Install grounding device according to application standard.
Do not touch live parts with naked skin, wet gloves or wet clothes.
Be sure you are insulated from ground and workpiece.
Cover the cover plate of the machine before power on to avoid an
electric shock.
Confirm the safety of your working position.
Beware of fire hazard!
Please install the machine on non-combustible materials to avoid
a fire.
Make ensure there are no inflammables near the welding position
to avoid a fire.
Beware of explosion !
Do not install the machine in an environment with explosive gas
to avoid an explosion.
Replacing the components can be dangerous.
Only professionals can replace the components of the machine.
Make sure there are no foreign bodies such as wire leads, screws, gaskets and metal bars
falling into the machine inside when replacing the components.
Make sure the connecting wires inside the machine are correctly connected after replacing
the PC Bs, and the n the mac hine can be r un. Oth erwis e, t here is a r isk of da ma ge to
prop erty.
Precautions for operation
Smoke-may be harmful to your health!
Keep your head away from the smoke to avoid inhalation of waste gas
in welding.
Keep the working environment well ventilated with exhaust or ventilation
equipment when welding.
Arc radiation-may hurt your eyes and burn your skin!
Use proper welding mask and wear protective clothing to protect your
eyes and body.
Use proper mask or curtain to protect onlooker from being injured.
Magnetic field can make cardiac pacemaker a bit wonky!
People with cardiac pacemaker should consult the doctor before carrying
out welding.
Stay away from the welding source to reduce the affect of magnetic filed.
Improper use and operation may result in a fire or an explosion!
Welding spark may result in a fire, so please make ensure there are no
inflammables near the welding position, and pay attention to fire safety.
Ensure there is fire extinguisher nearby, and make sure someone has
been trained to operate the fire extinguisher.
Do not weld closed container.
Do not use this machine for pipe thawing.
Hot workpiece can cause severe scald!
Do not touch hot workpiece with bare hands.
Cool the welding torch for a while after continuously working.
Excessive noise does great harm to people’s hearing!
Wear ear covers or other hearing protectors when welding.
Give warning to onlooker that noise may be potentially hazardous to
hearing.
Moving parts may injure your body!
Please keep away from moving parts (like fan).
Each door, panel, cover, baffle plate, and protective device the like
should be closed and located correctly.
Seek professional support when trouble strikes!
When trouble strikes in installation and operation, please inspect
according to related contents in this manual.
If you still cannot understand fully, or you still cannot solve the problem,
please contact the dealer or the service center of JASIC to obtain
professional support.
Precautions for discard
Pay attention to the following when discarding the welding machine:
Burning the electrolytic capacitors in the main circuit or on the PCBs may cause an explosion.
Burning the plastic parts such as the front panel may produce poisonous gas.
Dispose it as industrial waste.
Figure 1-2: Appearance and size of the machine Unit: mm()
2
1.4 Composition and configuration of the welding machine system
1) Composition
Figure 1-3: Composition of the welding machine system
2 Configuration)
Table 1-3: Configuration of ARC200 Z269()
Name
Welding machine
Quick plug
Operator’s manual
Material code
10046173
10004613
10047281
Specification
ARC140 (Z269)
DKJ16-25(black)
ARC series
Quantity pcs ()
1
2
1
Remark
Standard configuration
Standard configuration
Standard configuration
1. GENERAL DESCRIPTION
第一章 产品概述
Name
Welding machine
Quick plug
Operator’s manual
Name
Welding machine
Quick plug
Operator’s manual
Table 1-4: Configuration of ARC200104) (Z
Material code
10046171
10004614
10047281
Table 1-5: Configuration of ARC200 276) (Z
Material code
10046174
10004614
10047281
Specification
ARC200 (Z104)
DKJ35-50(black)
ARC series
Specification
ARC200(Z276)
DKJ35-50(black)
