Version No: 1 Issue Date: March 31, 2006 Manual No: 0-4854
Operating Features:
50
1
SMAW
GTAW
PHASE
60
INVERTER
Hz
115V230
V
CC
DC
Page 2
WE APPRECIATE YOUR BUSINESS!
Congratulations on your new Thermal Arc® product. We are proud to
have you as our customer and will strive to provide you with the best
service and reliability in the industry. This product is backed by our
extensive warranty and world-wide service network. To locate your
nearest distributor or service agency call 800-752-7621, or visit us
on the web at www.thermalarc.com.
This Operating Manual has been designed to instruct you on the correct
use and operation of your Thermal Arc® product. Your satisfaction with
this product and its safe operation is our ultimate concern. Therefore,
please take the time to read the entire manual, especially the Safety
Precautions. They will help you to avoid potential hazards that may
exist when working with this product.
YOU ARE IN GOOD COMPANY!
The Brand of Choice for Contractors and Fabricators Worldwide.
Thermal Arc® is a Global Brand of Arc Welding Products for Thermadyne
Industries Inc. We manufacture and supply to major welding industry
sectors worldwide including; Manufacturing, Construction, Mining,
Automotive, Aerospace, Engineering, Rural and DIY/Hobbyist.
We distinguish ourselves from our competition through marketleading, dependable products that have stood the test of time. We
pride ourselves on technical innovation, competitive prices, excellent
delivery, superior customer service and technical support, together
with excellence in sales and marketing expertise.
Above all, we are committed to develop technologically advanced
products to achieve a safer working environment within the welding
industry.
Page 3
!
WARNING
Read and understand this entire Manual and your employer’s safety practices before installing, operating, or
servicing the equipment.
While the information contained in this Manual represents the Manufacturer’s best judgment, the Manufacturer
assumes no liability for its use.
Instruction Manual Number 0-4854 for:
ArcMaster 160 S Inverter Welding Power Supply Part No. 10-3066
Published by:
Thermadyne Industries, Inc.
82 Benning Street
West Lebanon, New Hampshire, USA 03784
(603) 298-5711
Reproduction of this work, in whole or in part, without written permission of the publisher is
prohibited.
The publisher does not assume and hereby disclaims any liability to any party for any loss or
damage caused by any error or omission in this Manual, whether such error results from negligence, accident, or any other cause.
Publication Date: March 31, 2006
Record the following information for Warranty purposes:
Where Purchased: _______________________________
Purchase Date: _______________________________
Equipment Serial #: _______________________________
Page 4
ARCMASTER® 160 S
SECTION 1:
SAFETY INSTRUCTIONS AND WARNINGS .................................................. 1-1
PROTECT YOURSELF AND OTHERS FROM POSSIBLE SERIOUS INJURY OR DEATH. KEEP CHILDREN AWAY. PACEMAKER WEARERS KEEP AWAY UNTIL
CONSULTING YOUR DOCTOR. DO NOT LOSE THESE INSTRUCTIONS. READ OPERATING/INSTRUCTION MANUAL BEFORE INSTALLING, OPERATING
OR SERVICING THIS EQUIPMENT.
Welding products and welding processes can cause serious injury or death, or damage to other equipment or property, if the operator does not strictly
observe all safety rules and take precautionary actions.
Safe practices have developed from past experience in the use of welding and cutting. These practices must be learned through study and training before
using this equipment. Some of these practices apply to equipment connected to power lines; other practices apply to engine driven equipment. Anyone
not having extensive training in welding and cutting practices should not attempt to weld.
Safe practices are outlined in the American National Standard Z49.1 entitled: SAFETY IN WELDING AND CUTTING. This publication and other guides to what
you should learn before operating this equipment are listed at the end of these safety precautions. HAVE ALL INSTALLATION, OPERATION, MAINTENANCE,
AND REPAIR WORK PERFORMED ONLY BY QUALIFIED PEOPLE.
WARNING
1.01 Arc Welding Hazards
WARNING
ELECTRIC SHOCK can kill.
Touching live electrical parts can cause fatal shocks or
severe burns. The electrode and work circuit is electrically
live whenever the output is on. The input power circuit and
machine internal circuits are also live when power is on. In
semiautomatic or automatic wire welding, the wire, wire reel,
drive roll housing, and all metal parts touching the welding
wire are electrically live. Incorrectly installed or improperly
grounded equipment is a hazard.
1. Do not touch live electrical parts.
2. Wear dry, hole-free insulating gloves and body protection.
3. Insulate yourself from work and ground using dry insulating mats or
covers.
4. Disconnect input power or stop engine before installing or servicing
this equipment. Lock input power disconnect switch open, or remove
line fuses so power cannot be turned on accidentally.
5. Properly install and ground this equipment according to its Owner’s
Manual and national, state, and local codes.
6. Turn off all equipment when not in use. Disconnect power to equipment
if it will be left unattended or out of service.
7. Use fully insulated electrode holders. Never dip holder in water to cool it
or lay it down on the ground or the work surface. Do not touch holders
connected to two welding machines at the same time or touch other
people with the holder or electrode.
8. Do not use worn, damaged, undersized, or poorly spliced cables.
9. Do not wrap cables around your body.
March 31, 20061-1
10. Ground the workpiece to a good electrical (earth) ground.
11. Do not touch electrode while in contact with the work (ground)
circuit.
12. Use only well-maintained equipment. Repair or replace damaged parts
at once.
13. In confi ned spaces or damp locations, do not use a welder with AC
output unless it is equipped with a voltage reducer. Use equipment
with DC output.
14. Wear a safety harness to prevent falling if working above fl oor level.
15. Keep all panels and covers securely in place.
WARNING
ARC RAYS can burn eyes and skin; NOISE can damage
hearing. Arc rays from the welding process produce intense
heat and strong ultraviolet rays that can burn eyes and skin.
Noise from some processes can damage hearing.
1. Wear a welding helmet fi tted with a proper shade of fi lter (see ANSI
Z49.1 listed in Safety Standards) to protect your face and eyes when
welding or watching.
2. Wear approved safety glasses. Side shields recommended.
3. Use protective screens or barriers to protect others from fl ash and
glare; warn others not to watch the arc.
4. Wear protective clothing made from durable, fl ame-resistant material
(wool and leather) and foot protection.
5. Use approved ear plugs or ear muffs if noise level is high.
Page 8
ARCMASTER® 160 S
WARNING
FUMES AND GASES can be hazardous to your health.
Welding produces fumes and gases. Breathing these fumes
and gases can be hazardous to your health.
1. Keep your head out of the fumes. Do not breath the fumes.
2. If inside, ventilate the area and/or use exhaust at the arc to remove
welding fumes and gases.
3. If ventilation is poor, use an approved air-supplied respirator.
4. Read the Material Safety Data Sheets (MSDSs) and the manufacturer’s
instruction for metals, consumables, coatings, and cleaners.
5. Work in a confi ned space only if it is well ventilated, or while wearing an
air-supplied respirator. Shielding gases used for welding can displace
air causing injury or death. Be sure the breathing air is safe.
6. Do not weld in locations near degreasing, cleaning, or spraying
operations. The heat and rays of the arc can react with vapors to form
highly toxic and irritating gases.
7. Do not weld on coated metals, such as galvanized, lead, or cadmium
plated steel, unless the coating is removed from the weld area, the
area is well ventilated, and if necessary, while wearing an air-supplied
respirator. The coatings and any metals containing these elements can
give off toxic fumes if welded.
1. Protect yourself and others from fl ying sparks and hot metal.
2. Do not weld where fl ying sparks can strike fl ammable material.
3. Remove all fl ammables within 35 ft (10.7 m) of the welding arc. If this
is not possible, tightly cover them with approved covers.
4. Be alert that welding sparks and hot materials from welding can easily
go through small cracks and openings to adjacent areas.
5. Watch for fi re, and keep a fi re extinguisher nearby.
6. Be aware that welding on a ceiling, fl oor, bulkhead, or partition can
cause fi re on the hidden side.
7. Do not weld on closed containers such as tanks or drums.
8. Connect work cable to the work as close to the welding area as practical
to prevent welding current from traveling long, possibly unknown paths
and causing electric shock and fi re hazards.
9. Do not use welder to thaw frozen pipes.
10. Remove stick electrode from holder or cut off welding wire at contact
tip when not in use.
WARNING
FLYING SPARKS AND HOT METAL can cause injury.
Chipping and grinding cause fl ying metal. As welds cool,
they can throw off slag.
1. Wear approved face shield or safety goggles. Side shields
recommended.
WARNING
WELDING can cause fi re or explosion.
Sparks and spatter fl y off from the welding arc. The fl ying
sparks and hot metal, weld spatter, hot workpiece, and hot
equipment can cause fi res and burns. Accidental contact of
electrode or welding wire to metal objects can cause sparks,
overheating, or fi re.
Eye protection filter shade selector for welding or cutting
(goggles or helmet), from AWS A6.2-73.
Wel ding or cutting Electr ode S izeFi l terWelding or cutting El ectrode S izeFil ter
Torch soldering2
Torch braz ing3 or 4Non-ferrous base metalAll11
Oxygen Cutting
LightUnder 1 in., 25 mm3 or 4Gas tungsten arc weldingAll12
Medium1 to 6 in., 25-150 mm4 or 5 (TIG)All12
HeavyOver 6 in., 150 mm5 or 6Atomic hydrogen weldingAll12
Gas welding
LightUnder 1/8 in., 3 mm4 or 5Plasma arc welding
Medium 1/8 to 1/2 in., 3-12 mm5 or 6
HeavyOver 1/2 in., 12 mm6 or 8Light12
Shielded metal-arc
Under 5/32 in., 4 mm10Heavy14
5/32 to 1/4 in., 12
Over 1/4 in., 6.4 mm14Light Under 300 Amp9
2. Wear proper body protection to protect skin.
Gas metal-arc
Ferrous base metalAll12
Carbon arc weldingAll12
Carbon arc air gouging
Plasma arc cutting
Medium 300 to 400 Amp12
Heavy Over 400 Amp14
March 31, 20061-2
Page 9
WARNING
CYLINDERS can explode if damaged.
Shielding gas cylinders contain gas under high pressure. If
damaged, a cylinder can explode. Since gas cylinders are
normally part of the welding process, be sure to treat them
carefully
.
1. Protect compressed gas cylinders from excessive heat, mechanical
shocks, and arcs.
2. Install and secure cylinders in an upright position by chaining them to
a stationary support or equipment cylinder rack to prevent falling or
tipping.
