BX1-160/180/200/250C2
AC ARC WELDING MACHINES
TABLE OF CONTENTS
SECTION 1— SAFETY PRECAUTIONS－READ BEFORE USING
1－1. Symbol Usage
1－2. Arc Welding Hazards
1－3. Additional Symbols For Installation,Operation,And Maintenance
1－4. EMF Information
SECTION 2— PRINCIPLES OF MANUAL METAL ARC WELDING(MMA)
SECTION 3— INSTALLATION AND CONNECTION INSTRUCTIONS
3－1. GENERAL DESCRIPTION
3－2. DESCRIPTIONS OF THE NAMEPLATE MARKS AND SYMBOLS
3－3. INSTALLATION
3－4. OPERATING INSTRUCTIONS
3－5. MAINTENANCE
SECTION 1 - SAFETY PRECAUTIONS - READ BEFORE USING
1-1. Symbol Usage
Means Warning! There are possible hazards with this procedure! The possible hazards
are shown in the adjoining symbols.
▲ Marks a special safety message.
Means "Note"; not safety related.
This group of symbols means Warning! Possible ELECTRIC SHOCK, MOVING PARTS,
and HOT PARTS hazards. Consult symbols and related instructions below for necessary
actions to avoid the hazards.
1-2. Arc Welding Hazards
▲The symbols shown below are used throughout this manual to call attention to and identify possible
hazards. When you see the symbol, watch out, and follow the related instructions to avoid the hazard.
The safety information given below is only a summary of the more complete safety information found in
the Safety Standards listed in Section 1-5. Read and follow all Safety Standards.
▲Only qualified persons should install, operate, maintain, and repair this unit.
▲During operation, keep everybody, especially children, away.
ELECTRIC SHOCK can kill.
Touching live electrical parts can cause fatal shocks or severe burns. The electrode and work circuit is
electrically live whenever the output is on. The input power circuit and machine internal circuits are also
live when power is on. In semiautomatic or automatic wire welding, the wire, wire reel, drive roll housing,
and all metal parts touching the welding wire are electrically live. Incorrectly installed or improperly
grounded equipment is a hazard.
●Do not touch live electrical parts.
●Wear dry, hole-free insulating gloves and body protection.
●Insulate yourself from work and ground using dry insulating mats or covers big enough to prevent any physical
contact with the work or ground.
●Do not use AC output in damp areas, if movement is confined, or if there is a danger of falling.
●Use AC output ONLY if required for the welding process.
●If AC output is required, use remote output control if present on unit.
●Disconnect input power or stop engine before installing or servicing this equipment. Lockout/tagout input
power according to OSHA 29 CFR 1910.147 (see Safety Standards).
●Properly install and ground this equipment according to its Owner's Manual and national, state, and local codes.
●Always verify the supply ground-check and be sure that input power cord ground wire is properly connected to
ground terminal in disconnect box or that cord plug is connected to a properly grounded receptacle outlet.
When making input connections, attach proper grounding conductor first- double-check connections.
●Frequently inspect input power cord for damage or bare wiring-replace cord immediately if damaged - bare
wiring can kill.
●Turn off all equipment when not in use.
●Do not use worn, damaged, undersized, or poorly spliced cables.
●Do not drape cables over your body.
●If earth grounding of the workpiece is required, ground it directly with a separate cable.
●Do not touch electrode if you are in contact with the work, ground, or another electrode from a different
machine.
●Use only well-maintained equipment. Repair or replace damaged parts at once. Maintain unit according to
manual.
●Wear a safety harness if working above floor level.
●Keep all panels and covers securely in place.
●Clamp work cable with good metal-to-metal contact to workpiece or worktable as near the weld as practical.
●Insulate work clamp when not connected to workpiece to prevent contact with any metal object.
●Do not connect more than one electrode or work cable to any single weld output terminal.
SIGNIFICANT DC VOLTAGE exists after removal of input power on inverters.
●Turn Off inverter, disconnect input power, and discharge input capacitors according to instructions in
Maintenance Section before touching any parts.
FUMES AND GASES can be hazardous.
Welding produces fumes and gases. Breathing these fumes and gases can be hazardous to your health.
●Keep your head out of the fumes. Do not breathe the fumes.
