Tweco 161S User Manual

Art# A-09194_AB

50
60

Hz

161 S

®

THERMAL ARC

INVERTER ARC WELDER

Operating Manual

Revision: AD Issue Date: January 14, 2011 Manual No.: 0-5073
Operating Features:

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
1-800-462-2782, 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.

!

WARNINGS

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.

Operating Manual Number 0-5073 for:
Thermal Arc 161 S Power Source Arc Welder Part No. W1003600
Thermal Arc 161 S System with Stick Kit & Case Part No. W1003602
Thermal Arc 161 S System with Stick/TIG Kit & Case Part No. W1003603

Published by:
Thermadyne Industries Inc.
82 Benning Street
West Lebanon, New Hampshire, USA 03784
[phone]

www.thermalarc.com

Copyright
Thermadyne Industries Inc.

®

All rights reserved.

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: September 16, 2010
Revision Date: January 14, 2011

Record the following information for Warranty purposes:

Where Purchased: ____________________________________

Purchase Date: ____________________________________

Equipment Serial #: ____________________________________

©

2010 by

i

TABLE OF CONTENTS

SECTION 1:SAFETY INSTRUCTIONS AND WARNINGS ................................................ 1-1

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

1.02 General Safety Information for Victor CS Regulator .......................................... 1-4

1.03 Principal Safety Standards .............................................................................. 1-5

1.04 Symbol Chart .................................................................................................. 1-6

1.05 Precautions De Securite En Soudage A L’arc .................................................. 1-7

1.06 Dangers relatifs au soudage à l’arc ................................................................. 1-7

1.07 Informations Générales de Sécurité .............................................................. 1-10

1.08 Principales Normes De Securite ................................................................... 1-12

1.09 Graphique de Symbole .................................................................................. 1-13

SECTION 2:INTRODUCTION ............................................................................... 2-1

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

2.02 Equipment Identification ................................................................................. 2-1

2.03 Receipt of Equipment ...................................................................................... 2-1

2.04 Description ..................................................................................................... 2-1

2.05 Transportation Methods .................................................................................. 2-1

2.06 Duty Cycle ....................................................................................................... 2-1

2.07 Specifications ................................................................................................. 2-2

SECTION 3:INSTALLATION ................................................................................ 3-1

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

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

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

3.04 Electromagnetic Compatibility ........................................................................ 3-4

3.05 Setup for Welding ........................................................................................... 3-5

3.06 STICK (SMAW) Setup ..................................................................................... 3-6

3.07 LIFT TIG (GTAW) Setup................................................................................... 3-7

3.08 Victor Regulator .............................................................................................. 3-8

3.09 Leak Testing the System ............................................................................... 3-10

3.10 When You Finish Using the Regulator ........................................................... 3-10

3.11 Storage of the Regulator ............................................................................... 3-10

TABLE OF CONTENTS

SECTION 4:OPERATION .................................................................................... 4-1

4.01 Front Panel ..................................................................................................... 4-1

4.02 Welding Current Control Explanation .............................................................. 4-2

4.03 STICK (SMAW) Electrode Polarity................................................................... 4-3

4.04 Effects of Stick Welding Various Materials ...................................................... 4-3

4.05 GTAW Electrode Polarity ................................................................................. 4-4

4.06 Guide for Selecting Filler Wire ........................................................................ 4-4

4.07 Tungsten Electrode Current Ranges ................................................................ 4-4

4.08 Shielding Gas Selection .................................................................................. 4-4

4.09 Tungsten Electrode Types ............................................................................... 4-4

4.10 TIG Welding Parameters for Steel ................................................................... 4-5

4.11 Arc Welding Practice ....................................................................................... 4-5

4.12 Welding Position ............................................................................................. 4-6

4.13 Joint Preparations ........................................................................................... 4-7

4.14 Arc Welding Technique ................................................................................... 4-8

4.15 The Welder ...................................................................................................... 4-8

4.16 Striking the Arc ............................................................................................... 4-8

4.17 Arc Length ...................................................................................................... 4-8

4.18 Rate of Travel .................................................................................................. 4-8

4.19 Making Welded Joints ..................................................................................... 4-9

4.20 Distortion ...................................................................................................... 4-11

4.21 The Cause of Distortion ................................................................................ 4-11

4.22 Overcoming Distortion Effects ...................................................................... 4-12

SECTION 5:SERVICE ....................................................................................... 5-1

5.01 Maintenance and Inspection ........................................................................... 5-1

5.02 STICK (SMAW) Welding Problems ................................................................ 5-2

5.03 TIG Welding Problems ................................................................................... 5-3

5.04 Power Source Problems ................................................................................ 5-4

APPENDIX 1: OPTIONS AND ACCESSORIES ............................................................ A-1

APPENDIX 2: REPLACEMENT PARTS ................................................................... A-2

APPENDIX 3: SYSTEM SCHEMATIC ..................................................................... A-4

LIMITED WARRANTY

WARRANTY SCHEDULE

Art# A-09756

Art# A-09755

Thermal Arc 161S Stick System

Part Number W1003602

• Thermal Arc 161S power supply in toolbox

• Tweco electrode holder, 13ft (4m) lead

• Tweco ground clamp, 10ft (3.1m) lead

• 4 GP 1/8" (3.2mm) dia stick electrodes

• 230V to 115V adapter

• Quick set-up DVD

• Operating manual

Thermal Arc 161S TIG/Stick System

Part Number W1003603

• Thermal Arc 161 S power supply in toolbox

• 17V TIG torch, 12.5ft (3.8m) with accessory kit

• Tweco electrode holder, 13ft (4m) lead

• Tweco ground clamp, 10ft (3.1m) lead

• 4 GP 1/8” (3.2mm) dia. stick electrodes

• Victor CutSkill 2G Gas Regulator

• 230V to 115V adapter

• Quick set-up DVD

• Operating manual

SAFETY INSTRUCTIONS THERMAL ARC 161 S

!

SECTION 1:

SAFETY INSTRUCTIONS AND WARNINGS

WARNING

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.

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 semi-automatic 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.

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 confined 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 floor
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 fitted with a proper shade of filter (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 flash and
glare; warn others not to watch the arc.

4. Wear protective clothing made from durable, flame-resistant
material (wool and leather) and foot protection.

5. Use approved ear plugs or ear muffs if noise level is high.

Manual 0-5073 1-1 Safety InstructionsSafety Instructions

THERMAL ARC 161 S SAFETY INSTRUCTIONS

Welding or Cutting

Operation

Electrode Siz

e

Metal Thickness

or Weldin

g

Current

Filter

Shade

No.

Welding or Cutting

Operation

Electrode Siz

e

Metal Thickness

or Weldin

g

Filter

Shade

No.

Torch soldering 2

Gas metal-arc
welding (MIG)

Torch brazing 3 or 4 Non-ferrous base metal All 11

Oxygen Cutting

Non-ferrous base metal All 12

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

Carbon arc welding All 12

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

Carbon arc air gouging

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

Shielded metal-arc

welding

(stick) electrodes

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

5/32 to 1/4 in.,

4 to 6.4 mm

12

Plasma arc cutting

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

Medium 300 to 400 Amp 12

Heavy Over 400 Amp 14

Eye protection filter shade selector for welding or cutting

(goggles or helmet), from AWS A6.2-73.

WARNING

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 breathe 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 confined 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.

WELDING can cause fire or explosion.
Sparks and spatter fly off from the welding arc. The flying

sparks and hot metal, weld spatter, hot workpiece, and
hot equipment can cause fires and burns. Accidental
contact of electrode or welding wire to metal objects
can cause sparks, overheating, or fire.

1. Protect yourself and others from flying sparks and hot metal.

2. Do not weld where flying sparks can strike flammable material.

3. Remove all flammables 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 fire, and keep a fire extinguisher nearby.

6. Be aware that welding on a ceiling, floor, bulkhead, or partition
can cause fire 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 fire 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.

Safety Instructions 1-2 1-2 Manual 0-5073Manual 0-5073

SAFETY INSTRUCTIONS THERMAL ARC 161 S

!

2. If used in a closed area, vent engine exhaust outside and away
from any building air intakes.

WARNING

FLYING SPARKS AND HOT METAL can cause injury.

Chipping and grinding cause flying metal. As welds cool,
they can throw off slag.

1. Wear approved face shield or safety goggles. Side shields
recommended.

2. Wear proper body protection to protect skin.

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
fittings designed for the specific 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.

WARNING

ENGINE FUEL can cause fire or explosion.

Engine fuel is highly flammable.

1. Stop engine before checking or adding fuel.

2. Do not add fuel while smoking or if unit is near any sparks or open
flames.

3. Allow engine to cool before fueling. If possible, check and add fuel
to cold engine before beginning job.

4. Do not overfill 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 fingers 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 finished and before starting engine.

WARNING

WARNING

Engines can be dangerous.

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.

WARNING

ENGINE EXHAUST GASES can kill.

Engines produce harmful exhaust gases.

1. Use equipment outside in open, well-ventilated areas.

Manual 0-5073 1-3 Safety InstructionsSafety Instructions

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.

THERMAL ARC 161 S SAFETY INSTRUCTIONS

!

!

!

!

1.02 General Safety Information for Victor
CS Regulator

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. 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.

This product contains chemicals, including lead, or
otherwise produces chemicals known to the State of
California to cause cancer, birth defects and other re­productive harm. Wash hands after handling. (California
Health & Safety Code § 25249.5 et seq.)

LEAD WARNING

A Fire Prevention

Welding and cutting operations use fire or combustion as a basic
tool. The process is very useful when properly controlled. However,
it can be extremely destructive if not performed correctly in the proper
environment.

1. The work area must have a fireproof floor.

2. Work benches or tables used during welding or cutting
operations must have fireproof tops.

3. Use heat resistant shields or other approved material to pro­tect nearby walls or unprotected flooring from sparks and hot
metal.

4. Keep an approved fire extinguisher of the proper size and
type in the work area. Inspect it regularly to ensure that it
is in proper working order. Know how to use the fire extin­guisher.

5. Move combustible materials away from the work site. If you
can not move them, protect them with fireproof covers.

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, Office of Technology Assessment, Biological Effects
of Power Frequency Electric & Magnetic Fields - Background Paper,
OTA-BP-E-63 (Washington, DC: U.S. Government Printing Office, May

1989): “...there is now a very large volume of scientific findings based
on experiments at the cellular level and from studies with animals
and people which clearly establish that low frequency magnetic fields
interact with, and produce changes in, biological systems. While most
of this work is of very high quality, the results are complex. Current
scientific 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 definite 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.

ABOUT PACEMAKERS:

The above procedures are among those also normally
recommended for pacemaker wearers. Consult your
doctor for complete information.

WARNING

NEVER perform welding, heating, or cutting operations
on a container that has held toxic, combustible or
flammable liquids, or vapors. NEVER perform welding,
heating, or cutting operations in an area containing com­bustible vapors, flammable liquids, or explosive dust.

B Housekeeping

WARNING

NEVER allow oxygen to contact grease, oil, or other
flammable substances. Although oxygen by itself will
not burn, these substances become highly explosive.
They can ignite and burn violently in the presence of
oxygen.

Keep ALL apparatus clean and free of grease, oil and other flammable
substances.

C Ventilation

WARNING

Adequately ventilate welding, heating, and cutting work
areas to prevent accumulation of explosive or toxic
concentrations of gases. Certain combinations of metals,
coatings, and gases generate toxic fumes. Use respira­tory protection equipment in these circumstances. When
welding/brazing, read and understand the Material Safety
Data Sheet for the welding/brazing alloy.

