GASES
Fumes and gases, can cause discomfort or harm, particularly in confined
spaces. Shielding gases can cause asphyxiation. Therefore:
1. Keep your head out of the fumes. Do not breathe the fumes and gases.
2. Always provide adequate ventilation in the work area by natural or mechanical means.
Do not weld, cut or gouge on materials such as galvanized steel, stainless steel,
copper, zinc, lead beryllium or cadmium unless positive mechanical ventilation is
provided. Do not breathe fumes from these materials.
3. Do not operate near degreasing and spraying operations. The heat or arc can react
with chlorinated hydrocarbon vapors to form phosgene, a highly toxic gas and other
irritant gases.
4. If you develop momentary eye, nose or throat irritation while operating, this is an
indication that ventilation is not adequate. Stop work and take necessary steps to
improve ventilation in the work area. Do not continue to operate if physical discomfort
persists.
5. Refer to ANSI/ASC Standard Z49.1 for specific ventilation recommendations.
6. WARNING: This product when used for welding or cutting, produces fumes or gases
which contain chemicals known to the State of California to cause birth defects and in
some cases cancer (California Health & Safety Code §25249.5 et seq.)
CYLINDER HANDLING
Cylinders, if mishandled, can rupture and violently release gas. A sudden
rupture of cylinder valve or relief device can injure or kill. Therefore:
1. Locate cylinders away from heat, sparks and flames. Never strike an arc on a
cylinder.
2. Use the proper gas for the process and use the proper pressure reducing regulator
designed to operate from the compressed gas cylinder. Do not use adaptors. Maintain
hoses and fittings in good condition. Follow manufacturer's operating instructions for
mounting regulator to a compressed gas cylinder.
3. Always secure cylinders in an upright position by chain or strap to suitable hand
trucks, undercarriages, benches, wall, post or racks. Never secure cylinders to work
tables or fixtures where they may become part of an electrical circuit.
4. When not in use, keep cylinder valves closed. Have valve protection cap in place if
regulator is not connected. Secure and move cylinders by using suitable hand trucks.
MOVING PARTS
Moving parts, such as fans, rotors and belts can cause injury.
Therefore:
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1 SAFETY
1. Keep all doors, panels, guards and covers closed and securely in place.
2. Stop engine or drive systems before installing or connecting unit.
3. Have only qualified people remove covers for maintenance and troubleshooting as
necessary
4. To prevent accidental starting of equipment during service, disconnect negative (-)
battery cable from battery.
5. Keep hands, hair, loose clothing and tools away from moving parts.
6. Reinstall panels or covers and close doors when service is finished and before
starting engine.
WARNING!
FALLING EQUIPMENT CAN INJURE
• Only use lifting eye to lift unit. Do NOT use running gear, gas cylinders or any
other accessories.
• Use equipment of adequate capacity to lift and support unit.
• If using lift forks to move unit, be sure forks are long enough to extend beyond
opposite side of unit.
• Keep cables and cords away from moving vehicles when working from an aerial
location.
WARNING!
EQUIPMENT MAINTENANCE
Faulty or improperly maintained equipment can cause injury or death. Therefore:
1. Always have qualified personnel perform the installation, troubleshooting and
maintenance work. Do not perform any electrical work unless you are
qualified to perform such work.
2. Before performing any maintenance work inside a power source, disconnect
the power source from the incoming electrical power.
3. Maintain cables, earthing wire, connections, power cord and power supply in
safe working order. Do not operate any equipment in faulty condition.
4. Do not abuse any equipment or accessories. Keep equipment away from
heat sources such as furnaces, wet conditions such as water puddles, oil or
grease, corrosive atmospheres and inclement weather.
5. Keep all safety devices and cabinet covers in position and in good repair.
6. Use equipment only for its intended purpose. Do not modify it in any manner.
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1 SAFETY
CAUTION!