●If inside, ventilate the area and/or use exhaust at the arc to remove welding fumes and gases.
●If ventilation is poor, use an approved air-supplied respirator.
●Read the Material Safety Data Sheets (MSDSs) and the manufacturer's instructions for metals, consumables,
coatings, cleaners, and degreasers.
●Work in a confined space only if it is well ventilated, or while wearing an air-supplied respirator. Always have a
trained watchperson nearby. Welding fumes and gases can displace air and lower the oxygen level causing
injury or death. Be sure the breathing air is safe.
●Do not weld in locations near degreasing, cleaning, or spraying operations. The heat and rays of the arc can react
with vapors to form highly toxic and irritating gases.
●Do not weld on coated metals,such as galvanized, lead, or cadmium plated steel, unless the coating is removed
from the weld area, the area is well ventilated, and if necessary, while wearing an air-supplied respirator. The
coatings and any metals containing these elements can give off toxic fumes if welded.
ARC RAYS can burn eyes and skin.
Arc rays from the welding process produce intense visible and invisible (ultraviolet and infrared) rays
that can burn eyes and skin. Sparks fly off from the weld.
●Wear a welding helmet fitted with a proper shade of filter to protect your face and eyes when welding or
watching (see ANSI Z49.1 and Z87.1 listed in Safety Standards).
●Wear approved safety glasses with side shields under your helmet.
●Use protective screens or barriers to protect others from flash and glare; warn others not to watch the arc.
●Wear protective clothing made from durable, flame-resistant material (leather and wool) and foot protection.
WELDING can cause fire or explosion.
Welding on closed containers, such as tanks, drums, or pipes, can cause them to blow up. Sparks can fly off
from the welding arc. The flying sparks, hot workpiece, and hot equipment can cause fires and burns.
Accidental contact of electrode to metal objects can cause sparks, explosion, overheating, or fire. Check and
be sure the area is safe before doing any welding.
●Protect yourself and others from flying sparks and hot metal.
●Do not weld where flying sparks can strike flammable material.
●Remove all flammables within 35 ft (10.7 m) of the welding arc. If this is not possible, tightly cover them with
approved covers.
●Be alert that welding sparks and hot materials from welding can easily go through small cracks and openings to
adjacent areas.
●Watch for fire, and keep a fire extinguisher nearby.
●Be aware that welding on a ceiling, floor,bulkhead,or partition can cause fire on the hidden side.
●Do not weld on closed containers such as tanks, drums,or pipes,unless they are properly prepared according to
AWS F4.1 (see Safety Standards).
●Connect work cable to the work as close to the welding area as practical to prevent welding current from
traveling long, possibly unknown paths and causing electric shock and fire hazards. Do not use welder to thaw
frozen pipes.
●Remove stick electrode from holder or cut off welding wire at contact tip when not in use.
●Wear oil-free protective garments such as leather gloves, heavy shirt, cuffless trousers, high shoes, and a cap.
●Remove any combustibles, such as a butane lighter or matches, from your person before doing any welding.
FLYING METAL can injure eyes.
●Welding, chipping, wire brushing, and grinding cause sparks and flying metal. As welds cool, they can throw off
slag.
●Wear approved safety glasses with side shields even under your welding helmet.
BUILDUP OF GAS can injure or kill.
●Shut off shielding gas supply when not in use.
●Always ventilate confined spaces or use approved air-supplied respirator.
HOT PARTS can cause severe burns.
●Do not touch hot parts bare handed.
●Allow cooling period before working on gun or torch.
MAGNETIC FIELDS can affect pacemakers.
●Pacemaker wearers keep away.
●Wearers should consult their doctor before going near arc welding, gouging, or spot welding operations.
NOISE can damage hearing.
●Noise from some processes or equipment can damage hearing.
●Wear approved ear protection if noise level is high.
CYLINDERS can explode if damaged.
Shielding gas cylinders contain gas under high pressure.If damaged,a cylinder can explode.Since gas
cylinders are normally part of the welding process, be sure to treat them carefully.
●Protect compressed gas cylinders from excessive heat, mechancal shocks, slag, open flames, sparks, and arcs.
●Install cylinders in an upright position by securing to a stationary support or cylinder rack to prevent falling or
tipping.
●Keep cylinders away from any welding or other electrical circuits.
