flopower FLOW160DA000 Operator's Manual And Parts List

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160 DualArc AC Stick Welder

(Model #FLOW160DA000)

Operator’s Manual and Parts List

Florida Power & Welding International, LLC

+1. 305. 698. 2220
www.flopower.com

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User Manual 160 DualArc ENG

FLOW160DA025

CONTENTS

INTRODUCTION ………………………………………………………………………………………………………………………… 3

DESCRIPTION AND SPECIFICATIONS ………………………………………………………………………………………………………………………… 3

FLOPOWER LIMITED WARRANTY ………………………………………………………………………………………………………………………… 4

SAFETY PRECAUTIONS ………………………………………………………………………………………………………………………… 5-6

COMPONENTS/ACCESSORIES ………………………………………………………………………………………………………………………… 7

ASSEMBLY AND INSTALLATION ………………………………………………………………………………………………………………………… 8

OPERATION ………………………………………………………………………………………………………………………… 9

ARC WELDING BASICS ………………………………………………………………………………………………………………………… 10-12

BASIC CARE ………………………………………………………………………………………………………………………… 13

TECHNICAL SPECIFICATIONS ………………………………………………………………………………………………………………………… 14

WIRING SCHEMATIC ………………………………………………………………………………………………………………………… 14

PARTS LIST ………………………………………………………………………………………………………………………… 15

TROBLESHOOTING ………………………………………………………………………………………………………………………… 16-17

REFERENCE PUBLICATIONS ………………………………………………………………………………………………………………………… 18

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User Manual 160 DualArc ENG

FLOW160DA025

INTRODUCTION

Congratulations on the purchase of your welder! The welding machine you now own is the result of careful research aimed at providing good quality and easy to use equipment.

The 160 DualArc welder is a compact, lightweight unit that delvers 160 Amps of AC (alternated current) welding current. It is ideal for basic repairs and general purpose welding.

It is designed for use with 220V and 110V circuits, making it a versatile and low-cost choice.

Before attempting to use the welder, please make sure to read this manual carefully! Should you have any technical problems or questions regarding this unit, contact us by email at [e-mail] or by
telephone at [phone] -- from outside the USA [phone].

DESCRIPTION AND SPECIFICATIONS

Process

Welding Current Range

Input Rated Duty Cycle

Overload Protection

Included Accessories

Weight

Arc welder for use with
coated electrodes (Shielded
Metal Arc Welding - SMAW)

55-160Amp AC

110VAC or 220VAC, 1 Phase,
50Hz or 60Hz

160Amp at 10%
113Amp at 20%
86Amp at 35%

Automatic shutdown

Face shield
Chipping hammer

47.7 lbs (21.5 kgs)

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User Manual 160 DualArc ENG

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FLOPOWER LIMITED WARRANTY

FLOPOWER warrants to its original retail purchaser that this unit is is free of defects in material and workmanship at the time it is shipped by FLOPOWER.

Within one year after the date of purchase, FLOPOWER will repair or replace any warranted parts or components that fail due to defects in material or workmanship, determined at FLOPOWER’s discretion through an
inspection conducted by the technical staff of FLOPOWER or its authorized resellers or repair service providers.

The reseller where the unit was purchased must be notified within 30 days of such defect or failure, and transport costs will be borne by the reseller.

The limited warranty shall not apply to:

 Units that have been disassembled or otherwise tampered by non-authorized personnel.
 Equipment that has been improperly installed (for example not-grounded), improperly operated (for example through the selection of the incorrect Voltage level) or mishandled (for example dented).
 Equipment which has not had resonable and necessary maintenance and care, or that has been exposed to water, rain, excessive moisture or excessive heat.
 Signs of natural wear and tear.

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User Manual 160 DualArc ENG

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SAFETY PRECAUTIONS

HEALTH HAZARDS:

Welding produces intense electric and magnetic emissions that may interfere with the proper functioning of cardiac pacemakers, hearing aids, or other electronic health equipment. If you use such devices, you should
consult your medical health professional and the manufacturer of the health device before using the welder.

GASES AND FUMES:

Gases and fumes produced during welding can be dangerous and hazardous to your health.

 Do not breathe welding fumes directly or allow others near you to do so. Work in an area that is properly ventilated.
 Use an air-supplied respirator if ventilation is not adequate to remove all fumes and gases.
 The kinds of fumes and gases from the welding operation depend on the kind of metal being used, coatings on the metal, and the different processes. You must be very careful when welding any metals which may

contain one or more of the following: Antimony, Chromium , Mercury, Beryllium, Arsenic, Cobalt, Nickel , Lead, Barium, Copper, Selenium, Silver, Cadmium, Manganese , Vanadium.

 Always read the Material Safety Data Sheets (MSDS) that should be supplied with the material you are welding. These MSDS’s will give you the information regarding the type and amount of fumes and gases that

may be dangerous to your health.

 For information on how to test for fumes and gases in your workplace, refer to the section on “REFERENCE PUBLICATIONS” at the end of this manual.
 Use smoke extraction equipment if necessary.
 Phosgene, a toxic gas, is generated from the vapors of chlorinated solvents and cleansers. Remove all sources of these vapors.
 This product, when used for welding or cutting, produces fumes or gases which contain chemicals known to the State of California to cause birth defects and, in some cases, cancer. (California Health & Safety Code

Sec. 25249.5 et seq.)

ELECTRIC SHOCK:

Electric shock can injure or kill. Electricity used during welding can cause severe or fatal shock to the operator or others in the workplace.

 Never touch any parts that are electrically “live” or “hot.” Wear dry welding gloves and protective clothing. Insulate yourself from the work piece or other parts of the welding circuit.
 Never store or operate the welding machine, its parts, the welding surface or electrode in a humid environment or near water sources. If the welder becomes wet for any reason, make absolutely sure that it is

completely dry before using the welder.

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 Replace or repair all worn or damaged parts.
 Disconnect the power source before performing any service or repairs.
 Read and follow all the instructions in this Operator’s Manual.

FIRE AND EXPLOSION:

Fire and explosion can be caused by hot slag, sparks, or the welding arc.

 Be sure there are no combustible or flammable materials and gases in the work area. Any material that cannot be removed must be protected.
 Ventilate all flammable or explosive vapors out of the weld area.
 Do not weld on containers that may have held combustibles.
 Provide a fire watch when working in an area where fire hazards may exist.

WELDING RAYS:

The welding process produces very bright ultraviolet rays. These arc rays can damage your eyes and burn your skin if you are not properly protected.

 To protect your eyes, always wear a welding helmet or shield. Also always wear safety glasses with side shields, goggles or other protective eye wear. The protective shade must be number 10 or higher for

welding up to 160A.

 Keep helmet and safety glasses in good condition. Replace lenses when cracked, chipped or dirty.
 Wear welding gloves and suitable clothing to protect your skin from the arc rays and sparks.
 Protect others in the work area from the arc rays. Use protective booths, screens or shields.

DUAL VOLTAGE WARNING: This unit is a dual voltage machine, and can be used both with 110VAC and 220VAC input power. It is very important to select the correct welding voltage in the machine according to the
power circuit being used. Failure to do so may result in electric shock, fire, harm to you and damage to the machine.

For a list of publications and documents which can help you adopt correct operating procedures and avoid harmful actions, please consult the section “REFERENCE PUBLICATIONS” at the end of this manual.