Safety Instructions 1-4 1-4 Manual 0-5073Manual 0-5073

SAFETY INSTRUCTIONS THERMAL ARC 161 S

!

!

!

D Personal Protection

Gas flames produce infrared radiation which may have a harmful effect
on the skin and especially on the eyes. Select goggles or a mask with
tempered lenses, shaded 4 or darker, to protect your eyes from injury
and provide good visibility of the work.

Always wear protective gloves and flame-resistant clothing to protect skin
and clothing from sparks and slag. Keep collars, sleeves, and pockets
buttoned. DO NOT roll up sleeves or cuff pants.

3. Store empty cylinders away from full cylinders. Mark them
“EMPTY” and close the cylinder valve.

4. NEVER use compressed gas cylinders without a pressure
reducing regulator attached to the cylinder valve.

5. Inspect the cylinder valve for oil, grease, and damaged
parts.

When working in a non-welding or cutting environment, always wear
suitable eye protection or face shield.

WARNING

Practice the following safety and operation precautions
EVERY TIME you use pressure regulation equipment.
Deviation from the following safety and operation
instructions can result in fire, explosion, damage to
equipment, or injury to the operator.

E Compressed Gas Cylinders

The Department of Transportation (DOT) approves the design and
manufacture of cylinders that contain gases used for welding or cut­ting operations.

1. Place the cylinder (Figure 1-1) where you will use it. Keep
the cylinder in a vertical position. Secure it to a cart, wall, work
bench, post, etc.

WARNING

DO NOT use the cylinder if you find oil, grease or dam­aged parts. Inform your gas supplier of this condition
immediately.

6. Momentarily open and close (called “cracking”) the cylinder
valve to dislodge any dust or dirt that may be present in the
valve.

CAUTION

Open the cylinder valve slightly. If you open the valve
too much, the cylinder could tip over. When cracking
the cylinder valve, DO NOT stand directly in front of
the cylinder valve. Always perform cracking in a well
ventilated area. If an acetylene cylinder sprays a mist
when cracked, let it stand for 15 minutes. Then, try to
crack the cylinder valve again. If this problem persists,
contact your gas supplier.

1.03 Principal Safety Standards

Safety in Welding and Cutting, ANSI Standard Z49.1, from American
Welding Society, 550 N.W. LeJeune Rd., Miami, FL 33126.

Figure 1-1: Gas Cylinders

WARNING

Cylinders are highly pressurized. Handle with care.
Serious accidents can result from improper handling
or misuse of compressed gas cylinders DO NOT drop
the cylinder, knock it over, or expose it to excessive
heat, flames or sparks. DO NOT strike it against other
cylinders. Contact your gas supplier or refer to CGA P­1 “Safe Handling of Compressed Gases in Containers”
publication.

NOTE

CGA P-1 publication is available by writing the Com­pressed Gas Association, 4221 Walney Road, 5th Floor,
Chantilly,VA 20151-2923

2. Place the valve protection cap on the cylinder whenever
moving it, placing it in storage, or not using it. Never drag or
roll cylinders in any way. Use a suitable hand truck to move
cylinders.

Safety and Health Standards, OSHA 29 CFR 1910, from Superintendent
of Documents, U.S. Government Printing Office, 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.

Manual 0-5073 1-5 Safety InstructionsSafety Instructions

THERMAL ARC 161 S SAFETY INSTRUCTIONS

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

Voltage Input

Single Phase

Three Phase

Three Phase Static
Frequency Converter­Transformer-Rectifier

Dangerous Voltage

Off

On

Panel/Local

Shielded Metal
Arc Welding (SMAW)

Gas Metal Arc
Welding (GMAW)

Increase/Decrease

Circuit Breaker

AC Auxiliary Power

Remote

Duty Cycle

Percentage

Amperage

Voltage

Hertz (cycles/sec)

Frequency

Negative

Positive

Direct Current (DC)

Protective Earth
(Ground)

Line

Line Connection

Auxiliary Power

Receptacle Rating­Auxiliary Power

Art # A-04130

115V 15A

t

t1

t2

%

X

IPM

MPM

t

V

Fuse

Wire Feed Function

Wire Feed Towards
Workpiece With
Output Voltage Off.

Preflow Time

Postflow Time

Spot Time

Spot Weld Mode

Continuous Weld
Mode

Press to initiate wirefeed and
welding, release to stop.

Purging Of Gas

Inches Per Minute

Meters Per Minute

Welding Gun

Burnback Time

Press and hold for preflow, release
to start arc. Press to stop arc, and
hold for preflow.

4 Step Trigger
Operation

2 Step Trigger
Operation

1.04 Symbol Chart

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

Safety Instructions 1-6 1-6 Manual 0-5073Manual 0-5073

SAFETY INSTRUCTIONS THERMAL ARC 161 S

!

1.05 Precautions De Securite En Soudage A L’arc

MISE EN GARDE

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 fin de ces instructions
de sécurité.

SEULES DES PERSONNES QUALIFIEES DOIVENT FAIRE DES TRAVAUX D’INSTALLATION, DE REPARATION, D’ENTRETIEN ET D’ESSAI.

1.06 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 semi­automatique avec fil, ce dernier, le rouleau ou la bobine
de fil, le logement des galets d’entrainement et toutes les
pièces métalliques en contact avec le fil de soudage sont
sous tension. Un équipement inadéquatement installé ou
inadéquatement mis à la terre est dangereux.

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
afin d’éviter une mise en marche accidentelle.

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 porte-électrodes raccordés à deux sources de courant en
même temps. Ne jamais toucher quelqu’un d’autre avec l’électrode
ou le porte-électrode.

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 confinés 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.

AVERTISSEMENT

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.

Manual 0-5073 1-7 Safety InstructionsSafety Instructions

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.

THERMAL ARC 161 S SAFETY INSTRUCTIONS

1. Portez une casque de soudeur avec filtre 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.

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

LES VAPEURS ET LES FUMEES SONT DANGEREUSES
POUR LA SANTE.

Le soudage dégage des vapeurs et des fumées dangere­uses à respirer.

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 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 fiches signalétiques et les consignes du fabricant relatives
aux métaux, aux produits consummables, aux revêtements et aux
produits nettoyants.

5. Ne travaillez dans un espace confiné 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.

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.

SELECTION DES NUANCES DE FILTRES OCULAIRS POUR LA PROTECTION

DES YEUX EN COUPAGE ET SOUDAGE (selon AWS á 8.2-73)

Opération de coupage

ou soudage

Brassage tendre
au chalumeau

Brassage fort
au chalumeau

Oxycoupage métaux ferreux toutes conditions 12

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

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

épais plus de 6 po. (150 mm) 5 ou 6

Soudage aux gaz Soudage á l'arc Plasma (PAW) toutes dimensions 12

mince moins de 1/8 po. (3 mm) 4 ou 5

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

épais plus de 1/2 po. (12 mm) 6 ou 8 épais 14

Soudage á l'arc avec
électrode enrobees
(SMAW)

Dimension d'électrode ou

Epiasseur de métal ou

Intensité de courant

toutes conditions 2

toutes conditions 3 ou 4 métaux non-ferreux toutes conditions 11

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

filtre oculaire

Opération de coupage

ou soudage

Soudage á l'arc sous gaz
avec fil plein (GMAW)

Soudage á l'arc sous gaz avec
électrode de tungstène
(GTAW)

Soudage á l'hydrogène
atomique (AHW)

Soudage á l'arc avec
électrode de carbone (CAW)

Gougeage Air-Arc avec
électrode de carbone

Dimension d'électrode ou

Epiasseur de métal ou

Intensité de courant

toutes conditions 12

toutes conditions 12

toutes conditions 12

épais plus de 400 amperès 14

Nuance de

filtre

oculaire

Safety Instructions 1-8 1-8 Manual 0-5073Manual 0-5073

SAFETY INSTRUCTIONS THERMAL ARC 161 S

AVERTISSEMENT

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 des brûlures. Le contact accidentel de l’électrode ou
du fil-électrode avec un objet métallique peut provoquer
des étincelles, un échauffement ou un incendie.

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 inflammables.

3. Enlevez toutes matières inflammables dans un rayon de 10, 7
mètres autour de l’arc, ou couvrez-les soigneusement avec des
bâches approuvées.

4. Méfiez-vous des projections brulantes de soudage susceptibles
de pénétrer dans des aires adjacentes par de petites ouvertures
ou fissures.

5. Méfiez-vous des incendies et gardez un extincteur à portée de la
main.

6. N’oubliez pas qu’une soudure réalisée sur un plafond, un plancher,
une cloison ou une paroi peut enflammer 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.

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.

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
fixe 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
spécifique; 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, identifiée dans la liste de documents ci-dessous.

9. Ne dégelez pas les tuyaux avec un source de courant.

10. Otez l’électrode du porte-électrode ou coupez le fil 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 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 confiné, les
fumées d’échappement doivent être envoyées à l’extérieur, loin
des prises d’air du bâtiment.

AVERTISSEMENT

LE CARBURANT PEUR CAUSER UN INCENDIE OU UNE
EXPLOSION.

Le carburant est hautement inflammable.

1. Arrêtez le moteur avant de vérifier le niveau e carburant ou de
faire le plein.

Manual 0-5073 1-9 Safety InstructionsSafety Instructions

THERMAL ARC 161 S SAFETY INSTRUCTIONS

2. Ne faites pas le plein en fumant ou proche d’une source d’étincelles
ou d’une flamme nue.

3. Si c’est possible, laissez le moteur refroidir avant de faire le plein
de carburant ou d’en vérifier 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

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 qualifiées 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.

6. Réinstallez les capots ou les protecteurs et fermez les portes après
des travaux d’entretien et avant de faire démarrer le moteur.

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.

PLOMB AVERTISSEMENT

Ce produit contient des produits chimiques, comme
le plomb, ou engendre des produits chimiques,
reconnus par l’état de Californie comme pou­vant être à l’origine de cancer, de malformations
fœtales ou d’autres problèmes de reproduction.
Il faut se laver les mains après toute manipulation.
(Code de Californie de la sécurité et santé, paragraphe

25249.5 et suivants)

1.07 Informations Générales de Sécurité

A Prévention D’incendie

Les opérations de soudage utilisent le feu ou la combustion comme outil
de base. Ce processus est très utile quand il est correctement contrôlé.

1. La zone doit comporter un sol ignifugé.

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.

Safety Instructions 1-10 1-10 Manual 0-5073Manual 0-5073

2. Les établis ou tables utilisés pendant les opérations de
soudage doivent avoir un revêtement ignifuge.

3. Utilisez des écrans résistants à la chaleur ou en matériau
approuvé pour protéger les cloisons proches ou le sol vul­nérable des étincelles et du métal chaud.

4. Gardez un extincteur approuvé du bon type et de la bonne taille
dans la zone de travail. Inspectez-le régulièrement pour vous
assurer qu’il est en état de fonctionner. Apprenez à vous en
servir.

5. Enlevez tous les matériaux combustibles de la zone de travail.
Si vous ne pouvez pas les enlever, protégez-les avec une couvre
ignifuge.

SAFETY INSTRUCTIONS THERMAL ARC 161 S

!

!

!

!

!

AVERTISSEMENT

N’effectuez JAMAIS d’opérations de soudage sur un
récipient qui a contenu des liquides ou vapeurs toxiques,
combustibles ou inflammables. N’effectuez JAMAIS
d’opérations de soudage dans une zone contenant des
vapeurs combustibles, des liquides inflammables ou des
poussières explosives.

B Entretien des Locaux

AVERTISSEMENT

Ne laissez jamais l’oxygène en contact avec la graisse,
l’huile ou d’autres substances inflammables. Bien que
l’oxygène ellemême ne brûle pas, ces substances peuvent
devenir extrêmement explosives. Elles peuvent prendre
feu et brûler violemment en présence d’oxygène.

