Arc WDRMPRROA16A Rossi 160 Amp Inverter Stick Welder User Manual

User Manual

[Revision 2.0]

READ THIS MANUAL CAREFULLY BEFORE USE – FAILURE TO DO SO MAY RESULT IN INJURY, PROPERTY DAMAGE AND MAY

VOID WARRANTY. • KEEP THIS MANUAL FOR FUTURE REFERENCE. • Products covered by this manual may vary in

appearance, assembly, inclusions, specifications, description, and packaging.

MMA160A Industrial Multi-Metal Welder

E&OE © Rossi 2

Safety

Safety messages are designed to alert you to possible dangers or hazards that could cause death, injury or

equipment or property damage if not understood or followed. Safety messages have the following symbols:

You WILL be KILLED or

SERIOUSLY INJURED if you do

not follow instructions.

You CAN be KILLED or

SERIOUSLY INJURED if you do

not follow instructions.

You CAN be INJURED if you do

not follow instructions or equipment

damage may occur.

It is vital that you read and understand this

user manual before using the product,

including safety warnings, and any assembly

and operating instructions. Keep the manual

for future reference.

Safety precautions and recommendations

detailed here must be fully understood and

followed to reduce the risk of injury, fire,

explosion, electrical hazard, and/or property

damage.

Safety information presented here is generic

in nature – some advice may not be

applicable to every product. The term

"equipment" refers to the product, be it

electrical mains powered, battery powered or

combustion engine powered.

• Before Use - If you are not familiar with the

safe operation/handling of the equipment or

are in any way unsure of any aspect of

suitability or correct use for your

application, you should complete training

conducted by a person or organization

qualified in safe use and operation of this

equipment, including fuel/electrical handling

and safety.

• Do NOT operate the equipment in

flammable or explosive environments, such

as in the presence of flammable liquids,

gases, or dust. The equipment may create

sparks or heat that may ignite flammable

substances.

• Keep clear of moving parts.

• Equipment may be a potential source of

electric shock or injury if misused.

• Do NOT operate the equipment if it is

damaged, malfunctioning or is in an

excessively worn state.

• Do NOT allow others to use the equipment

unless they have read this manual and are

adequately trained.

• Keep packaging away from children - risk

of suffocation! Operators must use the

equipment correctly. When using the

equipment, consider conditions and pay

due care to persons and property.

General Work Area Safety

•

Work areas should be clean and well it.

• Do not operate the equipment if

bystanders, animals etc are within

operating range of the equipment or the

general work area.

• If devices are provided for connecting dust

extraction / collection facilities, ensure

these are connected and used properly.

Dust collection can reduce dust-related

hazards.

General Personal Safety

•

Wear appropriate protective equipment

when operating, servicing, or when in the

operating area of the equipment to help

protect from eye and ear injury, poisoning,

burns, cutting and crush injuries. Protective

equipment such as safety goggles,

respirators, non-slip safety footwear, hard

hat, hearing protection etc should be used

for appropriate equipment / conditions.

Other people nearby should also wear

appropriate personal protective equipment.

Do not wear loose clothing or jewellery,

which can be caught in moving parts. Keep

hair and clothing away from the equipment.

• Stay alert and use common sense when

operating the equipment. Do not over-

reach. Always maintain secure footing and

balance.

• Do not use the equipment if tired or under

the influence of drugs, alcohol, or

medication.

• This equipment is not intended for use by

persons with reduced physical, sensory, or

mental capabilities.

General Fuel Safety

•

Petrol/fuel/gasoline is extremely flammable

– keep clear of naked flames or other

ignition sources.

• Do not spill fuel. If you spill fuel, wipe it off

the equipment immediately – if fuel gets on

your clothing, change clothing.

• Do NOT smoke near fuel or when

refuelling.

• Always shut off the engine before

refuelling.

• Do NOT refuel a hot engine.

• Open the fuel cap carefully to allow any

pressure build-up in the tank to release

slowly.

• Always refuel in well-ventilated areas.

• Always check for fuel leakage. If fuel

leakage is found, do not start, or run the

engine until all leaks are fixed.

General Carbon-Monoxide Safety

•

Using a combustion engine indoors CAN

KILL IN MINUTES. Engine exhaust

contains carbon-monoxide – a poison you

cannot smell or see.

