HITBOX 160A Stick Welder User Manual

1. Introduction and Overview

This manual provides comprehensive instructions for the safe and effective operation, maintenance, and troubleshooting of your HITBOX 160A Stick Welder. This versatile 2-in-1 machine supports both Lift TIG and MMA (ARC) welding, making it suitable for a wide range of applications from beginner projects to professional tasks. Its compact and portable design ensures convenience for various welding needs.

Figure 1: HITBOX 160A Stick Welder, a compact and portable welding machine.

2. Safety Information

Welding can be hazardous if proper safety precautions are not observed. Always prioritize your safety and the safety of others in the work area. This machine incorporates multiple safety features including over-heating, over-current, over-loading protection, and Voltage Reduction Device (VRD) for enhanced user safety.

• Eye and Face Protection: Always wear a welding helmet with appropriate shade lenses to protect your eyes and face from arc flash and sparks.
• Body Protection: Wear flame-resistant clothing, welding gloves, and sturdy footwear to protect against burns and electrical shock.
• Ventilation: Ensure adequate ventilation to remove welding fumes, which can be harmful if inhaled. Work in a well-ventilated area or use fume extraction equipment.
• Electrical Safety: Ensure the welding machine is properly grounded. Do not operate in wet conditions. Inspect cables and connections for damage before each use.
• Fire Prevention: Keep a fire extinguisher nearby. Remove all flammable materials from the welding area. Be aware of hot metal and sparks.
• Work Area: Keep the work area clean and free of clutter. Ensure stable footing.

Figure 2: Internal view highlighting safety features such as Overcurrent, Overvoltage, Overheating, and Overload Protection.

3. Product Features

• Beginner-Friendly Operation: Simple setup and adjustable current via a single knob make this welder ideal for new users.
• Ultra-Compact & Portable: Measuring 4.5x5.9x9.2 inches and weighing only 5.9 lbs, it is designed for easy transport and use in various locations, including outdoor maintenance, farming, and home repairs.
• Powerful Welding Capabilities: Features superior Anti-Stick, Arc Force, and Hot Start functions for reliable ignition of welding rods up to 3.2 mm. Compatible with E6010, E6011, and E6013 rods.
• Versatile Material Compatibility: Capable of welding various metals including cast iron, mild steel, sheet metal, carbon steel, square pipe, and stainless steel, up to 6mm thick.
• Intuitive LCD Interface: Equipped with a smart LCD display, alarm LED, and clear welding current readout for simplified operation.
• Integrated Safety Features: Includes over-heating, over-current, over-loading protection, and VRD (Voltage Reduction Device) for enhanced user safety.

Figure 3: The large digital display provides clear and easy-to-read information for precise control.

4. Package Contents

Upon unpacking, please verify that all items listed below are present and undamaged:

• 1x HITBOX 160A Stick Welder (ARC200D MINI3-CA)
• 1x Instruction Manual
• 1x Ground Clamp (4.9 ft cable)
• 1x Electrode Holder (4.9 ft cable)
• 5x Welding Rods (2.0 mm)
• 1x Cleaning Brush

Figure 4: Visual representation of the included accessories: Instruction Manual, Ground Clamp, Electrode Holder, Welding Rods, and Cleaning Brush.

5. Setup

Follow these steps to set up your welding machine for operation:

1. Power Connection: Ensure the welder is connected to a stable 110V power supply. Verify that the power outlet can handle the required amperage.
2. Electrode Holder Connection: Connect the electrode holder cable to the negative ("-") terminal on the front panel of the welder. Securely twist the connector into place.
3. Ground Clamp Connection: Connect the ground clamp cable to the positive ("+") terminal on the front panel of the welder. Securely twist the connector into place.
4. Insert Electrode: Insert the welding electrode (rod) into the electrode holder. Ensure it is firmly gripped.
5. (Optional) TIG Torch Connection: If performing Lift TIG welding, connect the WP17V TIG Torch (sold separately) to the positive ("+") terminal and the gas line (if applicable) to the appropriate gas inlet.

6. Operating Instructions

6.1 Control Panel Overview

The welder features a user-friendly control panel with a digital LCD screen and a multi-function knob for mode selection and parameter adjustment.

• Digital LCD Screen: Displays current welding parameters (amperage), selected mode (MMA/Lift TIG), and status indicators (Arc Force, Hot Start, Anti-Stick, VRD, ERR).
• Rotate and Confirm Knob: Used to navigate through settings and adjust amperage. Press to confirm selections.

6.2 MMA (ARC) Welding

This mode is used for stick welding with coated electrodes.

1. Select MMA Mode: Use the control knob to select "MMA" on the digital display.
2. Set Amperage: Adjust the amperage according to the electrode type and thickness of the material being welded. Recommended rods are E6010/E6011/E6013, below 3.2 mm.
3. Prepare Workpiece: Ensure the workpiece is clean and the ground clamp is securely attached to it, providing good electrical contact.
4. Start Welding: Strike the arc by lightly touching the electrode to the workpiece and quickly lifting it slightly to establish the arc. Maintain a consistent arc length and travel speed.
5. Features: The built-in Hot Start, Arc Force, and Anti-Stick features will assist in smooth arc ignition, stable arc, and preventing electrode sticking.

Figure 5: Demonstrates the welding process using the MMA (ARC) mode, highlighting the quality of the weld bead.

6.3 Lift TIG Welding

This mode allows for precise TIG welding, requiring a separate TIG torch and gas supply (not included).

1. Connect TIG Torch: Ensure the WP17V TIG Torch is correctly connected to the positive ("+") terminal and the gas line is connected to your argon gas cylinder.
2. Select Lift TIG Mode: Use the control knob to select "Lift TIG" on the digital display.
3. Set Amperage: Adjust the amperage suitable for your material and desired weld.
4. Prepare Workpiece: Ensure the workpiece is clean and the ground clamp is securely attached.
5. Start Welding: Gently touch the tungsten electrode to the workpiece to initiate the arc, then lift it slightly to establish the arc. Maintain a consistent arc length and feed filler rod as needed.

Figure 6: Comparison of setup for Stick welding (left) and Lift TIG welding (right), showing the optional TIG torch connection.

7. Maintenance

Regular maintenance ensures the longevity and optimal performance of your welding machine.

• Cleaning: Periodically clean the exterior of the machine with a dry cloth. Use compressed air to clear dust from the ventilation openings.
• Cable Inspection: Regularly inspect the electrode holder cable, ground clamp cable, and power cord for any signs of damage, cuts, or frayed insulation. Replace damaged cables immediately.
• Connection Check: Ensure all connections (electrode holder, ground clamp, power plug) are tight and free from corrosion.
• Storage: Store the welder in a dry, clean environment, away from excessive dust, moisture, and extreme temperatures.

8. Troubleshooting

This section provides solutions to common issues you might encounter.

9. Specifications

10. Warranty and Support

HITBOX provides 2 years of quality support for this welding machine. For any technical assistance, warranty claims, or inquiries, please contact HITBOX customer service through your purchase platform or the official HITBOX website.

Please retain your proof of purchase for warranty validation.