ADDITIONAL SAFETY INFORMATION
For more information on safe practices for electric arc welding and cutting
equipment, ask your supplier for a copy of “Precautions and Safe Practices for Arc
Welding, Cutting and Gouging”, Form 52-529.
The following publications are recommended:
• ANSI/ASC Z49.1 - “Safety in Welding and Cutting”
• AWS C5.5 - “Recommended Practices for Gas Tungsten Arc Welding”
• AWS C5.6 - “Recommended Practices for Gas Metal Arc welding”
• AWS SP - “Safe practices” - Reprint, Welding Handbook
• ANSI/AWS F4.1 - “Recommended Safe Practices for Welding and Cutting of
• OSHA 29 CFR 1910 - "Safety and health standards"
• CSA W117.2 - "Code for safety in welding and cutting"
• NFPA Standard 51B, “Fire Prevention During Welding, Cutting, and Other Hot
• CGA Standard P-1, “Precautions for Safe Handling of Compressed Gases in
• ANSI Z87.1, "Occupational and Educational Personal Eye and Face Protection
Containers That Have Held Hazardous Substances”
Work"
Cylinders”
Devices"
1.3 User responsibility
Users of ESAB equipment have the ultimate responsibility for ensuring that anyone who works on or
near the equipment observes all the relevant safety precautions. Safety precautions must meet the
requirements that apply to this type of equipment. The following recommendations should be observed
in addition to the standard regulations that apply to the workplace.
All work must be carried out by trained personnel well-acquainted with the operation of the equipment.
Incorrect operation of the equipment may lead to hazardous situations which can result in injury to the
operator and damage to the equipment.
1. Anyone who uses the equipment must be familiar with:
• its operation
• location of emergency stops
• its function
• relevant safety precautions
• welding and cutting or other applicable operation of the equipment
2. The operator must ensure that:
• no unauthorised person is stationed within the working area of the
equipment when it is started up
• no-one is unprotected when the arc is struck or work is started with the
equipment
3. The workplace must:
• be suitable for the purpose
• be free from drafts
4. Personal safety equipment:
• Always wear recommended personal safety equipment, such as safety
glasses, flame-proof clothing, safety gloves
• Do not wear loose-fitting items, such as scarves, bracelets, rings, etc.,
which could become trapped or cause burns
5. General precautions:
• Make sure the return cable is connected securely
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1 SAFETY
• Work on high voltage equipment may only be carried out by a qualified
electrician
• Appropriate fire extinguishing equipment must be clearly marked and close
at hand
• Lubrication and maintenance must not be carried out on the equipment
during operation
WARNING!
Wire feeders are intended to be used in GMAW (MIG/MAG) mode only.
If used in any other welding mode, such as SMAW (MMA), the welding cable between wire
feeder and power source must be disconnected, or else the wire feeder becomes live or
energized.
If equipped with ESAB cooler
Use ESAB approved coolant only. Non-approved coolant might damage the equipment and jeopardize
product safety. In case of such damage, all warranty undertakings from ESAB cease to apply.
Recommended ESAB coolant ordering number: 0465720002.
For ordering information, see the "ACCESSORIES" chapter in the instruction manual.
WARNING!
Arc welding and cutting can be injurious to yourself and others. Take precautions when
welding and cutting.
ELECTRIC SHOCK - Can kill
• Do not touch live electrical parts or electrodes with bare skin, wet gloves or
wet clothing
• Insulate yourself from work and ground.
• Ensure your working position is safe
ELECTRIC AND MAGNETIC FIELDS - Can be dangerous to health
• Welders having pacemakers should consult their physician before welding.
EMF may interfere with some pacemakers.
• Exposure to EMF may have other health effects which are unknown.
• Welders should use the following procedures to minimize exposure to EMF:
○ Route the electrode and work cables together on the same side of
your body. Secure them with tape when possible. Do not place your
body between the torch and work cables. Never coil the torch or
work cable around your body. Keep welding power source and
cables as far away from your body as possible.
○ Connect the work cable to the workpiece as close as possible to the
area being welded.