ARC series
Quantity pcs ()
Quantity pcs ()
33
Remark
1
2
1
1
2
1
Standard configuration
Standard configuration
Standard configuration
Remark
Standard configuration
Standard configuration
Standard configuration
Table 1-6: Configuration of ARC200D 225 (Z)
Name
Welding machine
Quick plug
Operator’s manual
Name
Welding machine
Quick plug
Operator’s manual
1. GENERAL DESCRIPTION
Name
Welding machine
Quick plug
Operator’s manual
Material code
10046195
10004614
10047281
Table 1-7: Configuration of ARC250D226 (Z)
Material code
10046196
10004614
10047281
Table 1-8: Configuration of ARC250227 (Z)
Material code
10046188
10004614
10047281
Specification
ARC200D(Z225)
DKJ35-50(black)
ARC series
Specification
ARC250D(Z226)
DKJ35-50(black)
ARC series
Specification
ARC250(Z227)
DKJ35-50(black)
ARC series
Quantity pcs ()
1
2
1
Quantity pcs ()
1
2
1
Quantity pcs ()
1
2
1
Remark
Standard configuration
Standard configuration
Standard configuration
Remark
Standard configuration
Standard configuration
Standard configuration
Remark
Standard configuration
Standard configuration
Standard configuration
1.5 Functions and characteristics of the welding machine
ARC series are inverter welding machines made by our company with advanced inverter
technology. These machines are mature models and with stable performance. This series
includes several single-voltage and double-voltage models.
Advanced VMOS or IGBT inverter technology
High inverter frequency greatly reduces the volume and weight of the welding machine.
Great reduction in magnetic and resistance loss obviously enhances the welding efficiency
and energy saving effect.
Working frequency is beyond audiorange, which almost eliminates noise pollution.
Leading control mode
Advanced control technology meets various welding applications and greatly improves the
welding performance
It can be widely used in acid and basic electrode welding.
Easy arc ignition, little spatter, stable current and good shaping.
Common characteristics of MMA welding machines
Portable, energy saving, with excellent dynamic characteristics and high efficiency, stable
arc, molten pool easy to control, higher no-load voltage, better compensation of power and
arc force, able to meet various welding requirements, applicable to aerial work, field work,
indoor and outdoor decoration, etc.
Characteristics of double-voltage models
It adopts automatic switching mode for voltage.
Unique circuit design prolongs the service life of the capacitor and IGBT.
New air duct design balances the temperature inside the machine and prolongs the service
External characteristic of maximum output
External characteristic of minimum output
Relationship with ratedload
I2 ( A)
Figure 1-6: Output characteristic curves
5
2. INSTALLATION AND CONNECTION
2.1 Installation requirements
1)Connection of input cable
In order to ensure personal safety and avoid electric shock, please ground the machine reliably
by connecting the ground wire (yellow-green wire) of the machine to the grounding device in
the switching box.
A primary power supply cable is available for this welding machine. Connect the power supply
cable to the rated input power. The primary cable should be tightly connected to the correct
socket to avoid oxidization. Check whether the voltage value varies in acceptable range with a
multi-meter.
The cross section of the leads used in the switching box should meet the requirements of the
maximum input capacity of the machine.
2)Connection of output cable
Insert the plugs with the cable of the electrode holder and the cable of the earth clamp respectively
into the quick sockets on the front panel of the machine, and tighten them to clockwise.
Operator can choose DCEN connection according to workpiece and electrode application
2. INSTALLATION AND CONNECTION
requirement. Generally, DCEP connection is recommended for basic electrode, while there is
no special requirement for acid electrode.
DCEN: Connect the electrode holder to “-” output
terminal, and the workpiece to “+” output terminal.
DCEP: Connect the electrode holder to “+” output
terminal, and the work clamp to “-” output terminal.
