USER'S MANUAL

MMA SERIES WELDING MACHINE

SMART WELDER MMA 140-160-170-

180-200

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 REVISION 2016-03-30

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 Preface
This manual includes hardware description and operation introduction of the MMA series equipment. For
your and other people’s safety, please read the manual carefully.

Pay attention

Pay attention to the words after the signs below.

Sign Description
The words after this sign means there is great potential danger,
which may cause major accident, damage or even death, if it is not
followed.
The words after this sign means there is some potential danger,
which may cause hurt or property lose, if it is not followed.
The words after this sign means there is potential risk, which may
cause equipment fault or break, if it is not followed.

Version

Version YF-TAE-0013, A3, Released on 30th, 03, 2016.

The contents of this manual are updated irregularity for updating of product. The manual is only used as
operation guide, except for other promises. No warranties of any kind, either express or implied are
made in relation to the description, information or suggestion or any other contents of the manual.

The images shown here are indicative only. If there is inconsistency between the image and the actual
product, the actual product shall govern.

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 Content

1 Safety warning..................................................................................................................................4

2 Product.............................................................................................................................................8

2.1 General...................................................................................................................................8

2.2 Technical data.........................................................................................................................9

3 Installation.......................................................................................................................................11

4 Operation........................................................................................................................................13

4.1 Structure................................................................................................................................13

4.2 Operation instruction.............................................................................................................15

4.3 Welding environment and safety...........................................................................................15

4.4 Welding problems and resolution..........................................................................................16

5 Daily maintenance and checking...................................................................................................17

6 Trouble shooting and fault finding..................................................................................................19

Appendix Ⅰ Circuit diagram.................................................................................................................20

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 1. DECLARATION OF CONFORMITY

TER SRL - Via Leopardi, 13 - 36030 Caldogno (VI) Italy

declares that the machines descripted in this manual must be use solely for
professional purposes in an industrial environment and they are manufactured in
compliance with the instructions contained in the harmonized standard:
2014/35/EU (LDV) – 2014/30/EU (EMC) – 2002/95 (RoHs)
and with the instructions contained in the harmonized standard, if applicable:
EN 60974-1 EN 60974-2 EN 60974-3 EN 60974-5 EN 60974-7 EN 60974-10 EN 60974-12

Date 30/03/2016

Maurizio Terzo

General director

IN CASE OF ANY TECHNICAL PROBLEM ASK FOR QUALIFIED

SERVICE ASSISTANCE

The equipment don’t compiles with EN/ IEC 61000-3-12.

The installer or the user must be sure that it can be connected to the public low voltage power line, if necessary, in consultation with the network
distributor.

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 1 Safety warning
The safety notes listed in this manual is to ensure correct use of the machine and to keep you and
other people from being hurt.

The design and manufacture of welding machine considers safety. Please refer to the safety
warning listed in the manual to avoid accidents.

Different damage would be caused by wrong operation of the equipment as follows. Please read the user
manual carefully to reduce such damage.

Sign Description

 Any contact of electric parts may cause fatal electric shock or burnt.

 Gas and fumes are harmful to health.

 Operation in narrow space may cause choke .

 Spark and hot workpiece after welding may cause fire.

 Bad connected cable may cause fire.
 Uncompleted connection of workpiece side circuit may cause fire.
 Never weld on the case of tinder stuff, or it may cause explode.
 Never weld airtight containers such as slot, pipe etc., or it may break.

 Arc ray may cause eye inflammation or skin burnt.

 Spark and residue will burn your eyes and skin.

 Toppling over of the gas cylinder will cause body hurt.

 Wrong use of the gas cylinder will lead to high-pressure gas eruption
and cause human hurt.

 Never let fingers, hair, clothes or etc. near the moving parts such as
the fan.

 The wire shoot out of the torch may stab eyes, face and other naked
parts.

 Never stand in front of the swing equipment or under it, or it may fail
and cause injury.

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 Please follow the rules below to avoid heavy accidents.

 Never use the equipment to do other things but welding.

