Thermal Arc 161 S Operators Manual_(0

Thermal Arc 161 S Operators Manual_(0

161 S

THERMAL ARC

®

InvERTER ARC WELdER

Art# A-09194_AB

Operating Manual

Revision: AD

Operating Features:

Issue Date: January 14, 2011 Manual No.: 0-5073

50

60

Hz

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

Thermal Arc 161 S System with Stick Kit & Case

Part No. W1003600

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

(603) 298-5711 www.thermalarc.com

Copyright

©

2010 by

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 #:

____________________________________

____________________________________

____________________________________

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

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

Art# A-09755

Art# A-09756

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.

W�ld�ng p��du��� and w�ld�ng p�������� �an �au�� �����u� �nju��� �� d�a�h, �� damag� �� ��h�� �qu�pm�n� �� p��p�����, �� �h� �p��a��� d��� n��

������l�� �b���v� all �a����� �ul�� and �ak� p���au���na��� a����n�.

�a�� p�a������ hav� d�v�l�p�d ���m pa�� �xp����n�� �n �h� u�� �� w�ld�ng and �u���ng. Th��� p�a������ mu�� b� l�a�n�d �h��ugh ��ud�� and

��a�n�ng b����� u��ng �h�� �qu�pm�n�. ��m� �� �h��� p�a������ appl�� �� �qu�pm�n� ��nn����d �� p�w�� l�n��; ��h�� p�a������ appl�� �� �ng�n� d��v�n �qu�pm�n�. An���n� n�� hav�ng �x��n��v� ��a�n�ng �n w�ld�ng and �u���ng p�a������ �h�uld n�� a���mp� �� w�ld.

�a�� p�a������ a�� �u�l�n�d �n �h� Am����an Na���nal ��anda�d Z49.1 �n���l�d: �AFETY �N WELD�NG AND CUTT�NG. Th�� publ��a���n and ��h�� gu�d�� �� wha� ���u �h�uld l�a�n b����� �p��a��ng �h�� �qu�pm�n� a�� l����d a� �h� �nd �� �h��� �a����� p���au���n�. HAVE ALL INSTALLATION,

OPERATION, MAINTENANCE, AND REPAIR WORK PERFORMED ONLY BY QUALIFIED PEOPLE.

1.01 Arc Welding Hazards

8. D� n�� u�� w��n, damag�d, und����z�d, �� p���l�� �pl���d

�abl��.

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.

9. D� n�� w�ap �abl�� a��und ���u� b�d��.

10. G��und �h� w��kp���� �� a g��d �l������al (�a��h) g��und.

11. D� n�� ��u�h �l�����d� wh�l� �n ��n�a�� w��h �h� w��k (g��und)

����u��.

12. U�� �nl�� w�ll-ma�n�a�n�d �qu�pm�n�. R�pa�� �� ��pla�� damag�d pa��� a� �n��.

13. �n ��nfin�d �pa��� �� damp l��a���n�, d� n�� u�� a w�ld�� w��h AC

�u�pu� unl��� �� �� �qu�pp�d w��h a v�l�ag� ��du���. U�� �qu�pm�n� w��h DC �u�pu�.

14. W�a� a �a����� ha�n��� �� p��v�n� �all�ng �� w��k�ng ab�v� fl��� l�v�l.

15. K��p all pan�l� and ��v��� ���u��l�� �n pla��.

1. D� n�� ��u�h l�v� �l������al pa���.

2. W�a� d���, h�l�-���� �n�ula��ng gl�v�� and b�d�� p��������n.

3. �n�ula�� ���u���l� ���m w��k and g��und u��ng d��� �n�ula��ng ma��

�� ��v���.

4. D����nn��� �npu� p�w�� �� ���p �ng�n� b����� �n��all�ng ��

���v���ng �h�� �qu�pm�n�. L��k �npu� p�w�� d����nn��� �w���h

�p�n, �� ��m�v� l�n� �u��� �� p�w�� �ann�� b� �u�n�d �n a���d�n�all��.

5. P��p��l�� �n��all and g��und �h�� �qu�pm�n� a����d�ng �� ��� Own��’�

Manual and na���nal, ��a��, and l��al ��d��.