Gardez TOUS les appareils propres et exempts de graisse, huile ou
autres substances inflammables.

C Aération

AVERTISSEMENT

Ventilez les zones de soudage, chauffage et découp­age de façon adéquate pour éviter l’accumulation de
gaz explosifs ou toxiques. Certaines combinaisons de
métaux, revêtements et gaz génèrent des fumées tox­iques: Utilisez un équipement de protection respiratoire
dans ces circonstances. Si vous soudez ou brasez, lisez
et assimilez la fiche technique de sécurité de matériau
relative à l’alliage de soudage/brasage.

D Protection Personnelle

Les flammes de gaz produisent une radiation infrarouge qui peut avoir
un effet néfaste sur la peau, et particulièrement sur les yeux. Choisis­sez des lunettes ou un masque avec des verres trempés assombris
au niveau 4 ou plus sombre, pour protéger vos yeux des dommages
et garder une bonne visibilité sur le travail.

Portez en permanence des gants de protection et des vêtements
ignifuges pour la protection de la peau et des vêtements contre les
étincelles et le laitier. Gardez col, manches et poches boutonnés. Il ne
faut pas remonter vos manches ou les pantalons à revers.

AVERTISSEMENT

Mettez en pratique les procédures de sécurité et de
mode opératoire suivantes à chaque fois que vous
utilisez cet appareil de régulation de pression. Si vous
déviez de ces procédures, cela peut entraîner incendie,
explosion, dégâts matériels et/ou blessures corporelles
pour l’opérateur.

E Bouteilles de Gaz Comprimé

Le Département des Transports américain (DOT) approuve la concep­tion et la fabrication des bouteilles qui contiennent les gaz utilisés pour
les opérations de soudage ou de découpage.

1. Placez la bouteille (Le schéma 1) là où elle sera utilisée. Gardez-la
en position verticale. Fixez-la sur un chariot une cloison, un établi,
etc.

Le schéma 1-1: Cylindres de gaz

AVERTISSEMENT

Les bouteilles sont sous haute pression. Manipulez-les avec
précautions. Des accidents sérieux peuvent résulter d’une
mauvaise manutention ou d’un mauvais emploi des bouteilles
de gaz comprimé. NE faites PAS tomber la bouteille, ne la cognez
pas, ne l’exposez pas à une chaleur excessive, aux flammes ou
étincelles. NE la cognez PAS contre d’autres bouteilles. Contactez
votre fournisseur de gaz ou reportezvous à la publication CGA
P-1 “Manipulation sécurisée des gaz comprimés en conteneur”
pour plus d’informations sur l’utilisation et la manutention des
bouteilles.

AVIS

Ce document CGA p. t peut être obtenu en écrivant à
“Compressed Gas Association”, 4221 Walney Roed,
5th Floor. Chantilly, VA 20151.2923, USA.

Quand vous travaillez dans un environnement non dédié au soudage
ou découpage, portez toujours une protection des yeux appropriées
ou un masque facial.

Manual 0-5073 1-11 Safety InstructionsSafety Instructions

2. Placez le bouchon de protection de vanne sur la bouteille
à chaque fois que vous la déplacez ou ne l’utilisez pas. Ne
faites jamais glisser ou rouler d’aucune manière les bouteilles.
Utilisez un diable approprié pour les déplacer.

3. Entreposez les bouteilles vides à l’écart des bouteilles pleines.
Marquez-les “VIDE” et refermez leur vanne.

4. N’utilisez JAMAIS des bouteilles de gaz comprimé sans un
régulateur de pression en série sur la vanne de bouteille.

5. Inspectez la vanne de bouteille pour y détecter de l’huile ou
de la graisse, ou dès pièces endommagées.

THERMAL ARC 161 S SAFETY INSTRUCTIONS

!

AVERTISSEMENT

N’UTILISEZ PAS la bouteille si vous trouvez de l’huile,
de la graisse ou des pièces endommagées. Informez
immédiatement votre fournisseur de’ gaz de cet état.

6. Ouvrez et fermez momentanément la vanne de la bouteille,
délogeant ainsi d’éventu lIes poussières ou saletés. qui pour­raient être présentes dans la vanne.

Mise en Garde

Ouvrez la vanne de bouteille légèrement. Si vous l’ouvrez
trop en grand, la bouteille pourrait se renverser. Quand
vous ouvrez/fermez rapidement la vanne de bouteille, ne
vous tenez pas directement devant. Opérez toujours cette
opération dans une zone bien ventilée. Si une bouteille
d’acétylène crache un brouillard, laissez reposer pendant
15 minutes. Essayez de nouveau la vanne. Si le problème
persiste, contactez votre fournisseur de gaz.

1.08 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 Office, 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.

Safety Instructions 1-12 1-12 Manual 0-5073Manual 0-5073

SAFETY INSTRUCTIONS THERMAL ARC 161 S

Soudage á L’arc Avec
Electrode Non Fusible
(GTAW)

Decoupe Arc Carbone
(CAC-A)

Courant Constant

Tension Constante
Ou Potentiel Constant

Haute Température

Force d'Arc

Amorçage de L’arc au
Contact (GTAW)

Inductance Variable

Tension

Mono Phasé

Trois Phasé

Tri-Phase Statique

Fréquence Convertisseur
Transformateur-Redresseur

Tension dangereuse

Hors Tension

Sous Tension

Panneau/Local

Soudage Arc Electrique
Avec Electrode Enrobé
(SMAW)

Soudage á L’arc Avec
Fil Electrodes Fusible
(GMAW)

Augmentez/Diminuer

Disjoncteur

Source AC Auxiliaire

Distant

Facteur de Marche

Pourcentage

Intensité de Courant

Tension

Hertz (cycles/sec)

Fréquence

Négatif

Positif

Courant Continue (DC)

Terre de Protection

Ligne

Connexion de la Ligne

Source Auxiliaire

Classement de Prise­Source Auxiliaire

Art # A-07639

115V 15A

t

t1

t2

%

X

IPM

MPM

t

Fusible

Déroulement du Fil

Alimentation du Fil Vers
la Pièce de Fabrication
Hors Tension

Durée de Pré-Dèbit

Durée de Post-Dèbit

Duréc du Pulse

Soudure Par Point

Appuyez pour dèruarer
l’alimentation du fils et la soudure,
le relâcher pour arrêter.

Purge Du Gaz

Mode Continu de
Soudure

Pouces Par Minute

Mètres Par Minute

Torch de

Soudage

Probléme de Terre

Maintenez appuyez pour pré-dèbit,
relailez pour initier l'arc. Appuyez
pour arrêter l'arc, et mainteuir pour
pré-dèbit.

Détente à 4-Temps

Détente à 2-Temps

V

1.09 Graphique de Symbole

Seulement certains de ces symboles apparaîtront sur votre modèle.

Manual 0-5073 1-13 Safety InstructionsSafety Instructions

This page left blank intentionally.

INTRODUCTION THERMAL ARC 161 S

!

!

SECTION 2:

INTRODUCTION

2.01 How to Use This Manual

This Operating Manual usually applies to the part numbers
listed on page i. If none are underlined, they are all covered
by this manual. To ensure safe operation, read the entire
manual, including the chapter on safety instructions and
warnings. Throughout this manual, the word 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

Gives information regarding possible personal
injury. Warnings will be enclosed in a box
such as this.

CAUTION

Refers to possible equipment damage. Cau­tions will be shown in bold type.

2.04 Description

This compact inverter welding machine has infinitely
adjustable welding current from 10 to 160 amps. It uses
standard general purpose STICK (SMAW) 3/32” (2.5mm)
electrodes for light gauge work, generally less than
1/8” (3.2mm) thick and STICK (SMAW) 1/8” (3.2mm)
electrodes for heavier material. The unit also has a LIFT
TIG (GTAW) welding mode that offers stable TIG welding
characteristics when used with a suitable TIG torch and
shielding gas.

2.05 Transportation Methods

WARNING

ELECTRIC SHOCK can kill. DO NOT TOUCH
live electric parts. Disconnect input power
conductors from de-energized supply line
before moving the welding power source.

NOTE

Offers helpful information concerning certain
operating procedures. Notes will be shown
in italics

2.02 Equipment Identification

The unit’s identification number (specification or part
number), model, and serial number usually appear on
a nameplate attached to the machine. Equipment which
does not have a nameplate attached to the machine is
identified only by the specification or part number printed
on the shipping container. Record these numbers 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 file 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
identification numbers as described above along with a
full description of the parts in error.

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 secure unit on a proper skid before transporting.

2.06 Duty Cycle

The rated duty cycle of a Welding Power Source, is the
percentage of a ten minute time period that it may be
operated at its rated output current without exceeding
the temperature limits of the insulation of the component
parts. To explain the 10 minute duty cycle period, suppose
a Welding Power Source is designed to operate with
a 30% duty cycle at 160 amperes and 26.4 volts. This
means that it has been designed and built to provide the
rated amperage (160A) for 3 minutes, i.e. arc welding
time, out of every 10 minute period (30% of 10 minutes
is 3 minutes). During the other 7 minutes of the 10
minute period the Welding Power Source must idle and
be allowed to cool.

Manual 0-5073 2-1 Introduction

THERMAL ARC 161 S INTRODUCTION

2.07 Specifications

Power Source Part Number W1003600
Mains Power

Nominal Supply Voltage AC 115V AC 208/230V
Number of Phases Single Phase Single Phase
Input Voltage Range AC 104- 127V AC 187- 253V
Nominal Supply Frequency 50/60 Hz 50/60 Hz
Effective Input Current (l1eff) 16.7 Amps 12.7 Amps
Maximum Input Current (l1 max) ∆ 27.3 Amps ∆ 25 Amps
Single Phase Generator Requirements [Continuous rating at

nominal supply voltage with maximum output for STICK (SMAW)
welding]

Welding Output

Welding Current Range 10 - 110 Amps 10 - 160 Amps
Nominal DC Open Circuit Voltage (OCV) 71V 71V
Welding Output, 104º F (40º C), 10 min.

100A @ 35%, 24.0V

(Quoted figures refer to STICK (SMAW) output)

60A @ 100%, 22.4V
Rated Input Current (A) 27.3A 25A
for STICK (SMAW) Welding Io = 100A @ 24.0V Io = 160A @ 26.4V
Rated Input Current (A) 19A 15.5A
for LIFT TIG (GTAW) Welding Io = 110A @ 14.4V Io = 160A @ 16.4V
Rated Output for STICK (SMAW) Welding 24.0V, 100A @ 35% 26.4V, 160A @ 30%
Rated Output for LIFT TIG (GTAW) Welding 14.4V, 110A @ 50% 16.4V, 160A @ 30%
Duty Cycle (%) 35% @ 100A 30% @ 160A
Welder Type Inverter Power Source
Output Terminal Type Heavy Duty DinseTM 50

Classification

Protection Class IP23S
Standards EN 60974-1

Cooling Method Fan Cooled

Dimensions and Weight

Welding Power Source Mass 17.4 lb. (7.9 kg)
Welding Power Source Dimensions (Height x Width x Depth) H 9.0” x W 5.3” x D 15.5”

∆ The recommended time delay fuse or circuit breaker size is 30 amp. An individual branch circuit capable of carrying 30 amperes

and protected by fuses or circuit breaker is recommended for this application. 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)

4 KVA 6 KVA

160A @ 30%, 26.4V

80A @ 60%, 23.2V

100A @ 60%, 24.0V
80A @ 100%, 23.2V

EN50199

(H230mm x W135mm x D393mm)

Thermal Arc continuously strives to produce the best product possible and therefore reserves the right to change, improve or revise the speci­fications 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 specified in the table above are optimal values, your values may differ. Individual equipment may differ from the above specifications
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..