• Use combustion engines OUTSIDE only,

and far away from windows, doors, and

vents.

General Equipment Use and Care

•

Keep packaging away from children and

pets, potential risk of suffocation or

choking.

• The equipment is designed for domestic

use only.

• Handle the equipment safely and carefully.

• Before use, inspect the equipment for

misalignment or binding of moving parts,

loose components, damage, or any other

condition that may affect its operation. If

damaged, have the equipment repaired by

an authorised service centre or technician

before use.

• Prevent unintentional starting of the

equipment - ensure equipment and power

switches are in the OFF position before

connecting or moving equipment. Do not

carry equipment with hands or fingers

touching any controls. Remove any tools or

other items that are not a part of the

equipment from it before starting or

switching on.

• Do not force the equipment. Use the

correct equipment for your application.

Equipment will perform better and be safer

when used within its design and usage

parameters.

• Use the equipment and accessories etc. in

accordance with these instructions,

considering working conditions and the

work to be performed. Using the equipment

for operations different from those intended

could result in hazardous situations.

• Always keep equipment components

(engines, hoses, handles, controls, frames,

housings, guards etc) and accessories

(cutting tools, nozzles, bits etc) properly

maintained. Keep the equipment clean and,

where applicable, properly lubricated.

• Store the equipment out of reach of

children or untrained persons. To avoid

burns or fire hazards, let the equipment

cool completely before transporting or

storing. Never place or store the equipment

near flammable materials, combustible

gases, or liquids etc.

• The equipment is not weather-proof, and

should not be stored in direct sunlight, at

high ambient temperatures or locations that

are damp or humid.

• Do not clean equipment with solvents,

flammable liquids, or harsh abrasives.

• For specific equipment safety use and care,

see Equipment Safety.

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MMA160A Industrial Multi-Metal Welder

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General Electrical Safety

•

Inspect electrical equipment, extension

cords, power bars, and electrical fittings for

damage or wear before each use. Repair or

replace damaged equipment immediately.

• Ensure all power sources conform to

equipment voltage requirements and are

disconnected before connecting or

disconnecting equipment.

• When wiring electrically powered

equipment, follow all electrical and safety

codes.

• Always use a Residual Current Device

(RCD) (GFCI) / Earth Leakage Circuit

Breaker / Safety Switch when operating this

item (electrical items only).

• High voltage / high current power lines may

be present. Use extreme caution to avoid

contact or interference with power lines.

Electrical shock can be fatal.

General Electrical Safety

•

Electrically grounded equipment must have

an approved cord and plug and be

connected to a grounded electrical outlet.

• Do NOT bypass the ON/OFF switch and

operate equipment by connecting and

disconnecting the electrical cord.

• Do NOT use equipment that has exposed

wiring, damaged switches, covers or

guards.

• Do NOT use electrical equipment in wet

conditions or in damp locations.

• Do NOT use electrical cords to lift, move or

carry equipment.

• Do NOT coil or knot electrical cords, and

ensure electrical cords are not trip hazards.

General Service Information

•

The equipment must be serviced or

repaired at authorised service centres by

qualified personnel only.

• Replacement parts must be original

equipment manufacturer (OEM) to ensure

equipment safety is maintained.

• Do NOT attempt any maintenance or repair

work not described in this manual.

• After use, the equipment and components

may still be hot – allow the equipment to

cool and disconnect spark plugs and/or

electrical power sources and/or batteries

from it before adjusting, changing

accessories, or performing repair or

maintenance.

• Do NOT adjust while the equipment is

running.

• Perform service-related activities in suitable

conditions, such as a workshop.

• Replace worn, damaged or missing

warning/safety labels immediately.

Child Choking Hazard!

• W

ARNING: CHOKING HAZARD - CHILDREN UNDER 8 YRS. CAN CHOKE OR SUFFOCATE ON SMALL PARTS. ADULT

SUPERVISION REQUIRED.

• Carefully inspect anything a baby or child could gain access to, including this product & packaging.

• Dangers include anything of a size that could become stuck or lodged in a baby or child's airway.

• Dangers include things like raw, hard fruit and vegetable pieces, large pieces of meat, bones or sausage skins, popcorn, nuts,

hard lollies and corn chips, small magnets and batteries, coins, beads, marbles and small uninflated balloons, broken toys and smaller toys,

buttons, keys, and coins. But there are also many more.