 Follow related regulations for the construction of the input-driven power source, choice of
place, usage of high-pressure gas, storage, configuration, safe-keeping of workpiece after
welding and disposal of waste, etc.
 Nonessential do not enter the welding area.
 People using heart pacemaker is not allowed to get close to the welding machine or area
without doctor’s permission. The magnetism created by energizing the welding machine can
have a bad effect to the pacemaker.
 Install, operation, check and maintain the equipment by profession personnel.
 Understanding the contents of the user manual for safety.

Please follow the rules below to avoid electric shock。

 Keep away from any electric parts.

 Earth the machine and workpiece by professional personnel.
 Cut off the power before installation or checking, and restart 5 minutes later. The capacitance
is chargeable device. Please ensure it has no voltage before start again even if the power
source is cut off.
 Do not use wire with inadequate section surface or damage insulation sleeve or even exposed
conductor.
 Do ensure well isolation of wire connection.
 Never use the device when the enclosure is removed.
 Never use broken or wet insulation gloves.
 Use firenet when work at high position.
 Check and maintain regularly, don’t use it until the broken parts are fixed well.
 Turn off the power when not in used.
 Follow the national or local related standard and regulations when using the AC welding
machine at narrow or high position.

Please follow the below notes to avoid fire and explode, etc.

 No combustible in welding area.

 Keep off combustible when welding.
 Keep hot workpiece after welding away from flammable gas.
 Do move away the combustible around when weld the dooryard, ground and wall,.
 The wire connection of base metal should be as close to the welding place as possible.
 Never weld those facilities with gas pipe or airtight slot.
 Put fire extinguisher around the welding area to prevent fire.

The gas and fumes are harmful to health, please wear protective device
according to regulations.

 Wear exhaust equipment and breathe preventive facilities to prevent gas poisoning or choke.
 Use suggested part exhaust equipment and breathe preventive facilities to prevent hurt or
poisoning by gas and other powder, please.
 To prevent oxygen-deficiency, air out the gas-filled room which is full of CO 2 and argon on the
bottom, When operating on trunks, boilers, cabins, etc.
 Please accept the supervisor’s inspection when operating in narrow space. Air the room and
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 wear breathe preventive facilities.
 Never operate in degrease, washing or spray space.
 Using breathe preventive facilities when weld shielded steel for it will cause poisonous dust
and gas.

The arc, spark, residue and noise are harmful to health, please wear
protective appliance.

 Eye protection against arc is recommended when welding or supervise welding.

 Please wear preventive spectacles.
 Welder’s gloves, welder’s goggles, long sleeve clothes, leather apron, and other standard
protection equipments must be worn for welding operation.
 A screen to protect other people against the arc must be set in the welding place.

Please follow the notes below to avoid gas cylinder toppling over or
broken.

 Use the gas cylinder correctly.

 Use the equipped or recommended gaseous regulator.
 Read the manual of gaseous regulator carefully before using it, and pay attention to the safety
notes.
 Fix the gas cylinder with appropriate holder and other relative parts.
 Never put the cylinder under high temperature or sunshine environment.
 Keep your face away from the gas cylinder exit when opening it.
 Put on the gas shield when it is not used.
 Never put the torch on the gas cylinder. The electrode can not meet the gas cylinder.

Any touch of the switch part will cause injury, please note the following.

 Never use the machine when the enclosure is off.

 Install, operate, check and maintain the machine by professional person.
 Keep your fingers, hair, clothes etc. away from the switch parts such as the fan.

The wire end may deal damage, please note the following.

 Never look into the electric conduction hole when checking the wire feeding is normal or not, ,
or the shooting wire may stab your eyes and face.
 Keep your eyes, face or other naked parts away from the end of torch when feeding the wire
manually or pressing the switch.

For better work efficiency and power source maintenance, please note
the following.

 Precautions against toppling over.

 Never use the welding equipment for pipe thawing.
 Lift the power source from side when use the up-down forklift truck to avoid toppling over.

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  When using the crane for lift, tie the rope to the ears with an angle no more than φ15 to the
vertical direction.
 When lifting the welding machine which equipped with gas cylinder and wire feeder, download
them from the power source and ensure the horizontal of the machine. Do fix the gas cylinder
with belt or chain when moving it to avoid body hurt.
 Ensure fastness and insulation when lifting the wire feeder through the swing ring for welding.