Introduction 2-2 Manual 0-5073

INSTALLATION THERMAL ARC 161 S

!

SECTION 3:

INSTALLATION

3.01 Environment

These units are designed for use in environments with increased hazard of electric shock. Examples of environments
with increased hazard of electric shock 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 increased hazard of electric shock do not include places where electrically conductive parts 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 32°F (0°C) to 104° F (40° 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” (300mm) or more from walls or similar that could restrict natural air flow for
cooling

WARNING

Thermal Arc advises that this equipment be electrically connected by a qualified 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. Lock-out/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

Manual 0-5073 3-1 3-1 InstallationInstallation

THERMAL ARC 161 S INSTALLATION

Welding Power Supply

Primary Power Cable

120

120V,V,

20A, 1Ø

15A, 1Ø

208-230V, 50A, 1Ø

The Adapters enable
connection to all these
power outlets

Art# A-09862

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.

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.

Refer to Figure 3-1:

1. Connect end of ground (GREEN or GREEN/YELLOW) 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 3-1 as a guide to select line fuses for the disconnect switch.

Input Voltage Circuit Breaker or Fuse Size

115V 30A

208-230V 50A

Table 3-1: Fuse Guide

CAUTION

The time-delay fuses or circuit breaker of an individual branch circuit may have nuisance tripping when
welding with this product due to the amperage rating of the time-delay fuses or circuit breaker.

Figure 3-1: Electrical Input Connections

Installation 3-2 3-2 Manual 0-5073Manual 0-5073

INSTALLATION THERMAL ARC 161 S

Input Power

Each unit incorporates an INRUSH circuit. When the MAIN CIRCUIT SWITCH is turned on, the inrush circuit provides
pre-charging for the input capacitors. A relay in the Power Control Assembly (PCA) will turn on after the input capacitors
have charged to operating voltage (after approximately 5 seconds)

NOTE

Damage to the PCA could occur if 253 VAC or higher is applied to the Primary Power Cable.

Model Primary Supply Lead

Size (Factory Fitted)

Thermal Arc

161 S

12 AWG (3.3mm²)

Table 3-2: Primary Circuit Sizes to Achieve Maximum Current

Minimum Primary

Current Circuit Size

(Vin/Amps)

115V/27.3A - 100A @ 35%

115V/20A 110A @ 50% ­208-230V/25A - 160A @ 30%
208-230V/15A 160A @ 30% -

LIFT TIG (GTAW) STICK (SMAW)

Current & Duty Cycle

Manual 0-5073 3-3 3-3 InstallationInstallation

THERMAL ARC 161 S INSTALLATION

3.04 Electromagnetic Compatibility

WARNING

Extra precautions for Electromagnetic
Compatibility may be required when this
Welding Power Source is used in a domestic
situation.

A. Installation and Use - Users Responsibility

The user is responsible for installing and using the welding
equipment according to the manufacturer’s instructions.
If electromagnetic disturbances are detected then it shall
be the responsibility of the user of the welding equipment
to resolve the situation with the technical assistance of
the manufacturer. In some cases this remedial action
may be as simple as earthing the welding circuit, see
NOTE below. In other cases it could involve constructing
an electromagnetic screen enclosing the Welding Power
Source and the work, complete with associated input
filters. In all cases, electromagnetic disturbances shall be
reduced to the point where they are no longer Trouble­some.

B. Assessment of Area

Before installing welding equipment, the user shall make
an assessment of potential electromagnetic problems in
the surrounding area. The following shall be taken into
account.

1. Other supply cables, control cables, signaling and
telephone cables; above, below and adjacent to the
welding equipment.

The size of the surrounding area to be considered will
depend on the structure of the building and other activities
that are taking place. The surrounding area may extend
beyond the boundaries of the premises.

C. Methods of Reducing Electromagnetic Emissions

1. Mains Supply

Welding equipment should be connected to the

mains supply according to the manufacturer’s
recommendations. If interference occurs, it may be
necessary to take additional precautions such as
filtering of the mains supply. Consideration should
be given to shielding the supply cable of permanently
installed welding equipment in metallic conduit or
equivalent. Shielding should be electrically continuous
throughout its length. The shielding should be
connected to the Welding Power Source so that good
electrical contact is maintained between the conduit
and the Welding Power Source enclosure.

2. Maintenance of Welding Equipment

The welding equipment should be routinely maintained

according to the manufacturer’s recommendations. All
access and service doors and covers should be closed
and properly fastened when the welding equipment
is in operation. The welding equipment should not
be modified in any way except for those changes
and adjustments covered in the manufacturer’s
instructions. In particular, the spark gaps of arc
striking and stabilizing devices should be adjusted
and maintained according to the manufacturer’s
recommendation

3. Welding Cables

2. Radio and television transmitters and receivers.

3. Computer and other control equipment.

4. Safety critical equipment, e.g. guarding of industrial
equipment.

5. The health of people around, e.g. the use of pace­makers and hearing aids.

6. Equipment used for calibration and measurement.

7. The time of day that welding or other activities are to
be carried out.

8. The immunity of other equipment in the environment:
the user shall ensure that other equipment being used
in the environment is compatible: this may require
additional protection measures.

Installation 3-4 3-4 Manual 0-5073Manual 0-5073

The welding cables should be kept as short as possible

and should be positioned close together, running at or
close to the floor level.

4. Equipotential Bonding

Bonding of all metallic components in the welding

installation and adjacent to it should be considered.
However, metallic components bonded to the work
piece will increase the risk that the operator could
receive a shock by touching the metallic components
and the electrode at the same time. The operator
should be insulated from all such bonded metallic
components.

INSTALLATION THERMAL ARC 161 S

5. Earthing of the Work Piece

Where the work piece is not bonded to earth for

electrical safety, nor connected to earth because of its
size and position, e.g. ship’s hull or building steelwork,
a connection bonding the work piece to earth may
reduce emissions in some, but not all instances. Care
should be taken to prevent the earthing of the work
piece increasing the risk of injury to users, or damage
to other electrical equipment. Where necessary, the
connection of the work piece to earth should be made
by direct connection to the work piece, but in some
countries where direct connection is not permitted, the
bonding should be achieved by suitable capacitance,
selected according to national regulations.

6. Screening and Shielding

Selective screening and shielding of other cables

and equipment in the surrounding area may alleviate
problems of interference. Screening the entire
welding installation may be considered for special
applications.

3.05 Setup for Welding

NOTE

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 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 fine tune the welding current 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.

CAUTION

Remove any packaging material prior to use.
Do not block the air vents at the front or rear
of the Welding Power Source.

Manual 0-5073 3-5 3-5 InstallationInstallation

THERMAL ARC 161 S INSTALLATION

200A

Set Welding Current
as specified by the
Electrode Manufacturer.

Set Process Selection
Switch to SMAW (Stick)

Positive Output
Terminal
(Dinse™ 50)

Negative Output
Terminal
(Dinse™ 50)

Art #: A-09878

3.06 STICK (SMAW) Setup

STICK (SMAW) Mode Sequence of Operation

Before any welding is to begin, be sure to wear all
appropriate and recommended safety equipment.

1. Switch the ON/OFF Switch (located on the rear panel)
to OFF.

2. Connect the ground clamp cable to the negative output
terminal, and the electrode holder cable to the positive
output terminal.

This set up is known as DC Electrode Positive or
reverse polarity. Please consult with the stick electrode
manufacturer for specific polarity recommendations.

Installation 3-6 3-6 Manual 0-5073Manual 0-5073

Figure 3-2: Setup for STICK (SMAW) Welding

CAUTION

NOTE

3. Connect the ground clamp to your workpiece.

4. Plug the power cable into the appropriate outlet, and
turn the switch to the “ON” position. The power L.E.D
light should illuminate.

5. Set the “Process Selection Switch” to STICK.

6. Set the weld current control knob to the desired
amperage.

7. Install a stick electrode in the electrode holder.

8. You are now ready to begin STICK Welding

NOTE

Gently strike the electrode on the work piece to generate a
welding arc, and slowly move along the work piece while
holding a consistent arc length above base metal.

INSTALLATION THERMAL ARC 161 S

Set Process Selection
Switch to GTAW (Lift TIG).

Positive Output
Terminal
(Dinse™ 50)

Negative
Output
Terminal
(Dinse™ 50)

Art #: A-09880

Set Welding Current
as specified by the
Electrode Manufacturer.

Secure the gas cylinder in an
upright position by chaining it
to a stationary support to prevent
falling or tipping.

3.07 LIFT TIG (GTAW) Setup

LIFT TIG (GTAW) Sequence of Operation

Before any welding is to begin, be sure to wear all
appropriate and recommended safety equipment.

1. Switch the ON/OFF Switch (located on the rear panel)
to OFF.

2. Connect the ground clamp cable to positive output
terminal, and the TIG torch cable to the negative output
terminal.

This set up is known as Straight Polarity or DC Electrode
Negative. This is commonly used for DC TIG welding on
most materials such as steel and stainless steel.

Manual 0-5073 3-7 3-7 InstallationInstallation

Figure 3-3: Setup for LIFT TIG (GTAW) Welding

CAUTION

NOTE

3. Using a secured Argon cylinder, slowly crack open then
close the cylinder valve while standing off to the side
of the valve. This will remove any debris that may be
around the valve & regulator seat area.

4. Install the regulator (for details of VICTOR regulator,
please refer to 3.08 ) and tighten with a wrench.

5. Connect the gas hose to the outlet of the Argon
regulator, and tighten with a wrench.

6. Be sure the gas valve on the torch is closed, and
slowly open the Argon Cylinder Valve to the fully open
position.

7. Connect the ground clamp to your work piece.

8. Plug the power cable into the appropriate outlet, and
turn the switch to the “ON” position. The power L.E.D.
light should illuminate.

THERMAL ARC 161 S INSTALLATION

!

!

9. Set the “Process Selection Switch” to LIFT TIG

10. Set the weld current control knob to the desired
amperage.

11. The tungsten must be ground to a blunt point in order
to achieve optimum welding results. It is critical
to grind the tungsten electrode in the direction the
grinding wheel is turning.

12. Install the tungsten with approximately 1/8” to ¼”
sticking out from the gas cup, ensuring you have
correct sized collet.

13. Tighten the back cap then open the valve on the
torch.

14. You are now ready to begin TIG Welding.

3.08 Victor Regulator

Pressure regulator (Figure 3-4) attached to the cylinder
valve reduce high cylinder pressures to suitable low
working pressures for welding, cutting, and other
applications.

2. The regulator body will be stamped “IN” or “HP”
at the inlet port. Attach the inlet port to the system
supply pressure connection.

3. Wrap pipe threads with Teflon tape 1 1/2 to 2
turns to effect a seal. If other sealants are used,
they must be compatible with the gas that will be
used in the system.

4. If gauges are to be attached to the regulator and
the regulator is stamped and listed by a third party
(i.e. “UL” or “ETL”). The following requirements
must be met:

a) Inlet gauges over 1000 PSIG (6.87 mPa) shall

conform with the requirements of UL 404,
“Indicating Pressure Gauges for Compressed
Gas Service.”

b) Low pressure gauges must be UL recognized

for the class of regulator they are being used
on according to UL252A.

WARNING

Figure 3-4: Victor CS Regulator

Use the regulator for the gas and pressure for
which it is designed. NEVER alter a regulator
for use with any other gas.

