Tweco 160S User Manual

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Page 1

160 S

ARCMASTER

INVERTER ARC WELDER

Operating Manual

Version No: 1 Issue Date: March 31, 2006 Manual No: 0-4854

Operating Features:

SMAW

GTAW

PHASE

INVERTER

115V230

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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.

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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

www.thermalarc.com

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 #: _______________________________

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ARCMASTER® 160 S

SECTION 1:

SAFETY INSTRUCTIONS AND WARNINGS .................................................. 1-1

1.01 Arc Welding Hazards .................................................................................1-1

1.02 Principal Safety Standards ........................................................................1-4

1.03 Precautions de Securite en Soudage A L’Arc ............................................1-5

1.04 Dangers relatifs au soudage à l’arc ...........................................................1-5

1.05 Principales Normes De Securite ...............................................................1-8

SECTION 2:

INTRODUCTION AND DESCRIPTION ......................................................... 2-1

2.01 How To Use This Manual ..........................................................................2-1

2.02 Equipment Identiﬁ cation ...........................................................................2-1

2.03 Receipt Of Equipment ...............................................................................2-1

2.04 Symbol Chart ............................................................................................2-2

2.05 Description ................................................................................................2-3

2.06 Functional Block Diagrams ........................................................................2-3

2.07 Transporting Methods ...............................................................................2-4

Table of Contents

SECTION 3:

INSTALLATION RECOMMENDATIONS ........................................................ 3-1

3.01 Environment ..............................................................................................3-1

3.02 Location ....................................................................................................3-1

3.03 Electrical Input Connections ......................................................................3-1

3.04 Speciﬁ cations ............................................................................................3-4

3.05 Duty Cycle .................................................................................................3-5

SECTION 4:

OPERATOR CONTROLS ........................................................................ 4-1

4.01 ArcMaster 160 S Controls .........................................................................4-1

4.02 Weld Parameter Descriptions for ArcMaster 160 S ...................................4-2

4.03 Weld Parameters for ArcMaster 160 S ......................................................4-3

4.04 Power Source Features .............................................................................4-4

SECTION 5:

SET-UP FOR SMAW (STICK) AND GTAW (TIG) ............................................. 5-1

SECTION 6:

SEQUENCE OF OPERATION .................................................................... 6-1

6.01 Stick Welding ............................................................................................ 6-1

6.02 DC Lift TIG Welding ..................................................................................6-1

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ARCMASTER® 160 S

SECTION 7:

BASIC TIG WELDING GUIDE ................................................................... 7-1

7.01 Electrode Polarity ...................................................................................... 7-1

7.02 Tungsten Electrode Current Ranges ..........................................................7-1

7.03 Tungsten Electrode Types .........................................................................7-1

7.04 Guide for Selecting Filler Wire Diameter ...................................................7-1

7.05 Shielding Gas Selection ............................................................................7-2

7.06 TIG Welding Parameters for Low Carbon & Low Alloy Steel Pipe ............. 7-2

7.07 Welding Parameters for Steel....................................................................7-2

SECTION 8:

BASIC ARC WELDING GUIDE .................................................................. 8-1

8.01 Electrode Polarity ...................................................................................... 8-1

8.02 Effects of Stick Welding Various Materials ................................................8-1

SECTION 9:

ROUTINE MAINTENANCE ..................................................................... 9-1

SECTION 10:

BASIC TROUBLESHOOTING ..................................................................10-1

10.01 TIG Welding Problems ..........................................................................10-1

10.02 Stick Welding Problems ........................................................................10-3

10.03 Power Source Problems .......................................................................10-4

SECTION 11:

VOLTAGE REDUCTION DEVICE (VRD) ....................................................... 11-1

11.01 VRD Speciﬁ cation .................................................................................11-1

11.02 VRD Maintenance .................................................................................11-1

11.03 Switching VRD On/Off ........................................................................... 11-2

SECTION 12:

POWER SOURCE ERROR CODES ............................................................ 12-1

SECTION 13:

OPTIONS AND ACCESSORIES ................................................................ 13-1

APPENDIX A:

INTERCONNECT DIAGRAM ................................................................... A-2

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ARCMASTER® 160 S

March 31, 2006iv

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ARCMASTER® 160 S

SECTION 1:

SAFETY INSTRUCTIONS AND WARNINGS

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, 2006 1-1

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.