Electromagnetic interference needing attention.

 It may need extra preventive measures when the equipment is used in particular location.
 Before the installation, please estimate the potential electromagnetism problems of the
environment as follows.

a) Upper and lower parts of the welding equipments and other nearby power cable, control
cable, signal cable and phone cable.

b) Wireless electric as well as TV radiation and reception equipment.

c) Computer and other control equipments.

d) Safety-recognition equipment etc. Such as supervise of industrial equipments.

e) Health of people around. Such as personnel using the heart pacemaker or audiphone.

f) Equipments for adjustment and measurement.

g) Anti-disturb capability of other used equipments .Users should ensure these equipments
and the environment are compatible, which may need extra preventive measures.

h) Practical state of the welding and other activities.

 Users should observe the following dos and don’ts to decrease radiation interference.

a) Connect the welding equipments to the power supply lines.

b) Maintain the welding equipments regularly.

c) The cable should be short enough to be close to each other and the ground.

d) Ensure the safety of all the welding metal parts and other parts nearby.

e) The workpiece should be well earth.

f) Shield or protect the other cable and equipments to decrease the effects of disturbances.
The welding equipments can be complete shielded in some special conditions.

 Users are responsible for interference due to welding.

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 2 Product
2.1 General

MMA series welding machine applies the most advanced inversion technology in the world.

The appearance of the invert arc welding machine comes after the invert power theory and
components. The principle of the technology is to transform the power frequency of 50Hz/60Hz into
direct current and invert it into high frequency (33KHz) through high-power device IGBT, then
perform voltage-drop and commutation with the output high-power D.C power supply via full digital
Pulse Width Modulation (PWM) control technology. Since the switch power inversion technology is
adopted, the weight and volume decrease greatly while the conversion efficiency increase for more
than 30%.

Our welding power source can offer stronger, more concentrated and more stable arc. When the
welding rod and work piece get short circuit, its response will be quicker. It means that it is easy to
design welding machine with different dynamic characteristics, and it can even adjust the
characteristics to make arc softer or harder.

Under MMA mode, the machine has slope characteristic. The welding current, push current and
heat arc initiation current is set by the same knob synchronously, which makes good performance
of arc initiation, stable power output, welding shape and internal quality.

MMA series welding machine is widely used to weld different materials, such as carbon steel,
stainless steel, alloy steel, copper, non-ferrous metal, etc. It can apply to different electrode,
including acid electrode, basic electrode and cellulose electrode. Compared with the other
products, it has advantages of light, handy, easy to installation and operation, efficient and energy
saving. The conversion rate is above 85%. It applies for higher levels welding, field work and
indoors operation.

Thanks for purchasing our products and looking forward to your precious advice, we will try our
best to perfect our products and service.

The machine is mainly used in industrial fields. It will cause radion interference if used
indoors. Please take through precaution measures.

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 2.2 Technical data

Type
MMA140 MMA 160
Item

1 phase 1 phase
Power voltage (V)
230V15% 230V15%

Frequency (Hz) 50/60 50/60

Rated input current (A) 23.5 28

Output current adjustment (A) 15-140 15-160

Output voltage (V) 20.6-25.6 20.6-26.4

No-load voltage(V) 92 92

Duty cycle (%)/ 40℃ 20 20

Power factor 0.73 0.73

Efficiency (%) 85 85

Insulation grade F F

Housing protection grade IP21 IP21

Weight (kg) 3.5 3.5

Overall dimension (mm) 288*123*220 288*123*220

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 Type
MMA 170 MMA 180 MMA 200
Item

1 phase 1 phase 1 phase

Power voltage (V)
230V15% 230V15% 230V15%

Frequency (Hz) 50/60 50/60 50/60

Rated input current (A) 31 31 34

Output current adjustment (A) 20-170 20-180 20-200

Output voltage (V) 20.8-26.8 20.8-27.2 20.8-28

No-load voltage(V) 62 63 63

Power factor
20 20 20

Duty cycle (%)/ 40℃ 0.73 0.73 0.73

Efficiency (%) 85 85 85

Insulation grade F F F

Housing protection grade IP21 IP21 IP21

Weight (kg) 5.0 5.0 5.0

Overall dimension (mm) 320*123*220 320*123*220 320*123*220

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 3 Installation
The welding equipment is equipped with power voltage compensation device. It keeps the machine
work normally when power voltage fluctuating ±15% of rated voltage.