• Pay particular attention to accessories, nuts, bolts, screws, washers, caps, covers, loose parts, parts that could be removed or break off, pieces

of packaging, staples, tape etc.

• In the case of any doubt, secure the item of concern in an appropriate manner, or completely remove the possibility of access by a baby or child.

Safety Precautions: Arc Welding

WARNING! READ ALL SAFETY WARNINGS, INSTRUCTIONS, ILLUSTRATIONS, AND SPECIFICATIONS PROVIDED WITH THIS MACHINE.

F

AILURE TO FOLLOW ALL INSTRUCTIONS LISTED BELOW MAY RESULT IN ELECTRIC SHOCK, FIRE AND/OR SERIOUS INJURY. SAVE

ALL WARNINGS AND INSTRUCTIONS FOR FUTURE REFERENCE. ONLY QUALIFIED PERSONS SHOULD INSTALL, OPERATE,

MAINTAIN, AND REPAIR THIS UNIT.

Electric Shock

•

Touching live electrical parts can cause fatal shocks or severe burns. The electrode and work circuit are electrically live whenever the output is

on. The input power circuit and machine circuits are also live when power is on. 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.

• Do not connect more than one electrode or work cable to any single weld output terminal.

• Disconnect input power or stop the machine before installing or servicing this equipment.

• 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.

• Frequently inspect input power cord for damage or bare wiring ‒ replace cord immediately if damaged ‒ bare wiring can kill.

• Do not touch electrode if you are in contact with the work, ground, or another electrode from a different machine.

Fumes and Gases

•

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.

• 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 cleaning, or spraying operations. The heat and rays of the arc can react with vapours to form highly toxic and

irritating gases.

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• 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.

Arc Rays

•

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.

• 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.

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. C heck 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 feet (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 by required 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.

• Cylinders can explode if damaged; Shielding gas cylinders contain gas under high pressure and damaged cylinder can explode, so be sure to

treat them carefully.

• Keep cylinders away from any welding or other electrical circuits. Never hang 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. Do not install or place unit on,

over, or near combustible surfaces or flammables. Do not overload building wiring ‒ be sure power supply system is properly sized, rated, and

protected to handle this unit.

Further Cases

•

Hot parts can cause severe burns. Do not touch hot parts bare handed. Allow cooling period before working on gun or torch.

• Overuse can cause overheating; Al low cooling period and follow rated duty cycle. Reduce the current before starting to weld again. Do not block

or filter airflow to unit.

• High -frequency due to welding can cause interference, it can interfere with radio navigation, safety services, sensors computers, and

communications equipment.

• Be sure all the equipment in the welding area is electromagnetically compatible. 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.

• 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.

• Welding wire can cause injury; Do not press gun trigger until instructed to do so. Do not point gun toward any part of the body, other people, or

any metal when threading welding wire.

• Electrostatic discharge can damage printed circuit boards. Put on grounded wrist strap before handling boards or parts. Use proper static -proof

bags and boxes to store, move, or ship PC boards.

Disposal

•

Waste electrical products should not be disposed of with household waste. Please recycle where facilities exist. Check with your Local Authority

or local store for recycling advice.

• Do not dispose this product with normal household waste but take it to a collection point and recycling of electrical and electronic equipment. This

is indicated by the symbol on the product, user manual or packaging. Re-use, material utilization or other forms of old appliances, you make an

important contribution in protecting our environment.

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MMA160A Industrial Multi-Metal Welder

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Safety Symbols

The product may have safety warning labels attached to it, explained below. Understand the symbols on your

product and their meanings. If any stickers become unreadable, unattached etc., replace them.

Flammable Material Hazard

Flammable liquids, gases, or

substances etc may present.

Avoid ignition sources and open

flames. Danger of fire.

Read User Manual

Read and fully understand

product safety warnings,

operation, procedures etc before

using the product.

Use Hand Protection

Wear appropriate hand protection

and take due care as the product

or use of the product may present

hand hazards.

Carbon-Monoxide Hazard

Do not use the product in

confined areas or without

adequate ventilation. Carbon-

monoxide poisoning can be fatal.

Electrocution / Electrical Shock

Hazard

High voltage or high current

electricity may be present or

required by the product. Take

due care when handling electrical

products, cables, plugs and

leads. Electrical shock can be

fatal.

