HITBOX ARC 200A Stick Welder (Model ARC120) Instruction Manual

1. Important Safety Instructions

Read and understand all safety warnings and instructions before operating this welding machine. Failure to follow these instructions may result in electric shock, fire, serious injury, or death.

• Electric Shock: Welding current can kill. Do not touch live electrical parts. Wear dry, insulating gloves and protective clothing.
• Fumes and Gases: Welding produces fumes and gases. Keep your head out of the fumes. Use ventilation or exhaust to remove fumes and gases from the breathing zone.
• Arc Rays: Arc rays can injure eyes and burn skin. Wear a welding helmet with a proper shade filter. Wear protective clothing to protect skin.
• Fire and Explosion: Welding can cause fire or explosion. Keep flammable materials away from the welding area. Have a fire extinguisher nearby.
• Hot Parts: Welded parts are hot. Allow them to cool before touching.
• Electromagnetic Fields (EMF): Welding current creates electromagnetic fields. Consult your physician if you have a pacemaker or other medical implant.

2. Product Overview

The HITBOX ARC 200A Stick Welder (Model ARC120) is a portable DC inverter welding machine designed for Stick (MMA) welding. It features a compact design, digital display, and adjustable current output for various welding tasks.

2.1 Components and Controls

Figure 2.1: Front view of the HITBOX ARC 200A Stick Welder. Shows the digital display, adjustment knob, and positive/negative terminals.

Figure 2.2: Internal components of the HITBOX ARC 200A Stick Welder, highlighting the fan, high power capacitors, LED display, adjustment knob, IGBT, strong radiator, copper transformer, negative terminal, and positive terminal.

• Digital Display: Shows the current welding amperage.
• Adjustment Knob: Used to set the welding current (amperage).
• Positive Terminal (+): Connects to the electrode holder cable.
• Negative Terminal (-): Connects to the work clamp cable.
• Power Switch: Located on the rear panel, turns the machine on/off.
• Cooling Fan: Located on the rear panel, ensures proper cooling during operation.

3. Specifications

Figure 3.1: Dimensions of the HITBOX ARC 200A Stick Welder. Approximately 9 inches (23cm) wide, 6 inches (15.5cm) high, and 4 inches (10cm) deep.

Figure 3.2: Illustration of the 60% duty cycle, indicating the machine's operational capacity over a 10-minute period.

4. Setup

4.1 Unpacking and Inspection

Carefully remove the welding machine and all accessories from the packaging. Inspect for any damage that may have occurred during shipping. Report any damage to your supplier immediately.

• Welding Machine (ARC120)
• Electrode Holder with Cable
• Work Clamp with Cable
• Power Cord (NEMA L6-30P)

Figure 4.1: The HITBOX ARC 200A Stick Welder shown with its included electrode holder, work clamp, and power cord.

4.2 Electrical Connection

This machine operates on 220V AC power. Ensure your power supply meets the requirements. The power cord is equipped with a NEMA L6-30P plug. If your outlet is different, consult a qualified electrician for proper installation or use an appropriate adapter.

• Connect the power cord to a suitable 220V AC outlet.
• Ensure the power switch on the rear of the machine is in the "OFF" position before plugging in.

4.3 Cable Connections

Connect the electrode holder and work clamp cables to the appropriate terminals on the front panel of the welding machine.

1. Insert the connector of the electrode holder cable into the Positive (+) terminal and twist to secure.
2. Insert the connector of the work clamp cable into the Negative (-) terminal and twist to secure.
3. Attach the work clamp securely to the workpiece or welding table, ensuring good electrical contact.

5. Operating Instructions

5.1 Preparing for Welding

• Safety Gear: Always wear appropriate personal protective equipment (PPE), including a welding helmet with a suitable shade, welding gloves, flame-resistant clothing, and safety shoes.
• Work Area: Ensure your welding area is clean, well-ventilated, and free from flammable materials.
• Electrode Selection: Choose the correct type and size of electrode for your material and desired weld.

5.2 Welding Process

1. Turn on the welding machine using the power switch on the rear panel.
2. Adjust the welding current using the adjustment knob on the front panel. The digital display will show the selected amperage. Refer to electrode manufacturer recommendations for appropriate current settings.
3. Insert the electrode into the electrode holder.
4. Position the work clamp securely on the workpiece.
5. Strike an arc by lightly touching the electrode to the workpiece and quickly lifting it slightly to establish the arc.
6. Maintain a consistent arc length and travel speed to achieve a quality weld.
7. After welding, turn off the machine and allow the workpiece to cool.

Figure 5.1: Examples of various weld beads, illustrating different appearances of completed welds.

6. Maintenance

Regular maintenance ensures the longevity and safe operation of your welding machine. Always disconnect the power supply before performing any maintenance.

• Cleaning: Periodically clean the machine's exterior with a dry cloth. Use compressed air to blow out dust and debris from the ventilation openings.
• Cable Inspection: Regularly inspect welding cables, electrode holder, and work clamp for damage, cuts, or loose connections. Replace damaged components immediately.
• Storage: Store the welder in a clean, dry environment when not in use.

7. Troubleshooting

8. Warranty and Support

For warranty information or technical support, please contact HITBOX customer service. Keep your purchase receipt as proof of purchase.

Visit the official HITBOX store for more products and support: HITBOX Store