0463 764 001
FUMES AND GASES - Can be dangerous to health
• Keep your head out of the fumes
• Use ventilation, extraction at the arc, or both, to take fumes and gases away
from your breathing zone and the general area
ARC RAYS - Can injure eyes and burn skin
• Protect your eyes and body. Use the correct welding screen and filter lens
and wear protective clothing
• Protect bystanders with suitable screens or curtains
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1 SAFETY
NOISE - Excessive noise can damage hearing
Protect your ears. Use earmuffs or other hearing protection.
MOVING PARTS - Can cause injuries
• Keep all doors, panels and covers closed and securely in place. Have only
qualified people remove covers for maintenance and troubleshooting as
necessary. Reinstall panels or covers and close doors when service is
finished and before starting engine.
• Stop engine before installing or connecting unit.
• Keep hands, hair, loose clothing and tools away from moving parts.
FIRE HAZARD
• Sparks (spatter) can cause fire. Make sure therefore that there are no
inflammable materials nearby
• Do not use on closed containers.
HOT SURFACE - Parts can burn
• Do not touch parts bare handed.
• Allow cooling period before working on equipment.
• To handle hot parts, use proper tools and/or insulated welding gloves to
prevent burns.
MALFUNCTION - Call for expert assistance in the event of malfunction.
PROTECT YOURSELF AND OTHERS!
CAUTION!
This product is solely intended for arc welding.
ESAB has an assortment of welding accessories and personal protection equipment for
purchase. For ordering information contact your local ESAB dealer or visit us on our website.
1.4 California proposition 65 warning
WARNING!
Welding or cutting equipment produces fumes or gases which contain chemicals known in
the State of California to cause birth defects and, in some cases, cancer. (California Health
& Safety Code Section 25249.5 et seq.)
WARNING!
This product can expose you to chemicals including lead, which are known to the state of
California to cause cancer and birth defects or other reproductive harm. Wash hands after
use.
For more information, go to www.P65Warnings.ca.gov.
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2 INTRODUCTION
2 INTRODUCTION
2.1 HandyArc Inverter
A new generation of machines from the HandyArc family, with a more modern design, super resistant
construction and the highest technology on the market. Compact and suitable for locksmith, repair and
light maintenance services, they are ready for any job, whether in the field, in the workshop or factory.
Like all ESAB equipment, they comply with IEC 60974-1, being approved in the most rigorous quality
standards and global norms.
2.2 Packing
The equipment packaging consists of:
• Inverter Source HandyArc
• Electrode holder cable
• Work claw cable
• Shoulder strap
• User guide
• Warranty term
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3 TECHNICAL DATA
3 TECHNICAL DATA
Duty cycle
According to the IEC 60974-1 standard, the duty cycle is the relationship between the welding period
(Open Arc) in a period of 10 minutes. To explain, the time period used by the IEC standard (10
minutes) is used in the following example. Suppose a welding source is designed to operate at a duty
cycle of 15% to 90 amps. This means that the equipment was built to supply the welding current (90A)
for 1.5 minutes, that is, the arc welding time, every 10 minutes (15% of 10 minutes is 1.5 minutes) .
During the other 8.5 minutes of the 10-minute period, the welding source must remain on and cool.
Enclosure class
The IP code indicates the enclosure class, i.e. the degree of protection against penetration by solid
objects or water.
Equipment marked IP21S is intended for indoor use.
Application class
The symbol indicates that the power source is designed for use in areas with increased electrical
hazard.