Toxic Fumes / Dust Hazard

Using the product or by-products

from use may produce fumes,

smoke or particles that could be

harmful if inhaled. Wear

appropriate breathing protection

and have adequate ventilation.

Explosive Material Hazard

Combustible liquids, gases, or

substances etc may be present.

Avoid ignition sources and open

flames. Danger of explosion.

Cutting / Amputation Hazard

The product may have blades,

edges or mechanical devices that

can cause severe cut injury to

fingers, limbs etc. Take due care

when handling and using the

product.

Crush Hazard

The product may have blades,

edges or mechanical devices that

can cause severe crush injury to

fingers, limbs etc. Take due care

when handling and using the

product.

Single Operator Only

The product must be operated by

a single person only. More than

one person operating the product

may introduce additional hazards.

Use Face Protection

Wear appropriate full-face

protection and take due care as

the product or use of the product

may present face and eye

hazards.

Use Foot Protection

Wear appropriate foot protection

and take due care as the product

or use of the product may present

foot hazards.

Use Eye / Ear / Head Protection

Wear appropriate eye and / or

ear and / or head protection and

take due care as the product or

use of the product may present

eye, hearing, and head hazards.

Running Hazard

Do not run on or near the product

as doing so may present a fall

hazard.

Diving Hazard

Do not dive into the product as

doing so may present a neck /

head injury hazard.

Adult Supervision Required

Always supervise children and

other users of a product to

prevent drowning or injury.

Skin Penetration / Puncture

Hazard

The product may produce

pressure, emit liquids or objects

that can cause severe injury to

fingers, limbs, blood etc. Take

due care when handling and

using the product.

Hot Surface Hazard

Be aware that the product may

produce high temperatures and

hot surfaces that can cause burn

injuries.

Flying Debris Hazard

Be aware that the product or use

of the product may present

hazards produced by flying

debris. Wear appropriate clothing

and protective devices.

Moving Parts Hazard

Be aware that the product

contains or uses mechanical

devices that move or rotate.

Always wait for moving parts to

stop fully before handling the

product, adjusting, maintenance

etc.

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Carbon-Monoxide Hazard

Do not use the product in

confined areas or without

adequate ventilation. Carbon-

monoxide poisoning can be fatal.

Pull Hazard

Be aware that the product

contains or uses mechanical

devices that can pull in objects

and can cause severe injury to

fingers, limbs etc. Take due care

when handling and using the

product.

Slope / Fall Injury Hazard

Be aware that using the product

on sloping surfaces or in slippery

conditions may present additional

dangers from falls and contact

with blades, moving parts, hot

surfaces etc.

"Slam Dunk" Warning

Do NOT attempt "slam dunk"

manoeuvres as this may result in

severe injury due to falling,

product breakage or collapse etc.

Electrocution / Electrical Shock

Hazard - Outdoor

High voltage or high current

electricity may be present or

required by the product. Do NOT

use in rain, damp, or wet

conditions. Electrical shock can

be fatal.

Electrocution / Electrical Shock

Hazard - Disconnect

High voltage or high current

electricity may be present or

required by the product. Always

disconnect the product from the

electrical supply before handling

the product, adjusting,

maintenance etc.

Power Line Electrocution

Hazard

High voltage / high current power

lines may be present. Use

extreme caution to avoid contact

or interference with power lines.

Electrical shock can be fatal.

"Kick-Back" Hazard

High level of "kick-back" hazard

that can cause the machine to

suddenly rotate towards operator.

Kick-back injury can be fatal.

Winch Operator Position

Hazard

Do NOT stand between winch

and load. Do NOT use winch to

move people.

Winch Lift Hazard

Do NOT LIFT load vertically. Use

machine to PULL only.

Cable Hazard

Ensure that load bearing cable is

not kinked or knotted.

Winch Cable Hazard

Ensure that there is a minimum

number of cable coils on

winching mechanism.

Winch Hook Hazard

Carry hook to load – do NOT

throw or run.

Flash / Blinding Hazard

Wear appropriate eye protection

for welding. Direct exposure to

weld arcs may cause permanent

eye injury.

Laser Hazard

Laser may be in use – do NOT

look directly at laser or allow

others to.