6. Tu�n ��� all �qu�pm�n� wh�n n�� �n u��. D����nn��� p�w�� ��

�qu�pm�n� �� �� w�ll b� l��� una���nd�d �� �u� �� ���v���.

7. U�� �ull�� �n�ula��d �l�����d� h�ld���. N�v�� d�p h�ld�� �n wa��� ��

���l �� �� la�� �� d�wn �n �h� g��und �� �h� w��k �u��a��. D� n��

��u�h h�ld��� ��nn����d �� �w� w�ld�ng ma�h�n�� a� �h� �am�

��m� �� ��u�h ��h�� p��pl� w��h �h� h�ld�� �� �l�����d�.

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. W�a� a w�ld�ng h�lm�� fi���d w��h a p��p�� �had� �� fil��� (���

AN�� Z49.1 l����d �n �a����� ��anda�d�) �� p������ ���u� �a�� and

����� wh�n w�ld�ng �� wa��h�ng.

2. W�a� app��v�d �a����� gla����. ��d� �h��ld� ����mm�nd�d.

3. U�� p�������v� �����n� �� ba������ �� p������ ��h��� ���m fla�h and gla��; wa�n ��h��� n�� �� wa��h �h� a��.

4. W�a� p�������v� �l��h�ng mad� ���m du�abl�, flam�-������an� ma����al (w��l and l�a�h��) and ���� p��������n.

5. U�� app��v�d �a� plug� �� �a� mu��� �� n���� l�v�l �� h�gh.

Manual 0-5073 1-1

THERMAL ARC 161 S SAFETY INSTRUCTIONS

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. K��p ���u� h�ad �u� �� �h� �um��. D� n�� b��a�h� �h� �um��.

2. �� �n��d�, v�n��la�� �h� a��a and/�� u�� �xhau�� a� �h� a�� �� ��m�v� w�ld�ng �um�� and ga���.

3. �� v�n��la���n �� p���, u�� an app��v�d a��-�uppl��d ���p��a���.

4. R�ad �h� Ma����al �a����� Da�a �h���� (M�D��) and �h� manu�a��u���’� �n���u����n ��� m��al�, ��n�umabl��, ��a��ng�, and �l�an���.

5. W��k �n a ��nfin�d �pa�� �nl�� �� �� �� w�ll v�n��la��d, �� wh�l� w�a��ng an a��-�uppl��d ���p��a���. �h��ld�ng ga��� u��d ��� w�ld�ng �an d��pla�� a�� �au��ng �nju��� �� d�a�h. B� �u�� �h� b��a�h�ng a�� �� �a��.

6. D� n�� w�ld �n l��a���n� n�a� d�g��a��ng, �l�an�ng, �� �p�a���ng

�p��a���n�. Th� h�a� and �a��� �� �h� a�� �an ��a�� w��h vap��� ��

���m h�ghl�� ��x�� and �����a��ng ga���.

7. D� n�� w�ld �n ��a��d m��al�, �u�h a� galvan�z�d, l�ad, ��

�adm�um pla��d ����l, unl��� �h� ��a��ng �� ��m�v�d ���m �h� w�ld a��a, �h� a��a �� w�ll v�n��la��d, and �� n�����a���, wh�l� w�a��ng an a��-�uppl��d ���p��a���. Th� ��a��ng� and an�� m��al� ��n�a�n�ng

�h��� �l�m�n�� �an g�v� ��� ��x�� �um�� �� w�ld�d.

WARNING

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. P������ ���u���l� and ��h��� ���m fl���ng �pa�k� and h�� m��al.

2. D� n�� w�ld wh��� fl���ng �pa�k� �an ����k� flammabl� ma����al.

3. R�m�v� all flammabl�� w��h�n 35 �� (10.7 m) �� �h� w�ld�ng a��.

�� �h�� �� n�� p����bl�, ��gh�l�� ��v�� �h�m w��h app��v�d ��v���.

4. B� al��� �ha� w�ld�ng �pa�k� and h�� ma����al� ���m w�ld�ng �an

�a��l�� g� �h��ugh �mall ��a�k� and �p�n�ng� �� adja��n� a��a�.

5. Wa��h ��� fi��, and k��p a fi�� �x��ngu��h�� n�a�b��.

6. B� awa�� �ha� w�ld�ng �n a ���l�ng, fl���, bulkh�ad, �� pa������n

�an �au�� fi�� �n �h� h�dd�n ��d�.