3)Connection of welding instruments
12354
Figure 2-2: Connection of quick plug
35
1
2
4
Figure 2-3: Connection of electrode holder
4
1
2
3
5
Figure 2-4: Connection of earth clamp
Figure 2-1: Connection of output cable
1
Output cable
3
Copper sleeve
5
Copper connector
1
Output cable
3
Copper sleeve
5
Electrode holder
1
Output cable
3
Bolt
5
Iron clip
6
2
Rubber sleeve
4
Bolt
2
Rubber sleeve
4
Bolt
2
Copper clip
4
Nut
4) Preset the welding current according to the type and size of the electrode, clip the electrode
and then welding can be carried out by short circuit arc starting. For welding parameters, please
refer to the table below.
Note: This table is suitable for mild steel welding. For other materials, consult related materials
and welding process for reference.
2.2 Precautions
2. INSTALLATION AND CONNECTION
7
3. OPERATION
3.1 Operation method
3.2 Panel functions of ARC140 (Z269)
3. OPERATION
No.Part nameFunction
1
2
3
1
4
1 0
4
2
3
4
5
5
Power
indicator
output
“+”
terminal
Overheating
indicator
Current
control knob
“-”
output
terminal
To indicate the machine is powered on
when it illuminates.
To connect the welding output cable.
To indicate the temperature inside the machine
is too high and the machine is under overheating
protection status when it illuminates.
To adjust the output current value.
To connect the welding output cable.
Figure 3-1: Front panel of Z269
1
Figure 3-2: Back panel of Z269
2
No.Part nameFunction
Power
1
3
switch
2
CableFor power supply input.
Cooling fan
3
To control the ON/OFF of the input
power of the machine.
For heat dissipation through forced
air cooling.
8
3.3 Panel functions of ARC200 Z104 ()
No.Part nameFunction
1
Fault
2
3
Figure 3-3: Front panel of Z104
4
Power
1
indicator
2
Digital meter To display the welding current.
“-”
output
Z104
5
6
3
4
5
6
terminal
Current
control knob
Abnormity
indicator
“+”
output
terminal
To indicate the machine is powered on
when it illuminates.
To connect the welding output cable.
To adjust the output current value.
To indicate the machine is under
overcurrent or overheating protection
status when it illuminates.
To connect the welding output cable.
3. OPERATION
1
Figure 3-4: Back panel of Z104
2
No.Part nameFunction
Power
1
3
switch
CableFor power supply input.
2
Cooling fan
3
To control the ON/OFF of the input
power of the machine.
For heat dissipation through forced
air cooling.
9
3.4 Panel functions of ARC200 Z276 ()
1
2
OC
3
3. OPERATION
4
Figure 3-5: Front panel of Z276
1
No.Part nameFunction
5
6
7
Overcurrent
1
indicator
2
Digital meter To display the welding current.
Arc force
3
control knob
output
“+”
4
terminal
Current
5
control knob
Overheating
6
indicator
“-”
output
7
terminal
To indicate the machine is under overcurrent
protection status when it illuminates.
To adjust the arc force current value.
To connect the welding output cable.
To adjust the output current value.
To indicate the temperature inside the machine
is too high and the machine is under overheating
protection status when it illuminates.
To connect the welding output cable.
3
Figure 3-6: Back panel of Z276
No.Part nameFunction
2
Power
1
switch
2
CableFor power supply input.
Cooling fan
3
To control the ON/OFF of the input
power of the machine.
For heat dissipation through forced
air cooling.
10
3.5 Panel functions of ARC200D Z225RC250D226) ()/A (Z
No.Part nameFunction
Digital meter To display the welding current.
1
1
220V
380V
2
2
3
4
00
Figure 3-7: Front panel of Z225 226/Z
1
5
6
Z225
7
8
2
3
4
5
6
7
8
Arc force
control knob
Overheating
indicator
“+”
output
terminal
Voltage
indicator
Current
control knob
Voltage
indicator
“-”
output
terminal
To adjust the arc force current value.
To indicate the temperature inside the machine
is too high and the machine is under overheating
protection status when it illuminates.
To connect the welding output cable.
To indicate 220V is used when it
illuminates.
To adjust the output current value.
To indicate 380V is used when it
illuminates.
To connect the welding output cable.