3. Keep cylinders away from any welding or other electrical circuits.
4. Never allow a welding electrode to touch any cylinder.
5. Use only correct shielding gas cylinders, regulators, hoses, and fi ttings
designed for the specifi c application; maintain them and associated
parts in good condition.
6. Turn face away from valve outlet when opening cylinder valve.
7. Keep protective cap in place over valve except when cylinder is in use
or connected for use.
8. Read and follow instructions on compressed gas cylinders, associated
equipment, and CGA publication P-1 listed in Safety Standards.
ARCMASTER® 160 S
3. Allow engine to cool before fueling. If possible, check and add fuel to
cold engine before beginning job.
4. Do not overfi ll tank — allow room for fuel to expand.
5. Do not spill fuel. If fuel is spilled, clean up before starting engine.
WARNING
MOVING PARTS can cause injury.
Moving parts, such as fans, rotors, and belts can cut fi ngers and hands
and catch loose clothing.
1. Keep all doors, panels, covers, and guards closed and securely
in place.
2. Stop engine before installing or connecting unit.
3. Have only qualified people remove guards or covers for
maintenance and troubleshooting as necessary.
4. To prevent accidental starting during servicing, disconnect
negative (-) battery cable from battery.
5. Keep hands, hair, loose clothing, and tools away from moving
parts.
6. Reinstall panels or guards and close doors when servicing is
fi nished and before starting engine.
!
WARNING
Engines can be dangerous.
ENGINE EXHAUST GASES can kill.
Engines produce harmful exhaust gases.
1. Use equipment outside in open, well-ventilated areas.
2. If used in a closed area, vent engine exhaust outside and away from
any building air intakes.
ENGINE FUEL can cause fi re or explosion.
Engine fuel is highly fl ammable.
WARNING
WARNING
WARNING
SPARKS can cause BATTERY GASES TO EXPLODE; BATTERY
ACID can burn eyes and skin.
Batteries contain acid and generate explosive gases.
1. Always wear a face shield when working on a battery.
2. Stop engine before disconnecting or connecting battery cables.
3. Do not allow tools to cause sparks when working on a battery.
4. Do not use welder to charge batteries or jump start vehicles.
5. Observe correct polarity (+ and –) on batteries.
WARNING
STEAM AND PRESSURIZED HOT COOLANT can burn face,
eyes, and skin.
The coolant in the radiator can be very hot and under
pressure.
1. Stop engine before checking or adding fuel.
2. Do not add fuel while smoking or if unit is near any sparks or open
fl ames.
March 31, 20061-3
1. Do not remove radiator cap when engine is hot. Allow engine to cool.
2. Wear gloves and put a rag over cap area when removing cap.
3. Allow pressure to escape before completely removing cap.
Page 10
ARCMASTER® 160 S
1.02 Principal Safety Standards
! WARNING
This product, when used for welding or cutting, produces
fumes or gases which contain chemicals know to the State of
California to cause birth defects and, in some cases, cancer.
(California Health & Safety code Sec. 25249.5 et seq.)
NOTE
Considerations About Welding And The Effects of Low
Frequency Electric and Magnetic Fields
The following is a quotation from the General Conclusions Section of the
U.S. Congress, Offi ce of Technology Assessment, Biological Effects of Power
Frequency Electric & Magnetic Fields - Background Paper, OTA-BP-E-63
(Washington, DC: U.S. Government Printing Offi ce, May 1989): “...there
is now a very large volume of scientifi c fi ndings based on experiments at
the cellular level and from studies with animals and people which clearly
establish that low frequency magnetic fi elds and interact with, and produce
changes in, biological systems. While most of this work is of very high
quality, the results are complex. Current scientifi c understanding does
not yet allow us to interpret the evidence in a single coherent framework.
Even more frustrating, it does not yet allow us to draw defi nite conclusions
about questions of possible risk or to offer clear science-based advice on
strategies to minimize or avoid potential risks.”
To reduce magnetic fields in the workplace, use the following
procedures.
1. Keep cables close together by twisting or taping them.
2. Arrange cables to one side and away from the operator.
3. Do not coil or drape cable around the body.
4. Keep welding power source and cables as far away from body
as practical.
Safety in Welding and Cutting, ANSI Standard Z49.1, from American Welding
Society, 550 N.W. LeJeune Rd., Miami, FL 33126.
Safety and Health Standards, OSHA 29 CFR 1910, from Superintendent of
Documents, U.S. Government Printing Offi ce, Washington, D.C. 20402.
Recommended Safe Practices for the Preparation for Welding and Cutting
of Containers That Have Held Hazardous Substances, American Welding
Society Standard AWS F4.1, from American Welding Society, 550 N.W.
LeJeune Rd., Miami, FL 33126.
National Electrical Code, NFPA Standard 70, from National Fire Protection
Association, Batterymarch Park, Quincy, MA 02269.
Safe Handling of Compressed Gases in Cylinders, CGA Pamphlet P-1, from
Compressed Gas Association, 1235 Jefferson Davis Highway, Suite 501,
Arlington, VA 22202.
Code for Safety in Welding and Cutting, CSA Standard W117.2, from
Canadian Standards Association, Standards Sales, 178 Rexdale Boulevard,
Rexdale, Ontario, Canada M9W 1R3.
Safe Practices for Occupation and Educational Eye and Face Protection,
ANSI Standard Z87.1, from American National Standards Institute, 1430
Broadway, New York, NY 10018.
Cutting and Welding Processes, NFPA Standard 51B, from National Fire
Protection Association, Batterymarch Park, Quincy, MA 02269.
ABOUT PACEMAKERS:
The above procedures are among those also normally
recommended for pacemaker wearers. Consult your doctor
for complete information.
March 31, 20061-4
Page 11
ARCMASTER® 160 S
1.03 Precautions De Securite En Soudage A L’arc
!
LE SOUDAGE A L’ARC EST DANGEREUX
PROTEGEZ-VOUS, AINSI QUE LES AUTRES, CONTRE LES BLESSURES GRAVES POSSIBLES OU LA MORT. NE LAISSEZ PAS LES ENFANTS S’APPROCHER,
NI LES PORTEURS DE STIMULATEUR CARDIAQUE (A MOINS QU’ILS N’AIENT CONSULTE UN MEDECIN). CONSERVEZ CES INSTRUCTIONS. LISEZ LE
MANUEL D’OPERATION OU LES INSTRUCTIONS AVANT D’INSTALLER, UTILISER OU ENTRETENIR CET EQUIPEMENT.
Les produits et procédés de soudage peuvent sauser des blessures graves ou la mort, de même que des dommages au reste du matériel et à la propriété,
si l’utilisateur n’adhère pas strictement à toutes les règles de sécurité et ne prend pas les précautions nécessaires.
En soudage et coupage, des pratiques sécuritaires se sont développées suite à l’expérience passée. Ces pratiques doivent être apprises par étude ou
entraînement avant d’utiliser l’equipement. Toute personne n’ayant pas suivi un entraînement intensif en soudage et coupage ne devrait pas tenter de
souder. Certaines pratiques concernent les équipements raccordés aux lignes d’alimentation alors que d’autres s’adressent aux groupes électrogènes.
La norme Z49.1 de l’American National Standard, intitulée “SAFETY IN WELDING AND CUTTING” présente les pratiques sécuritaires à suivre. Ce document
ainsi que d’autres guides que vous devriez connaître avant d’utiliser cet équipement sont présentés à la fi n de ces instructions de sécurité.
SEULES DES PERSONNES QUALIFIEES DOIVENT FAIRE DES TRAVAUX D’INSTALLATION, DE REPARATION, D’ENTRETIEN ET D’ESSAI.
1.04 Dangers relatifs au soudage à l’arc
AVERTISSEMENT
L’ELECTROCUTION PEUT ETRE MORTELLE.
Une décharge électrique peut tuer ou brûler gravement.
L’électrode et le circuit de soudage sont sous tension dès
la mise en circuit. Le circuit d’alimentation et les circuits
internes de l’équipement sont aussi sous tension dès la mise
en marche. En soudage automatique ou semi-automatique
avec fi l, ce dernier, le rouleau ou la bobine de fi l, le logement
des galets d’entrainement et toutes les pièces métalliques
en contact avec le fi l de soudage sont sous tension. Un
équipement inadéquatement installé ou inadéquatement
mis à la terre est dangereux.
MISE EN GARDE
Ne jamais toucher quelqu’un d’autre avec l’électrode ou le porteélectrode.
8. N’utilisez pas de câbles électriques usés, endommagés, mal épissés
ou de section trop petite.
9. N’enroulez pas de câbles électriques autour de votre corps.
10. N’utilisez qu’une bonne prise de masse pour la mise à la terre de la
pièce à souder.
11. Ne touchez pas à l’électrode lorsqu’en contact avec le circuit de
soudage (terre).
12. N’utilisez que des équipements en bon état. Réparez ou remplacez
aussitôt les pièces endommagées.
13. Dans des espaces confi nés ou mouillés, n’utilisez pas de source de
courant alternatif, à moins qu’il soit muni d’un réducteur de tension.
Utilisez plutôt une source de courant continu.
14. Portez un harnais de sécurité si vous travaillez en hauteur.
15. Fermez solidement tous les panneaux et les capots.
1. Ne touchez pas à des pièces sous tension.
2. Portez des gants et des vêtements isolants, secs et non troués.
3. Isolez-vous de la pièce à souder et de la mise à la terre au moyen de
tapis isolants ou autres.
4. Déconnectez la prise d’alimentation de l’équipement ou arrêtez
le moteur avant de l’installer ou d’en faire l’entretien. Bloquez le
commutateur en circuit ouvert ou enlevez les fusibles de l’alimentation
afi n d’éviter une mise en marche accidentelle.
5. Veuillez à installer cet équipement et à le mettre à la terre selon le
manuel d’utilisation et les codes nationaux, provinciaux et locaux
applicables.
6. Arrêtez tout équipement après usage. Coupez l’alimentation de
l’équipement s’il est hors d’usage ou inutilisé.
7. N’utilisez que des porte-électrodes bien isolés. Ne jamais plonger les
porte-électrodes dans l’eau pour les refroidir. Ne jamais les laisser
traîner par terre ou sur les pièces à souder. Ne touchez pas aux porteélectrodes raccordés à deux sources de courant en même temps.
March 31, 20061-5
LE RAYONNEMENT DE L’ARC PEUT BRÛLER LES YEUX ET LA
PEAU; LE BRUIT PEUT ENDOMMAGER L’OUIE.
L’arc de soudage produit une chaleur et des rayons
ultraviolets intenses, susceptibles de brûler les yeux et la
peau. Le bruit causé par certains procédés peut endommager
l’ouïe.