●Never drape a welding torch over a gas cylinder.
●Never allow a welding electrode to touch any cylinder.
●Never weld on a pressurized cylinder-explosion will result.
●Use only correct shielding gas cylinders, regulators, hoses,and fittings designed for the specific application;
maintain them and associated parts in good condition.
●Turn face away from valve outlet when opening cylinder valve.
●Keep protective cap in place over valve except when cylinder is in use or connected for use.
●Read and follow instructions on compressed gas cylinders, associated equipment, and CGA publication P-1
listed in Safety Standards.
1-3. Additional Symbols For Installation, Operation, And Maintenance
FIRE OR EXPLOSION hazard.
●Do not install or place unit on, over, or near combustible surfaces.
●Do not install unit near flammables.
●Do not overload building wiring - be sure power supply system is properly sized, rated, and protected to handle
this unit.
FALLING UNIT can cause injury.
●Use lifting eye to lift unit only, NOT 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.
OVERUSE can cause OVERHEATING.
●Allow cooling period; follow rated duty cycle.
●Reduce current or reduce duty cycle before starting to weld again.
●Do not block or filter airflow to unit.
MOVING PARTS can cause injury.
●Keep away from moving parts such as fans.
●Keep all doors, panels, covers, and guards closed and securely in place.
ARC WELDING can cause interference.
●Electromagnetic energy can interfere with sensitive electronic equipment such as computers and
computer-driven equipment such as robots.
●Be sure all equipment in the welding area is electromagneticallycompatible.
●To reduce possible interference, keep weld cables as short as possible, close together, and down low, such as on
the floor.
●Locate welding operation 100 meters from any sensitive electronic equipment.
●Be sure this welding machine is installed and grounded according to this manual.
●If interference still occurs, the user must take extra measures such as moving the welding machine, using
shielded cables, using line filters, or shielding the work area.
1-4. EMF Information
Considerations About Welding And The Effects Of Low Frequency Electric And Magnetic Fields Welding
current, as it flows through welding cables, will cause electromagnetic fields. There has been and still is some
concern about such fields. However, after examining more than 500 studies spanning 17 years of research, a
special blue ribbon committee of the National Research Council concluded that: "The body of evidence, in the
committee's judgment, has not demonstrated that exposure to power-frequency electric and magnetic fields is a
human-health hazard." However, studies are still going forth and evidence continues to be examined. Until the
final conclusions of the research are reached, you may wish to minimize your exposure to electromagnetic fields
when welding or cutting.
To reduce magnetic fields in the workplace, use the following procedures:
1. Keep cables close together by twisting or taping them.
2. Arrange cables to one side and away from the operator.
3. Do not coil or drape cables around your body.
4. Keep welding power source and cables as far away from operator as practical.
5. Connect work clamp to workpiece as close to the weld as possible.
No one can learn to weld simply by reading about it .Skill comes only with practice. The following pages will
help the inexperienced welder to understand welding and develop his skill .For more detailed information order a
book on Arc Welding.
The operator’s knowledge of arc welding must go beyond the arc itself .He must known how to control the arc,
and this requires a knowledge of welding circuit and the equipment that provides the electric current used in the
arc. The welding circuit begins where the electrode cable is attached to the welding machine and ends where the
work cable is attached to the welding machine .Current flows through the electrode cable to the electrode holder,
through the electrode and across the arc. On the work side of the arc, the current flows through base metal to the
work cable and back to the welding machine .the circuit must be compete for the current to flow. To weld, the
work clamp must be tightly connected to clean base metal .Remove paint, rust ,etc. as necessary to get a good
connection .Connect the work clamp as close as possible to the area you wish to weld. Avoid the welding circuit to
pass through hinges, bearings, electronic components or similar devices that can be damaged.
The electric arc is made between the work and the tip end of a small metal wire, the electrode, which is
clamped in a holder and the holder is held by the welder. A gap is made in the welding circuit by holding the tip of
the electrode 1.5-2.0mm away from the work or base metal being welded. The electric arc is established in this
gap and is held and moved along the joint to be welded, melting the metal as it is moved.
Arc welding is manual skill requiring a steady hand, good physical condition, and good eyesight .the operator
controls the welding arc and, therefore, the quality of the weld made.