3. OPERATION
Figure 3-8 Back panel of Z225 226: /Z
2
No.Part nameFunction
3
Power
1
switch
CableFor power supply input.
2
Cooling fan
3
To control the ON/OFF of the input
power of the machine.
For heat dissipation through forced
air cooling.
11
3.6 Panel functions of ARC250 Z227 ()
No.Part nameFunction
1
5
1
Power
indicator
To indicate the machine is powered on
when it illuminates.
2
3
3. OPERATION
4
Figure 3-9: Front panel of Z227
1
2
Digital meter
Arc force
Z227
3
control knob
6
7
2
4
5
6
7
“+”
output
terminal
Current
control knob
Overcurrent
indicator
“-”
output
terminal
To display the welding current.
To adjust the arc force current value.
To connect the welding output cable.
To adjust the output current value.
To indicate the machine is under overcurrent
protection status when it illuminates.
To connect the welding output cable.
No.Part nameFunction
Power
1
3
switch
CableFor power supply input.
2
Cooling fan
3
To control the ON/OFF of the input
power of the machine.
For heat dissipation through forced
air cooling.
Figure 3-10: Back panel of Z227
12
4. MAINTENANCE
4.1 Daily maintenance
WARNING
The power of the switching box and the welding machine should be shut down before
daily checking (except appearance checking without contacting the conductive body)
to avoid personal injury accidents such as electric shock and burns.
Table 4-1: Daily checking of the welding machine
ItemsChecking requirementsRemarks
Whether any of the components are damaged
Front panel
Back panel
Cover
Chassis
Routine
or loosely connected;
Whether the output quick sockets are tightened;
Whether the abnormity indicator illuminates.
Whether the input power cable and buckle are
in good condition;
Whether the air intake is unobstructed.
Whether the bolts are loosely connected.
Whether the screws are loosely connected.
Whether the machine enclosure has color fading
or overheating problems;
Whether the fan sounds normal when the machine
is running;
Whether there is abnormal smell, abnormal
vibration or noise when the machine is running.
If unqualified, check the interior
of the machine, and tighten or
replace the components.
If unqualified, tighten or replace
the components.
If abnormal, check the interior
of the machine.
4. MAINTENANCE
Items
Earth cable
Welding cable
Table 4-2: Daily checking of the cables
Checking requirements
Whether the grounding wires (including workpiece
GND wire and welding machine GND wire) break off.
Whether the insulating layer of the cable is worn,
or the conductive part of the cable is exposed;
Whether the cable is drawn by an external force;
Whether the cable connected to the workpiece
is well connected.
13
Remarks
If unqualified, tighten or replace
the components.
Use appropriate methods
according to the work site
situation to ensure safety
and normal welding.
4.2 Periodic check
WARNING
Periodic check should be carried out by qualified professionals to ensure safety.
Thepower of the switching box and the welding machine should be shut down
before periodic check to avoid personal injury accidents such as electric shock
and burns. Due to the discharge of capacitors, checking should be carried out
5 minutes after the machine is powered off.
Tips:
4. MAINTENANCE
14
5. TROUBLESHOOTING
Table 5-1: Troubleshooting for ARC200104 (Z)
Malfunction PhenomenaCause and Solution
a. Make sure that the mains voltage is normal.
b. Make sure that the input cable is reliably connected to the power switch, and that the
The power indicator/meter
display does not illuminate;
the fan does not work; no
welding output.
The power indicator/meter
display illuminates;
the fan does not work;
no welding output.
power switch can be switched on or off normally.
c. Check whether any of the silicon bridge, MOS tube or rectifier diode are damaged,
and whether the gate resistor is burned out. Replace them if necessary.
d. Check whether the connecting wires on PCBs are reliably connected.
e. Power it on, and switch the digital multimeter to DC 1000V. Check if there is 310V DC at both
terminals of the DC bus CON4 on the top PCB. If there is, replace the top PCB. Otherwise,
replace the bottom PCB.
a. The 220V input power is unstable (the input cable is too thin and too long), which leads
to overvoltage protection. Replace the input cable with a larger diameter and tighten the
joint. Shut down the machine and restart it after 5~10 minutes, and then it will recover.
b. The power switch is continuously switched on and off in a short time, which leads to
overvoltage protection. Shut down the machine and restart it after 5~10 minutes, and
then it will recover.
c. The wire connecting the power switch with the power PCB breaks is loosely connected. Tighten it.
d. The 24V relay on the power PCB is damaged or not closed. Check the 24V power
supply and the relay. Replace the relay if necessary.