1. Portez une casque de soudeur avec fi ltre oculaire de nuance appropriée
(consultez la norme ANSI Z49 indiquée ci-après) pour vous protéger
le visage et les yeux lorsque vous soudez ou que vous observez
l’exécution d’une soudure.
2. Portez des lunettes de sécurité approuvées. Des écrans latéraux sont
recommandés.
3. Entourez l’aire de soudage de rideaux ou de cloisons pour protéger
les autres des coups d’arc ou de l’éblouissement; avertissez les
observateurs de ne pas regarder l’arc.
AVERTISSEMENT
Page 12
ARCMASTER® 160 S
4. Portez des vêtements en matériaux ignifuges et durables (laine et cuir)
et des chaussures de sécurité.
5. Portez un casque antibruit ou des bouchons d’oreille approuvés lorsque
le niveau de bruit est élevé.
AVERTISSEMENT
7. Ne soudez des tôles galvanisées ou plaquées au plomb ou au cadmium
que si les zones à souder ont été grattées à fond, que si l’espace est
bien ventilé; si nécessaire portez un respirateur à adduction d’air.
Car ces revêtements et tout métal qui contient ces éléments peuvent
dégager des fumées toxiques au moment du soudage.
AVERTISSEMENT
LES VAPEURS ET LES FUMEES SONT DANGEREUSES POUR
LA SANTE.
Le soudage dégage des vapeurs et des fumées dangereuses
à respirer.
LE SOUDAGE PEUT CAUSER UN INCENDIE OU UNE
EXPLOSION
L’arc produit des étincellies et des projections. Les particules
volantes, le métal chaud, les projections de soudure et
l’équipement surchauffé peuvent causer un incendie et
1. Eloignez la tête des fumées pour éviter de les respirer.
2. A l’intérieur, assurez-vous que l’aire de soudage est bien ventilée ou
des brûlures. Le contact accidentel de l’électrode ou du
fi l-électrode avec un objet métallique peut provoquer des
étincelles, un échauffement ou un incendie.
que les fumées et les vapeurs sont aspirées à l’arc.
3. Si la ventilation est inadequate, portez un respirateur à adduction d’air
approuvé.
4. Lisez les fi ches signalétiques et les consignes du fabricant relatives aux
métaux, aux produits consummables, aux revêtements et aux produits
nettoyants.
5. Ne travaillez dans un espace confi né que s’il est bien ventilé; sinon,
portez un respirateur à adduction d’air. Les gaz protecteurs de soudage
peuvent déplacer l’oxygène de l’air et ainsi causer des malaises ou la
mort. Assurez-vous que l’air est propre à la respiration.
6. Ne soudez pas à proximité d’opérations de dégraissage, de nettoyage
ou de pulvérisation. La chaleur et les rayons de l’arc peuvent réagir
avec des vapeurs et former des gaz hautement toxiques et irritants.
1. Protégez-vous, ainsi que les autres, contre les étincelles et du métal
chaud.
2. Ne soudez pas dans un endroit où des particules volantes ou des
projections peuvent atteindre des matériaux infl ammables.
3. Enlevez toutes matières infl ammables dans un rayon de 10, 7 mètres
autour de l’arc, ou couvrez-les soigneusement avec des bâches
approuvées.
4. Méfi ez-vous des projections brulantes de soudage susceptibles de
pénétrer dans des aires adjacentes par de petites ouvertures ou
fi ssures.
5. Méfi ez-vous des incendies et gardez un extincteur à portée de la
main.
SELECTION DES NUA NCES DE FILTRES OCULAIRS POUR LA PROT ECTI O N
DES YEUX EN COUPAGE ET SOUDAGE (selon A WS á 8.2-73)
Opération de coupage
ou soudage
Brassage tendre
au chalumeau
Brassage fort
au chalumeau
Oxycoupagemétaux ferreuxtoutes condit ions12
moyen de 1 á 6 po. (25 á 150 mm)4 ou 5
Soudage aux gazSoudage á l'ar c P lasma (PAW)toutes dimensions12
moyen de 1/8 á 1/2 po. (3 á 12 mm)5 ou 6 mince12
Soudage á l'ar c avec
électr ode enr obees
(SMAW)
Dimension d'électrode ou
Epiasseur de métal ou
Int ensité de c our ant
tout es condit ions2
tout es condit ions3 ou 4métaux non- ferreuxtoutes condit ions11
mince moins de 1 po. (25 mm)2 ou 3
épaisplus de 6 po. ( 150 mm)5 ou 6
mince moins de 1/8 po. (3 mm)4 ou 5
épais plus de 1/2 po. ( 12 mm)6 ou 8épais14
moins de 5/32 po. ( 4 mm)10Coupage á l'arc P lasma (PAC)
5/32 á 1/ 4 po. (4 á 6.4 mm)12mince moins de 300 amperès9
plus de 1/4 po. (6.4 mm)14moyen de 300 á 400 amperès12
Nuance de
filt r e oc ulair e
Opération de coupage
ou soudage
Soudage á l'ar c sous gaz
av ec fil plein (GMAW)
Soudage á l'ar c sous gaz avec
électr ode de tungstène (GTA W)
Soudage á l'hydrogène
atomique (AHW)
Soudage á l'ar c avec
électr ode de c ar bone ( CAW)
Gougeage Air-Arc avec
électr ode de c ar bone
Dimension d'électrode ou
Epiasseur de métal ou
Int ensité de c our ant
tout es condit ions12
tout es condit ions12
tout es condit ions12
Nuance de
filt r e oc ulair e
épaisplus de 400 am perès14
March 31, 20061-6
Page 13
6. N’oubliez pas qu’une soudure réalisée sur un plafond, un plancher, une
cloison ou une paroi peut enfl ammer l’autre côté.
7. Ne soudez pas un récipient fermé, tel un réservoir ou un baril.
8. Connectez le câble de soudage le plus près possible de la zone de
soudage pour empêcher le courant de suivre un long parcours inconnu,
et prévenir ainsi les risques d’électrocution et d’incendie.
9. Ne dégelez pas les tuyaux avec un source de courant.
10. Otez l’électrode du porte-électrode ou coupez le fi l au tube-contact
lorsqu’inutilisé après le soudage.
11. Portez des vêtements protecteurs non huileux, tels des gants en cuir,
une chemise épaisse, un pantalon revers, des bottines de sécurité et
un casque.
AVERTISSEMENT
LES ETINCELLES ET LES PROJECTIONS BRULANTES
PEUVENT CAUSER DES BLESSURES.
Le piquage et le meulage produisent des particules
métalliques volantes. En refroidissant, la soudure peut
projeter du éclats de laitier.
1. Portez un écran facial ou des lunettes protectrices approuvées. Des
écrans latéraux sont recommandés.
2. Portez des vêtements appropriés pour protéger la peau.
AVERTISSEMENT
LES BOUTEILLES ENDOMMAGEES PEUVENT EXPLOSER
Les bouteilles contiennent des gaz protecteurs sous haute
pression. Des bouteilles endommagées peuvent exploser.
Comme les bouteilles font normalement partie du procédé
de soudage, traitez-les avec soin.
ARCMASTER® 160 S
LES MOTEURS PEUVENT ETRE DANGEREUX
LES GAZ D’ECHAPPEMENT DES MOTEURS PEUVENT ETRE
MORTELS.
Les moteurs produisent des gaz d’échappement nocifs.
1. Utilisez l’équipement à l’extérieur dans des aires ouvertes et bien
ventilées.
2. Si vous utilisez ces équipements dans un endroit confi né, les fumées
d’échappement doivent être envoyées à l’extérieur, loin des prises d’air
du bâtiment.
LE CARBURANT PEUR CAUSER UN INCENDIE OU UNE
EXPLOSION.
Le carburant est hautement infl ammable.
1. Arrêtez le moteur avant de vérifier le niveau e
carburant ou de faire le plein.
2. Ne faites pas le plein en fumant ou proche d’une source d’étincelles
ou d’une fl amme nue.
3. Si c’est possible, laissez le moteur refroidir avant de faire le plein de
carburant ou d’en vérifi er le niveau au début du soudage.
4. Ne faites pas le plein de carburant à ras bord: prévoyez de l’espace
pour son expansion.
5. Faites attention de ne pas renverser de carburant. Nettoyez tout
carburant renversé avant de faire démarrer le moteur.
AVERTISSEMENT
AVERTISSEMENT
1. Protégez les bouteilles de gaz comprimé contre les sources de chaleur
intense, les chocs et les arcs de soudage.
2. Enchainez verticalement les bouteilles à un support ou à un cadre fi xe
pour les empêcher de tomber ou d’être renversées.
3. Eloignez les bouteilles de tout circuit électrique ou de tout soudage.
4. Empêchez tout contact entre une bouteille et une électrode de
soudage.
5. N’utilisez que des bouteilles de gaz protecteur, des détendeurs, des
boyauxs et des raccords conçus pour chaque application spécifi que;
ces équipements et les pièces connexes doivent être maintenus en
bon état.
6. Ne placez pas le visage face à l’ouverture du robinet de la bouteille
lors de son ouverture.
7. Laissez en place le chapeau de bouteille sauf si en utilisation ou lorsque
raccordé pour utilisation.
8. Lisez et respectez les consignes relatives aux bouteilles de gaz
comprimé et aux équipements connexes, ainsi que la publication P-1
de la CGA, identifi ée dans la liste de documents ci-dessous.
March 31, 20061-7
DES PIECES EN MOUVEMENT PEUVENT CAUSER DES
BLESSURES.
Des pièces en mouvement, tels des ventilateurs, des rotors et
des courroies peuvent couper doigts et mains, ou accrocher
des vêtements amples.
1. Assurez-vous que les portes, les panneaux, les capots et les protecteurs
soient bien fermés.
2. Avant d’installer ou de connecter un système, arrêtez le moteur.
3. Seules des personnes qualifi ées doivent démonter des protecteurs ou
des capots pour faire l’entretien ou le dépannage nécessaire.
4. Pour empêcher un démarrage accidentel pendant l’entretien,
débranchez le câble d’accumulateur à la borne négative.
5. N’approchez pas les mains ou les cheveux de pièces en mouvement;
elles peuvent aussi accrocher des vêtements amples et des outils.
AVERTISSEMENT
Page 14
ARCMASTER® 160 S
6. Réinstallez les capots ou les protecteurs et fermez les portes après
des travaux d’entretien et avant de faire démarrer le moteur.
AVERTISSEMENT
DES ETINCELLES PEUVENT FAIRE EXPLOSER UN
ACCUMULATEUR; L’ELECTROLYTE D’UN ACCUMU-LATEUR
PEUT BRULER LA PEAU ET LES YEUX.