Regulators purchased with open 1/8”, 1/4”,
3/8”, or 1/2” NPT ports must be assembled
to their intended system.

WARNING

NOTE

DO NOT use a regulato r that delivers
pressure exceeding the pressure rating of the
downstream equipment unless provisions
are made to prevent over-pressurization (i.e.
system relief valve). Make sure the pressure
rating of the downstream equipment is
compatible with the maximum delivery
pressure of the regulator.

5. Be sure that the regulator has the correct pressure
rating and gas service for the cylinder used.

1. Note the maximum inlet pressure stamped on the
regulator. DO NOT attach the regulator to a system
that has a higher pressure than the maximum
rated pressure stamped on the regulator.

Installation 3-8 3-8 Manual 0-5073Manual 0-5073

INSTALLATION THERMAL ARC 161 S

!

Art # A-09845

!

!

Art # A-09828

!

6. Carefully inspect the regulator for damaged
threads, dirt, dust, grease, oil, or other flammable
substances. Remove dust and dirt with a clean
cloth. Be sure the inlet swivel filter is clean
and in place. Attach the regulator (Figure 3-5)
to the cylinder valve. Tighten securely with a
wrench.

WARNING

DO NOT attach or use the regulator if oil,
grease, flammable substances or damage is
present! Have a qualified repair technician
clean the regulator or repair any damage.

9. Slowly and carefully open the cylinder valve
(Figure 3-6) until the maximum pressure shows
on the high pressure gauge.

Figure 3-6: Open Cylinder Valve

10. On all cylinders, except acetylene, open the valve
completely to seal the valve packing. On gaugeless
regulators, the indicator will register the cylinder
contents open.

11. On acetylene cylinders, open the valve 3/4 of a
turn and no more than 1-1/2.

Figure 3-5: Regulator to Cylinder Valve

7. Before opening the cylinder valve, turn the
regulator adjusting screw counterclockwise until
there is no pressure on the adjusting spring and
the screw turns freely.

8. Relief Valve (where provided): The relief valve is
designed to protect the low pressure side of the
regulator from high pressures. Relief valves are
not intended to protect downstream equipment
from high pressures.

WARNING

DO NOT tamper with the relief valve or
remove it from the regulator.

WARNING

Acetylene delivery pressure must not exceed
15 PSIG (103 kPa) or 30 PSIG (207 kPa).
Acetylene can dissociate (decompose with
explosive violence) above these pressure
limits.

Keep the cylinder valve wrench, if one is
required, on the cylinder valve to turn off the
cylinder quickly, if necessary.

12. Attach the desired downstream equipment.

WARNING

CAUTION

Stand to the side of the cylinder opposite the
regulator when opening the cylinder valve.
Keep the cylinder valve between you and the
regulator. For your safety, NEVER STAND
IN FRONT OF OR BEHIND A REGULATOR
WHEN OPENING THE CYLINDER VALVE!

Manual 0-5073 3-9 3-9 InstallationInstallation

THERMAL ARC 161 S INSTALLATION

!

3.09 Leak Testing the System

Leak test the system before putting into operation.

1. Be sure that there is a valve in the downstream
equipment to turn off the gas flow.

2. With the cylinder valve open, adjust the regulator
to deliver the maximum required delivery
pressure.

3. Close the cylinder valve.

4. Turn the adjusting screw/knob counterclockwise
one turn.

a) If the high-pressure gauge reading drops,

there is a leak in the cylinder valve, inlet fitting,
or high-pressure gauge.

b) If the low-pressure gauge drops, there is a

leak in the downstream equipment, hose, hose
fitting, outlet fitting or low-pressure gauge.
Check for leaks using an approved leak detec­tor solution.

c) If the high-pressure gauge drops and the low-

pressure gauge increases at the same time,
there is a leak in the regulator seat.

3.10 When You Finish Using the
Regulator

1. Close the cylinder valve.

2. Open the valve on the downstream equipment.
This drains all pressure from the system.

3. Close the valve on the downstream equipment.

4. Turn the adjusting screw counterclockwise to
release the tension on the adjusting spring.

5. Check the gauges after a few minutes for
verification that the cylinder valve is closed
completely.

3.11 Storage of the Regulator

When the regulator is not in use and has been removed
from the cylinder, it should be stored in an area where
it will be protected from dust, oil, and grease. The inlet
and outlet should be capped to protect against internal
contamination and prevent insects from nesting.

d) If the regulator requires service or repair, take

it to a qualified repair technician.

5. Once leak testing has been performed and there
are no leaks in the system, slowly open the
cylinder valve and proceed.

If a leak has been detected anywhere in the
system, discontinue use and have the system
repaired. DO NOT use leaking equipment. Do
not attempt to repair a leaking system while
the system is under pressure.

WARNING

Installation 3-10 3-10 Manual 0-5073Manual 0-5073

OPERATION THERMAL ARC 161 s

Art# A-09884

(B) Power On
Indicator

(C) Fault
Indicator

(A) Process
Selection
Switch

(D) Welding
Current
ǂ Control

SECTION 4:

OPERATION

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 the electrode.
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 electrode, 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 fine tune the welding current
to suit the specific application. Refer to the electrode
manufacture's literature for further information.

4.01 Front Panel

Front Panel

The welding power source is protected by a self re-setting
thermostat. The indicator will illuminate if the duty cycle
of the power source has been exceeded. If the Over Heat
light illuminates wait for the Over Heat light to extinguish
before resuming welding.

(A) Process Selection Switch

Switches between LIFT TIG and STICK Welding modes.

(B) Power On Indicator

The Power ON Indicator illuminates when the ON/OFF
switch is in the ON position and the nominal mains volt­age is present.

(C) Fault Indicator

The welding power source is protected by a self resetting
thermostat and over primary current protection devices.
Welding can not take place if the Fault Indicator lights up
or lights up continuously.

Thermostat Protection

If the Fault Indicator lights up then the duty cycle of the
power source has been exceeded, Leave the power on
and wait for the Warning Indicator to extinguish before
resuming welding.

Over Primary Current Protection

If the Fault Indicator lights up continuously then the
primary current into the main transformer has been ex­ceeded. Have an Accredited Thermal Arc Service Provider
inspect then repair the welder.

(D) Welding Current Control

The welding current is increased by turning the Weld
Current control knob clockwise or decreased by turning
the Weld Current control knob counterclockwise. The
welding current should be set according to the specific
application. Refer to the electrode manufacture's literature
for further information.

(E) ON/OFF Switch (located on rear panel - not
shown)

This switch controls the Mains Supply Voltage to the
Power Source.

Figure 4-1: Thermal Arc 161 S Controls

Manual 0-5073 4-1 4-1 Operation Operation

THERMAL ARC 161 S OPERATION

15 Amp Outlet

20 Amp Outlet

Output Scale for 115V

Output Scale for 230V

Art# A-09752

4.02 Welding Current Control
Explanation

15 Amp Outlet

The mains power 15 Amp circuit breaker or fuse should
not trip at this Weld Current value when STICK welding.

The environmental conditions that may cause the mains
power 15 Amp circuit breaker or fuse to trip are:

a) High ambient temperature

b) Worn parts in circuit breaker

c) Using an extension cable

d) Low line mains power voltage

20 Amp Outlet

The mains power 20 Amp circuit breaker or fuse should
not trip at this Weld Current value when STICK welding.

The environmental conditions that may cause the mains
power 20 Amp circuit breaker or fuse to trip are:

a) High ambient temperature

b) Worn parts in circuit breaker

Output Scale for 115V

The inside number scale identifies the available

output weld current for STICK or LIFT TIG weld modes.

STICK Mode: Identifies the STICK weld point for 15

Amp outlet.

Identifies the STICK weld point for 20

Amp outlet.

Exceeding these points will cause nui-

sance tripping of the circuit breaker or
fuse.

LIFT TIG Mode: A 15 Amp outlet is capable of supply-

ing enough input power for all LIFT TIG
output weld current values.

Nuisance tripping should not occur on a 15 Amp outlet.

Output Scale for 208/230V

The outside number scale identifies the available output
weld current for STICK or LIFT TIG weld modes.

Nuisance tripping should not occur on a 50A 208/230V
outlet for both STICK & LIFT TIG Modes.

c) Using an extension cable

d) Low line mains power voltage

Figure 4-2: Current Control

Operation 4-2 4-2 Manual 0-5073Manual 0-5073

OPERATION THERMAL ARC 161 S

4.03 STICK (SMAW) Electrode Polarity

Stick electrodes are generally connected to the "+" Posi­tive Output Terminal and the work lead to the "−" Nega­tive Output Terminal but if in doubt consult the electrode
manufacturers literature for further information.

4.04 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 pre-heating of heavy sections
necessary to give proper fusion of weld and base metal.

Types of Electrodes

Arc Welding electrodes are classified 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.

Metal Being Joined Electrode Comments

Mild Steel E6011 This electrode is used for all-position welding or for welding on

rusty, dirty, less-than-new metal. It has a deep, penetrating arc
and is often the first choice for repair or maintenance work.

Mild Steel E6013 This all-position, electrode is used for welding clean, new sheet

metal. Its soft arc has minimal spatter, moderate penetration and
an easy-to-clean slag.

Mild Steel E7014 All positional, ease to use electrode for use on thicker steel than

E6013. Especially suitable sheet metal lap joints and fillet welds,
general purpose plate welding.

Mild Steel E7018 A low-hydrogen, all-position electrode used when quality is an

issue or for hard-to-weld metals. It has the capability of producing
more uniform weld metal, which has better impact properties at
low temperatures.

Cast Iron Eni-Cl Suitable for joining all cast irons except white cast iron.

Stainless Steel E318L-16 High corrosion resistances. Ideal for dairy work etc.

Manual 0-5073 4-3 4-3 Operation Operation

THERMAL ARC 161 S OPERATION

4.05 GTAW Electrode Polarity

Connect the TIG torch to the "-" Negative Output Terminal and the work lead to the "+" Positive Output 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.

4.06 Guide for Selecting Filler Wire

Filler Wire Diameter DC Current (Amps)

1/16" (1.6mm) 20 - 90

3/32" (2.4mm) 65 - 115

1/8" (3.2mm) 100 - 165

4.07 Tungsten Electrode Current Ranges

Electrode Diameter DC Current

.040” (1.0mm) 25 - 85
1/16” (1.6mm) 50 - 160
3/32” (2.4mm) 135 - 235

4.08 Shielding Gas Selection

Carbon Steel Welding Argon

Stainless Steel Welding Argon

Nickel Alloy Welding Argon

Copper Welding Argon

Titanium Welding Argon

4.09 Tungsten Electrode Types

Electrode Type

(Ground Finish)

Thoriated 2%

Ceriated 2%

DC welding of mild steel, stainless steel
and copper.

AC & DC welding of mild steel, stainless
steel, copper, aluminum, magnesium and
their alloys.

Welding Application Features Color Code

Alloy Shielding Gas

Excellent arc starting, long life, high
current carrying capacity.

Longer life, more stable arc, easier
starting, wider current range,
narrower & more concentrated arc.