5. TROUBLESHOOTING
The fan works; the output
current is unstable or cannot
be controlled by potentiometer
when welding.
The fan works; the power
indicator and meter display
are normal;
no welding output.
The fan works;
the abnormity indicator
illuminates;
no welding output.
The electrode holder becomes
very hot.
Excessive spatter in MMA
welding.
a. Make sure that the mains voltage is normal.
b. Check if the connecting wires on the control PCB are reliably connected.
c. Check if the current adjustment potentiometer is damaged, and replace it if necessary.
d. Replace the control module on the top PCB.
a. Open circuit or poor contact problems exit at the joints of output terminals.
b. There is about DC 310V from the power PCB to CON4 (VH-07) on the top PCB. Check
if the silicon bridge breaks or is not well connected. 2) Check if any of the 5 big electrolytic
capacitors (470uF/400V) have leakage problem, and replace them if necessary.
c. Check if the driving MOSFET Z24/9Z24 for VT7-VT10 on the top PCB is damaged,
and replace it if necessary.
d. The control circuit fails. Please contact your distributor or JASIC.
a. Overcurrent protection occurs. Shut down the machine, and restart it after the
abnormity indicator does not illuminate, and then it will recover .
b. Overheating protection occurs. It will recover automatically after 5~10 minutes.
c. The inverter circuit fails. Pull out the power supply socket (near the fan VH-07) for
the main transformer on the top PCB, and restart the machine.
1) If the abnormity indicator still illuminates, some of the MOSFETs on the top PCB
is damaged. Replace it if necessary.
2) If the abnormity indicator does not illuminate:
The transformer on the center PCB may be damaged. Check the inductance and
Q value of the primary of the main transformer. The primary of the transformer is
paralleled. For a single main transformer, L=1.5~2.4mH, Q>40. Replace the main
transformer when the inductance and Q value is small.
Some of the secondary rectifier diodes of the transformer may be damaged. Replace
it if necessary.
d. The feedback circuit (wire) fails.
a. The rated current of the electrode holder is smaller than its actual working current.
Replace it with a bigger rated current.
b. Check if the screw or wire of the electrode holder is reliably connected.
The output polarity connection is incorrect. Exchange the polarity.
()
15
Table 5-2 Troubleshooting for ARC140 269RC200 276: (Z)/A (Z)
Malfunction PhenomenaCause and Solution
a. Make sure that the mains voltage is normal.
The power indicator does
not illuminate;
the fan does not work;
no welding output.
b. Make sure that the input cable is reliably connected to the power switch, and
that the power switch can be switched on or off normally.
c. Check whether any of the silicon bridge, IGBT or rectifier diode are damaged,
and whether the gate resistor is burned out. Replace them if necessary.
d. Power it on, and switch the digital multimeter to DC V. Check if there is 310V
DC at both terminals of the DC bus on the top PCB If there is,
replace the top PCB. Otherwise, replace the bottom PCB
The fan works;
the output current is unstable
or cannot be controlled by
potentiometer when welding.
5. TROUBLESHOOTING
a. Make sure that the mains voltage is normal.
b. Check if the connecting wires on the control PCB are reliably connected.
c. Check if the current adjustment potentiometer is damaged, and replace it if
necessary.
d. Replace the control PCB→rectifier PCB.
a. Check if the connecting wires on PCBs are reliably connected.
b. Open circuit or poor contact problems exit at the joints of output terminals.
c. The protection indicator illuminates: Pull out the thermal switch, and check if
the protection indicator still illuminates. If so, replace the control PCB.