Les accumulateurs contiennent de l’électrolyte acide et
dégagent des vapeurs explosives.
1. Portez toujours un écran facial en travaillant sur un accumu-lateur.
2. Arrêtez le moteur avant de connecter ou de déconnecter des câbles
d’accumulateur.
3. N’utilisez que des outils anti-étincelles pour travailler sur un
accumulateur.
4. N’utilisez pas une source de courant de soudage pour charger un
accumulateur ou survolter momentanément un véhicule.
5. Utilisez la polarité correcte (+ et –) de l’accumulateur.
1.05 Principales Normes De Securite
Safety in Welding and Cutting, norme ANSI Z49.1, American Welding Society,
550 N.W. LeJeune Rd., Miami, FL 33128.
Safety and Health Standards, OSHA 29 CFR 1910, Superintendent of
Documents, U.S. Government Printing Offi ce, Washington, D.C. 20402.
Recommended Safe Practices for the Preparation for Welding and Cutting
of Containers That Have Held Hazardous Substances, norme AWS F4.1,
American Welding Society, 550 N.W. LeJeune Rd., Miami, FL 33128.
National Electrical Code, norme 70 NFPA, National Fire Protection
Association, Batterymarch Park, Quincy, MA 02269.
Safe Handling of Compressed Gases in Cylinders, document P-1,
Compressed Gas Association, 1235 Jefferson Davis Highway, Suite 501,
Arlington, VA 22202.
Code for Safety in Welding and Cutting, norme CSA W117.2 Association
canadienne de normalisation, Standards Sales, 276 Rexdale Boulevard,
Rexdale, Ontario, Canada M9W 1R3.
Safe Practices for Occupation and Educational Eye and Face Protection,
norme ANSI Z87.1, American National Standards Institute, 1430 Broadway,
New York, NY 10018.
Cutting and Welding Processes, norme 51B NFPA, National Fire Protection
Association, Batterymarch Park, Quincy, MA 02269.
AVERTISSEMENT
LA VAPEUR ET LE LIQUIDE DE REFROIDISSEMENT BRULANT
SOUS PRESSION PEUVENT BRULER LA PEAU ET LES YEUX.
Le liquide de refroidissement d’un radiateur peut être brûlant
et sous pression.
1. N’ôtez pas le bouchon de radiateur tant que le moteur n’est pas
refroidi.
2. Mettez des gants et posez un torchon sur le bouchon pour l’ôter.
3. Laissez la pression s’échapper avant d’ôter complètement le
bouchon.
March 31, 20061-8
Page 15
SECTION 2:
INTRODUCTION AND DESCRIPTION
ARCMASTER® 160 S
2.01 How To Use This Manual
This Owner’s Manual applies to just specifi cation or part
numbers listed on page i.
To ensure safe operation, read the entire manual, including
the chapter on safety instructions and warnings.
Throughout this manual, the words WARNING, CAUTION, and NOTE may appear. Pay particular attention to the information
provided under these headings. These special annotations are
easily recognized as follows:
!
WARNING
A WARNING gives information regarding possible
personal injury.
CAUTION
A CAUTION refers to possible equipment
damage.
NOTE
A NOTE offers helpful information concerning
certain operating procedures.
Additional copies of this manual may be purchased by
contacting Thermal Arc at the address and phone number in
your area listed in the inside back cover of this manual. Include
the Owner’s Manual number and equipment identifi cation
numbers.
Electronic copies of this manual can also be downloaded at
no charge in Acrobat PDF format by going to the
Thermal Arc web site listed below and clicking on the
Literature Library link:
http://www.thermalarc.com
2.02 Equipment Identifi cation
The unit’s identifi cation number (specifi cation or part number),
model, and serial number usually appear on a nameplate
attached to the control panel. In some cases, the nameplate
may be attached to the rear panel. Equipment which does
not have a control panel such as gun and cable assemblies is
identifi ed only by the specifi cation or part number printed on
the shipping container. Record these numbers on the bottom
of page i for future reference.
2.03 Receipt Of Equipment
When you receive the equipment, check it against the invoice
to make sure it is complete and inspect the equipment for
possible damage due to shipping. If there is any damage,
notify the carrier immediately to fi le a claim. Furnish complete
information concerning damage claims or shipping errors to
the location in your area listed in the inside back cover of
this manual.
Include all equipment identifi cation numbers as described
above along with a full description of the parts in error.
Move the equipment to the installation site before un-crating
the unit. Use care to avoid damaging the equipment when
using bars, hammers, etc., to un-crate the unit.
March 31, 20062-1
Page 16
ARCMASTER® 160 S
2.04 Symbol Chart
Note that only some of these symbols will appear on your model.
On
Off
Dangerous Voltage
Increase/Decrease
Circuit Breaker
AC Auxiliary Power
Fuse
Amperage
Voltage
X
%
Single Phase
Three Phase
Three Phase Static
Frequency ConverterTransformer-Rectifier
Remote
Duty Cycle
Percentage
Panel/Local
Shielded Metal
Arc Welding (SMAW)
Gas Metal Arc
Welding (GMAW)
Wire Feed Function
Wire Feed Towards
Workpiece With
t1
Output Voltage Off.
Welding Gun
Purging Of Gas
Continuous Weld
Mode
Spot Weld Mode
Spot Time
t
Preflow Time
Postflow Time
t2
Hertz (cycles/sec)
Frequency
Negative
Positive
Direct Current (DC)
Protective Earth
(Ground)
Line
Line Connection
Auxiliary Power
Gas Tungsten Arc
Welding (GTAW)
Air Carbon Arc
Cutting (CAC-A)
Constant Current
Constant Voltage
Or Constant Potential
High Temperature
Fault Indication
Arc Force
Touch Start (GTAW)
Variable Inductance
2 Step Trigger
Operation
Press to initiate wirefeed and
welding, release to stop.
4 Step Trigger
Operation
Press and hold for preflow, release
to start arc. Press to stop arc, and
hold for preflow.
Burnback Time
t
Disturbance In
Ground System
IPM
MPM
Inches Per Minute
Meters Per Minute
115V 15A
Receptacle RatingAuxiliary Power
Voltage Input
V
Art # A-04130
March 31, 20062-2
Page 17
ARCMASTER® 160 S
2.05 Description
The Thermal Arc™ ArcMaster 160 S is a self contained single-phase DC arc welding power sources with Constant Current
(CC) output characteristics. This unit is equipped with a Digital Volt/Amperage Meter and lift arc starter, and high-frequency
arc starter for use with Gas Tungsten Arc Welding (GTAW), and Shielded Metal Arc Welding (SMAW) processes. The power
source is totally enclosed in an impact resistant, fl ame resistant and non-conductive plastic case.
(V)
OCV
18V
STICK PROCESS
Art # A-05037
160A5A(A)
210A
OCV
10V
(V)
LIFT-TIG PROCESS
160A25A(A)
Figure 1 - ArcMaster 160 S Volt-Ampere curve
NOTE
Volt-Ampere curves show the maximum Voltage and Amperage output capabilities of the welding power source.
Curves of other settings will fall between the curves shown.
2.06 Functional Block Diagrams
Figure 2 illustrates the functional block diagram of the 160 S-power supply.
Input
Power
Main
Circuit
Switch
Input
Diode
Filter
Capacitor
DC Power
Primary
Voltage
Sensor
To each control circuit
+/-12VDC +18VDC
+24VDC +5VDC
Torch Control
Connection
(CON1)
Figure 2-2: 160 S Functional Block Diagram
IGBT
Inverter
Themal
Detector
Trouble
Sensing
Circuit
Transformers
Thermal
Sensor
Circuit
Main
(T1)
Primary
Circuit
Sensor
Drive
Circuit
Sequence
Current
Adjustment
Circuit
Panel Circuit Boad
Output
Diodes
Stick Mode
VRD
Sensing
Circuit
Control
Reference
Adjustment &
Mode select Switch
Lift Tig Mode
Output Short
Sensing
Circuit
Output
Inductor
Fan Control
Circuit
Hall Current
Transformer
(HCT1)
Fan
March 31, 20062-3
Page 18
ARCMASTER® 160 S
2.07 Transporting Methods
These units are equipped with a handle for carrying
purposes.
!
WARNING
ELECTRIC SHOCK can kill. DO NOT TOUCH
live electrical parts. Disconnect input power
conductors from de-energized supply line before
moving the welding power source.
!
WARNING
FALLING EQUIPMENT can cause serious personal
injury and equipment damage.
Lift unit with handle on top of case.
Use handcart or similar device of adequate capacity.
If using a fork lift vehicle, place and secure unit on a proper
skid before transporting.
March 31, 20062-4
Page 19
SECTION 3:
INSTALLATION RECOMMENDATIONS
ARCMASTER® 160 S
3.01 Environment
The ArcMaster 160 S is designed for use in adverse
environments.
Examples of environments with increased adverse conditions
are -
a. In locations in which freedom of movement is restricted,
so that the operator is forced to perform the work in a
cramped (kneeling, sitting or lying) position with physical
contact with conductive parts,
b. In locations which are fully or partially limited by
conductive elements, and in which there is a high risk
of unavoidable or accidental contact by the operator,
c. In wet or damp hot locations where humidity or
perspiration considerably reduces the skin resistance
of the human body and the insulation properties of
accessories.
Environments with adverse conditions do not include places
where electrically conductive parts are in the near vicinity of
the operator, which can cause increased hazard, have been
insulated.
3.02 Location
Be sure to locate the welder according to the following
guidelines:
• In areas free from moisture and dust.
• Ambient temperature between 0 degrees C to 40
degrees C.
• In areas free from oil, steam and corrosive gases.
• In areas not subjected to abnormal vibration or shock.
• In areas not exposed to direct sunlight or rain.
• Place at a distance of 12” (304.79mm) or more from
walls or similar that could restrict natural irfl ow for
cooling.
!
WARNING
Thermal Arc advises that this equipment be
electrically connected by a qualifi ed electrician.
3.03 Electrical Input Connections
!
WARNING
ELECTRIC SHOCK can kill; SIGNIFICANT DC
VOLTAGE is present after removal of input
power.
DO NOT TOUCH live electrical parts.
SHUT DOWN welding power source, disconnect input power
employing lockout/tagging procedures. Lockout/tagging
procedures consist of padlocking line disconnect switch in
open position, removing fuses from fuse box, or shutting
off and red-tagging circuit breaker or other disconnecting
device.
• Electrical Input Requirements
Operate the welding power source from a single-phase 50/60
Hz, AC power supply. The input voltage must match one of the
electrical input voltages shown on the input data label on the
unit nameplate. Contact the local electric utility for information
about the type of electrical service available, how proper
connections should be made, and inspection required.