Figure 1 The welding arc
What Happens in the Arc
Figure 1 illustrates the action that takes place in the electric arc. it closely resembles what is actually seen
during welding .
The “arc stream ”is seen in the middle of the picture .this is the arc created by the current flowing through the
space between the end of the electrode and the work .The temperature of this arc is about 60000 F. ,Which is more
than enough to melt the base metal .The arc is very bright ,as well as hot ,and cannot be looked at with the naked
eye without risking painful injury.The very dark lens, specially designed for arc welding, must be used with the
hand or face shield whenever viewing the arc.
The arc melts the base metal and actually digs into it, much as water through a nozzle on a garden hose digs
into the earth .The molten metal forms a molten pool or crater and tends to flow away from the arc .As it moves
away from the arc, it cools and solidifies. A slag forms on top of the weld to protect it during cooling.
The function of the covered electrode is much more than simply to carry current to the arc .The electrode is
composed of a core of metal wire around which has been extruded and baked chemical covering. The core wire
melts in the arc and tiny droplets of molten metal shoot across the arc into the molten pool .The electrode provides
additional filler metal for the joint to fill the groove or gap between the two pieces of the base metal. The covering
also melts or burns in the arc.It has several functions.It makes the arc steadier, provides a shield of smoke-like gas
around the arc to keep oxygen and nitrogen in the air away from the molten metal, and provides a fluxe for the
molten pool. The flux picks up impurities and forms the protective slag .The principal differences between the
various types of electrodes are in their coatings. By varying the coating, it is possible to greatly alter the operating
characteristics of electrodes. By understanding the differences in the various coating, you will gain a better
understanding of selecting the best electrode for the job you have at hand .In selecting an electrode you should
consider:
1. The type of deposit you want, e.g. mild steel, stainless, low alloy.
2. The thickness of the plate or base metal you want to weld.
3. The position it must be welded in (down hand, out-of-position).
4. The surface condition of the base metal to be weld.
5. Your ability to handle and obtain the desired electrode.
Four simple manipulations are of prime importance. Without complete mastery of these four, further welding
is futile .With compete mastery of the four, welding will be easy.
1. The Correct Welding Position
Illustrated is the correct welding position for right-handed people (For left-handed it is opposite):
a. Hold the electrode holder in your right hand
b. Touch left hand to underside of right hand.
c. Put the left elbow into your left side.
Weld with two the hand whenever possible .This gives complete control over the movements of electrode.
Whenever possible, weld from left to right (if right-hand).This enables you to see clearly what you are doing.
Hold the electrode at a slight angle as shown.
Figure 2 Correct Welding Position
2. The Correct Way to Strike An Arc
Be sure the work clamp makes good electrical contract to the work .
Lower your headshield and scratch the electrode slowly over the metal, and you will see sparks flying. While
scratching, lift the electrode 3 mm and the arc is established.
NOTE: If you stop moving the electrode while scratching, the electrode will stick.
NOTE: Most beginners try to strike the arc by a fast jabbing motion down on the plate .Result: They either stick
or their motion is so fast that they break the arc immediately.
3. The Correct Arc Length
The arc length is the distance from the tip of the electrode core wire to the base metal.
Once the arc has been established, maintaining the correct arc length becomes extremely important .The arc
should be short,approximately 1.5-3.0 mm long .As the electrode burns off the electrode must be fed to the work
to maintain correct arc length.
The easiest way to tell whether the arc has the correct length is by listening to its sound. A nice,short arc has a
distinctive,“crackling”sound ,very much like eggs frying in a pan.The incorrect, long arc has a hollow, blowing
or hissing sound.
4. The Correct Welding Speed
The important thing to watch while welding is the puddle of molten metal right behind the arc.DO NOT
watch the arc itself.It is the appearance of the puddle and the ridge where the molten puddle solidifies that
indicate correct welding speed.The ridge should be approximately 10mm behind the electrode.
Figure 3
Most beginners tend to weld too fast, resulting in a thin, uneven,“wormy” looking bead.They are not
watching the molten metal.
IMPORTANT: For general welding it is not necessary to weave the arc; neither forwards and backwards nor
sideways. Weld along at a steady pace. You will find it easier.