HandyArc 132i DV HandyArc 142i HandyArc 162i
Mains voltage
Mains frequency 50/60 Hz 50/60 Hz 50/60 Hz 50/60 Hz
Primary current I
max
Permissible load at SMAW
100% duty cycle 40 A/21.6 V 58 A/22.3 V 62.6 A/22.2 V 72 A/22.9 V
60% duty cycle 52 A/22.1 V 75 A/23 V 81 A/23.2 V 92 A/23.7 V
20% duty cycle 90 A/23.6 V 130 A/25.2 V 140 A/25.6 V 160 A/26.4 V
Power factor at
maximum current
Efficiency at
maximum current
Open circuit
voltage
Apparent power 3.56 kVA 5.5 kVA 5.94 kVA 7.04 kVA
Consumed power 2.8 kW 4.2 kW 4.7 kW 5.5 kW
Maximum effective
current
127 V +/-10%
1~50/60 Hz
20-90 A 20-130 A 20-140 A 20-160 A
0.82 0.77 0.77 0.77
82% 82% 83% 83%
75 V 65 V 75 V 75 V
12.5 A 11 A 12.1 A 14.3 A
220 V +/-10%
1~50/60 Hz
220 V +/-10%
1~50/60 Hz
127 V +/-10%
1~50/60 Hz
Maximum rated
current
Dimensions
l × w × h
Weight 3.5 kg 3.7 kg
Recommended
transformer
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28 A 25 A 27 A 32 A
300 × 115 × 232 mm (11.8×4.5×9.1in.)
≥ 5.4 kVA ≥ 8.3 kVA ≥ 9 kVA ≥10.5 kVA
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3 TECHNICAL DATA
Recommended
circuit breaker
(type B)
HandyArc 132i DV HandyArc 142i HandyArc 162i
≥30 A ≥30 A ≥30 A ≥35 A
Operating
temperature
-10 to 40 °C (+14 to +104°F)
Enclosure class IP 21S
Application class
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4 INSTALLATION
4 INSTALLATION
The installation must be carried out by a professional.
CAUTION!
This product is intended for industrial use. In a domestic environment this product may
cause radio interference. It is the user's responsibility to take adequate precautions.
4.1 Receiving
When receiving the equipment, remove all the material from the packaging and check if there is any
damage that may have occurred during transport, check if all materials, accessories, etc. were
removed before disposing of the packaging. Any claims for damage in transit should be directed to the
transport company.
DANGER!
There is a risk of tipping over during the transport operation if the machine is tilted more
than 10 °. In this case, provide the appropriate locking means.
4.2 Environment
This equipment is designed for use in environments with a higher risk of electric shock.
• Examples of environments with a higher risk of electric shock are:
1. In places where freedom of movement is restricted, so that the operator is
forced to perform the work in a limited position (kneeling, sitting or lying)
with physical contact with conductive parts.
2. In places totally or partially limited by conductive elements and where
there is a high risk of unavoidable or accidental contact by the operator.
• Environments with a higher risk of electric shock do not include locations where
electrically conductive parts near the operator, which may cause a high risk, have been
isolated.
4.3 Workplace
To operate the equipment safely, make sure that the workplace;
• Is in areas free from moisture and dust.
• Has an ambient temperature between 0 ° and 40 °C.
• Is in areas free of oil, steam and corrosive gases.
• Is in areas not subjected to abnormal vibration or shock.
• Is in areas not exposed to direct sunlight or rain.
• Is placed at a distance of 300 mm or more from walls and other things that could restrict
the flow of natural air for cooling.
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4 INSTALLATION
4.4 Ventilation
Since inhaling the weld smoke can be harmful, make sure that the weld area is effectively ventilated
(avoid airflow directly to the weld bead).
4.5 Power grid requirements
The mains voltage must be within ± 10% of the rated mains voltage. If the actual mains voltage is
outside this value, the welding current can vary causing failure of the internal components and thereby
impairing the equipment's operation.
The welding machine must be:
• Properly installed, if necessary, by a qualified electrician.
• Correctly grounded (electrically) according to local regulations.
• Connected to mains with duly specified fuse.
NOTE!
Any electrical work must be performed by a qualified specialized electrician.
CAUTION!
The grounding terminal is connected to the source chassis. It must be connected to a
grounding point of the electrical installation at the workplace. Be careful not to invert the
grounding conductor (green / yellow cable) of the input cable to any of the phases of the
main switch or circuit breaker, as this would put the chassis under electrical voltage. Do not
use the network neutral for grounding.