Red

Grey

Operation 4-4 4-4 Manual 0-5073Manual 0-5073

OPERATION THERMAL ARC 161 S

4.10 TIG Welding Parameters for Steel

DC Current

Base Metal

Thickness

0.040"

(1.0mm)

0.045"

(1.22mm)

1/16"

(1.6mm)

1/8"

(3.2mm)

3/16"

(4.8mm)

1/4"

(6.4mm)

Mild Steel

35-45 20-30

40-50 25-35 Lap/Filler

45-55 30-45

50-60 35-50 Lap/Filler

60-70 40-60

70-90 50-70 Lap/Filler

80-100 65-85

90-115 90-110 Lap/Filler

115-135 100-125

140-165 125-150 Lap/Filler

160-175 135-160

170-200 160-180 Lap/Filler

Stainless

Steel

Electrode
Diameter

0.040"

(1.0mm)

0.040"

(1.0mm)

1/16"

(1.6mm)

1/16" (1.16mm) 3/32" (2.4mm)

3/32" (2.4mm) 1/8" (3.2mm)

1/8" (3.2mm) 5/32" (4.0mm)

Filler Rod

Diameter

1/16"

(1.6mm)

1/16"

(1.6mm)

1/16"

(1.6mm)

Argon Gas Flow

Rate Joint / Type

10 CFH

(5 LPM)

13 CFH

(6 LPM)

15 CFH

(7 LPM)

15CFH

(7 LPM)

21CFH

(10 LPM)

21CFH

(10 LPM)

Butt/Corner

Butt/Corner

Butt/Corner

Butt/Corner

Butt/Corner

Butt/Corner

4.11 Arc Welding Practice

The techniques used for arc welding are almost identical regardless of what types of metals are being joined. Naturally
enough, different types of electrodes would be used for different metals as described in the preceding section.

Manual 0-5073 4-5 4-5 Operation Operation

THERMAL ARC 161 S OPERATION

Art A-07691

Art # A-07692

Art# A-07693

Art # A-07694

Art # A-07687

Art # A-07688

Art # A-07689

Art # A-07690

4.12 Welding Position

The electrodes dealt with in this publication can be used in most positions, i.e. they are suitable for welding in flat,
horizontal, vertical and overhead positions. Numerous applications call for welds to be made in positions intermediate
between these. Some of the common types of welds are shown in Figures 4-2 through 4-9.

Figure 4-3: Flat position, down hand butt weld

Figure 4-7: Vertical position, butt weld

Figure 4-4: Flat position, gravity fillet weld

Figure 4-5: Horizontal position, butt weld

Figure 4-6: Horizontal - Vertical (HV) position

Figure 4-8: Vertical position, fillet weld

Figure 4-9: Overhead position, butt weld

Figure 4-10: Overhead position, fillet weld

Operation 4-6 4-6 Manual 0-5073Manual 0-5073

OPERATION THERMAL ARC 161 S

Gap varies from
1/16” (1.6mm) to 3/16” (4.8mm)
depending on plate thickness

Joint

Open Square Butt

1/16” (1.6mm) max

1/16” (1.6mm)

Single Vee Butt Joint

Not less than

70°

Double Vee Butt Joint

1/16” (1.6mm)

Lap Joint

Tee Joints

(Fillet both sides of the

joint)

Edge Joint

Fillet Joint

Corner Weld

Plug Weld Plug Weld

Not less than

70°

Single Vee Butt Joint

Not less than

45°

1/16” (1.6mm) max

Art # A-07695_AC

4.13 Joint Preparations

In many cases, it will be possible to weld steel sections without any special preparation. For heavier sections and for
repair work on castings, etc., it will be necessary to cut or grind an angle between the pieces being joined to ensure
proper penetration of the weld metal and to produce sound joints.

In general, surfaces being welded should be clean and free of rust, scale, dirt, grease, etc. Slag should be removed
from oxy-cut surfaces. Typical joint designs are shown in Figure 4-10.

Figure 4-11: Typical joint designs for arc welding

Manual 0-5073 4-7 4-7 Operation Operation

THERMAL ARC 161 S OPERATION

Art # A-07696

4.14 Arc Welding Technique

A Word to Beginners

For those who have not yet done any welding, the simplest
way to commence is to run beads on a piece of scrap
plate. Use mild steel plate about 1/4" (6.4mm) thick and
a 1/8" (3.2mm) electrode. Clean any paint, loose scale or
grease off the plate and set it firmly on the work bench so
that welding can be carried out in the downhand position.
Make sure that the work clamp is making good electri­cal contact with the work, either directly or through the
work table. For light gauge material, always clamp the
work lead directly to the job, otherwise a poor circuit will

probably result.

4.15 The Welder

Place yourself in a comfortable position before beginning
to weld. Get a seat of suitable height and do as much work
as possible sitting down. Don’t hold your body tense. A
taut attitude of mind and a tensed body will soon make
you feel tired. Relax and you will find that the job becomes
much easier. You can add much to your peace of mind
by wearing a leather apron and gauntlets. You won’t be
worrying then about being burnt or sparks setting alight
to your clothes.

Place the work so that the direction of welding is across,
rather than to or from, your body. The electrode holder
lead should be clear of any obstruction so that you can
move your arm freely along as the electrode burns down.
If the lead is slung over your shoulder, it allows greater
freedom of movement and takes a lot of weight off your
hand. Be sure the insulation on your cable and electrode
holder is not faulty, otherwise you are risking an electric
shock.

4.16 Striking the Arc

Practice this on a piece of scrap plate before going on to
more exacting work. You may at first experience difficulty
due to the tip of the electrode “sticking” to the work piece.
This is caused by making too heavy a contact with the
work and failing to withdraw the electrode quickly enough.
A low amperage will accentuate it. This freezing-on of the
tip may be overcome by scratching the electrode along
the plate surface in the same way as a match is struck. As
soon as the arc is established, maintain a 1/16" (1.6mm)
to 1/8" (3.2mm) gap between the burning electrode end
and the parent metal. Draw the electrode slowly along as
it melts down.

Another difficulty you may meet is the tendency, after the
arc is struck, to withdraw the electrode so far that the arc
is broken again. A little practice will soon remedy both
of these faults.

Figure 4-12: Striking an arc

4.17 Arc Length

The securing of an arc length necessary to produce a
neat weld soon becomes almost automatic. You will find
that arc produces a crackling or spluttering noise and
the weld metal comes across in large, irregular blobs.
The weld bead is flattened and spatter increases. A short
arc is essential if a high quality weld is to be obtained
although if it is too short there is the danger of it being
blanketed by slag and the electrode tip being solidified
in. If this should happen, give the electrode a quick twist
back over the weld to detach it. Contact or “touch-weld”
electrodes such as E7014 electrode do not stick in this
way, and make welding much easier.

4.18 Rate of Travel

After the arc is struck, your next concern is to maintain
it, and this requires moving the electrode tip towards the
molten pool at the same rate as it is melting away. At the
same time, the electrode has to move along the plate to
form a bead. The electrode is directed at the weld pool at
about 20° from the vertical. The rate of travel has to be
adjusted so that a well-formed bead is produced.

If the travel is too fast, the bead will be narrow and strung
out and may even be broken up into individual globules.
If the travel is too slow, the weld metal piles up and the
bead will be too large.

Operation 4-8 4-8 Manual 0-5073Manual 0-5073

OPERATION THERMAL ARC 161 S

Art # A-07697

Art # A-07698

Art # A-07699

4.19 Making Welded Joints

Having attained some skill in the handling of an electrode,
you will be ready to go on to make up welded joints.

A. Butt Welds

Set up two plates with their edges parallel, as shown in
Figure 4-12, allowing 1/16" (1.6mm) to 3/32" (2.4mm)
gap between them and tack weld at both ends. This is to
prevent contraction stresses from the cooling weld metal
pulling the plates out of alignment. Plates thicker than 1/4"
(6.4mm) should have their mating edges beveled to form
a 70° to 90° included angle. This allows full penetration of
the weld metal to the root. Using a 1/8" (3.2mm) E7014
electrode at 120 amps, deposit a run of weld metal on the
bottom of the joint.

Do not weave the electrode, but maintain a steady rate of
travel along the joint sufficient to produce a well-formed
bead. At first you may notice a tendency for undercut to
form, but keeping the arc length short, the angle of the
electrode at about 20° from vertical, and the rate of travel
not too fast, will help eliminate this. The electrode needs
to be moved along fast enough to prevent the slag pool
from getting ahead of the arc. To complete the joint in thin
plate, turn the job over, clean the slag out of the back and
deposit a similar weld.

Figure 4-13: Butt weld

Heavy plate will require several runs to complete the joint.
After completing the first run, chip the slag out and clean
the weld with a wire brush. It is important to do this to
prevent slag being trapped by the second run. Subsequent
runs are then deposited using either a weave technique or
single beads laid down in the sequence shown in Figure
4-13. The width of weave should not be more than three
times the core wire diameter of the electrode. When the
joint is completely filled, the back is either machined,
ground or gouged out to remove slag which may be
trapped in the root, and to prepare a suitable joint for
depositing the backing run. If a backing bar is used, it
is not usually necessary to remove this, since it serves
a similar purpose to the backing run in securing proper
fusion at the root of the weld.

B. Fillet Welds

These are welds of approximately triangular cross-sec­tion made by depositing metal in the corner of two faces
meeting at right angles. Refer to Figure 4-5.

A piece of angle iron is a suitable specimen with which to
begin, or two lengths of strip steel may be tacked together
at right angles. Using a 1/8" (3.2mm) E7014 electrode at
120 amps, position angle iron with one leg horizontal and
the other vertical. This is known as a horizontal-vertical
(HV) fillet. Strike the arc and immediately bring the elec­trode to a position perpendicular to the line of the fillet
and about 45° from the vertical. Some electrodes require
to be sloped about 20° away from the perpendicular posi­tion to prevent slag from running ahead of the weld. Refer
to Figure 4-14. Do not attempt to build up much larger
than 1/4" (6.4mm) width with a 1/8" (3.2mm) electrode,
otherwise the weld metal tends to sag towards the base,
and undercut forms on the vertical leg. Multi-runs can be
made as shown in Figure 4-15. Weaving in HV fillet welds
is undesirable.

Figure 4-14: Weld build up sequence

Figure 4-15: Electrode position for HV fillet weld

Manual 0-5073 4-9 4-9 Operation Operation

THERMAL ARC 161 S OPERATION

Art # A-07700

Art # A-07701

Art # A-07702

Art # A-07703

Figure 4-16: Multi-runs in HV fillet weld

C. Vertical Welds

1. Vertical Up

Tack weld a three feet length of angle iron to your

work bench in an upright position. Use a 1/8"
(3.2mm) E7014 electrode and set the current at
120 amps. Make yourself comfortable on a seat
in front of the job and strike the arc in the corner
of the fillet. The electrode needs to be about 10°
from the horizontal to enable a good bead to be
deposited. Refer Figure 4-16. Use a short arc, and
do not attempt to weave on the first run. When
the first run has been completed de-slag the weld
deposit and begin the second run at the bottom.
This time a slight weaving motion is necessary
to cover the first run and obtain good fusion at
the edges. At the completion of each side motion,
pause for a moment to allow weld metal to build
up at the edges, otherwise undercut will form and
too much metal will accumulate in the centre of the
weld. Figure 4-17 illustrates multi-run technique
and Figure 4-18 shows the effects of pausing at
the edge of weave and of weaving too rapidly.

Figure 4-17: Single run vertical fillet weld

Figure 4-18: Multi run vertical fillet weld

Figure 4-19: Examples of vertical fillet welds

2. Vertical Down

The E7014 electrode makes welding in this

position particularly easy. Use a 1/8" (3.2mm)
electrode at 120 amps. The tip of the electrode is
held in light contact with the work and the speed
of downward travel is regulated so that the tip of
the electrode just keeps ahead of the slag. The
electrode should point upwards at an angle of
about 45°.