The line disconnect switch provides a safe and convenient
means to completely remove all electrical power from the
welding power supply whenever necessary to inspect or
service the unit.
NOTE
This unit is equipped with a 115 VAC (NEMA 5-15)
plug modeled on the two-conductor with earth
power cable that is connected at the welding
power source for single phase electrical input
power. For 230 VAC operation, have a qualifi ed
person install according to applicable codes, and
instructions.
Do not connect an input (WHITE or BLACK) conductor to the
ground terminal.
Do not connect the ground (GREEN) conductor to an input
line terminal.
March 31, 20063-1
Page 20
ARCMASTER® 160 S
Refer to fi gure 3 and:
1. Connect end of ground (GREEN) conductor to a suitable ground. Use a grounding method that complies with all applicable
electrical codes.
2. Connect ends of line 1 (BLACK) and line 2 (WHITE) input conductors to a de-energized line disconnect switch.
3. Use Table 1 and Table 2 as a guide to select line fuses for the disconnect switch.
Input VoltageFuse Size
115 V40 Amps
208-230 V45 Amps
Table 1 - Electrical Input Connections
NOTE
Fuse size is based on not more than 200 percent of the rated input amperage of the welding power source (Based
on Article 630, National Electrical Code).
Figure 3 - Electrical Input Connections
• Input Power
Each unit incorporates an INRUSH circuit and input voltage sensing circuit. When the MAIN CIRCUIT SWITCH is turned on, the
inrush circuit provides a pre-charging of the input capacitors. SCR’s in the Power Control Assembly (PCA) will turn on after the
input capacitors have charged to full operating voltage (after approximately 5 seconds).
NOTE
Note the available input power. Damage to the PCA could occur if 460VAC or higher is applied.
The following 115/208-230V Primary Current recommendations are required to obtain the maximum welding current and duty
cycle from this welding equipment:
Model
ArcMaster 160 S12/3 AWG minimum
Primary Supply Lead Size
(Factory Fitted)
Table 2 – 115/208-230V Primary Current Circuit sizes to achieve maximum current
Thermal Arc continuously strives to produce the best product possible and therefore reserves the right to change,
improve or revise the specifi cations or design of this or any product without prior notice. Such updates or
changes do not entitle the buyer of equipment previously sold or shipped to the corresponding changes, updates,
improvements or replacement of such items.
The values specifi ed in the table above are optimal values, your values may differ. Individual equipment may
differ from the above specifi cations due to in part, but not exclusively, to any one or more of the following;
variations or changes in manufactured components, installation location and conditions and local power grid
supply conditions.
0.5
0.3
Amperage Draw @ Rated Load
40
39
No Load
2.2
1.6
March 31, 20063-3
Page 22
ARCMASTER® 160 S
3.05 Duty Cycle
The duty cycle of a welding power source is the percentage
of a ten (10) minute period that it can be operated at a given
output without causing overheating and damage to the unit.
If the welding amperes decrease, the duty cycle increases. If
the welding amperes are increased beyond the rated output,
the duty cycle will decrease.
!
WARNING
Exceeding the duty cycle ratings will cause the
thermal overload protection circuit to become
energized and shut down the output until the unit
has cooled to normal operating temperature.
CAUTION
Continually exceeding the duty cycle ratings can
cause damage to the welding power source and
will void the manufacturer’s warranty.
NOTE
Due to variations that can occur in manufactured
products, claimed performance, voltages, ratings,
all capacities, measurements, dimensions and
weights quoted are approximate only. Achievable
capacities and ratings in use and operation will
depend upon correct installation, use, applications,
maintenance and service.
March 31, 20063-4
Page 23
4.01 ArcMaster 160 S Controls
ARCMASTER® 160 S
SECTION 4:
OPERATOR CONTROLS
Figure 4 – ArcMaster 160 S Power Source
1. Control Knob
This control sets the selected weld parameter, rotating it
clockwise increases the parameter and is indicated on
Gnd.
21
543
876
Front view of 8-Socket Receptacle
1Earth (Ground)
2
3
4
55k ohm (maximum) connection to 5k ohm remote control potentiometer
6Zero ohm (minimum) connection to 5k ohm remote control potentiometer
7Wiper arm connection to 5k ohm remote control potentiometer
8
Torch Switch Input (24V) to energize weld current.
(connect pins 2 & 3 to turn on welding current)
Torch Switch Input (0V) to energize weld current
(connect pins 2 & 3 to turn on welding current)
Connect pin 4 to pin 8 to instruct machine that a remote current control device is
connected (12V DC supply)
Connect pin 4 to pin 8 to instruct machine that a remote current control device is
connected (0V)
1 2 3 4 5 6 7 8
5k Ohms
the digital meter. Pushing the knob inward displays the
actual welding voltage.
2. Remote Control Socket
The 8 pin Remote Control Socket is used to connect
remote current control devices to the welding Power
Source. To make connections, align keyway, insert plug,
and rotate threaded collar fully clockwise.
noitcnuFniP tekcoS
March 31, 20064-1
Page 24
ARCMASTER® 160 S
3. Positive Terminal
Welding current fl ows from the Power Source via heavy
duty Dinse type terminal. It is essential, however, that
the male plug is inserted and turned securely to achieve
a sound electrical connection.
5. ON/OFF Switch
This switch connects the Primary supply voltage to the
inverter when in the ON position. This enables the Power
Supply.
4. Negative Terminal
Welding current fl ows from the Power Source via heavy
duty Dinse type terminal. It is essential, however, that
the male plug is inserted and turned securely to achieve
a sound electrical connection.
CAUTION
Loose welding terminal connections can cause
overheating and result in the male plug being
fused in the bayonet terminal.
When the welder is connected to the Primary
supply voltage, the internal electrical components
maybe at 240V potential with respect to earth.
6. Input Cable
The input cable connects the Primary supply voltage to
the equipment.
4.02 Weld Parameter Descriptions for ArcMaster 160 S
!
WARNING
Figure 4-3: ArcMaster 160 S Front Panel with Parameter Description
ParameterDescription
This parameter operates in STICK weld mode and is used to improve the start characteristics
HOT START
A
for stick electrodes. e.g. low hydrogen electrodes. It sets the peak start current on top of
the (WELD) current.
Weld Current (Amperage)- sets the STICK and TIG WELD current.
ARC CONTROL - This parameter provides a suitable short circuit current in STICK welding
to improve electrode sticking and arc stability.
LIFT TIG mode of operation. A remote control device is required for use during LIFT TIG
operation. See section 3.01, section 2 “Remote Control Socket”, for complete details of
the remote device.
STICK Mode of operation.
Table 3 – Weld Parameter Descriptions for ArcMaster 160 S
March 31, 20064-2
Page 25
4.03 Weld Parameters for ArcMaster 160 S
Weld
ParameterParameter Range
HOT START0 to 70A20A1AYesNo
Factory
Setting
ARCMASTER® 160 S
Weld Mode
Incremental
UnitSTICKLIFT TIG
WELD CUR
ARC CONTROL0 to 100%10%1%YesNo
4.04 Power Source Features
FeatureDescription
New Digital Control• Almost all welding parameters are adjustable
Touch Panel Switches• Touch switches eliminate mechanical damage
Front Control Cover• Protects front panel controls
Digital Meter
ON/OFF switch• Primary voltage Supply ON/OFF switch located on rear panel
Voltage Reduction Device (VRD)
(shipped de-activated, Field Capable)
see Section 11 for Activation Instructions
5 to 85A 115V
80A1AYesYes
5 to 160A 230V
Table 4 – Weld Parameters for ArcMaster 160 S
• Displays selected weld parameter value
• Displays weld current when welding
• Displays weld current for 20 seconds after weld has been
completed
• A selected weld parameter value can be adjusted at any time
even while welding
Reduces the OCV when the power supply is not in use. Eliminates the
need for add on voltage reducers and has no effect on arc starting.
• VRD fully complies to IEC 60974-1
• When Stick mode is selected the green VRD light is ON when
not welding and red when welding.
• When in TIG modes VRD is off.
• For the selected weld parameter, rotating the knob clockwise
increases the parameter
Control Knob
Self Diagnosis Using Error Codes
March 31, 20064-3
• Rotating the knob counterclockwise decreases the parameter
• A selected weld parameter value can be adjusted at any time
even while welding
• Pushing the knob in displays actual arc voltage.
• An error code is displayed on the Digital Meter when a problem
occurs with Primary supply voltage or internal component
problems. Refer to troubleshooting guide.
Page 26
ARCMASTER® 160 S
March 31, 20064-4
Page 27
ARCMASTER® 160 S
SECTION 5:
SET-UP FOR SMAW (STICK) AND GTAW (TIG)
Conventional operating procedures apply when using the Welding Power Source, i.e. connect work lead directly to work piece
and electrode lead is used to hold electrode. Wide safety margins provided by the coil design ensure that the Welding Power
Source will withstand short-term overload without adverse effects. The welding current range values should be used as a guide
only. Current delivered to the arc is dependent on the welding arc voltage, and as welding arc voltage varies between different
classes of electrodes, welding current at any one setting would vary according to the type of electrode in use. The operator
should use the welding current range values as a guide, then fi nally adjust the current setting to suit the application.
!
WARNING
Before connecting the work clamp to the work
and inserting the electrode in the electrode
holder make sure the Primary power supply is
switched off.
Figure 5-1: 160 S Set-up
March 31, 20065-1
Page 28
ARCMASTER® 160 S
March 31, 20065-2
Page 29
ARCMASTER® 160 S
SECTION 6:
SEQUENCE OF OPERATION
NOTE: Scroll Buttons are used to select the parameters to be set. The LED’s show which
function is being adjusted on the weld sequence graph. Refer to Symbols Table located in
the front of the manual for Symbol descriptions.
1
2
3
Figure 7-1: 160 S Front Panel
1. Scroll Buttons – used to select the parameter to be set.
The LED’s show which function is being adjusted on the
weld sequence graph.
2. Digital LED display – Welding amperage and parameter
values are displayed in this window. Internal warnings
such as over temperature, low or high input voltage
applied are signaled to the operator by a warning sound
and error message on the screen.
5
4
3. Control Knob – allows the operator to adjust the output
amperage within the entire range of the power source,
also used to set each parameter value. Pushing the knob
inward displays the actual welding voltage.
4. Process Button - This button selects between STICK or
LIFT TIG mode.
5. 8 pin remote control receptacle for connecting remote
device. A remote control device is required for use during
LIFT TIG operation. See section 4.01, section 2 “Remote
Control Socket”, for complete details of the remote
device.
