Arc 200 OWNER’S MANUAL WARNING: Read carefully and understand all ASSEMBLY AND OPERATION INSTRUCTIONS before operating. Failure to follow the safety rules and other basic safety precautions may result in serious personal injury.
Thank you very much for choosing a IRONTON product! For future reference, please complete the owner’s record below: Model: _______________ Purchase Date: _______________ Save the receipt, warranty and these instructions. It is important that you read the entire manual to become familiar with this product before you begin using it. This machine is designed for certain applications only. The distributor cannot be responsible for issues arising from modification.
GENERAL SAFETY RULES WARNING: Read and understand all instructions. Failure to follow all instructions listed below may result in serious injury. CAUTION: Do not allow persons to operate or assemble this Arc 200 until they have read this manual and have developed a thorough understanding of how the Arc 200 works. WARNING: The warnings, cautions, and instructions discussed in this instruction manual cannot cover all possible conditions or situations that could occur.
1.3 Use of Your Welder Do not operate the welder if the output cable, electrode, torch, wire or wire feed system is wet. Do not immerse them in water. These components and the welder must be completely dry before attempting to use them. -Follow the instructions in this manual. -Keep welder in the off position when not in use. -Connect ground lead as close to the area being welded as possible to ensure a good ground.
Fumes and Gases -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 and safe. -Work only in a well-ventilated area or use a ventilation device to remove welding fumes from the 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.
Hot Materials Welded materials are hot and can cause severe burns if handled improperly. -Do not touch welded materials with bare hands. -Do not touch MIG gun nozzle after welding until it has had time to cool down. Sparks/Flying Debris Welding creates hot sparks that can cause injury. Chipping slag off welds creates flying debris. -Wear protective apparel at all times: ANSI-approved safety glasses or shield, welder’s hat and ear plugs to keep sparks out of ears and hair.
Arc 200 USE AND CARE Do not modify the Arc 200 in any way. Unauthorized modification may impair the function and/or safety and could affect the life of the equipment. There are specific applications for which the Arc 200 was designed. Always check of damaged or worn out parts before using the Arc 200. Broken parts will affect the Arc 200 operation. Replace or repair damaged or worn parts immediately. Store idle Arc 200.
ON/OFF Switch In the “OFF” position no power is being supplied to the electrode holder. In the “ON” position power is supplied to the main transformer and control circuit. Indicator Lights There are two indicator lights: 1) Power and 2) Thermal Overload. When the machine is turned on, the power indicator will be on. When the thermal overload indicator is on, it indicates the machine has exceeded the duty cycle and the internal temperature is too high.
2.2. Install the axle tube/bracket for the axles and wheels on the axle. See following image. Stand the machine up and install the axle tube/bracket onto the back of panel using the screws and washers provided. (You may want to use a wooded block to hold the welder up for this step.) 2.3.
INSTALLATION 1. POWER REQUIREMENT - AC single phase 230V, 60 HZ with a 50 amp circuit breaker is required. DO NOT OPERATE THIS UNIT if the ACTUAL power source voltage is less than 207 volts AC or greater than 253 volts AC. High voltage danger from power source! Consult a qualified electrician for proper installation of receptacle. This welder must be grounded while in use to protect the operator from electrical shock. Do not remove grounding prong or alter the plug in any way.
Based on different welding position, there are different welding joint, see following images for more information. 4. GROUND CLAMP CONNECTION Clear any dirt, rust, scale, oil or paint on the ground clamp. Make certain you have a good solid ground connection. A poor connection at the ground clamp will waste power and heat. Make sure the ground clamp touches the metal. 5. ELECTRODE The welding electrode is a rod coated with a layer of flux.
6. SELECTING THE PROPER ELECTRODE There is no golden rule that determine the exact rod or heat setting required for every situation. The type and thickness of metal and the position of the work piece determine the electrode type and the amount of heat needed in the welding process. Heavier and thicker metals required more amperage. It is best to practice your welds on scrap metal which matches the metal you intend to work with to determine correct heat setting and electrode choice.
8. WELDING TECHNIQUES The best way to teach yourself how to weld is with short periods of practice at regular intervals. All practice welds should be done on scrap metal that can be discarded. Do not attempt to make any repairs on valuable equipment until you have satisfied yourself that your practice welds are of good appearance and free of slag or gas inclusions. 8.1 Holding the electrode The best way to grip the electrode holder is the way that feels most comfortable to you.
8.3 Types of weld bead The following paragraphs discuss the most commonly used arc welding beads. The stringer bead Formed by traveling with the electrode in a straight line while keeping the electrode centered over the weld joint. Stringer Bead Weave Bead 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.
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. ELECTRIC SHOCK CAN KILL! To prevent ELECTRIC SHOCK, do not perform any welding while standing, kneeling, or lying directly on the grounded workpiece. 8.6 Finish the bead As the coating on the outside of the electrode burns off, it forms an envelope of protective gases around the weld.
TROUBLESHOOTING SYMPTOM Unit Does Not Power Up Can Not Create An Arc POSSIBLE CAUSE Unit Is Not Plugged In Input Power Circuit Breaker Not On The Main Power Switch Is Not Working Work Piece is Painted Or Rusty Ground Clamp Is Connected Where There Is Paint Or Rust Ground Clamp Is Not Electrically Connected To The Work Piece Amperage Too Low for Electrode Not using recommended electrodes Poor Welding Performance, excessive spatter Electrode Sticks Damp Electrode Welding Bead Is Too Thin The electrode i
DIAGRAM & PARTS LIST Page 17 of 19
Reference # Part# Description Qty. 1 1.1.01.05.0010 HANDLE 1 2 2.05.18.007 INDEX PANEL 1 3 1.1.01.01.0066 ENCLOSURE 1 4 1.1.02.03.0391 TRANSFORMER 1 4.1 2.06.29.051 CLIP CLUTH 2 2.07.36.739 THERMO-RELAY 1 4.3 1.1.02.03.0003 MOVABLE IRON CORE 2 4.4 2.01.29.052 MOVABLE IRON CORE SUPPORTER 1 5 2.06.29.221 SPRING 1 6 2.01.29.920 AMPERAGE INDICATOR 1 7 2.04.31.205 RUBBER RING 1 8 2.05.08.002 AMPERAGE ADJUSTMENT KNOB 1 1.2.07.02.
WARRANTY EFFECTIVE JULY 1, 2014 LIMITED WARRANTY This warranty applies to the original purchaser and is subject to the terms and conditions listed below. This Limited Warranty is for new equipment sold after the above date, providing coverage for defects in material and workmanship at the time it is shipped from the factory. Limited to the warranty periods below, Northern Tool + Equipment will repair or replace the item under warranty that fails due to defects in material and workmanship.