The fan works;
the power indicator is normal;
no welding output.
Otherwise,the machine is under overheating protection. In this condition, it is
unnecessary to pull out the power plug, and it will recover automatically after
5~10 minutes when the machine is cooled down.
d. The protection indicator does not illuminate and there is no output: Pull out
the thermal switch, and check if there is no-load voltage. If there is, the thermal
switch is damaged. Otherwise, connect the metal part of 7815 with the black
probe and connect the metal part of IRF9Z24 or IRFZ24 with the red probe,
the check if the voltage is about 8.4V. If it is, replace the center PCB
Otherwise, replace the top PCB.
[1] [2].
[3].
[4].
The electrode holder becomes
very hot.
Excessive spatter in MMA
welding.
a. The rated current of the electrode holder is smaller than its actual working current.
Replace it with a bigger rated current.
b. Check if the screw or wire of the electrode holder is reliably connected.
The output polarity connection is incorrect. Exchange the polarity.
Notes:
[1] The DC bus for ARC140 (Z269) is P8, and the DC bus for ARC200 (Z276) is P9.
[2] The top PCB for ARC140 (Z269) is PM-48, and the top PCB for ARC200 ( 276) is PM-47.Z
[3] The bottom PCB for ARC140 (Z269) is PZ-75, and the top PCB for ARC200 (Z276) is PZ-86.
[4] The center PCB for ARC140 269 is PD-47, and the top PCB for ARC200 276 is PD-53. (Z) (Z)
16
Table 5-3: Troubleshooting for ARC200D 225RC250D226RC250227 (Z)/A(Z)/A (Z)
Malfunction PhenomenaCause and Solution
The power indicator does
not illuminate;
the fan does not work;
no welding output.
The power indicator
illuminates;
the fan does not work;
no welding output.
The fan works;
the output current is unstable
or cannot be controlled by
potentiometer when welding.
The fan works;
the power indicator is
normal;
no welding output.
The 220V indicator illuminates
when connecting the machine
to AC 380V (only for Z225 and
Z226)
Excessive spatter in MMA
welding.
a. Make sure that the power switch is closed.
b. Make sure that the input voltage is normal.
a. The wire connecting the power switch with the power PCB breaks is loosely
connected. Tighten it.
b. The 24V relay on the power PCB is damaged or not closed. Check the 24V power
supply and the relay. Replace the relay if necessary.
a. Check if the current adjustment potentiometer is damaged, and replace it if
necessary.
b. Check all joints (esp. connectors) for reliable connection.
a. Delay circuit is added for this machine to improve the reliability, so there is no
output within 5 seconds after the machine is powered on, while the fan and power
indicator appear normal. If there is still no output after 10 seconds or a longer time
after the machine is powered on, do the following checking.
b. Check if the connecting wires inside the machine are reliably connected.
c. Open circuit or poor contact problems exit at the joints of output terminals.
d. The overheating protection indicator illuminates:
1) Themachine is under overheating protection. In this condition, it is unnecessary
to pull out the power plug, and it will recover automatically after 5~10 minutes
when the machine is cooled down.
2) Check if the thermal switch is damaged, and replace it if necessary.
e. The protection indicator does not illuminate: Shut down the machine, and check
with a multimeter whether the two output terminals are short circuited. If so, check
if any of the diode or transformer on the center PCB is damaged or short circuited.
Replace them if necessary.
a. The mains voltage is below AC 310V. Check if there is any high-power machine
working nearby, which leads to the low mains voltage.
b. Check if the chip for judging voltage switching IC5 on the top PCB is damaged,
and replace it if necessary.
The output polarity connection is incorrect. Exchange the polarity.
5. TROUBLESHOOTING
17
SHENZHEN JASIC TECHNOLOGY CO., LTD.
No. 3, Qinglan 1st Road, Pingshan District, Shenzhen, Guangdong, China
www.jasictech.com
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