NOTE!
It is possible that the operation close to the computer facilities cause their malfunctions.
4.6 Electromagnetic compatibility
NOTE!
Extra precautions for electromagnetic compatibility may be necessary when welding
equipment is used in a domestic situation.
A. Installation and use - User responsibility
The user is responsible for installing and using the welding equipment according to the manufacturer's
instructions. If electromagnetic disturbances are detected, it must be the responsibility of the user of
the welding equipment to resolve the situation with the manufacturer's technical assistance. In some
cases, this corrective action can be quite simple, see NOTE below. In all cases, electromagnetic
disturbances must be reduced to the point where there are no more problems.
NOTE!
Welding equipment may or may not be grounded for safety reasons. The change in the
grounding arrangement must only be authorized by a trained person.
Welding equipment, when connected to a poorly grounded electrical network, can damage
the ground circuits of other equipment. Further guidance is provided in IEC 60974-13 Arc
Welding Equipment - Installation and use.
B. Evaluation of the area
Before installing the welding equipment, the user must make an assessment of possible
electromagnetic problems in the surrounding areas. The following must be taken into account:
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4 INSTALLATION
1. Other power cables, control cables, telephone cables; adjacent to the welding
equipment.
2. Radio and television transmitters and receivers.
3. Computers and other similar equipment.
4. Critical safety equipment, e.g. protection of industrial equipment.
5. The health of the people around you, e.g. use of pacemakers and hearing aids.
6. Equipment used for calibration and measurement.
7. The time of day when welding or other activities are to be carried out.
8. The immunity of other equipment in the environment: the user must ensure that the
other equipment being used in the environment is compatible: this may require
additional protection measures.
9. The size of the surrounding area to be considered will depend on the structure of the
building and other activities that are taking place. The surrounding area may extend
beyond the boundaries of the facility.
C. Methods of reducing electromagnetic emissions
1. Electrical network:
The welding equipment must be connected to the mains according to the
manufacturer's recommendations. If interference occurs, it may be necessary to take
additional precautions, such as installing filters in the electrical network. If necessary,
consider the shielding of the welding equipment's power cable, it must be installed
with a metallic mesh or equivalent. The grounding loop of the power cable must be
connected to the welding equipment frame, ensuring an efficient electromagnetic
shield.
2. Equipment maintenance:
Welding equipment must undergo routine maintenance in accordance with the
manufacturer's recommendations. Before operating the equipment, it is necessary to
ensure that the equipment is tightly closed and that there is no access to the internal
components. Welding equipment must not be modified in any way, except for those
changes and adjustments covered in the manufacturer's instructions.
3. Welding cables:
The welding cables must be kept at a length determined by the manufacturer and
must be positioned close to each other, operating at or near the floor level.
4. Workpiece grounding:
When the workpiece is not grounded for electrical safety, nor connected to the ground
because of its size or position (e.g. ship hull or structure in buildings), a connection
connecting the workpiece to the ground can reduce interference electromagnetic, but
not in all cases. Care must be taken to prevent grounding the workpiece, increasing
the risk of injury to users or damage to other electrical equipment.
5. Protection and shielding:
The protection and selective shielding of other cables and equipment in the
surrounding area can alleviate interference problems. The protection of the entire
welding installation can be considered in special applications.
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5 OPERATION
5 OPERATION
General safety regulations for handling the equipment can be found in the "SAFETY" chapter
of this manual. Read it through before you start using the equipment!
NOTE!
The user is responsible for defining the process and the respective procedure for welding
consumables (wire, gas) as well as the results of the operation and application.
WARNING!
Do not turn off the power during welding (with load).
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5 OPERATION
5.1 Welding with coated electrode / SMAW
Operating procedures for this equipment, for SMAW welding, apply to connect the work clamp cable to
the negative terminal of the equipment and the electrode holder cable to the positive terminal.
