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ARC INVERTER
INSTRUCTION MANUAL
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Contents
Warning
General Description
Block Diagram
Main Parameters
Circuit Diagram
Installation and Operation
Caution
Maintenance
Spare Parts List
Troubleshooting
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7
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EC DECLARATION OF CONFORMITY
We hereby declare that the following machines:
ARC120 / ARC140 Dual Voltage / ARC160 / ARC200B
correspond to the following edicts and standards:
EMC Directives: 73/23/EEC and 89/336/EEC
European Standard: EN/IEC60974
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ARC Inverter Instruction Manual
Welding and cutting is dangerous to the operator, people in or near the working area, and the
surrounding environment. Therefore, the performance of welding and cutting must only be done
under the strict and comprehensive observation of all relevant safety regulations. Please read and
understand this instruction manual carefully before installation and operation.
•Switching function modes during welding could potentially damage the equipment.
•Disconnect the electrode-holder cable from the equipment before welding.
•A safety switch is necessary to prevent the equipment from electric-leakage.
•Use only high quality welding tools and equipment with this Inverter.
•Operators should be suitably trained to use this equipment.
Warning
Electric Shock
•Connect the earth cable according to standard regulation.
•Avoid any contact with live components of the welding circuit, electrodes
and wires with bare hands. The operator should wear suitable welding
gloves while using this machine.
•The operator should keep the work piece insulated from himself/
herself.
Smoke and Gas generated while welding or cutting
•Avoid breathing in smoke and gas from welding or cutting.
•Make sure the are you are working in a well ventilated area.
Arc light-emission
•Always wear a welding helmet and appropriate work clothes while
welding.
•Measures should also be taken to protect people in or near the area
you are working.
Fire hazard
•Sparks from welding may cause re. Remove any ammable items from
the immediate area before welding.
•Have a re extinguisher nearby.
Noise
•Surface noise is generated while welding and cutting. Use suitable
hearing protection.
Machine Fault
•Consult this instruction manual in the case of a fault.
•Contact your local dealer or supplier for further advice.
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This welding machine is manufactured with advanced inverter technology. With power component
MOSFET and PWM technology, the inverter converts DC voltage, which is rectied from input
AC voltage, to high 100KHz frequency AC voltage; as a consequence, the voltage is transformed
and rectied. Therefore, it results in a smaller transformer and lighter inverter machine, which
increases welding performance by 30%. The high frequency oscillation, which enables the output
of high frequency DC, is employed in the arc-starting system. The features of this product are as
follows: stable current, reliable, fully portable, ecient and quiet in operation.
Warranty of maintenance for main components is one year. During the warranty period, all
maintenance is free of charge, not including any deliberate damage or alteration to this welding
equipment.
In the case of a fault with the inverter machine, only qualied electricians are authorized to carry
out repairs.
General Description
INPUT
PWM
CONTROL
Block Diagram
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ARC Inverter Instruction Manual
Main Parameters
ARC120 ARC140 DV ARC160 ARC200B
Fuse Rating 13 amp
110 volt 15 amps
240 volt 13 amps
16 amps 20 amps
Generator
Friendly
+ / − 15% + / − 15% + / − 10% + / − 10%
Input Power
Voltage
AC 230 volt
(single phase)
110 / 230 volt
(single Phase)
AC 230 volt
(single phase)
AC 230 volt
(single phase)
Rate Input
Power Capacity
3.8 KVA 4.4 KVA 5.3 KVA 7 KVA
Input Voltage
Frequency
50 / 60 Hz 50 / 60 Hz 50 / 60 Hz 50 / 60 Hz
Output Current
Range
10 − 120 amps 10 − 140 amps 20 − 160 amps 20 − 200 amps
Duty Cycle
(25°C)
120 amps @ 60%
110 volt 100 amps @ 100%
240 volt 140 amps @ 60%
155 amps @ 60% 200 amps @ 60%
Weight 5 kg 6.4 kg 8 kg 10 kg
Overall
Dimensions
230 x 120 x 170 mm 290 x 132 x 216 mm 371 x 155 x 295 mm 425 x 205 x 355 mm
Protection
Class
Ip23 Ip23 Ip23 Ip23
Diameter
of Rod
1.6 mm − 3.2 mm 1.6 mm − 3.2 mm 1.6 mm − 4.0 mm 1.6 mm − 5.0 mm
Circuit Diagram (single phase input)
MAIN SWITCH
FEEDBACK
POWER
SUPPLY
PROTECT
CIRCUIT
CONTROL
MODULE
DRIVE
MODULE
SNUBBER
CIRCUIT
AC 220 volt
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A : Mains Lead
A primary power supply cable is available for this welding equipment. Connect the power supply
cable with required voltage. Check whether the voltage value varies in the given range with a
multi-meter.
B : Connection of Output Cables
Two Dinze sockets are available for this welding equipment. Connect the plug to the socket on
the panel board. It is possibly damaging to both the plug and socket, if the plug and the socket
are incorrectly connected.
The electrode holder cable should be connected to the negative terminal, while the work piece
should be connected to the positive terminal.