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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 ize Fi l ter Welding or cutting El ectrode S ize Fil ter

Torch soldering 2

Torch braz ing 3 or 4 Non-ferrous base metal All 11

Oxygen Cutting

Light Under 1 in., 25 mm 3 or 4 Gas tungsten arc welding All 12

Medium 1 to 6 in., 25-150 mm 4 or 5 (TIG) All 12

Heavy Over 6 in., 150 mm 5 or 6 Atomic hydrogen welding All 12

Gas welding

Light Under 1/8 in., 3 mm 4 or 5 Plasma arc welding

Medium 1/8 to 1/2 in., 3-12 mm 5 or 6

Heavy Over 1/2 in., 12 mm 6 or 8 Light 12

Shielded metal-arc

Under 5/32 in., 4 mm 10 Heavy 14

5/32 to 1/4 in., 12

Over 1/4 in., 6.4 mm 14 Light Under 300 Amp 9

2. Wear proper body protection to protect skin.

Gas metal-arc

Ferrous base metal All 12

Carbon arc welding All 12

Carbon arc air gouging

Plasma arc cutting

Medium 300 to 400 Amp 12

Heavy Over 400 Amp 14

March 31, 20061-2

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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

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, 2006 1-3

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.

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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

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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, 2006 1-5

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

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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

Oxycoupage métaux ferreux toutes condit ions 12

moyen de 1 á 6 po. (25 á 150 mm) 4 ou 5

Soudage aux gaz Soudage á l'ar c P lasma (PAW) toutes dimensions 12

moyen de 1/8 á 1/2 po. (3 á 12 mm) 5 ou 6 mince 12

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 ions 2

tout es condit ions 3 ou 4 métaux non- ferreux toutes condit ions 11

mince moins de 1 po. (25 mm) 2 ou 3

épais plus 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 8 épais 14

moins de 5/32 po. ( 4 mm) 10 Coupage á l'arc P lasma (PAC)

5/32 á 1/ 4 po. (4 á 6.4 mm) 12 mince moins de 300 amperès 9

plus de 1/4 po. (6.4 mm) 14 moyen de 300 á 400 amperès 12

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 ions 12

Nuance de

filt r e oc ulair e

épais plus de 400 am perès 14

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

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, 2006 1-7

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, 2006 2-1

Page 16

ARCMASTER® 160 S

2.04 Symbol Chart

Note that only some of these symbols will appear on your model.

Off

Dangerous Voltage

Increase/Decrease

Circuit Breaker

AC Auxiliary Power

Fuse

Amperage

Voltage

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

Output Voltage Off.

Welding Gun

Purging Of Gas

Continuous Weld Mode

Spot Weld Mode

Spot Time

Preflow Time

Postflow Time

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

Disturbance In Ground System

IPM

MPM

Inches Per Minute

Meters Per Minute

115V 15A

Receptacle RatingAuxiliary Power

Voltage Input

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, 2006 2-3

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, 2006 3-1

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 Voltage Fuse Size

115 V 40 Amps

208-230 V 45 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 S 12/3 AWG minimum

Primary Supply Lead Size

(Factory Fitted)

Table 2 – 115/208-230V Primary Current Circuit sizes to achieve maximum current

Minimum Primary

Current Circuit Size

(Vin/Amps)

115/23 85A @ 100% 208/28 160A @ 35% 230/25 115/40 - 85A @ 100% 208/44 - 160A @ 35% 230/39 -

Current & Duty Cycle

TIG STICK

March 31, 20063-2

Page 21

3.04 Speciﬁ cations

Parameter 160 S

Duty Cycle TIG

Output Current TIG 5 – 160 (230V), 5 – 85 (115V) Range STICK 5 – 160 (230V), 5 – 85 (115V) Open Circuit Voltage 65V