6.01 Stick Welding
• Connect work lead to negative terminal
• Connect electrode lead to positive terminal
• Switch machine on
• Connect remote control device if required
Use the Scroll Buttons to move to the parameter to be set.
The LED will show which function is being adjusted on the
weld sequence graph. Use the control knob to adjust each
parameter.
• Set HOT START
• Set WELD current
• Set Arc Control
Commence welding
March 31, 20066-1
6.02 DC Lift TIG Welding
• Connect work lead to positive terminal
• Connect TIG torch to negative terminal
• Switch machine on
• Set WELD current.
• Connect remote control device. A remote control device
is required for use during LIFT TIG operation. See
section 4.01, section 2 “Remote Control Socket”, for
complete details of the remote device.
Use the Scroll Buttons to move to the parameter to be set.
The LED will show which function is being adjusted on the
weld sequence graph. Use the control knob to adjust each
parameter.
• Set WELD time
Commence welding
Page 30
ARCMASTER® 160 S
March 31, 20066-2
Page 31
ARCMASTER® 160 S
SECTION 7:
BASIC TIG WELDING GUIDE
7.01 Electrode Polarity
Connect the TIG torch to the - / TORCH terminal and the work lead to the + / WORK terminal for direct current straight polarity.
Direct current straight polarity is the most widely used polarity for DC TIG welding. It allows limited wear of the electrode since
70% of the heat is concentrated at the work piece.
Stick electrodes are generally connected to the ‘+’ terminal
and the work lead to the ‘−’ terminal but if in doubt consult
the electrode manufacturers literature.
8.02 Effects of Stick Welding Various
Materials
High tensile and alloy steels
The two most prominent effects of welding these steels
are the formation of a hardened zone in the weld area,
and, if suitable precautions are not taken, the occurrence
in this zone of under-bead cracks. Hardened zone and
under-bead cracks in the weld area may be reduced by
using the correct electrodes, preheating, using higher
current settings, using larger electrodes sizes, short runs
for larger electrode deposits or tempering in a furnace.
Manganese steels
The effect on manganese steel of slow cooling from
high temperatures is to embrittle it. For this reason it is
absolutely essential to keep manganese steel cool during
welding by quenching after each weld or skip welding to
distribute the heat.
Cast Iron
Most types of cast iron, except white iron, are weldable.
White iron, because of its extreme brittleness, generally
cracks when attempts are made to weld it. Trouble
may also be experienced when welding white-heart
malleable, due to the porosity caused by gas held in this
type of iron.
Copper and alloys
The most important factor is the high rate of heat
conductivity of copper, making preheating of heavy
sections necessary to give proper fusion of weld and
base metal.
Types of Electrodes
Arc Welding electrodes are classifi ed into a number of
groups depending on their applications. There are a
great number of electrodes used for specialized industrial
purposes which are not of particular interest for everyday
general work. These include some low hydrogen types
for high tensile steel, cellulose types for welding large
diameter pipes, etc. The range of electrodes dealt with in
this publication will cover the vast majority of applications
likely to be encountered; are all easy to use and all will
work on even the most basic of welding machines.
Metals being joined ElectrodeComments
Ideal electrodes for all general purpose work.
Mild steel6013
Mild steel7014
Cast iron99% Nickel
Stainless steel318L-16
Copper, Bronze, Brass, etc.
High Alloy Steels,
Dissimilar Metals,
Crack Resistance.
All Hard-To-Weld Jobs.
Bronze
5.7 ERCUSI-A
312-16
Table 10 - Types of Electrodes
Features include out standing operator appeal,
easy arc starting and low spatter.
All positional electrode for use on mild and
galvanized steel furniture, plates, fences,
gates, pipes and tanks etc. Especially suitable
for vertical-down welding.
Suitable for joining all cast irons except white
cast iron.
High corrosion resistance. Ideal for dairy work,
etc. On stainless steels.
Easy to use electrode for marine fi ttings, water
taps and valves, water trough fl oat arms, etc.
Also for joining copper to steel and for bronze
overlays on steel shafts.
It will weld most problematical jobs such as
springs, shafts, broken joins mild steel to
stainless and alloy steels.
Not suitable for Aluminum.
March 31, 20068-1
Page 34
ARCMASTER® 160 S
March 31, 20068-2
Page 35
ARCMASTER® 160 S
SECTION 9:
ROUTINE MAINTENANCE
The only routine maintenance required for the power supply is a thorough cleaning and inspection, with the frequency depending
on the usage and the operating environment.
!
WARNING
Disconnect primary power at the source before
opening the enclosure. Wait at least two minutes
before opening the enclosure to allow the primary
capacitors to discharge.
To clean the unit, open the enclosure (please refer to the 160 S Service Manual P/N 430429-513) and use a vacuum cleaner to
remove any accumulated dirt and dust. The unit should also be wiped clean, if necessary; with solvents that are recommended
for cleaning electrical apparatus.
CAUTION
Do not blow air into the power supply during
cleaning. Blowing air into the unit can cause
metal particles to interfere with sensitive electrical
components and cause damage to the unit.
March 31, 20069-1
Page 36
ARCMASTER® 160 S
Warning!
Disconnect input power before maintaining.
Visual check of
regulator and pressure
Visually inspect the torch
body and consumables
Maintain more often
if used under severe
conditions
Each Use
Visual check of torch
Consumable parts
Weekly
Visually inspect the
cables and leads.
Replace as needed
Replace all
broken parts
3 Months
Clean
exterior
of power supply
6 Months
Bring the unit to an authorized
Thermal Arc Service Center
to remove any accumulated dirt
and dust from the interior.
This may need to be done more
frequently under exceptionally
dirty conditions.
Art # A-07331
March 31, 20069-2
Page 37
ARCMASTER® 160 S
SECTION 10:
BASIC TROUBLESHOOTING
!
WARNING
There are extremely dangerous voltages and power levels present inside this product. Do not attempt to open or
repair unless you are an Accredited Thermal Arc Service Agent and you have had training in power measurements
and troubleshooting techniques.
If major complex subassemblies are faulty, then the Welding Power Source must be returned to an Accredited Thermal Arc
Service Agent for repair.
The basic level of troubleshooting is that which can be performed without special equipment or knowledge.
10.01 TIG Welding Problems
Weld quality is dependent on the selection of the correct consumables, maintenance of equipment and proper welding
technique.
DescriptionPossible CauseRemedy
1.Excessive beard build-up or poor
penetration or poor fusion at
edges of weld.
2.Weld bead too wide and fl at or
undercut at edges of weld or
excessive burn through
3.Weld bead too small or insuffi cient
penetration or ripples in bead are
widely spaced apart
4.Weld bead too wide or excessive
bead build up or excessive penetration in butt joint
5.Uneven leg length in fi llet jointWrong placement of fi ller rodRe-position fi ller rod
6.Electrode melts when arc is
struck.
7. Dirty weld pool.A. Electrode contaminated through
Welding current is too lowIncrease weld current and/or faulty
joint preparation
Welding current is too highDecrease weld current
Travel speed too fastReduce travel speed
Travel speed too slowIncrease travel speed
Electrode is connected to the ‘+’
terminal.
contact with work piece or fi ller rod
material.
B. Gas contaminated with air.B. Check gas lines for cuts and loose
Connect the electrode to the ‘−’
terminal.
A. Clean the electrode by grinding off
the contaminates.
fi tting or change gas cylinder.
March 31, 200610-1
Page 38
ARCMASTER® 160 S
DescriptionPossible CauseRemedy
8.Electrode melts or oxidizes when
an arc is struck.
9.Poor weld fi nish.Inadequate shielding gas.Increase gas fl ow or check gas line
10. Arc fl utters during TIG welding.A. Tungsten electrode is too large for
11. Welding arc can not be
established.
12. Arc start is not smooth.A. Tungsten electrode is too large for
A. No gas fl owing to welding region. A. Check the gas lines for kinks or
breaks and gas cylinder contents.
B. Torch is clogged with dust.B. Clean torch
C. Gas hose is cut.C. Replace gas hose.
D. Gas passage contains impurities.D. Disconnect gas hose from torch
then raise gas pressure and blow
out impurities.
E. Gas regulator turned off.E. Turn on.
F. Torch valve is turned off.F. Turn on.
G. The electrode is too small for the
welding current.
the welding current.
B. Absence of oxides in the weld pool. B. Refer Basic TIG Welding Guide for
A. Work clamp is not connected to
the work piece or the work/torch
leads are not connected to the right
welding terminals.
B. Torch lead is disconnected.B. Connect it to the ‘−‘ terminal.
C. Gas flow incorrectly set, cylinder
empty or the torch valve is off.
the welding current.
B. The wrong electrode is being used
for the welding job
C. Gas fl ow rate is too high.C. Select the correct rate for the
D. Incorrect shielding gas is being
used.
E. Poor work clamp connection to work
piece.
G. Increase electrode diameter or
reduce the welding current.
for gas fl ow problems.
A. Select the right size electrode. Refer
to Basic TIG Welding guide.
ways to reduce arc fl utter.
A. Connect the work clamp to the work
piece or connect the work/torch leads
to the right welding terminals.
C. Select the right fl ow rate, change
cylinders or turn torch valve on.
A. Select the right size electrode.
Refer to Section 7, Basic TIG Welding Guide.
B. Select the right electrode type.
Refer to Section 7, Basic TIG Welding Guide.
welding job.
Refer to Section 7, Basic TIG Welding Guide.
D. Select the right shielding gas.
Refer to Section 7, Basic TIG Welding Guide.
E. Improve connection to work piece.
March 31, 200610-2
Page 39
10.02 Stick Welding Problems
DescriptionPossible CauseRemedy
1. Gas pockets or voids in weld metal
(Porosity).
2. Crack occurring in weld metal soon
after solidifi cation commences
3. A gap is left by failure of the weld
metal to fi ll the root of the weld.
ARCMASTER® 160 S
A.
Electrodes are damp.
B.
Welding current is too high.
C.
Surface impurities such as oil,
grease, paint, etc.
A.
Rigidity of joint.
B.
Insuffi cient throat thickness.
C.
Cooling rate is too high.
A.
Welding current is too low.
B.
Electrode too large for joint.
C.
Insuffi cient gap.
D. Incorrect sequence.D. Use correct build-up sequence.
A.
Dry electrodes before use.
B.
Reduce welding current.
C.
Clean joint before welding.
A.
Redesign to relieve weld joint
of severe stresses or use crack
resistance electrodes.
B.
Travel slightly slower to allow
greater build up in throat.
C.
Preheat plate and cool slowly.
