Arc TOLWDRROBM16 ROSSI 160 Amp Portable Inverter MMA Stick User Manual

User Manual

[Revision 4.0 December 2023]

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.

MMA160 Mk III Inverter Welder

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

• 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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MMA160 Mk III Inverter Welder

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!

• WARNING: 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.

Inverter Welder Safety

ON THE PROCESS OF WELDING OR CUTTING, THERE WILL BE POSSIBILITY OF INJURY, SO PLEASE TAKE PROTECTION INTO

CONSIDERATION DURING OPERATION. FOR MORE DETAILS, PLEASE REVIEW THE OPERATOR SAFETY GUIDE, WHICH COMPLIES

WITH THE PREVENTIVE REQUIREMENTS OF THE MANUFACTURER.

Electric shock - May lead to death!!

• Set the earth fitting according to applying standard.

• Do not touch the bare electric parts and electrode with uncovered skin, wet gloves or clothes.

• Make sure you are insulated from the ground and the workshop.

• Make sure you are in safe position.

Gases and fumes - May be harmful to health!!

• Keep your head out of the gases and fumes.

• When arc welding, ventilators or air extractors should be used to avoid breathing gases.

Arc rays - Harmful to your eyes, burn your skin

• Wear suitable protective mask, light filter and protective garment to protect eyes and body.

• Prepare suitable protective mask or curtain to protect looker-on.

Fire

• Welding sparks may cause a fire, make sure there are no flammable objects or chemicals nearby.

Noise - Excessive noises will be harmful to hearing

• Use haring protection or others means to protect ear.

• Warn looker-on that noise is harmful to hearing.

Having trouble? Connect with authorised professionals

• If trouble happens during installation and operation, please follow this manual instruction to check up.

• If you fail to fully understand the manual, or fail to solve the problem with the instruction, you should contact the suppliers or the service centre for

professional help.

WARNING! THERMAL MAGNETIC AUTO CIRCUIT BREAKER PROTECTING SWITCH SHOULD BE USED WITH THE MACHINE.

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MMA160 Mk III Inverter Welder

Equipment

• Repair and maintenance to be performed by authorized personnel only.

• The welding machine is to be maintained in good operational conditions (dry and clean).

• The welding machine is not to be positioned in a closed space or next to a wall while welding in order to avoid problems with venting.

• The welding machine is to be properly connected to the power grid.

• avoid pulling on the power cable when moving the welding machine.

• the welding handle and work cable are to be properly maintained.

• Electricity is dangerous and loose connections can lead to injury and poor welding.

Work Area

• The welding arc emits sparks, fumes, and radiation.

• Remove all flammable materials and items from your work area.

• Ensure proper ventilation at the work area.

• Do not weld tanks or pipes that contain or used to contain flammable liquid or gas (danger of explosion or fire) or were cleaned by chlorine-based

detergents (danger of toxic fumes).

Operator

• Avoid coming in direct contact with the welding circuit. The open circuit voltage between the electrode holder, the work cable and the work piece

are dangerous.

• Do not weld when it is raining or in wet or damp places.

• Always use protective equipment DIN 9-10, including long sleeved pants and vest, gloves, welding helmet of proper rating and hat. Avoid

exposing the skin to the welding UV radiation.

Always Remember

• The radiation emitted by the welding arc can cause damage to the eyes and burns to the skin.

• The welding arc emits sparks and droplets of molten metal at very high temperatures, these stay hot for a relatively long time.

• The welding fumes produced when welding is dangerous.

• Every electrical shock is dangerous.

• Avoid direct exposure of the skin from the welding arc at a range of 15 meters.

• Take proper precautions to protect yourself and others from the potential dangers of the welding arc.

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MMA160 Mk III Inverter Welder

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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MMA160 Mk III Inverter Welder

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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MMA160 Mk III Inverter Welder

Table of Contents

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

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

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

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

Main Connections ....................................................................................................................................................... 9

Operation ..................................................................................................................................................... 10

Control Panel ............................................................................................................................................................ 10

Special Features ....................................................................................................................................................... 10

Welding Accessories: Connection and Application .................................................................................................. 10

Work Lead with Work Clamp.............................................................................................................................. 10

Welding Lead with Electrode Holder .................................................................................................................. 10

Welding Helmet .................................................................................................................................................. 11

Graphic Symbols and Indications ............................................................................................................................. 11

Operating the Welder................................................................................................................................................ 12

Operating Principle Block Diagram of Circuit .......................................................................................... 13

PWB Layout ................................................................................................................................................. 14

Specifications ............................................................................................................................................. 16

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MMA160 Mk III Inverter Welder

Parts Identification

No. Name

1

Digital Display

2

Welding Current Adjustment

3 Power On Light

4 Alarm Light – overheat

5 Alarm Light - electronics malfunction

6 Positive Port

7

Negative port

8

Input Power Cable

9

Input Power Cable connection to the machine

10 On/Off Switch

NOTE: Single phase inverter with voltage reduction for direct current welding using coated electrodes of diameters 1/16" - 1/8". Current is

continuously adjustable using the current adjustment knob (9).