Dimensions

Width Height Length

Output @ Rated Load

ARCMASTER® 160 S

CAV032CAV511tuptuO detaR

06158serepmA

7232stloV

%53%001elcyC ytuD 160A / 17V @ 35% 230VAC 130A / 15V @ 60% 230VAC 100A / 14V @ 100% 230VAC 85A / 13V @ 100% 115VAC 160A / 27V @ 35% 230VAC 130A / 25V @ 60% 230VAC

STICK

100A / 24V @ 100% 230VAC 85A / 23V @ 100% 115VAC

5.12” (130mm)

10.24” (260mm)

12.60” (320mm)

)gk 6.8( .sbl 59.81thgieW

Rated Input Voltage Single Phase 115VAC Single phase 230VAC

Output Amperes 160AA58

Output Volts V72V32

Duty Cycle %53%001

KVA 7.84.4

KW 2.54.2

Output @ No Load

KVA KW

Input Volts Single Phase

115V 230V

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, 2006 3-3

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.

2 1

5 4 3

8 7 6

Front view of 8-Socket Receptacle

1 Earth (Ground)

5 5k ohm (maximum) connection to 5k ohm remote control potentiometer 6 Zero ohm (minimum) connection to 5k ohm remote control potentiometer 7 Wiper arm connection to 5k ohm remote control potentiometer

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, 2006 4-1

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

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

Parameter Description

This parameter operates in STICK weld mode and is used to improve the start characteristics

HOT START

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

Parameter Parameter Range

HOT START 0 to 70A 20A 1A Yes No

Factory

Setting

ARCMASTER® 160 S

Weld Mode

Incremental

Unit STICK LIFT TIG

WELD CUR

ARC CONTROL 0 to 100% 10% 1% Yes No

4.04 Power Source Features

Feature Description

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

80A 1A Yes Yes

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, 2006 4-3

• 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, 2006 5-1

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.

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.

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, 2006 6-1

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.

7.02 Tungsten Electrode Current Ranges

Electrode Diameter DC Current (Amps)

0.040” (1.0mm) 30 – 60 1/16” (1.6mm) 60 – 115 3/32” (2.4mm) 100 – 165

1/8” (3.2mm) 135 – 200 5/32” (4.0mm) 190 – 280 3/16” (4.8mm) 250 – 340

Table 4 – Current ranges for varies tungsten electrode sizes

7.03 Tungsten Electrode Types

Electrode Type

(Ground Finish) Welding Application Features

Thoriated 2%

Ceriated 2%

DC welding of mild steel, stainless steel and copper.

DC welding of mild steel, stainless steel, copper, aluminium, magnesium and their alloys

Table 5 – Tungsten electrode types

7.04 Guide for Selecting Filler Wire Diameter

Filler Wire Diameter

1/16” (1.6 mm) 20 - 90 3/32” (2.4 mm) 65 - 115

1/8” (3.2 mm) 100 - 165

3/16” (4.8 mm) 200 - 350

Table 6 – Filler wire selection guide

Excellent arc starting, Long life, High current carrying capacity.

Longer life, More stable arc, Easier starting, Wider current range, Narrower more concentrated arc.

DC Current Range

(Amps)

Color Code

Red

Grey

NOTE

The ﬁ ller wire diameter speciﬁ ed in Table 9 is a guide only, other diameter wires may be used according to the welding application.