5.2 Control panel and connectors
1. Machine indicator LED on
2. Welding current control - The current adjustment knob controls the equipment's
welding current. The current increases by turning the knob clockwise and decreases
by turning it counterclockwise. The welding current must be defined according to the
type of electrode and specific application.
3. Overheat indicator - The welding equipment is protected by an internal thermostat.
The overheat indicator lights up when the internal thermostat is activated by
overtemperature, the most common cause is by exceeding the duty cycle of the
power supply. If the temperature indicator lights up, the equipment is disabled and
welding is interrupted to protect the equipment from burning. Make sure that the
equipment remains on and the fan is running so that the internal components cool.
When the equipment is cooled sufficiently, the temperature indicator goes off
automatically and the equipment returns to normal operation.
4. Positive output terminal - The positive terminal of the welding equipment is
generally used to connect the electrode holder cable. Consult the electrode
manufacturer's information for correct polarity.
5. Negative output terminal - The negative terminal of the welding equipment is
generally used to connect the work clamp cable. Consult the electrode manufacturer's
information for correct polarity.
WARNING!
Loose connections at the solder terminal can cause overheating and cause the male plug
to merge into the OKC terminal.
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5 OPERATION
5.3 Resources
Hot Start function
This function operates when welding with coated electrodes, improving the arc start characteristics.
The function automatically provides an increase in the voltage during the opening of the arc, causing
the arc to be opened with minimal splash and helping to prevent the electrode from sticking to the part
to be welded.
Arc Force function (Arc control)
This function operates when welding coated electrodes. When the welding arc is not stable, the
equipment automatically increases or decreases the current, in order to keep the arc open and stable.
With this you can prevent the electrode from sticking to the material being welded and thus make it
possible to “abuse” the welding positions always keeping the arc stable.
Anti Stick function
When the welding machine detects that a short circuit has been occurring for longer than in a normal
welding, this function is activated in order to lower the current and voltage until the machine is
automatically turned off, avoiding damaging both the welding machine and cables, electrode holder
and negative claw. With this automatic action of the equipment, the welder will be able to easily
remove the electrode "stuck" to the material being welded and will also be able to weld with much
lower currents than usual without sticking the electrode to the material.
5.4 Welding with coated electrodes (SMAW)
1) Turn on the equipment by placing the ON / OFF switch on the rear panel in the ON position.
2) Connect the electrode holder cable to the positive (+) solder terminal. Make sure that the male plug
of the cable is well connected to the equipment's OKC terminal.
3) The cable from the claw works to the solder terminal (-). Make sure that the cable's male plug is
well connected to the equipment's OKC terminal.
WARNING!
Before attaching the work claw to the part to be welded and inserting the electrode in
the electrode holder, make sure that the equipment is turned off.
CAUTION!
Remove any packaging material before use. It does not block air ventilation at the front
or rear of the welding equipment.
NOTE!
Consult the electrode manufacturer's information for correct polarity.
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5 OPERATION
1 Power supply (with regards to your model
3 Negative output terminal
tension)
2 Positive output terminal
Opening the arc
SMAW welding refers to welding with coated electrodes. The electric arc fuses the electrode and the
coating forms a protective layer (slag).
If, after opening the arc, the electrode is pressed against the part to be welded, the electrode merges
and adheres to the part making welding impossible. Therefore, the arc must be opened in the same
way as a match is lit. Quickly scratch the electrode against the part to be welded and then move it
apart to maintain an appropriate distance (approximately 2.5 mm). If the arc is too long, the arc starts
to crackle and extinguishes completely. Once the arc is open, move the electrode from left to right.
The electrode must have an angle of 60 ° with the part to be welded.
Electrode movement
In welding with coated electrodes (SMAW), there are three movements to be combined at the tip of the
electrode: the electrode moving to the melting pool along its axis (1); a small oscillation to reach the
desired width of the melting pool (2) and the movement of the electrode along the joint (3).