Choking Hazard

Children under 8 yrs. Can choke

or suffocate on small parts. Adult

supervision required.

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Table of Contents

Safety ............................................................................................................................................................. 2

Safety Symbols ........................................................................................................................................................... 5

Parts Identification ....................................................................................................................................... 8

Set-Up ............................................................................................................................................................ 9

Unpacking and Checking ............................................................................................................................................ 9

Intended Use .............................................................................................................................................................. 9

Installation ................................................................................................................................................................... 9

Parameters ............................................................................................................................................................... 10

Controls and Operational Features ........................................................................................................... 12

Operation ..................................................................................................................................................... 14

General ..................................................................................................................................................................... 14

Welding Pitfalls ......................................................................................................................................................... 15

Maintenance ................................................................................................................................................ 16

Storage ........................................................................................................................................................ 16

Troubleshooting ......................................................................................................................................... 17

Specifications ............................................................................................................................................. 18

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Parts Identification

No. Name

1

Current adjusting knob

2

Digital Display

3 VRD Switch

4 --

5 Quick connector socket: welding machine output (-)

6 Quick connector socket: welding machine output (+)

7

ON / OFF Switch

8

Power Input

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Set-Up

Unpacking and Checking

•

The equipment is packed in durable packages. Nevertheless, always, before using the equipment, make

sure it is not damaged during transportation/delivery.

•

Place the unit on a horizontal, solid, and clean surface. Shield it from heavy rain and scorching sun. Make

sure that cooling air circulates freely.

WARNING! The product must be fully assembled before operation! Do not use a product that is only

partly assembled or assembled with damaged parts! Do not connect the product to power supply before

it is completely assembled!

Intended Use

Welding machines are among the most essential tools for a welding professional. Welding machines generate

heat that melts metal parts, so that these parts can be joined.

In Manual Metal Arc Welding (MMA), consumable, flux -covered electrode and a ground clamp, a short -circuit

is initially made on the weld piece. An electric arc forms between electrode and workpiece, which heats up

enough to melt both. As the electrode melts, the flux coating on the electrode develops gas and slag, which help

protect the weld pool. The gas keeps air and other pollutants away, while slag forms on top of the weld pool to

protect the weld seam. The slag cools down and solidifies rapidly, protecting the weld area after the gas has

disappeared.

The machine uses a high performance IGBT Technology, which is very useful as they give power that can

be used for different welding processes.

Installation

1. Make sure that the air vent of the machine is not covered and clogged up to avoid failure of cooling system.

Some welding machines are equipped with VRD (Voltage Reduction Device) Technology.

2. Connect the welding tongs (grounding clamp and electrode holder) correctly according to the following

figure. First, make sure that cable, welding tongs and quick plugs are connected reliably.

3. Insert the quick plug that connects the electrode holder in the quick socket with the polarity of “+”, and then

tighten it by rotating clockwise.

4. Insert the quick plug that connects the grounding clamp into quick socket with the polarity of “-” on the panel

of welding machine, tighten it by rotating clockwise, the grounding clamp connects to the workpiece.

5. Pay attention to the polarity of connection, if connected improperly, unstable electric arc, large splashes and

sticky welding rod may occur.

6. Connect the power plug to the corresponding voltage class of distribution box according to the input voltage

class of the welding machine, don’t connect the voltage by mistake. Make sure that the tolerance of the

supply voltage is within the allowable range.

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Parameters

•

Current setting: The correct current, or amperage setting primarily depends on the diameter and type of

electrode selected. The side of the electrode box usually indicates operating ranges. Select an amperage

based on the material thickness, welding position (about 15 percent less heat for overhead work compared

to a flat weld) and observation of the finished weld.

•

Length of arc: The correct arc length varies with each electrode and application. As a good starting point,

arc length should not exceed the diameter of the metal portion of the electrode. Excessively long arcs (too

much voltage) produce spatter, low deposition rates, undercuts and sometimes porosity.

•

Angle of travel: Hold the rod perpendicular to the joint and tilt the top of the electrode in the direction of

travel approximately 5 to 15°. For welding vertical up, use a forehand technique and tilt the top of the rod 15°

away from the direction of travel.