•Positive connection electrode holder to “–”,while work piece to “+”
•Negative connection work piece to “–”, while electrode holder to “+”.
It is necessary to increase the diameter of cable in order to maintain and improve the performance
of voltage output.
C : On / O Switch
While the power supply switch is on, the built-in fan works and current meter displays the current
value.
D : Welding Current Output Setting
According to practical demand, set the parameters of current output by the operation of welding
current knob and arc-leading pulse knob.
E : O.C. Light
When the pilot lamp is lit, the machine is in a temporary shut down mode to prevent damage
from over heating. The machine will automatically restart when the internal temperature has
dropped to a safe operational level.
F : TIG / MMA Switch
Select between TIG and MMA welding process.
Installation and Operation
A A A
B
C
C
C
B B
D
F
D
E
E
E
G
F
D
F
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ARC Inverter Instruction Manual
G : Arc Force Knob (Arc200B only)
Arc Force knob is available for the improvement of arc-starting, especially in case of low current
input.
1. Working Environment
1.1 The location in which this welding equipment is installed should be free from dust, corrosive
chemical gas, ammable gas or materials.
1.2 Avoid the operation of welding in the open air unless the working area sheltered from the
elements. The ambient temperature of the working environment should be maintained within
–10°C to +40°C.
1.3 Allow a distance of at least 300mm (12”) between this machine and any walls.
1.4 Make sure the area you are working in is well ventilated.
2. Safety Tips
2.1 Ventilation: Good ventilation is of critical importance for the performance and service life of
this inverter welding machine. Maintain a minimum distance of 30cm (12”) between the inverter
machine and any other objects in or near the working area.
2.2 Do not operate this machine when the O.C. Light is lit.
A sudden halt may occur while the welding operation is carried out while this welding machine is
of over-load status. Under this circumstance, it is unnecessary to restart this welding equipment.
Keep the built-in fan working to bring down the temperature inside this welding equipment.
2.3 This welding equipment uses automatic voltage compensation, which enables the
maintaining of the voltage range within the given range. In case the voltage of input power
supply current exceeds the stipulated value, it is possibly damaging to the components of this
welding equipment.
2.4 An earth terminal is available for this welding equipment. Connect with the earth cable to
avoid static and electric shock.
2.5 DO NOT contact the output terminal when the welding operation is performed. An electric
shock will occur.
Caution
Exposure to extremely dusty, damp, or corrosive air is damaging to this machine. In order to
prevent any possible failure or fault of the inverter, clean any dust at regular intervals with
compressed air.
Please note: Proper maintenance should be carried out by a skilled and qualied technician on
a regular basis. Any attempts by an unauthorised or unskilled individual to remove the outer
casing, or conduct repairs or modications to the machine will void the warranty.
Maintenance
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Description
Part Number
ARC120 ARC140 DV ARC160 ARC200B
A Front Panel
B Cover
C Carrying Strap / Handle
D Dial
E Dinze Socket
F On / O Switch
G Power Cable
H Internal Fan
I Bottom PCB
J Heat Sink
K Center PCB
L Rubber Feet
M Top PCB
Spare Parts List
C
E
J
G
H
KL
M
A
D
F
ARC120
B
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ARC Inverter Instruction Manual
ARC140
ARC200B
ARC160
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Please note: In the event of a fault with this inverter welding machine, only qualied technicians
are authorised to undertake repairs.
Troubleshooting
Fault Symptoms Reason
No output from machine, O.C. Light not lit, internal fan
not working
1. Possible failure of voltage input. Consult an authorised
technician.
2. Possible failure of power supply. Check plug and power
cable for damage.
No output from machine, O.C. Light not lit, internal fan
not working, machine suddenly halts operation
1. Possible failure of power supply. Check plug and power
cable for damage.
2. The machine is in temporary shut down mode due to
over heating. Wait a few minutes for machine to cool
down and it will automatically re-start.
3. Power supply input is faulty. Check plug and power
cable for damage.
4. The machine is in temporary shut down mode due to
constantly being switched on and o. Unplug the machine
and wait 5 minutes before re-starting.
5. 24 volt relay board may be defective. Consult an
authorised technician for a replacement.
6. The top PCB is not receiving power. Consult an
authorised technician.
No output from machine, O.C. Light not lit, internal fan
is working
1. Possible loose connection in machine. Consult an
authorised technician.
2. Possible failure of Control Module / Drive Circuit /
Drive Module. Consult an authorised technician for a
replacement if necessary.
3. Possible failure of MOSFET / Transformers / Rectier
Diode / Internal connections. Consult an authorised
technician for a replacement if necessary.
No output from machine, O.C. Light is lit
1. The machine is in temporary shut down mode due to
over heating. Wait a few minutes for machine to cool
down and it will automatically re-start.
2. The machine is in temporary shut down mode due to
excess current.
3. Possible function failure of inverter machine. Unplug the
machine and perform the following checks:
a) If the fault indicator is on MOSFET the top PCB is
possibly faulty.
b) If the fault indicator is o there could be damage to
center PCB / possible damage to secondary rectier of
transformer.
c) Possible damage to feedback circuit.
Consult an authorised technician.
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ARC Inverter Instruction Manual
Notes
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