When using long cable, in order to reduce voltage drop, big section cable is suggested. If the cable
is too long, it will affect the performance of arcing and other system function, it is suggested to use
the recommend length.

 Make sure the intake of the machine is not covered or blocked to avoid the malfunction of the
cooling system.
 Use ground cable whose section no less than 6mm2 to connect the housing and earth. The
method is to connect the grounded interface in the back to the earth device, or make sure the
earth end of power interface has been reliably and independently grounded. Both ways can be
used together for better security.

Installation Procedures

a) Make sure cable with electrode holder and quick plug connected well. Connect the quick plug
to the socket “-” of the machine, and fasten it clockwise tightly.
b) Connect the quick plug at one end of the cable into the socket “+” of the machine, and fasten it
clockwise, the other end clamps the workpiece.
c) Please pay attention to the connecting terminal, DC welding machine has two connecting
ways: positive connection and negative connection. Positive connection: holder connects with
“-” terminal, while work piece with the “+” terminal. Negative connection: work piece with the“-”
terminal, holder with the “+” terminal. Choose suitable way according to the working situation.
If unsuitable choice is made, it will cause unstable arc, more spatters and conglutination. If
such problems occur, please change the polarity of the fastened plug. It should adopt negative
connection when welding with alkaline electrode, while positive connection when welding with
acid electrode.

This procedure shall be operated by electrician!

Connect proper power cable to the distribution box with corresponding capacity according to the
input voltage and current (See technical parameter table). Do not connect to the inappropriate
voltage and make sure that the difference of power supply is within permitted range.

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 The MMA series products has two different structures, metal case and matal and plastic
case. Following with these two kinds of Installation diagrams.

 Metal case

Power Supply
( 1 phase~AC230V)

Earth clamp

Workpiece
Electrode holder

 Metal and plastic case

Power Supply
( 1 phase~AC230V)

Earth clamp

Workpiece
Electrode holder

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 4 Operation
4.1 Panel layout

 Front Panel Layout

a) Metal case

b) Metal and plastic case

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  Back Panel

a) Metal case

MMA 140/160

MMA 170/180/200

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 b) Metal and plastic case

The images shown here are indicative only. The actual product may differ.

4.2 Operation instruction

 Turn on the power switch, the power indicator would light on, and the fan starts running.
 Set the welding current according to the welding requirement.
 Generally, welding current is adequate to welding electrode according with as following.

Specification φ2.5 φ3.2 φ4.0 φ5.0

Current 70-100A 110-140A 170-220A 230-280A

4.3 Welding environment and safety

 Working surrounding
a) Welding should be carried out in dry surroundings. The air humidity level should not be higher
than 90%.
b) The temperature should be between -10C to 40C.
c) Don’t use the welding machines in sunshine or rain. Keep it off water.
d) Don't use the machines in the places of dust or corrosive air.
e) MIG welding should not be carried out in places with quick air flow.
 Safety norms
Protection circuit of over-voltage, over-current and over-heat circuits are designed in the
welding machines. It will stop working automatically when the input voltage, output current or
internal temperature exceed the rated value. But if the machines are excessively used, such
as with input voltage higher than the rated, the machine might be damage. Please pay close
attention to the following matters.
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 a) Keep good ventilation!！
The welding machines work with high welding current. Nature air flow can’t reach the
requirement of heat dissipation. So the fans are installed as cooling system to ensure stable
performance.
Make sure the ventilation windows are not covered or blocked. The distance between the
machines and things around should not be less than 0.3m. Good ventilation is good for
welding performance and operational life.
b) Never over load!
Check the maximum rated current (according to the Duty Cycle chosen). Make sure the
welding current is never higher than the rated value. Over current running will obviously
shorten the operation life, even damage the machine .
c) Never over voltage!
The Input Voltage could be found in Technical data diagram. The auto-compensation
function will keep the welding current in the rated range. If the input voltage exceed the
permissible value, the machine would be damaged. Users should take protective measures in
advance to avoid it.
d) Make sure earth connected before operation.
On the rear panel of welding machine, a screw for earth connecting would be found. It must be
ground connected with cable whose section is bigger than 6mm 2 before operation, to avoid
accidents caused by static or electricity leak.