7. D� n�� w�ld �n �l���d ��n�a�n��� �u�h a� �ank� �� d�um�.

8. C�nn��� w��k �abl� �� �h� w��k a� �l��� �� �h� w�ld�ng a��a a� p�a����al �� p��v�n� w�ld�ng �u���n� ���m ��av�l�ng l�ng, p����bl�� unkn�wn pa�h� and �au��ng �l������ �h��k and fi�� haza�d�.

9. D� n�� u�� w�ld�� �� �haw ���z�n p�p��.

10. R�m�v� ����k �l�����d� ���m h�ld�� �� �u� ��� w�ld�ng w��� a�

��n�a�� ��p wh�n n�� �n u��.

Eye protection filter shade selector for welding or cutting

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

Welding or Cutting

Operation

Electrode Size

Metal Thickness

Filter

Shade

Welding or Cutting

Operation

Torch soldering

Torch brazing

Oxygen Cutting

Light

or Welding Current

Under 1 in., 25 mm

No.

2

3 or 4

Gas metal-arc welding (MIG)

Non-ferrous base metal

Non-ferrous base metal

3 or 4 Gas tungsten arc welding

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

Electrode Size

Metal Thickness or Welding

All

All

All

All

Filter

Shade

No.

11

12

12

12

Heavy Over 6 in., 150 mm

Gas welding

5 or 6 Atomic hydrogen welding

Carbon arc welding

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

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

Carbon arc air gouging

Heavy Over 1/2 in., 12 mm

Shielded metal-arc welding

(stick) electrodes

Under 5/32 in., 4 mm

5/32 to 1/4 in.,

4 to 6.4 mm

6 or 8

10

12

Plasma arc cutting

Light

Heavy

Over 1/4 in., 6.4 mm 14

All

All

Light Under 300 Amp

12

12

12

14

9

Medium 300 to 400 Amp 12

Heavy Over 400 Amp 14

�a����� �n���u����n�

SAFETY INSTRUCTIONS THERMAL ARC 161 S

2. �� u��d �n a �l���d a��a, v�n� �ng�n� �xhau�� �u���d� and awa��

���m an�� bu�ld�ng a�� �n�ak��.

WARNING

FLYING SPARKS AND HOT METAL can cause injury.

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

1. W�a� app��v�d �a�� �h��ld �� �a����� g�ggl��. ��d� �h��ld�

����mm�nd�d.

2. W�a� p��p�� b�d�� p��������n �� p������ �k�n.

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. P������ ��mp�����d ga� ���l�nd��� ���m �x�����v� h�a�, m��han��al

�h��k�, and a���.

2. �n��all and ���u�� ���l�nd��� �n an up��gh� p������n b�� �ha�n�ng

�h�m �� a ��a���na��� �upp��� �� �qu�pm�n� ���l�nd�� �a�k �� p��v�n�

�all�ng �� ��pp�ng.

3. K��p ���l�nd��� awa�� ���m an�� w�ld�ng �� ��h�� �l������al

����u���.

4. N�v�� all�w a w�ld�ng �l�����d� �� ��u�h an�� ���l�nd��.

5. U�� �nl�� ������� �h��ld�ng ga� ���l�nd���, ��gula����, h����, and fi���ng� d���gn�d ��� �h� �p���fi� appl��a���n; ma�n�a�n �h�m and a�����a��d pa��� �n g��d ��nd����n.

6. Tu�n �a�� awa�� ���m valv� �u�l�� wh�n �p�n�ng ���l�nd�� valv�.

7. K��p p�������v� �ap �n pla�� �v�� valv� �x��p� wh�n ���l�nd�� �� �n u�� �� ��nn����d ��� u��.

8. R�ad and ��ll�w �n���u����n� �n ��mp�����d ga� ���l�nd���, a�����a��d �qu�pm�n�, and CGA publ��a���n P-1 l����d �n �a�����

��anda�d�.

WARNING

ENGINE FUEL can cause fire or explosion.

Engine fuel is highly flammable.

1. ���p �ng�n� b����� �h��k�ng �� add�ng �u�l.