NOTE: When welding on thin plate, you will find that you will have to increase the welding speed, whereas
when welding on heavy plate ,it is necessary to go more slowly in order to get good penetration.
WELDING PRACTICE
The best way of getting practice in the four skills that enable you to maintain :
1. Correct Welding Position
2. Correct Way to Strike An Arc
3. Correct Arc Length
4. Correct Welding Speed
is to spend a little more time on the following exercise.
Use the following:
Mild Steel Plate: 5 mm or heavier
Electrode: 1/8’’ (3.2mm)
Current Setting: 100~120 Amps AC
Do the following:
1. Learn to strike the arc by scratching the electrode over the plate .Be sure the angle of the electrode is right and
Be sure to use both hands.
2. When you can strike an arc without sticking, practice the correct arc length.Learn to distinguish it by its
sound.
3. When you are sure that you can hold a short, crackling arc, start moving.Look at the molten puddle constantly,
and look for the ridge where the metal solidifies.
4. Run beads on a flat plate.Run them parallel to the top edge (the edge farthest away from you ) .This gives you
practice in running straight welds,and also,it gives you an easy way to check your progress .the 10th weld will
look considerderably better than the first weld,By constantly checking on your mistakes and your progress,
welding will soon be a matter of routine.
Common Metals
Most metals found around the farm or small shop are low carbon steel, sometimes referred to as mild steel.
Typical items made with this type of steel include most sheet metal, plate, pipe and rolled shapes such as channels,
angel irons and “I” beams .This Type of steel can usually be easily welded without special precautions.Some steel,
however,contains higher carbon. Typical applications include wear plates, axles, connecting rods, shafts,
plowshares and scraper blades. These higher carbon steels cabin be welded successfully in most cases;
however ,care must be taken to follow proper procedures, including preheating the metal to be welded and, in
some cases, carefully controlling the temperatures during and after the welding process ,For further information
on identifying various types of steel and other metals ,and for proper procedures for welding them ,we again
suggest you purchase a book on Arc Welding.
Regardless of the type of metal being welded, it is important in order to get a quality weld that it be free of
oil, paint, rust or other contaminants.
SECTION 3- INSTALLATION AND CONNECTION INSTRUCTIONS
3－1. GENERAL DESCRIPTION
BX1-160/180/200/250C2 are AC arc stick welder designed for those who have an occasional need for a
welder.It is suitable for light fabrication and repair welding.It is compact to allow portability and easy storage on a
shelf or under a workbench. It is developed specifically for the nonprofessional welder.
The technical specifications or parameters of these products are showed on its nameplate.
CAUTION: For different type welding machine,the technical specifications or parameters is different.
3－2. DESCRIPTIONS OF THE NAMEPLATE MARKS AND SYMBOLS
The Nameplate of BX1-160C2
The Nameplate of BX1-180C2
SECTION 3- INSTALLATION AND CONNECTION INSTRUCTIONS
The Nameplate of BX1-200C2
The Nameplate of BX1-250C2
Application standards: EN60974-6 or EN60974-1
Single-phase transformer, AC output.
Manual Metal Arc or MMA welding
U1：Rated AC input voltage of the welding power source (tolerance: ±10% )，e.g. 230VAC or 400VAC.
I1max：Max. input current
I1eff：Max. effective input current
X: duty cycle, It is the ratio between the load duration time and the full cycle time.
SECTION 3- INSTALLATION AND CONNECTION INSTRUCTIONS
Note1: This ratio is between 0~100%.
Note2: For this standard, one full cycle time is 10min.For example, if the rate is 40%, the loaded time shall be 4 minutes
and rest time shall be 6 minutes.
Duty cycle is based on a ten minute period.This means that the arc may be drawn for two minutes out of each
ten minute period without any danger of overheating .If it is used more than two minutes during several
successive ten minutes peiods, it may overheat.
U0：Non-load voltage
It is the open-circuit output voltage of the welding power source.
I2：output current
U2：Output load voltage
The rated loaded output voltage U2=20+0.04I2
A / V—A / V：The adjustable range of current and its corresponding load voltage.
IP：Protection grade . For example, IP21,approving the welding machine as suitable for use indoors; IP23,. approving the
welding machine as suitable for use outdoors in the rain.
S Suitable for hazardous environments.
Please read the User’s Manual carefully before use.