A.
Increase welding current
B.
Use smaller diameter
electrode.
C.
Allow wider gap.
Figure 8 – Example of insuffi cient gap or incorrect sequence
4. Portions of the weld run do not fuse
to the surface of the metal or edge
of the joint.
Figure 9 – Example of lack of fusion
A.BSmall electrodes used on heavy
cold plate.
Welding current is too low.
C. Wrong electrode angle.C. Adjust angle so the welding arc is
D. Travel speed of electrode is too
high.
E. Scale or dirt on joint surface.E.Clean surface before welding.
A.B.Use larger electrodes and pre-heat
the plate.
Increase welding current
directed more into the base metal
D. Reduce travel speed of electrode
March 31, 200610-3
Page 40
ARCMASTER® 160 S
5. Non-metallic parti cles are
trapped in the weld metal
(slag inclusion).
A. Non-metallic particles may be trapped
in undercut from previous run.
B. Joint preparation too restricted.B. Allow for adequate penetration and room
C. Irregular deposits allow slag to be
trapped.
D. Lack of penetration with slag trapped
beneath weld bead.
E. Rust or mill scale is preventing full
fusion.
F.Wrong electrode for position in which
welding is done.
A. If bad undercut is present, clean slag
out and cover with a run from a smaller
diameter electrode.
for cleaning out the slag.
C. If very bad, chip or grind out
irregularities.
D. Use smaller electrode with sufficient
current to give adequate penetration.
Use suitable tools to remove all slag
from corners.
E. Clean joint before welding.
F.Use electrodes designed for position in
which welding is done, otherwise proper
control of slag is diffi cult.
10.03 Power Source Problems
DescriptionPossible CauseRemedy
1. The welding arc cannot be
established
2. Maximum output welding current
can not be achieved with nominal
Mains supply voltage.
3. Welding current reduces when
welding
Figure 10 – Examples of slag inclusion
A.B.The Primary supply voltage has not
been switched ON.
The Welding Power Source switch
is switched OFF.
C. Loose connections internally.C. Have an Accredited Thermal Arc Service
Defective control circuitHave an Accredited Thermal Arc Ser vice
Poor work lead connection to the
work piece.
A.B.Switch ON the Primary supply
voltage.
Switch ON the Welding Power Source.
Agent repair the connection.
Agent inspect then repair the welder.
Ensure that the work lead has a
positive electrical connection to the
work piece.
March 31, 200610-4
Page 41
ARCMASTER® 160 S
SECTION 11:
VOLTAGE REDUCTION DEVICE (VRD)
11.01 VRD Specifi cation
DescriptionArcMaster 160 SNotes
VRD Open Circuit Voltage15.3 to 19.8VOpen circuit voltage between welding terminals
VRD Resistance 148 to 193 ohms
VRD Turn OFF Time0.2 to 0.3 seconds
11.02 VRD Maintenance
Routine inspection and testing (power source)
An inspection of the power source, an insulation resistance test and an earth resistance test shall be carried out.
a) For transportable equipment, at least once every 3 months; and
b) For fi xed equipment, at least once every 12 months.
The owners of the equipment shall keep a suitable record of the periodic tests.
The required resistance between welding
terminals to turn ON the welding power
The time taken to turn OFF the welding power
once the welding current has stopped
NOTE
A transportable power source is any equipment that is not permanently connected and fi xed in the position in
which it is operated.
In addition to the above tests and specifi cally in relation to the VRD fi tted to this machine, the following periodic tests should
also be conducted by an accredited Thermal Arc service agent.
DescriptionIEC 60974-1 Requirements
VRD Open Circuit VoltageLess than 20V; at Vin=115V or 230V
VRD Turn ON Resistance Less than 200 ohms
VRD Turn OFF TimeLess than 0.3 seconds
If this equipment is used in a location or environment with a high risk of electrocution then the above tests should be carried
out prior to entering this location.
March 31, 200611-1
Page 42
ARCMASTER® 160 S
11.03 Switching VRD On/Off
Switch the machine Off.
a) Remove the clear plastic cover from the control panel (see Figure 11).
• Lift up the cover so it rests on the top of the unit.
• Place a small flat bladed screw driver between the cover hinge on the front panel.
• Gently lift the cover hinge out of the front cover mounting hole.
• Remove the control’s clear plastic cover.
b) Remove four mounting screws from the control panel (see Figure 12).
c) Access the VRD control by gently prying back the front panel controls to reveal the VRD on/off potentiometer (see Figure 12).
d) Turning the VRD ON/OFF (see Figure 13).
• To turn VRD ON: rote the trim potentiometer (VR1) on the display PCB fully clockwise. When VRD is turned ON check
that it operates as per VRD Specifications on page 5-13.
• To turn VRD OFF: rote the trim potentiometer (VR1) on the display PCB fully counter clockwise.
Figure 11-1: VRD ON/OFF Step A
CAUTION
Do not pull back the front panel with excessive force as this will unplug control PCB. Plugging the control PCB back
into the front panel controls can only be achieved by removing the side covers.
March 31, 200611-2
Page 43
1
2
1
Figure 11-2: VRD ON/OFF Step B,C
ARCMASTER® 160 S
1
1
!
The VRD ON/OFF trim potentiometer MUST ONLY be positioned fully clockwise OR fully counter clockwise as the
VRD function will be unknown for every other position.
WARNING
Figure 11-3: VRD ON/OFF Step D
March 31, 200611-3
Page 44
ARCMASTER® 160 S
March 31, 200611-4
Page 45
Weld current ceases.
Buzzer sounds constantly.
E01 resets when TH1 decreases to
70ºC for about 30 seconds.
SECTION 12:
POWER SOURCE ERROR CODES
C for about 30 seconds
o
Weld current ceases. Buzzer
sounds constantly.’Fan operates at
max speed.
E02 resets when the TH2 decreases
to 70
Weld current ceases.
Buzzer sounds constantly.
Switch machine off then on to reset
E03 error.
Weld current ceases.
Buzzer sounds constantly.
Switch machine off.
ARCMASTER® 160 S
Buzzer sounds constantly.
Must switch machine off and then
on to reset E99 error code.
Let Power Source cool down
then keep within its duty cycle.
Have an Accredited Thermal Arc
Service Agent investigate.
Unblock vents then let Power
A.
B.
C.
The Welding Power Source’s duty
cycle has been exceeded.
Fan ceases to operate.
Air fl ow is restricted by vents being
A.
B.
C.
then keep within its duty cycle.
Source cool down.
A. Let Power Source cool down
cycle has been exceeded.
blocked.
A. The Welding Powe Source’s duty
B. Fan ceases to operate.B. Have an accredited Thermal Arc
C
o
Service Agent investigate.
Source cool down.
Reduce length of welding arc.
Have an Accredited Thermal
Arc Service Agent or a qualifi ed
C. Unblock vents then let Power
A.
B.
blocked.
Primary current is too high because
welding arc is too long.
Mains supply voltage is more than
10% below nominal voltage .
C. Air fl ow is restricted by vents being
A.
B.
electrician check for low Mains
voltage.
Have an Accredited Thermal
Arc Service Agent or a qualifi ed
electrician check or replace the
The Welding Power Source’s
temperature sensors have
malfunctioned.
temperature sensors.
A. Turn on/off switch on.Weld current ceases.
B. Have an accredited Thermal Arc
been turned off.
A. Main on/off switch on machine has
B. Mains supply (input) voltage has
Agent or a qualifi ed electrician
check the Mains voltage and
fuses.
been turned off.
Table 12-1: Power Source Error Codes
DescriptionPossible CauseRemedyRemarks
Temperature sensor TH1 (protects IGBTs)
is greater than 80ºC for about 1 second
1. E01 error code displayed
March 31, 200612-1
2. E02 error code displayed
for about 1 second
Temperature sensor TH2 (protects
secondary diodes) is greather than 80
Primary (input) current too high
3. E03 error code displayed
4. E94 error code displayed
Temperature sensor TH1 for IGBT’s or
sensor TH2 for secondary diodes are open
circuit.
6. E99 error code displayed
Mains supply (input) voltage has been
turned off but control circuit has power
from the primary capacitors.