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MMA160 Mk III Inverter Welder

Installation

Main Connections

Before connecting to the power grid, verify the supply voltage is in range of the machine parameters.

•

The power cable plug is to be connected to standard approved socket, with the proper protections.

•

The ground line (green & yellow) is to be connected to the grounding pin.

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MMA160 Mk III Inverter Welder

Operation

Control Panel

1. Power indicator: Displays if power supply is ON

or OFF.

2. Overheating alert: This can also indicate power

issues.

3. Internal voltage error: Unplug unit and power

up again. If problem persists, contact service

centre.

4. Current (Amperage) display: Displays the

current.

5. Amperage (current) adjustment

Special Features

•

HOT START - Easy ignition of the welding arc.

•

ARC FORCE - Eliminates Electrode Sticking to the Work Piece.

•

VRD - Reduce voltage at no-load condition for safer work.

•

SMART FAN - Power saving and reduction of dust as well as improved fan working life.

•

DUAL VOLTAGE - automatically identify the power grid voltage (110V or 220V) and operates accordingly

110V-220V adapter included.

•

EXCELLENT FOR WORKING WITH GENERATORS - The machine can work with a wide range of input

voltages (98V-265V).

Welding Accessories: Connection and Application

Work Lead with Work Clamp

The work clamp is to be connected directly to the work piece or the worktable with good electrical continuity to

the work piece.

CAREFUL! Avoid using coated or non-metallic, non-conducting workbenches.

Welding Lead with Electrode Holder

This cable has a special handle that holds the exposed part of the coated electrode.

20

160

MMA160 MK III

Current

1

2

3

4

5

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MMA160 Mk III Inverter Welder

Welding Helmet

You must always use a welding helmet to protect your eyes from the radiation emitted from the welding arc.

Using a welding helmet allows the welder to see the progression of the weld seam and keeping the correct

distance from the electrode tip to the work piece.

Graphic Symbols and Indications

•

U1: Rated AV input voltage (with tolerance ±10%).

•

I1max: Rated maximum input current.

•

I1eff: Maximum effective input current.

•

X: duty cycle. The ratio of given duration time/the full-cycle time.

Note 1: This ratio shall be within 0~1 and can be indicated by percentage.

Note 2: In this standard, the full-cycle time is 10min. For example, if the duty cycle is 60%, the load-applying

time shall be 6min and the following no-load time shall be 4min.

•

U0: No-load voltage. Open circuit voltage of secondary winding.

•

U2: Load voltage.

•

Output voltage of rated load: U2=(20+0.04I2) V.

•

A / V—A / V: range of current regulation and corresponding load voltage.

•

IP: degree of protection, such as IP21S.

Can be used in the environment which has high risk of electric shock.

Read this operation manual carefully before use.

Single-phase static frequency converter-transformer rectifier.

Symbol of single-phase AC power supply and rated frequency.

Symbol of manual metal arc welding with covered electrodes.

Insulation class.

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MMA160 Mk III Inverter Welder

Do not dispose of electric tools together with domestic garbage.

Do not use outdoors.

Operating the Welder

6. Once all the power connections to the power grid and the welding circuit are done, proceed as follows:

7. Connect the welding lead with the electrode holder according to the recommendation on the Electrode

package you are using (for most electrodes the "+" terminal).

8. In case of doubt or when un-clear get in touch with the manufacturer or an authorised service centre.

9. Turn the machine on using the ON/OFF switch (10), the ON indication light (3) will be lit at this stage and the

digital display will show the current the machine is set.

10. Adjust the welding current as needed according to the recommendation on the electrode package, using the

amperage adjustment dial (2).

Generally, welding current is adequate to welding electrode according with as following:

General recommendation based on thickness of the work piece:

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MMA160 Mk III Inverter Welder

Operating Principle Block Diagram of Circuit

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MMA160 Mk III Inverter Welder

PWB Layout

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MMA160 Mk III Inverter Welder

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MMA160 Mk III Inverter Welder

Specifications

Voltage 220-240V (15A Plug)

Output Current Range 20 - 160 Amps

Protection Class IP21

Duty Cycle 60% @ 160A, 100% @ 120A

No-Load Power 40W

Power Factor COS 0.85

Welding Electrodes 1.6 - 4.0mm

Generator Recommended 7.2kW

Power Plug Australian Standard

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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 TOLWDRROBM16 ROSSI 160 Amp Portable Inverter MMA Stick DC Welder

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