Symbol of single-phase AC power supply and rated frequency （e.g.50HZ or 60 HZ）.
： Beyond rain.
H or F： Insulation grade.
3－3. INSTALLATION
WARNING:Only qualified personnel should install,use,or service the welding machine.
Machine Installation Location - Place the welding machine to there where is free circulation of air.
Welding Machine Assembly
For BX1-160/180/200/250C2 welding machines, welding cables should be connected to the welding power
source Outputs .The input power cable should be connected to power supply.
Input Power and Grounding Connections
Only qualified persons should install,use or service this equipment. Protect yourself and others from
possible serious injury or death.
SECTION 3- INSTALLATION AND CONNECTION INSTRUCTIONS
WARNING: Do not operate with covers removed.Disconnect input power before servicing.
Do not touch electically live parts.
Before starting the installation,check with the power company to be sure your power supply is adequate for the
voltage,amperes,phase,and frequency specified on the welding machine nameplate,Also be sure the planned
installation will meet all local and national code requirements.Some welding machines may be operated from a
single phase line or from one phase of a two or three phase line.
CAUTION: BX1-160/180/200/250C2 welding machines may be connected to either 230V or 400V input power .
1. Before connecting the input cable to the power supply,check that the power(on-off) switch operates in the
position corresponding to the input voltage that the machine will be connected to.
CAUTION :If the power switch setting does not match the input power voltage,you may burn up the
welding machine!
2. Connect the “PE” or green/yellow grounding wire in the input cord to a system ground per the applicable
national and local codes.
3. Connect the flexible input cord of the welding machine to a single phase power supply of the proper voltage
and ampacity through a fused two-pole disconnect.
3－4. OPERATING INSTRUCTIONS
CAUTION :Duty cycle is based on a ten minute period.This means that the arc may be drawn for two minutes
out of each ten minute period without any danger of overheating .If it is used more than two minutes during
several successive ten minutes peiods, it may overheat.
Input Power Over-heat lamp
Supply Switch
Earth clamp and
welding cable
Welding Current
Adjustmenter or
Handwheel
Electrode holder and
welding cable
BX1-160C2 Welding Machine
SECTION 3- INSTALLATION AND CONNECTION INSTRUCTIONS
Power lamp
Input Power
Supply Selection
Switch
Over-heat lamp
Welding Current
Adjustmenter or
Handwheel
Earth clamp and
welding cable
AC Input power
Electrode holder and
welding cable
BX1-180/200/250C2 Welding Machine
Connect The Machine To Power Supply
With the help of input power selection switch or Input power switch, the switch should be selected to 230V or
400V input power.The welding machines should be connected to 230V or 400V input power.
Control Functions
The desired welding curent is set by turning the handwheel.Clockwise rotation raises the welding current,
counterclockwise rotation reduces the welding current.
Turn on the power supply ON/OFF switch. The MMA welding process will be carried out.
LED1:Pilot light of the power supply in the ON/OFF power source switch. The LED1 is lighted when the switch is
ON.
LED2: Pilot light of Over-heating , Over current or voltage.The LED2 is lighted with thermal overload protection or
over current.
LED2 is on, in case that this welding equipment is of overheating protection status. Overheating arises if this welding
power source is overloaded. This welding equipment automatically restarts when the temperature inside of this welding
equipment has fallen, and pilot lamp is off.
SECTION 3- INSTALLATION AND CONNECTION INSTRUCTIONS
3－5. MAINTENANCE
WARNING: ELECTRIC SHOCK can kill.Do not touch electrically live parts such as output terminals or
internal wiring. MOVING PARTS can injure.
Routine preventative maintenance is not required.
Substitution of output cable with larger sizes requiring connections to be made internally is not
recommended.Connections for additional lengths or larger sizes should be properly made externally.
If either output cable requires replacement for other reasons, it should be replaced with the appropriate part -and
only by qualified personnel .It is important that the connection to the transformer lead is made in the same manner
that it was originally.
Reference!
When starting (start) these equipments, a brief voltage drop may occur, in particular with bad quality. These
break-downs can affect other devices (e.g. flick a lamp). With a net impedance of Zmax< 0. 327OHM, such
disturbances are not to be expected. (Please contact your local energy suppliers for more information).