•

Speed of travel: The proper travel speed produces a weld bead with the desired contour (or crown), width

and appearance. Adjust travel speed so that the arc stays within the leading one -third of the weld pool. Slow

travel speeds produce a wide, convex bead with shallow penetration. Excessively high travel speeds also

decrease penetration, create a narrow and/or highly crowned bead, and possibly undercuts.

•

Manipulation: Each welder manipulates or weaves the electrode in a unique style. Develop your own style

by observing others, practicing, and creating a method that produces good results for you. Note that on

material 1/4 inch and thinner, weaving the rod typically creates a bead that is wider than necessary. In many

instances, plain, straight -ahead travel works fine. To create a wider bead on thicker material, manipulate the

electrode from side to side creating a continuous series of partially overlapping circles, or in a Z-shaped,

semicircle or stutter -step pattern. Limit side -to-side motion to two and a half times the diameter of the

electrode core.

To cover a wider area, make multiple passes or stringer beads. When welding vertical up, focus on welding

the sides of the joint and the middle will take care of itself.

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•

Diameter of welding rod and Welding current:

•

Thickness of steel plate and Diameter of welding rod:

NOTE: It is recommended that you try welding and rate of welding current first on something else than

the actual work piece. You can start welding after having made the necessary selections. Arc is lit by

scratching the welding piece with electrode. Length of arc is regulated by holding electrode tip at a

suitable distance from welding piece. Suitable arc length is usually about half the diameter of the

electrode wire.

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Controls and Operational Features

WARNING: This product may heat surfaces around it. Heat may be projected in any direction. Keep away

from any surface that could be affected by heat.

When the machine is turned ON, an auto-test is executed and power LED (GREEN) lights up and display will

turn ON. The Machine is ready to operate when the Front Control Panel lights up and the Power LED is ON.

The listed parts below are labelled in the product overview. *Some features may not be

present on all models.

•

Current adjusting knob:

Potentiometer is used to set the output current during welding.

•

Arc Force Regulator (for some models):

•

Arc force is a temporary increase of the output current during welding when the arc is too short. It also

enhances simple position welding, making the job easier. In order to produce an outstanding weld

performance on a variety of electrodes, the Arc Force can be finely adjusted with a simple knob.

•

Hot start Regulator (for some models):

Hot Start provides excellent arc ignition without the electrode sticking and avoiding any metallurgical default

in the weld.

•

Anti-sticking (inbuilt):

This electronic device minimizes the short circuit current in the event of the electrode sticking to the

workpiece. If a short circuit does occur, it will be easy to remove the electrode from the work piece and the

electrode gun and cable will remain undamaged. It also serves as a safety device in protecting the operator.

•

Multi metal capability (for some models):

This feature allows the machine to weld Zinc, Carbon steel, Copper, Iron and Aluminium.

•

Power ON/OFF LED:

This LED lights up when the machine is ON.

•

Heat LED:

This indicator will turn ON when the machine is overheated, and the output has been disabled. This normally

occurs when the duty cycle of the machine has been exceeded. Leave the machine ON to allow the internal

components to cool. When the indicator turns OFF, normal operation is again possible.

•

QC LED:

This turns ON when the machine is overheated/ overloaded.

•

Digital Display:

The meter displays the present welding current before welding and the actual welding current during

welding.

•

Quick connector socket: welding machine output (+):

Connect the electrode holder to this socket.

•

Quick connector socket: welding machine output (-):

Connect earth cable to this socket.

•

Power boost button (for some models):

Button to increase the output current up to 40% for using 4 or 5mm electrodes.

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MMA160A Industrial Multi-Metal Welder

•

Smart Fan:

This machine has a Smart Fan circuitry inside, which works only when cooling is required. This feature

reduces the amount of dirt, which can be drawn inside the machine and reduces power consumption. The

fan will continue to run whenever the machine is welding.

•

VRD:

VRD (Voltage Reduction Device) provides an additional measure of safety, especially when working in an

environment with a higher risk of electrical shock such as wet areas and hot, humid, sweaty conditions. VRD

reduces the welding power source’s open circuit voltage (OCV).

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MMA160A Industrial Multi-Metal Welder

Operation

General

In Manual metal arc (MMA) welding, the welding filler material is melted from the electrode to the weld pool.

Rate of welding current is selected on the basis of electrode size used and welding position. Arc forms between

electrode tip and welding piece. The melting electrode coating forms gas and slag, which protects the weld pool.