March 31, 2006 7-1

Page 32

ARCMASTER® 160 S

7.05 Shielding Gas Selection

Alloy Shielding Gas

Aluminium & alloys Welding Argon

Carbon Steel Welding Argon

Stainless Steel Welding Argon

Nickel Alloy Welding Argon

Copper Welding Argon

Titanium Welding Argon

Table 7 – Shielding gas selection

7.06 TIG Welding Parameters for Low Carbon & Low Alloy Steel Pipe

Electrode Type &

Diameter

Thoriated 2%

3/32” (2.4 mm)

Thoriated 2%

3/32” (2.4 mm)

Thoriated 2%

3/32” (2.4 mm)

Table 8– TIG welding parameters for low carbon & low alloy steel pipe

Current Range DC

Amperes

120 - 170 Yes

100 - 160 Yes

90 - 130 No

7.07 Welding Parameters for Steel

DC Current

Base Metal

Thickness

0.040”

1.0mm

0.045”

1.2mm 1/16”

1.6mm

1/8”

3.2mm 3/16”

4.8mm

¼”

6.4mm

DC Current for

Mild Steel

35-45 20-30 0.040” 40-50 25-35 Lap/ Fillet 45-55 30-45 0.040” 50-60 35-50 Lap/ Fillet 60-70 40-60 1/16”

70-90 50-70 Lap/ Fillet 80-100 65-85 1/16” 90-115 90-110 Lap/ Fillet

115-135 100-125 3/32” 140-165 125-150 Lap/ Fillet 160-175 135-160 1/8” 170-200 160-180 Lap/ Fillet

for Stainless

Steel

Table 9 – DC TIG welding parameters

Tungsten Electrode Diameter

1.0mm

1.6mm

2.4mm

3.2mm

Filler Rod for

Root Pass Joint Preparation

Filler Rod

Diameter

(if required)

1/16”

1.6mm 1/16”

1.6mm 3/32”

2.4mm

1/8”

3.2mm 5/32”

4.0mm

Argon Gas

Flow Rate

Liters/min Joint Type

5-7

Butt/Corner

March 31, 20067-2

Page 33

SECTION 8:

BASIC ARC WELDING GUIDE

ARCMASTER® 160 S

8.01 Electrode Polarity

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 Electrode Comments

Ideal electrodes for all general purpose work.

Mild steel 6013

Mild steel 7014

Cast iron 99% Nickel

Stainless steel 318L-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, 2006 8-1

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, 2006 9-1

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.

Description Possible Cause Remedy

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 joint Wrong placement of ﬁ ller rod Re-position ﬁ ller rod

6. Electrode melts when arc is struck.

7. Dirty weld pool. A. Electrode contaminated through

Welding current is too low Increase weld current and/or faulty

joint preparation

Welding current is too high Decrease weld current

Travel speed too fast Reduce travel speed

Travel speed too slow Increase 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, 2006 10-1

Page 38

ARCMASTER® 160 S

Description Possible Cause Remedy

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

Description Possible Cause Remedy

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

Electrodes are damp.

Welding current is too high.

Surface impurities such as oil, grease, paint, etc.

Rigidity of joint.

Insufﬁ cient throat thickness.

Cooling rate is too high.

Welding current is too low.

Electrode too large for joint.

Insufﬁ cient gap.

D. Incorrect sequence. D. Use correct build-up sequence.

Dry electrodes before use.

Reduce welding current.

Clean joint before welding.

Redesign to relieve weld joint of severe stresses or use crack resistance electrodes.

Travel slightly slower to allow greater build up in throat.

Preheat plate and cool slowly.

Increase welding current

Use smaller diameter electrode.

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, 2006 10-3

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

Description Possible Cause Remedy

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 circuit Have 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

Description ArcMaster 160 S Notes

VRD Open Circuit Voltage 15.3 to 19.8V Open circuit voltage between welding terminals

VRD Resistance 148 to 193 ohms

VRD Turn OFF Time 0.2 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.

Description IEC 60974-1 Requirements

VRD Open Circuit Voltage Less than 20V; at Vin=115V or 230V VRD Turn ON Resistance Less than 200 ohms VRD Turn OFF Time Less 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, 2006 11-1

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

Figure 11-2: VRD ON/OFF Step B,C

ARCMASTER® 160 S

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, 2006 11-3

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

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

The Welding Power Source’s duty

cycle has been exceeded.

Fan ceases to operate.