4.4 Welding problems and resolution

The phenomenon listed below may happen due to relevant accessories used, welding
material, surroundings and power supply. Pleas improve surroundings and avoid these
problems..
 Arc starting difficulty. Arc interruption happens easily.
a) Examine whether grounding wire clamp contacts with the work pieces well.
b) Examine whether each joint has improper contact.
 The output current fails to reach rated value.
The deviation of power voltage from rated value may cause that the output current does no
accord with adjusted value. When the power voltage is lower than rated value, the maximum
output current may be lower than rated value.
 The current can not keep stable during operation.
This situation may relate to the following factors:
a) The voltage of electric power network changes;
b) Serious interference from electric power network or other electric facilities.
 Gas vent in welds.
a) Examine whether the gas supply circuit has leakage.
b) Examine whether there is sundries such as oil, dirt, rust, paint etc. on the surface.

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 5 Daily maintenance and checking
 Daily maintenance
a) Remove dust regularly with dry compressed air. If the welding machine is used in surroundings
with heavy smoke and polluted air, it is necessary to remove dust at least one time one month.
b) The pressure of compressed air shall fall to required level to prevent damage to small
components in the machine.
c) Examine inside electric joints and ensure perfect contact (Especially plugs and sockets).
Fasten the loosing joints. In case of oxidation, remove oxide film with sand paper and connect
again.
d) Prevent water from entering into the machine and prevent the machine from getting moist. If
any, blow and dry. Measure the insulation with megohmmeter to make sure it is qualified to
use.
e) If the welding machine is not used for a long time, pack the machine in original package and
store in dry surroundings.
f) Every time the wire feeder operates for 300hours, grind the electrical carbon brush and clear
up the armature commutator. Rinse speed reducer, apply 2# Molybdenum Disulfide lubricant
to the turbine, whirlpool rod and bearing.

All the maintenance and testing must be carried out when the power supply is totally cut
off. Please make sure the power is off before opening the closure.

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  Daily checking

WELDING POWER
Position Checking keys Remarks
 Operation,conversion and
installation of the switch
Operation Lead to unstable arc and wire
control board sending
 Check the state of the power
indicator light

 Check if the fan state and the Clean the residue and check the
Cool-down fan
sound is normal of not reason and solve it
 Check if there is abnormal
liberation and sound when the
power is on
 Check if there is smell when the
Power part power is on

 Whether the outside color change

or get warm
 Whether the wire feeder pipe is
broken,and the connector is loosen
Outer parts
 Whether the outer shell or other
connect parts are loosen

CABLE
Position Checking keys Remarks
 Wearing-out of the cable insulated
material

Output cable  Cable connecting head naked For life security and stable
(insulation damage), or loosen (the welding, adopt suitable method to
end of power supply, and cable of check according to working place
main material connecting point)
 Simple check daily
 If the connection between the plug
and the power socket is firm
 If the power input end cable fixed  Careful and in-depth check on
Input cable fixed period
 If the input cable is worn out and
bares the conductor

In case of leakage and to ensure

 If the earth cable that connects
safety, please do perform daily
Earth cable the main part is broken and
checking
connects tightly

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 6 Trouble shooting and fault finding
Notes: The following operations must be performed by qualified electricians with valid
certifications. Before maintenance, you are suggested to contact local distributor to verify
qualification.

Malfunctions Solution

The meter shows nothing;  Confirm the power switch is on.

 Power supply available for input cable.
 Check if the silicon bridge is damaged.
Fan does not rotate;
 There is malfunction occurs in the supplementary power
No welding output source on control board (contact dealers).

 Check if all the sockets in the machine are connected well.

The meter shows;  There is open circuit or badness of connect at the joint of
output terminal.
Fan works normally;  The control cable on the torch is broken off or the switch is
damaged.
No welding output
 The control circuit is damaged.(contact to dealers)

the meter shows;  It might be over-current protection, please turn off the power
switch; restart the machine after the abnormal indicator light
winked.
Fan works normally;
 It might be overheating protection, please wait for about 2-3
minutes until the machine renew without turn off the power
Abnormal indicator lights. switch.