Page 46
ARCMASTER® 160 S
March 31, 200612-2
Page 47
ARCMASTER® 160 S
SECTION 13:
OPTIONS AND ACCESSORIES
PRODUCTPART NO.DESCRIPTION
Carry Case 600304 Accommodates the power supply, regulator, stick work lead, TIG torch &
accessory kit
Stick Kit 90924A Work clamp with 15’ #4 cable, and stick electrode with 15’ #4 cable
TIG Kit 600288 Includes regulator/fl owgauge, 12.5ft 150 Amp TIG torch with valve,
accessory kit includes 1 ea of 0040”x7”, 1/16”x7”, 3/32”x7” 2% Tungsten
with collet & collet bodies, 1 ea 1/4”, 5/16”, 3/8” alumina cup, 15’ cable
with clamp & T25 dinse plug
W4009101 Includes regulator/fl owgauge, 12.5ft 150 Amp TIG torch with valve and rotary
amperage control, accessory kit includes 1 ea of 0.040”x7”, 1/16”x7”,
3/32”x7” 2% Tungsten with collet & collet bodies, 1 ea 1/4”, 5/16”, 3/8”
alumina cup, 15’ cable with clamp & T25 dinse plug
Dinse Connector 10-1068 T25mm Dinse style male plug
Adaptor 10-4003 8-pin male to 14-pin female (6”)
Hand Held Pendant 10-4014 Includes contactor On/Off switch and current control with 25ft cable
and 8-pin male plug
Foot Control 10-4015 Contactor On/Off and current control with 15ft cable and 8-pin male plug
10-4016 Contactor On/Off and current control with 25ft cable and 8-pin male plug
Extension Cable 10-4017 3ft with 8-pin male plug and 8-pin female cable receptacle
10-4018 15ft with 8-pin male plug and 8-pin female cable receptacle
10-4019 25ft with 8-pin male plug and 8-pin female cable receptacle
10-4020 50ft with 8-pin male plug and 8-pin female cable receptacle
10-4021 75ft with 8-pin male plug and 8-pin female cable receptacle
Torch Switch On/Off 10-4006 15ft torch mounted with 8-pin male plug
10-4007 25ft torch mounted with 8-pin male plug
Torch Switch On/Off w/current
control
10-400815ft torch mounted with 8-pin male plug - adapts to 5/8”-7/8” torch
10-4009 15ft torch mounted with 8-pin male plug - adapts to 7/8”-1-1/8” torch
handle
10-4010 15ft torch mounted with 8-pin male plug - adapts to 1-1/8”-1-3/8” torch
handle
10-4011 25ft torch mounted with 8-pin male plug - adapts to 5/8”-7/8” torch
10-4012 25ft torch mounted with 8-pin male plug - adapts to 7/8”-1-1/8” torch
handle
10-4013 25ft torch mounted with 8-pin male plug - adapts to 1-1/8”-1-3/8” torch
handle
600296 Rotary amperage control 5k 15’ velcro for TD8
600297 Rotary amperage control 5k 25’ velcro for TD8
March 31, 200613-1
Page 48
ARCMASTER® 160 S
PC B 2
Main Circu it Board
[WK -5467]
C
Q1A
Q3A
C
G round
8
CON1
(F ron t View )
Lin e1
Lin e2
+
SIDE CH ASSIS 1
+
SIDE CH ASSIS 1
12
345
67
FAN1
+-
TH1
TH2
TB7
D1
+
TB1
S1
TB10
TB11
TB9
TB8
TB12
TB2
TB3
-
TB1
TB2
TB3
PC B 6
IG B T Gate
Circ uit Boa rd
[WK -5460]
+
TB5
TB6
1
2
CN2
3
4
1
CN5
2
1
2
CN6
3
TB5
TB6
CN1
2345
2345
CN7
G
E
Q1B
C
G
E
Q1C
C
PC B 7
G
E
C
G
E
C
G
E
C
G
E
61
61
IG B T Gate
Circ uit Boa rd
[WK -5460]
Q2A
Q2B
Q2C
CN1
2345
2345
CN7
PC B 1
Contr ol Sour ce
1
2
3
4
5
CN1
6
7
8
Circ uit Bord
[WK -5466]
G
E
Q3B
C
G
E
C
G
E
C
G
E
C
G
E
C
G
E
61
61
Q3C
Q4A
Q4B
Q4C
1
2
3
CN3
4
5
6
1
2
3
4
1
2
3
4
CN101
5
6
7
TB4
TB7
123456
1 : Case Ground
2 : Contactor Control 1/+ 24VDC
3 : Contactor Control 2/GND
4 : +12VDC Supply
5 : Potentiom e ter M aximum
6 : Potentiom e ter M inimum (GND)
7 : A mperage Control Wiper 0- 10VDC
8 : Remote Installed =12VDC
78
CN103CN4
March 31, 2006A-2
Page 49
PC B 3
2nd Diode
Circ uit Boar d
[WK -5468]
ARCMASTER® 160 S
D2
T1
TB1
TB3
TB4
TB2
D3
C1
R1
2
+12
-12
CT1
3
TB6
TO1
+Output
TB51
4
TB7
IS
GND
SIDE CH ASSIS 2
FCH1
Terminal
TO2
-O ut pu t
Terminal
CN1
2345
61
+12
-12
IS
GND
Circ uit Boar d
CN1
PC B 4
Contr ol
[WK -5449]
CN2
CN2
1
2
3
4
5
6
7
PC B 5
Panel
Circ uit Boar d
[WK -5448]
CN3
March 31, 2006A-3
Page 50
LIMITED WARRANTY
y
r
t
f
f
r
y
y
This information applies to Thermal Arc products that were purchased in the USA and Canada.
April 2006
®
LIMITED WARRANTY: Thermal Arc
warrants to customers of a uthorized distributors ("Purchaser") that its pro ducts will be free
of defects in workmanship or material. Should any failure to conform to this warrant
appear within the warranty period stated below, Thermal Arc shall, upon notification
thereof and substantiation that the product has been stored, installed, operated, and
maintained in accordance with Thermal Arc's specifications, instructions,
recommendations and recognized standard industry practice, and not subject to misuse,
repair, neglect, alteration, or damage, correct such defects by suitable repair o
replacement, at Thermal Arc's sole option, of any components or parts of the produc
determined by Thermal Arc to be defective.
This warranty is exclusive and in lieu of any warranty o
merchantability, fitness for any particular purpose, or other warranty o
quality, whether express, implied, or statutory.
Limitation of liability: Therm al Arc shall no t under any circumstan ces be liable for specia l,
indirect, incidental, or consequential dam ages, including but not limited to lost profits and
business interruption. The remedies of the purchaser set forth herein are exclusive, and
the liability of Thermal A rc with respect to any con tract, or anything done in connection
therewith such as the performance or breach thereof, or from the manufacture, sale,
delivery, resale, or use of any goods covered by or furnished by Thermal Arc, whethe
arising out of contract, tort, includin g negligence or strict liability, or under any warranty,
or otherwise, shall not exceed the price of the goods upon which such liability is based.
, Inc., A Thermadyne Company ("Thermal Arc"),
No employee, agent, or representative of Thermal Arc is authorized to change this
warranty in any way or grant any other warranty, and Thermal Arc shall not be bound b
any such attempt. Correction of non-conformities, in the manner and time provided
herein, constitutes fulfillment of thermal’s obligations to purchaser with respect to the
product.
This warranty is void, and seller bears no liability hereunder, if purchaser used
replacement parts or accessories which, in Thermal Arc's sole judgment, impaired the
safety or performance of any Thermal Arc product. Purchaser’s rights under this warrant
are void if the product is sold to purchaser by unauthorized persons.
The warranty is effective for the time stated below beginning on the date that the
authorized distributor delivers the products to the Purchaser. Notwithstanding the
foregoing, in no event shall the warranty period extend more than the time stated plus
one year from the date Thermal Arc delivered the product to the authorized distributor.
Warranty repairs or replacement claims under this limited warranty must be submitted to
Thermal Arc via an authorized Therm al Arc repair facility within thirty (30) days of
purchaser's discovery of any defect. Thermal Arc shall pay no transportation costs of any
kind under this warranty. Transportation charges to send products to an authorized
warranty repair facility shall be the responsibility of the Purchaser. All returned go ods
shall be at the Purchaser's risk and expense. This warranty dated April 1
supersedes all previous Thermal Arc warranties. Thermal Arc
Trademark of Thermal Arc, Inc.
®
is a Registered
st
2006
Page 51
WARRANTY SCHEDULE
This information applies to Thermal Arc products that were purchased in the USA and Canada.
April 2006
ENGINE DRIVEN WELDERSWARRANTY PERIODLABOR
Scout, Raider, Explorer
Original Main Power Stators and Inductors.................................................................................. 3 years
Original Main Power Rectifiers, C ontrol P. C. Boards ....................... .............. ............... ............... 3 years
All other original circuits and components including, but not limited to, relays,
switches, contactors, solenoids, fans, power switch semi-conductors..........................................1 year
Engines and associated components are NOT warranted by Thermal Arc, although
most are warranted by the engine manufacturer............................................................. See the Engine Manufactures Warranty for
Origina l M a in P o w e r Ma g ne t i c s..... ... .. .. .. .. .. .... .. .. .. ... .. .. .. .. .... .. .. .. ... .. .. .. .. .. .... .. .. .. ... .. .. .. .. .... .. .. .. ... ....5 years 3 years
Origina l M a in P o w e r R ec t ifi e rs, Control P .C . B o a rds , p o w e r s w itc h se mi-condu c t o rs ............... .. 3 years 3 years
All other original circuits and components including, but not limited to, relays,
switches, contactors, solenoids, fans, electric motors...................................................................1 year1 year
PLASMA WELDING EQUIPMENTWARRANTY PERIODLABOR
Ultima 150
Origina l M a in P o w e r Ma g ne t i c s..... ... .. .. .. .. .. .... .. .. .. ... .. .. .. .. .... .. .. .. ... .. .. .. .. .. .... .. .. .. ... .. .. .. .. .... .. .. .. ... .... 5 years 3 years
Origina l M a in P o w e r Re ct i fie rs, Control P .C . B o a rds, power sw itc h se mi-condu c t o rs ............... .. 3 years 3 yea rs
Welding Cons ole, Weld Controller, Weld Timer ............ .............. ............... ............... ............... .... 3 years 3 years
All other original circuits and components including, but not limited to, relays,
switches, contactors, solenoids, fans, electric motors, Coolant Recirculator................................1 year 1 year
Origina l M a in P o w e r Ma g ne t i c s..... ... .. .. .. .. .. .... .. .. .. ... .. .. .. .. .... .. .. .. ... .. .. .. .. .. .... .. .. .. ... .. .. .. .. .... .. .. .. ... .....1 year 1 year
Original Main Power Rectifiers, Control P.C. Boards ....................................................................1 year 1 year
All other original circuits and components including, but not limited to, relays,
switches, contactors, solenoids, fans, power switch semi-conductors ..........................................1 year 1 year
160S, 300S, 400S
Origina l M a in P o w e r Ma g ne t i c s..... ... .. .. .. .. .. .... .. .. .. ... .. .. .. .. .... .. .. .. ... .. .. .. .. .. .... .. .. .. ... .. .. .. .. .... .. .. .. ... ....5 years 3 years
Original Main Power Rectifiers, Control P.C. Boards ...................................................................3 years 3 years
All other original circuits and components including, but not limited to, relays,
switches, contactors, solenoids, fans, power switch semi-conductors ..........................................1 year 1 year
GENERAL ARC EQUIPMENT WARRANTY PERIODLABOR
Water Recirculators.......................................................................................................................1 year 1 year
Plasma Welding Torch es................................................................................................. ............180 days 180 days
Gas Re gul a t o rs (S u p p l ie d wi th p o w e r s o u rc e s ) ............ .. .... .. .. .. .. ... .. .. .. .. .. .... .. .. ... .. .. .. .. .. .. .... .. ... .. .180 da ys Nil
MIG and TIG Torches (Supplied with power sources)..................................................................90 days Nil
Europe Building
Chorley North Industrial Park
Chorley, Lancashire
England, PR6 7Bx
Telephone: 44-1257-261755
Fax: 44-1257-224800
Thermadyne Asia Sdn Bhd
Lot 151, Jalan Industri 3/5A
Rawang Integrated Industrial Park - Jln Batu Arang
48000 Rawang Selangor Darul Ehsan
West Malaysia
Telephone: 603+ 6092 2988
Fax : 603+ 6092 1085
Cigweld, Australia
71 Gower Street
Preston, Victoria
Australia, 3072
Telephone: 61-3-9474-7400
Fax: 61-3-9474-7510
Thermadyne Italy
OCIM, S.r.L.
Via Benaco, 3
20098 S. Giuliano
Milan, Italy
Tel: (39) 02-98 80320
Fax: (39) 02-98 281773
Thermadyne, China
RM 102A
685 Ding Xi Rd
Chang Ning District
Shanghai, PR, 200052
Telephone: 86-21-69171135
Fax: 86-21-69171139