The welder can choose the movement of the electrode based on the shape of the joint, the welding
position, the specification of the electrode, welding current and its experience and skill, etc.
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5 OPERATION
1 Electrode movement 4 Electrode
2 Electrode oscillation (left to right) 5 Weld
3 Electrode movement along the joint 6 Part to be welded
Joint format for coated electrode
1 Top 3 Superimposed
2 Angle 4 "T"
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6 MAINTENANCE
6 MAINTENANCE
WARNING!
The mains supply must be disconnected during cleaning and maintenance.
CAUTION!
Only persons with the appropriate electrical knowledge (authorised personnel) may remove
the safety plates.
CAUTION!
The product is covered by manufacturer's warranty. Any attempt to carry out repair work by
non-authorised service centers or personnel will invalidate the warranty.
NOTE!
Regular maintenance is important for safe and reliable operation.
NOTE!
Perform maintenance more often during severe dusty conditions.
Before each use - make sure that:
• Product and cables are not damaged,
• The torch is clean and not damaged.
6.1 Preventive maintenance
Under normal operating conditions, the equipment does not require any special maintenance service.
It is only necessary to clean them internally at least once a month with low-pressure, dry, oil-free
compressed air. As for equipment that operates in more severe environments such as shipyards,
fertilizer or other chemical products, salt plants and places with a high incidence of dust, it is
necessary to clean them internally at least once a week with low-pressure, dry, oil-free compressed
air.
After cleaning with compressed air under low pressure, check the tightness of the electrical
connections and the fixation of the components. Check for possible cracks in the insulation of
electrical wires or cables, including welding, or in other insulators and replace them if defective.
6.2 Corrective maintenance
Use only original spare parts provided by ESAB. The use of non-original or unapproved parts leads to
the automatic cancellation of the warranty given.
Spare parts can be obtained from ESAB Authorized Services or from the sales branches indicated on
the last page of this manual. Always inform the model and serial number of the equipment under
consideration.
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7 TROUBLESHOOTING
7 TROUBLESHOOTING
WARNING!
There are extremely dangerous voltage and power levels present in this product. Do not
attempt to open or repair it unless you are a qualified electrician and have been trained in
power measurements and troubleshooting techniques.
If the major complex subsets are defective, the welding power source must be returned to an
accredited ESAB service provider for repair. The basic level of problem solving is what can be done
without special equipment or knowledge.
Description Possible cause Solution
1. The welding arc does not start. A) Equipment disconnected.
B) Poor internal connections.
2. Temperature led on. A) The duty cycle of the
power supply has been
exceeded.
B) Internal failure.
A) Turn on the equipment.
B) Let an ESAB accredited
service provider repair the
connection.
A) Leave the power on and let
it cool.
B) Let an ESAB accredited
service provider repair the
connection.
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8 ELECTRICAL SCHEME
8 ELECTRICAL SCHEME
Figure 17: HandyArc 142i 162i
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8 ELECTRICAL SCHEME
Figure 18: HandyArc 132i DV
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9 DIMENSIONS
9 DIMENSIONS
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10 ORDERING SPARE PARTS
10 ORDERING SPARE PARTS
CAUTION!
Repair and electrical work should be performed by an authorised ESAB service technician.
Use only ESAB original spare and wear parts.
HandyArc equipment was built and tested according to the standards. After the service or repair is
carried out, it is the obligation of the repairing company to ensure that the product does not differ
from the model mentioned.
Spare parts and wear parts can be ordered through your nearest ESAB dealer, see esab.com. When
ordering, please state product type, serial number, designation and spare part number in accordance
with the spare parts list. This facilitates dispatch and ensures correct delivery.
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10 ORDERING SPARE PARTS
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ESAB AB, Lindholmsallén 9, Box 8004, 402 77 Gothenburg, Sweden, Phone +46 (0) 31 50 90 00
http://manuals.esab.com
For contact information visit http://esab.com
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