WARNING! Make sure that welding cable and earth cable connections are tight. If a connection is slack,

it will result in voltage drop that will cause the connection to heat. During welding, it is forbidden to pull

off any plug or cable in use, or it will lead to life-threatening danger and sever e damage to the machine.

1. Always fix earth cable clamp directly on the welding piece. Clean connection surface of earth clamp from

paint and rust. Connect the clamp carefully so that contact surface is as large as possible.

2. Turn the power switch to “ON” position. Cooling fan inside the machine should begin to work once welding

starts. Some welding machines are equipped with automatic cooling technology; Smart fan will work only

when welding starts and helps to cool the internal circuit and components.

3. Clamp the welding rod on the electrode holder, the machine is in the manual welding mode and in the

standby state.

4. In accordance with the thickness of welding workpiece, diameter of welding rod, working position and

technology needs, make sure suitable welding current. If current is too high, intensified splashing may lead

to inferior formation of weld and if low, the melted welding stick becomes fluid and drop transfer would not

proceed smoothly.

For beginners, the first difficulty is priming the arc. For best results, proceed as follows:

1. Test the current intensity and the electrode on a piece of scrap material. Hold the electrode approximately 2

cm above the start of the joint and hold the face shield in front of your face. Touch the workpiece with the

electrode and stroke it repeatedly on and off the workpiece to start the arc. Remove the electrode with a firm

lateral jerk.

2. Watch the arc only through the face shield and keep the arc length approximately 1 ‒ 1.5 times the

diameter of the electrode. The arc length is very important as it has an influence on the welding current and

welding voltage.

3. Incorrect current intensity produces a poor quality and a weak joint. Hold the electrode at an angle

approximately 70 ‒ 80° to the workpiece in the direction of advancement. If the angle is too large, the slag

can penetrate the joint; if the angle is too small, the arc flutters and sprays molten metal. In both cases, a

weak, porous joint is produced.

4. Wait until the joint has cooled completely before removing the slag. If you wish to continue welding a joint

after taking a break, the slag at the end of the joint must be removed first. Prime the arc in the joint and melt

the electrode at the point where the two joints meet.

NOTE: Always use tongs or pliers to remove spent electrodes and to move parts that you have just

welded. Please note that the electrode holder must always be put down so that it is insulated after you

have completed the welding work. Do not remove the slag until the weld has cooled. If you want to

continue a weld after an interruption, the slag from your initial attempt must first be removed. Do not

bang the electrode on the workpiece as this could damage the electrode covering, making it more

difficult to prime the arc.

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MMA160A Industrial Multi-Metal Welder

Welding Pitfalls

The arc welding technique is an acquired skill and requires considerable practice before perfect results are

obtained. The diagrams below will help to explain the pitfalls (problems) in your technique and how to overcome

them.

Arc too short.

This causes irregular masses of weld to be deposited,

with slag contamination on an uneven surface.

Arc too long.

This causes poor penetration, resulting in a weak

weld with excessive spatter and porosity.

Electrode moved too slowly.

This causes a very wide and heavy deposit which

overlaps at the sides. It is wasteful both in terms of

time and electrode use.

Electrode moved too quickly.

This causes poor penetration with a ‘stringy’ and

incomplete weld deposit. Slag is very hard to remove.

Current too low.

This causes poor penetration and causes the

electrode to stick to the workpiece too readily. Also

results in a very irregular and high weld deposit.

Current too high.

This causes excessive penetration with spatter and

deep pointed crater. It may also cause holes to be

burned in the workpiece.

The perfect weld.

With the correct combination of arc length, current

regulation, inclination, and speed of the electrode,

you will (with practice) produce the perfect weld.

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MMA160A Industrial Multi-Metal Welder

Maintenance

All maintenance works must be conducted under the condition of complete power failure; please make

sure that power plug is pulled out.

•

Regularly remove dust/dirt on the welding machine with dry compressed air. When used in heavy fumes and

polluted atmosphere, do this job at least once a month. Compressed air should drop down to the required

pressure to prevent damaging the small parts and units in machine.

•

Avoid water or moisture getting into welding machine, or else, blow the welding machine to dry immediately,

then measure the insulation with insulation resistance meter, it can only be used when the measuring result

is accepted.

•

In the event that the welding machine is not used for an extended period, it should be placed into the original

package and stored in a cool, dry place.