Air ﬂ ow is restricted by vents being

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

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

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

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

Description Possible Cause Remedy Remarks

Temperature sensor TH1 (protects IGBTs)

is greater than 80ºC for about 1 second

1. E01 error code displayed

March 31, 2006 12-1

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

PRODUCT PART 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

10-4008 15ft 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, 2006 13-1

Page 48

ARCMASTER® 160 S

PC B 2

Main Circu it Board

[WK -5467]

Q1A

Q3A

G round

CON1

(F ron t View )

Lin e1

Lin e2

SIDE CH ASSIS 1

345

FAN1

TH1

TH2

TB7

TB1

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

CN5

1 2

CN6

TB5

TB6

CN1

2345

CN7

G E

Q1B

G E

Q1C

PC B 7

G E

IG B T Gate

Circ uit Boa rd

[WK -5460]

Q2A

Q2B

Q2C

CN1

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

G E

Q3C

Q4A

Q4B

Q4C

1 2 3

CN3

4 5 6

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

CN103 CN4

March 31, 2006A-2

Page 49

PC B 3

2nd Diode

Circ uit Boar d

[WK -5468]

ARCMASTER® 160 S

TB1

TB3

TB4

TB2

+12

-12

CT1

TB6

TO1

+Output

TB51

TB7

GND

SIDE CH ASSIS 2

FCH1

Terminal

TO2

-O ut pu t

Terminal

CN1

2345

+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, 2006 A-3

Page 50

LIMITED WARRANTY

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

2006

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WARRANTY SCHEDULE

This information applies to Thermal Arc products that were purchased in the USA and Canada.

April 2006

ENGINE DRIVEN WELDERS WARRANTY PERIOD LABOR 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

Details

GMAW/FCAW (MIG) WELDING EQUIPMENT WARRANTY PERIOD LABOR Fabricator 131, 181; 190, 210, 251, 281; Fabstar 4030; PowerMaster 350, 350P, 500, 500P; Excelarc 6045. Wire Feeders; Ultrafeed, Portafeed

Original Main Power Transformer and Inductor............................................................................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 years

All other original circuits and components including, but not limited to, relays,

switches, contactors, solenoids, fans, electric motors...................................................................1 year 1 year

GTAW (TIG) & MULTI-PROCESS INVERTER WELDING EQUIPMENT WARRANTY PERIOD LABOR 160TS, 300TS, 400TS, 185AC/DC, 200AC/DC, 300AC/DC, 400GTSW, 400MST, 300MST, 400MSTP

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 year 1 year

PLASMA WELDING EQUIPMENT WARRANTY PERIOD LABOR 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

SMAW (Stick) WELDING EQUIPMENT WARRANTY PERIOD LABOR Dragster 85

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 PERIOD LABOR

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

Replac ement repa i r pa rts ...... .. .. .. .. ... .. .. .. .. .... .. .. .. ... .. .. .. .. .... .. .. .. .. ... .. .. .. .. .... .. .. .. .. ... .. .. .. .... .. .. .. .. .......90 days Nil

MIG, TIG and Plasma welding torch consumable items...................................................................Nil Nil

3 years 3 years

1 year

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GLOBAL CUSTOMER SERVICE CONTACT INFORMATION

Thermadyne USA

2800 Airport Road Denton, Tx 76207 USA Telephone: (940) 566-2000 800-426-1888 Fax: 800-535-0557 Email: sales@thermalarc.com

Thermadyne Canada

2070 Wyecroft Road Oakville, Ontario Canada, L6L5V6 Telephone: (905)-827-1111 Fax: 905-827-3648

Thermadyne Europe

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

Thermadyne International

2070 Wyecroft Road Oakville, Ontario Canada, L6L5V6 Telephone: (905)-827-9777 Fax: 905-827-9797

Page 54

World Headquarters

Thermadyne Holdings Corporation Suite 300, 16052 Swingley Ridge Road St. Louis, MO 63017

Telephone: (636) 728-3000 Fascimile: (636) 728-3010 Email: sales@thermalarc.com

www.thermalarc.com