Operation 4-10 4-10 Manual 0-5073Manual 0-5073

OPERATION THERMAL ARC 161 S

Art # A-07704

3. Overhead Welds

Apart from the rather awkward position necessary,

overhead welding is not much more difficult that
downhand welding. Set up a specimen for over­head welding by first tacking a length of angle
iron at right angles to another piece of angle iron
or a length of waste pipe. Then tack this to the
work bench or hold in a vice so that the specimen
is positioned in the overhead position as shown
in the sketch. The electrode is held at 45° to
the horizontal and tilted 10° in the line of travel
(Figure 4-19). The tip of the electrode may be
touched lightly on the metal, which helps to give a
steady run. A weave technique is not advisable for
overhead fillet welds. Use a 1/8" (3.2mm) E6012
electrode at 120 amps, and deposit the first run
by simply drawing the electrode along at a steady
rate. You will notice that the weld deposit is rather
convex, due to the effect of gravity before the
metal freezes.

4.20 Distortion

Distortion in some degree is present in all forms of
welding. In many cases it is so small that it is barely
perceptible, but in other cases allowance has to be made
before welding commences for the distortion that will
subsequently occur. The study of distortion is so complex
that only a brief outline can be attempted hear.

4.21 The Cause of Distortion

Distortion is cause by:

A. Contraction of Weld Metal:

Molten steel shrinks approximately 11 per cent in volume
on cooling to room temperature. This means that a cube
of molten metal would contract approximately 2.2 per
cent in each of its three dimensions. In a welded joint, the
metal becomes attached to the side of the joint and cannot
contract freely. Therefore, cooling causes the weld metal
to flow plastically, that is, the weld itself has to stretch if
it is to overcome the effect of shrinking volume and still
be attached to the edge of the joint. If the restraint is very
great, as, for example, in a heavy section of plate, the weld
metal may crack. Even in cases where the weld metal does
not crack, there will still remain stresses “locked-up” in
the structure. If the joint material is relatively weak, for ex­ample, a butt joint in 5/64" (2.0mm) sheet, the contracting
weld metal may cause the sheet to become distorted.

Figure 4-20: Overhead fillet weld

B. Expansion and Contraction of Parent Metal in the
Fusion Zone:

While welding is proceeding, a relatively small volume
of the adjacent plate material is heated to a very high
temperature and attempts to expand in all directions. It
is able to do his freely at right angles to the surface of
the plate (i.e., “through the weld”), but when it attempts
to expand “across the weld” or “along the weld”, it meets
considerable resistance, and to fulfill the desire for con­tinued expansion, it has to deform plastically, that is, the
metal adjacent to the weld is at a high temperature and
hence rather soft, and, by expanding, pushes against the
cooler, harder metal further away, and tends to bulge (or
is “upset”). When the weld area begins to cool, the “up­set” metal attempts to contract as much as it expanded,
but, because it has been “upset”, it does not resume its
former shape, and the contraction of the new shape exerts
a strong pull on adjacent metal. Several things can then
happen.

Manual 0-5073 4-11 4-11 Operation Operation

THERMAL ARC 161 S OPERATION

Art # A-07705

Art # A-07706

Art # A-07707

Art # A-07708

B

PreheatPreheat

Dotted lines show effect if no preheat is used

Weld

C

Art # A-07709

The metal in the weld area is stretched (plastic deforma­tion), the job may be pulled out of shape by the powerful
contraction stresses (distortion), or the weld may crack,
in any case, there will remain “locked-up” stresses in
the job. Figures 4-20 and 4- 21 illustrate how distortion
is created.

Figure 4-21: Parent metal expansion

Figure 4-22: Parent metal contraction

4.22 Overcoming Distortion Effects

There are several methods of minimizing distortion ef­fects.

D. Presetting

It is possible in some cases to tell from past experience or
to find by trial and error (or less frequently, to calculate)
how much distortion will take place in a given welded
structure. By correct pre-setting of the components to be
welded, constructional stresses can be made to pull the
parts into correct alignment. A simple example is shown
in Figure 4-22.

E. Preheating

Suitable preheating of parts of the structure other than
the area to be welded can be sometimes used to reduce
distortion. Figure 4-23 shows a simple application. By
removing the heating source from b and c as soon as
welding is completed, the sections b and c will contract
at a similar rate, thus reducing distortion.

Figure 4-23: Principle of presetting

A. Peening

This is done by hammering the weld while it is still hot.
The weld metal is flattened slightly and because of this
the tensile stresses are reduced a little. The effect of
peening is relatively shallow, and is not advisable on the
last layer.

B. Distribution of Stresses

Distortion may be reduced by selecting a welding se­quence which will distribute the stresses suitably so
that they tend to cancel each other out. See Figures 4-25
through 4-28 for various weld sequences. Choice of a
suitable weld sequence is probably the most effective
method of overcoming distortion, although an unsuitable
sequence may exaggerate it. Simultaneous welding of
both sides of a joint by two welders is often successful
in eliminating distortion.

C. Restraint of Parts

Forcible restraint of the components being welded is often
used to prevent distortion. Jigs, positions, and tack welds
are methods employed with this in view.

Figure 4-24: Reduction of distortion by preheating

Figure 4-25: Examples of distortion

Operation 4-12 4-12 Manual 0-5073Manual 0-5073

OPERATION THERMAL ARC 161 S

Art # A-07710

Art # A-07711

Art # A-07712

Art # A-07713

Figure 4-26: Welding sequence

Figure 4-27: Step back sequence

Figure 4-28: Chain intermittent welding

Figure 4-29: Staggered intermittent welding

Manual 0-5073 4-13 4-13 Operation Operation

This Page Intentionally Blank.

SERVICE THERMAL ARC 161 S

Warning!
Disconnect input power before maintaining.

Each Use

Visual check of
regulator and pressure

Visual check of torch
Consumable parts

Weekly

Visually inspect
the torch body
and consumables

Visually inspect the
cables and leads.
Replace as needed

3 Months

Clean
exterior
of power supply

6 Months

Replace all
broken parts

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.

Maintain more often
if used under severe
conditions

Art # A-08549_AB

SECTION 5:

SERVICE

5.01 Maintenance and Inspection

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.

To clean the unit, open the enclosure 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.

WARNING

There are extremely dangerous voltages and
power levels present inside this product.
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.

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.

Manual 0-5073 5-1 5-1 ServiceService

THERMAL ARC 161 S SERVICE

Insufficient Gap

Incorrect Sequence

Art # A-05866_AC

Not cleaned,
or incorrect
electrode

Slag
trapped in
undercut

Slag trapped in root

Art # A-05868_AB

Art # A-05867_AC

Lack of
inter-run fusion

Lack of side fusion,
scale dirt, small electrode,
amperage too low

Lack of root fusion

Lack of fusion caused by dirt,
electrode angle incorrect,
rate of travel too high

5.02 STICK (SMAW) Welding Problems

Description Possible Cause Remedy

1. Gas pockets or voids in weld metal
(Porosity).

A. Electrodes are damp.

B. Welding current is too high.

A. Dry electrodes before use.

B. Reduce welding current.

2. Crack occurring in weld metal soon
after solidification commences.

3. A gap is left by failure of the weld
metal to fill the root of the weld.

4. Portions of the weld run do not fuse
to the surface of the metal or edge
of the joint

C. Surface impurities such as oil,

grease, paint, etc.

A. Rigidity of joint.

B. Insufficient throat thickness.

C. Cooling rate is too high.
A. Welding current is too low.

B. Electrode too large for joint.

C. Insufficient gap.

D. Incorrect sequence.

A. Small electrodes used on

heavy cold plate.

B. Welding current is too low.

C. Wrong electrode angle.

C. Clean joint before welding

A. Redesign to relieve weld joint of severe

stresses or use crack resistance
electrodes.

B. Travel slightly slower to allow greater

build up in throat.

C. Preheat plate and cool slowly.
A. Increase welding current

B. Use smaller diameter electrode.

C. Allow wider gap.

D. Use correct build-up sequence.

A. Use larger electrodes and preheat

the plate.

B. Increase welding current

C. Adjust angle so the welding arc is

directed more into the base metal

5. Non-metallic particles are trapped

Service 5-2 5-2 Manual 0-5073Manual 0-5073

in the weld metal (slag inclusion).

D. Travel speed of electrode is too

high.

E. Scale or dirt on joint surface.

A. Non-metallic particles may

be trapped in undercut from
previous run.

B. Joint preparation too restricted.

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.

D. Reduce travel speed of electrode

E. Clean surface before welding.

A. If bad undercut is present, clean slag

out and cover with a run from a smaller
diameter electrode.

B. Allow for adequate penetration and

room for cleaning out the slag.

C. If very bad, chip or gr i nd 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 difficult.

SERVICE THERMAL ARC 161 S

5.03 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 bead build-up or poor
penetration or poor fusion at
edges of weld.

2. Weld bead too wide and flat or
undercut at edges of weld or
excessive burn through.

3. Weld bead too small or insufficient
penetration or ripples in bead are
widely spaced apart.

4. Weld bead too wide or excessive
bea d bu ild up or ex cess ive
penetration in butt joint.

5. Uneven leg length in fillet joint. Wrong placement of filler rod. Re-position filler rod.

6. E lectrode melts when arc is
struck.

7. Dirty weld pool. A. Electrode contaminated through

8. Poor weld finish. Inadequate shielding gas. Increase gas flow or check gas line

9. Arc flutters during TIG welding. Tungsten electrode is too large

10. We l d in g ar c c a nn o t b e
established.

11. Electrode melts or oxidizes when
an arc is struck.

Welding current is too low Increase weld current and/or

change joint preparation.

Welding current is too high. Decrease welding current.

Travel speed too fast. Reduce travel speed.

Travel speed is too slow. Increase travel speed.

Electrode is connected to the "+"

Positive Output Terminal.

contact with work piece or filler
rod material.

B. Gas contaminated with air.

for the welding current.

A. Work clamp is not connected to

the work piece or the work/torch
leads are not connected to the
correct welding terminals.

B. Torch lead is disconnected.

C. Gas flow incorrectly set, cylinder

empty or the torch valve is off.

A. No gas is flowing to welding

region.
B. Torch is clogged with dust.
C. Gas hose is cut.
D. Gas passage contains impurities.

E. Gas regulator turned off.
F. Torch valve is turned off.
G. The electrode is too small for the

welding current.

Connect th e elec trode to th e

"-" Negative Output Terminal.

A. Clean the electrode by grinding

contaminates off.

B. Check gas lines for cuts and loose

fitting or change gas cylinder.

for problems

Select the right size electrode.

Refer to section Tungsten Electrode
Current Ranges.

A. Connect the work clamp to the

work piece or connect the work/
torch leads to the correct welding
terminals.

B. Connect it to the "-" Negative

Output Terminal.

C. Select the right flow rate, change

cylinder or turn torch valve on.

A. Check the gas lines for kinks or

breaks or cylinder contains gas.
B. Clean torch.
C. Replace gas hose.
D. Disconnect gas hose from torch

then raise gas pressure and blow

out impurities.
E. Turn on.
F. Turn on.
G. Increase electrode diameter or

reduce the welding current.

Manual 0-5073 5-3 5-3 ServiceService

THERMAL ARC 161 S SERVICE

TIG Welding Problems (Continued)

Description Possible Cause Remedy

12. Arc start is not smooth. A. Tungsten electrode is too large
for the welding current.

B. The wrong electrode is being

used for the welding job.

C. Gas flow rate is too high.

D. Incorrect shield gas is being

used.

E. Poor work clamp connection

to work piece.

WARNING

There are extremely dangerous voltages and power levels present inside this product. Do not attempt to
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.

A. Refer to section Tungsten Electrode

Current Ranges for the correct size.

B. Refer to section Tungsten Electrode

Types for the correct electrode type.

C. Select the correct flow rate for the

welding job.