•

Any improper or incorrect operation may cause failure and damage to the welder. Routine maintenance on

the power control switch, grounding device, welding electrode holder, coupling device and set screws should

be performed on a regular basis.

•

Measure the welder’s insulation resistance with an insulation resistance meter.

NOTE: Repairing welding equipment should be carried out by a qualified person using original spare

parts. This ensures the safety of the device as well as yourself.

Storage

Store the equipment and accessories out of children’s reach in a dark and dry place at above freezing

temperature. The ideal storage temperature is between 5 - 30℃. Store the electric tool in its original packaging.

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MMA160A Industrial Multi-Metal Welder

Troubleshooting

The following operations must be performed by qualified electricians with valid certifications. Before

maintenance, please contact the manufacturer for professional suggestions.

Problems Causes and Solutions

Meter doesn’t display, fan doesn’t work, no welding

output.



Make sure power switch is OFF.



Make sure the power source connecting to input cable

is working alright.

Meter is normal, fan is working, no welding output.



Check if connector of output terminal is broken or

damaged.



Check if the control board is damaged (contact the

manufacturer or an authorised service centre).

QC indicator is ON, fan is working, meter is normal.



IGBT is damaged.



Quick recovery rectifier is damaged.



Control board is broken.



The feedback circuit is faulty.

Too much spatter.

Output terminal polarity connection is wrong. Change the

polarity.

Erratic welding output current or potentiometer is

out of control.



The potentiometer is damaged.



Check if the connectors are in poor contact, especially

plugs.

Power switch doesn’t work.



Power switch is broken.



Rectifier bridge is broken, Replace it.



Check if there is any short circuiting of the inner

machine.

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MMA160A Industrial Multi-Metal Welder

Specifications

Input Voltage 220-240V

Power Factor COS 0.93

Output Current Range 20 - 160 Amps

Protection Class IP21

Duty Cycle 60% @ 160A, 100% @ 125A

Generator Recommended 7.2kW

Power Plug 15A

Power Cord Length 1.8m

Earth Clamp Cable Length 2m

Electrode Cable Length 3m

Welding Electrodes 1.6 - 4.0mm

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Some experts believe that the incorrect or prolonged use of almost any

product may cause serious injury or death. To help reduce your risk of

serious injury or death, refer to the information below. For more information,

see www.datastreamserver.com/safety



Consult all documentation, packaging,

and product labelling before use. Note

that some products feature

documentation available online. It is

recommended to print and retain the

documentation.



Before each use, check the product for

loose/broken/damaged/missing parts,

wear, or leaks (if applicable). Never use a

product with

loose/broken/damaged/missing parts,

wear, or leaks.



Products must be inspected and serviced

(if applicable) by a qualified technician

every 6 months. This is based on

average residential use by persons of

average size and strength, and on a

property of average metropolitan size.

Use beyond these recommendations may

require more frequent

inspections/servicing.



Ensure that all users of the product have

completed a suitable industry recognised

training course before being allowed

access to the product.



The product has been supplied by a general merchandise

retailer that may not be familiar with your specific

application or description of application. Be sure to attain

third-party approval from a qualified specialist for your

application before use, regardless of any assurances from

the retailer or its representatives.



This product is not intended for use where fail-safe

operation is required. As with any product (for example,

automobile, computer, toaster), there is the possibility of

technical issues that may require the repair or

replacement of parts, or the product itself. If the possibility

of such failure and the associated time it may take to

rectify could in any way inconvenience the user, business,

or employee, or financially affect the user, business, or

employee, then the product is not suitable for your

requirements. This product is not intended for use where

incorrect operation or a failure of any kind, including but

not limited to, a condition requiring product return,

replacement, parts replacement, or service by a

technician may cause financial loss, loss of employee

time or an inconvenience requiring compensation.



If this product has been purchased in error when

considering the information presented here, contact the

retailer directly for details of their returns policy, if

required.

diagrams, or images may be reproduced or transmitted in any form or by any means, electronic or

mechanical, including photocopying, scanning, or recording, or any information storage and retrieval system,

without express permission or consent from the publisher.

Arc WDRMPRROA16A Rossi 160 Amp Inverter Stick Welder

Product's Documents

Product manual

Specifications

ROSSI WDRMPRROA16A Questions and Answers