 It might be multifunction of inverter circuit. (contact dealers)

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 Appendix Ⅰ Circuit diagram
 MMA 140/160 circuit diagram
CON12

5
4
3
2
1
C7
R2
D5 R46 D1
1

2
2
C0N1 Q14 3
1 Q13 1 L4 CON4
1
C17 D2
C46 R45 R19 1
C1 R18 1
R51 2 C8

3
R21 C49

2
1 L1 2 BD1 R43 R44 2 T1 3 3
C3 C4
PTC1 C43 C44 C45 R32 C37
C5 C6 C42
t

4 3 D3 D4 C39
R50 R49
D6
CON2 C2 C50 CON5
3 4 C47 1 4
1 R20 R54 R55
K1

3
1
T2
1 2 L6
CON3 D24
1

2
D7 +12V
J4
R56 U7
1 Q1 1 Q2 4 1 R16
D8 +24V
C28 3
1

2 C27
ZD10
+24V ZD1 R15 C48
3

3
R4 C16
2 Q3

C9 U6 +12V
RV-1 1 4 R33
3

3
t
2 3 R24 Q10
2
R1 R3
CON10
R25
D11 D12 CON11

1
R9 J3

3
R47
D10 ZD4
3

ZD12
R57 R26 2 Q9
+12V R7 2 R28
Q4 R10
+12V R52 R27
+24V CON9 C12 R48 R31

1
C11 ZD2 ZD5
1

1
7 R8
2 C29
C10 3 C13 R34 R36 R29
6
ZD3 D17 D16
R13 ZD11
5
+12V
1
4
1

D13 ZD6
3

U2
4 T3
R11 3 C30
D9 Q5
1

U1 2 3
4
1

5
AC-L
R14
C32 C34
4 C38
1

AC-N ZD7 4
4
C31
2

13
+12V C14 R12 13
3 C53
+12V 5 R38 1 3
2

5
2 Q8 Q7
GND 10
+24V 10 XH-07
1 1 R5
2

1
1

+24V
2

R6 1
3

+12V
RW1 2
2

R40
1

D22 +12V 1 3
C24 R42 R37 3
4
5
R39
6
C33
R41
D23

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  MMA 170/180/200 circuit diagram

1
2
3
D32

C13

2
DB1 1 1
RR1 2

C
PCON1 PCON4 1 3 3

2
A K D2
Q1
2 2

C
t C7 C9 C1 C11 R20 R3 R21 1 R5 R7 1 R9
1 1 Q3
* K1 1
4
R1
3 4 2

3
4 L1 3 2 3
AC230V C3 C6 D3
1 2 1 2 3
CON1 C8 C10 C2 C12 R4 R23
R2
PCON5 1 R35 1

2
Q2 200:1
PCON2 2 2
2 R6 R8 Q4
3 1 1 3
2 1 R10 D4
4
1
* D1 C14 L3 PCON3
C4 C5 3
C15

3
R11 1
4
2
T1
D5 C20
D6
o
Hle

PCON5
电路1 R17 Hole
RZ0030-01A_Power.sch
R14 R16
H8
C21
* VCC +15V
VGND GND
GND GND 1
* VGND INPUT/VOL
2
+3V3
ACINPUT- PCON6
ACINPUT+ 1
电路2
2
+15V RZ0030-01A_MCU.sch 3
R12 D33
1
2
1

2
E
E
G

G
e
e
e

e
iv
iv
iv

iv

GND
D
D
r
r
D

D
r

GND
INPUT/VOL 1
2
CON2
+3V3 3
D8
TEMP/CHECK 2
POWER/EN 1
LP/CURRENT
GND 1
H1 H5
2
Hole Hole MOT/COOL
3
D9

H2 H6
1
2

Hole Hole 1
CON3 2
3
D7
H3 H7 电路3
风机
Hole Hole RZ0030-01A_Sampling.sch

LP/CURRENT
H4 C22 R18
Hole
LP1 2
CON4
LP2 1

GND

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