D. Use 100% argon for TIG welding.

E. Improve connection to work piece.

5.04 Power Source Problems

Description Possible Cause Remedy

1. The welding arc cannot be
established.

2. The welding arc cannot
be established when the
Warning Indicator lights up
continuously

3. M a x imum output weldin g
current cannot be achieved with
nominal Mains supply voltage.

4. Welding current reduces when
welding.

5. Circuit breaker (or fuse) trips
during welding.

6. The welding arc cannot beTh e welding arc cannot be
established when Fault Indicator
is flashing.

A. The Primary supply voltage

has not been switched ON.

B. The Welding Power Source

switch is switched OFF.

C. Loose connections internally.

The machines duty cycle has been
exceeded

Defective control circuit Have an Accredited Thermal Arc

Poor work lead connection to the
work piece.

The circuit breaker (or fuse) is
under size.

The input current to the main
transformer has been exceeded.

A. Switch ON the Primary supply

voltage.

B. Switch ON the Welding Power

Source.

C. Have an Accredited Thermal

Arc Service Provider repair the
connection.

Wait for the Warning IndicatorWarning IndicatorIndicator
to extinguish before resuming
welding

Service Provider inspect then
repair the welder.

Ensure that the work lead has a
positive electrical connection to
the work piece.
The recommended circuit breaker
(or fuse) size is 30 amp. An
individual branch circuit capable
of carry ing 30 amperes and
protected by fuses or circuit
breaker is recommended for this
application.

Have an Accredited Thermal Arc
Service Provider inspect then
repair the welder.

Service 5-4 5-4 Manual 0-5073Manual 0-5073

APPENDIX THERMAL ARC 161 S

APPENDIX 1: OPTIONS AND ACCESSORIES

Description Part Number

17V style TIG Torch with 12.5ft lead, gas valve, 50mm dinse connection and accessory kit W4012600
VICTOR AF210-580 Regulator, Argon-CO2 Flowgauge with 5/8" - 18 UNF connection 0781-4169
Power Adapter-230V,50A Socket (Nema 6-50R) to 115V, 15A Plug (Nema 5-15P) W4014000
USA Graphics Auto-Darkening welding helmet, spare cover lens and operating manual W4011700
Canadian Graphics Auto-Darkening welding helmet, spare cover lens and operating manual W4011800
Claret Color Auto-Darkening welding helmet, spare cover lens and operating manual W4011900
Black Graphics Auto-Darkening welding helmet, spare cover lens and operating manual W4012000

Manual 0-5073 A-1 Appendix

THERMAL ARC 161 S APPENDIX

APPENDIX 2: REPLACEMENT PARTS

Item No Description Part No. Reference Designator

1 Handle W7003040

2 Panel,Cover, W7003051

3 Resistor,4 ohm,60W W7003055 R1

4 Rectifier W7003010

5 Thermistor W7003016 THC1, THC2

6 Control PCB W7003057 PCB2

7 Main Power PCB W7003061 PCB1

8 Front Control PCB3 W7003047 PCB3

9 Inductor W7003089

10 Clear Cover Sheet W7003060

11 Front Panel W7003022

12 Front Panel Label W7003062

13 Knob, control, red, 20 ODx6 ID W7003079

14 Rubber Boot W7003064

15 Output Terminal, 50mm dinse W7003020

16 Base Panel W7003073

17 Fan,24V DC W7003090

18 Rear Panel W7003054

19 ON/OFF Switch W7003053 SW1

20 Capacitor,10uF,300VAC W7003094 C1

21 Current Sensor,161-201TS W7003076 Current Sensor

WARNING

There are extremely dangerous voltages and power levels present inside this product. Do not attempt to
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.

Appendix A-2 Manual 0-5073

APPENDIX THERMAL ARC 161 s

1

2

3

10

11

12

13

14

15

4

5

6

7

8

17

18

19

9

16

Art # A-09896

20

21

Manual 0-5073 A-3 Appendix

THERMAL ARC 161 S APPENDIX

Art # A-09897_AC

G

D

S

G

D

S

PUT

230VAC/115VAC

50/60Hz

G

DS

AC
OU
T A

CO
UT

DC -

DC

+

RE
D

BLACK

J2-1

J2-2

J2-3

J2-4

J2-5

J2-6

J2-7

J2-8

-24V

GND

+15V

IGBT Driver A

IGBT Driver B

GND

Over Current Signal

Over Current Signal

J3-1

J3-2

J3-3

J3-4

J3-5

J3-6

J3-7

J3-8

J4-6

J4-5

J4-4

J4-3J4-

2

J4-1+15V

POT WIPER

Faul

t

Pr
oc
ess Sw

it
ch

GND

N/A

J7-2

J7-1

J8­2

J8

-1

GN
D

-24V

J7-3

+15V

GND

RED

BLACK

J9-2

J9-1

J1-2

J1-1

RED

J10-1

J10-2

Main Power

PC
B1

Contro

l PC

B2

Front Panel PCB3

8

1

J2
,J
3

J4,
J11

6

1

2

1

4

1

J1,J8,J9

J10

,

1 2

3

7J6J

PC
B MOUNTED HARNESS

CONN

ECTORS PI

N
OUT

VI
EWED FROM CO

MP
ONENT

SI
DE OF

BO
ARD

1 2

J6-1

J6-2

J6-3

J6-4

GND

+15V

-15V

Current Feedback

3

J7J8 J

J 6

J1

J4

CO
NNECTO

R
LA

YOUT

DI
AG

RA
M

JC

OT

TUOM

I

BFIJF

1

VRD

ON

OFF

FA
N

PF
C
CIRCU

IT

SHEETMETAL COVE

R

MBIN

WV

IN

RE
D

BLAC

K

J11

-5

J11-4

J11-3

J11

-2

J11-1

STICK

LI
FT

TIG

PROCESS SELEC

TO
R

CURREN

T

CO
NT
ROL

FAULT

AC

POS

NE
G

+

-

BLACK

WV

IN

FJ

OT

JC

MBIN

IMOUT

IFB

RED

YELLOW

GRAY

WHITE

J5-1

J5-2

J5

60W4

Ω

J5

RX

JC

IN

115VAC

STICK

--1

.5VD

C

115VAC

LIFT

TIG --4.5V

DC

230VA

C

--0
.5VD

C

C1

Current

Sensor

ON

APPENDIX 3: SYSTEM SCHEMATIC

Appendix A-4 Manual 0-5073

LIMITED WARRANTY

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

January 2009

LIMITED WARRANTY: Thermal Arc®, Inc., A Thermadyne Company (“Thermal Arc”), warrants
to customers of authorized distributors (“Purchaser”) that its products will be free of defects
in workmanship or material. Should any failure to conform to this warranty appear within the

warranty period stated below, Thermal Arc shall, upon notication thereof and substantiation that

the product has been stored, installed, operated, and maintained in accordance with Thermal

Arc’s specications, instructions, recommendations and recognized standard industry practice,
and not subject to misuse, repair, neglect, alteration, or damage, correct such defects by suitable

repair or replacement, at Thermal Arc’s sole option, of any components or parts of the product
determined by Thermal Arc to be defective.

This warranty is exclusive and in lieu of any warranty of merchantability,

tness for any particular purpose, or other warranty of quality, whether

express, implied, or statutory.

Limitation of liability: Thermal Arc shall not under any circumstances be liable for special, indirect,

incidental, or consequential damages, including but not limited to lost prots and business

interruption. The remedies of the purchaser set forth herein are exclusive, and the liability of

Thermal Arc with respect to any contract, 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, whether arising out of contract, tort, including
negligence or strict liability, or under any warranty, or otherwise, shall not exceed the price of the
goods upon which such liability is based.

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 by any such attempt.
Correction of non-conformities, in the manner and time provided herein, constitutes fulllment
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 warranty 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 Thermal 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 goods shall be at the Purchaser’s

risk and expense. This warranty dated January 1st 2009 supersedes all previous Thermal Arc
warranties. Thermal Arc® is a Registered Trademark of Thermal Arc, Inc.

WARRANTY SCHEDULE

January 2009

SAFETY EQUIPMENT WARRANTY PERIOD LABOR

Auto-Darkening Welding Helmet (Electronic Lens)

Harness Assembly

2 year
1 Month

2 year

1 Month

ENGINE DRIVEN WELDERS WARRANTY PERIOD LABOR
Scout, Raider, Explorer

Original Main Power Stators and Inductors......................................................................................

.............. 3 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

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 140; 180; 190, 210, 251, 281; Fabstar 4030;
PowerMaster 350, 350P, 500, 500P; 320SP; 400SP; 500SP; Excelarc 6045.
Wire Feeders; Ultrafeed, Portafeed

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

............... 5 years 3 years

Original Main Power Rectifiers, Control P.C. Boards, power switch semi-conductors .....................

............... 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

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

Original Main Power Magnetics........................................................................................................

............... 5 years 3 years

Original Main Power Rectifiers, Control P.C. Boards, power switch semi-conductors .....................

............... 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

Original Main Power Magnetics........................................................................................................

.............. 5 years 3 years

Original Main Power Rectifiers, Control P.C. Boards, power switch semi-conductors .....................

.............. 3 years 3 years

Welding Console, 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

STICK (SMAW) WELDING EQUIPMENT WARRANTY PERIOD LABOR
Thermal Arc 95S

Original Main Power Magnetics........................................................................................................

................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,..............................................................................................................

................1 year

1 year

161S, 161STL, 201TS

Original Main Power Magnetics 3 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

1 year 1 year

160S, 300S, 400S

Original Main Power Magnetics........................................................................................................

............... 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 Torches ..................................................................................................................

..............180 days 180 days

Gas Regulators (Supplied with power sources)................................................................................

..............180 days Nil

MIG and TIG Torches (Supplied with power sources) ......................................................................

...............90 days Nil

Replacement repair parts..................................................................................................................

...............90 days Nil

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

...................Nil Nil

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

W O RL D H EA DQ UA RT ER S: 16 05 2 S wi ng ley Ri dg e Roa d, Su it e 300 • S t. Lo ui s, Mi ss ou ri 63 01 7 U .S. A.

A Global Cutting & Welding Market Leader

™

U.S. Customer Care: 800-426-1888 /

FAX

800-535-0557 • Canada Customer Care: 905-827-4515 /

FAX

800-588-1714

International Customer Care: 940-381-1212 /

FAX

940-483-8178 • www.thermalarc.com

Denton, TX USA
U.S. Customer Care

Ph: 1-800-426-1888(tollfree)
Fax: [phone] (tollfree)

International Customer Care

Ph: 1-940-381-1212
Fax: [phone]

Miami, FL USA
Sales Office, Latin America

Ph: 1-954-727-8371
Fax: [phone]

Oakville, Ontario, Canada
Canada Customer Care

Ph: 1-905-827-4515
Fax: [phone] (tollfree)

Chorley, United Kingdom
Customer Care

Ph: [phone]
Fax: [phone]

Milan, Italy
Customer Care

Ph: [phone]
Fax: [phone]

Cikarang, Indonesia
Customer Care

Ph: 6221-8990-6095
Fax: [phone]

Rawang, Malaysia
Customer Care

Ph: [phone]
Fax: [phone]

Melbourne, Australia
Australia Customer Care

Ph: 1300-654-674 (tollfree)
Ph: 61-3-9474-2988
Fax: [phone]

International

Ph: 61-3-9474-7508
Fax: [phone]

Shanghai, China
Sales Office

Ph: [phone]
Fax: [phone]

Singapore
Sales Office

Ph: [phone]
Fax: [phone]

Form No. 0-5073 (12/17/2010) © 2010 Thermadyne Industries, Inc. www.thermadyne.com Printed in U.S.A.

THE AMERICAS EUROPE ASIA/PACIFIC