2. D� n�� add �u�l wh�l� �m�k�ng �� �� un�� �� n�a� an�� �pa�k� �� �p�n flam��.

3. All�w �ng�n� �� ���l b����� �u�l�ng. �� p����bl�, �h��k and add �u�l

�� ��ld �ng�n� b����� b�g�nn�ng j�b.

4. D� n�� �v��fill �ank — all�w ���m ��� �u�l �� �xpand.

5. D� n�� �p�ll �u�l. �� �u�l �� �p�ll�d, �l�an up b����� ��a���ng

�ng�n�.

WARNING

MOVING PARTS can cause injury.

M�v�ng pa���, �u�h a� �an�, ������, and b�l�� �an �u� fing��� and hand� and �a��h l���� �l��h�ng.

1. K��p all d����, pan�l�, ��v���, and gua�d� �l���d and

���u��l�� �n pla��.

2. ���p �ng�n� b����� �n��all�ng �� ��nn����ng un��.

3. Hav� �nl�� qual�fi�d p��pl� ��m�v� gua�d� �� ��v��� ��� ma�n��nan�� and ���ubl��h����ng a� n�����a���.

4. T� p��v�n� a���d�n�al ��a���ng du��ng ���v���ng, d����nn��� n�ga��v� (-) ba������ �abl� ���m ba������.

5. K��p hand�, ha��, l���� �l��h�ng, and ���l� awa�� ���m m�v�ng pa���.

6. R��n��all pan�l� �� gua�d� and �l��� d���� wh�n ���v���ng

�� fin��h�d and b����� ��a���ng �ng�n�.

!

Engines can be dangerous.

WARNING

WARNING

ENGINE EXHAUST GASES can kill.

Eng�n�� p��du�� ha�m�ul �xhau�� ga���.

1. U�� �qu�pm�n� �u���d� �n �p�n, w�ll-v�n��la��d a��a�.

WARNING

SPARKS can cause BATTERY GASES TO EXPLODE;

BATTERY ACID can burn eyes and skin.

Ba������� ��n�a�n a��d and g�n��a�� �xpl���v� ga���.

1. Alwa��� w�a� a �a�� �h��ld wh�n w��k�ng �n a ba������.

2. ���p �ng�n� b����� d����nn����ng �� ��nn����ng ba������ �abl��.

3. D� n�� all�w ���l� �� �au�� �pa�k� wh�n w��k�ng �n a ba������.

4. D� n�� u�� w�ld�� �� �ha�g� ba������� �� jump ��a�� v�h��l��.

5. Ob���v� ������� p�la����� (+ and –) �n ba�������.

Manual 0-5073 1-3

THERMAL ARC 161 S

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. D� n�� ��m�v� �ad�a��� �ap wh�n �ng�n� �� h��. All�w �ng�n� ��

���l.

2. W�a� gl�v�� and pu� a �ag �v�� �ap a��a wh�n ��m�v�ng �ap.

3. All�w p����u�� �� ���ap� b����� ��mpl���l�� ��m�v�ng �ap.

SAFETY INSTRUCTIONS

1.02 General Safety Information for Victor

CS Regulator

A Fire Prevention

W�ld�ng and �u���ng �p��a���n� u�� fi�� �� ��mbu����n a� a ba���

���l. Th� p������ �� v���� u���ul wh�n p��p��l�� ��n���ll�d. H�w�v��,

�� �an b� �x���m�l�� d����u���v� �� n�� p�����m�d �������l�� �n �h� p��p��

�nv���nm�n�.

1. Th� w��k a��a mu�� hav� a fi��p���� fl���.

2. W��k b�n�h�� �� �abl�� u��d du��ng w�ld�ng �� �u���ng

�p��a���n� mu�� hav� fi��p���� ��p�.

3. U�� h�a� ������an� �h��ld� �� ��h�� app��v�d ma����al �� p��-

���� n�a�b�� wall� �� unp�������d fl����ng ���m �pa�k� and h�� m��al.

4. K��p an app��v�d fi�� �x��ngu��h�� �� �h� p��p�� ��z� and

���p� �n �h� w��k a��a. �n�p��� �� ��gula�l�� �� �n�u�� �ha� ��

�� �n p��p�� w��k�ng ��d��. Kn�w h�w �� u�� �h� fi�� �x��ngu��h��.

5. M�v� ��mbu���bl� ma����al� awa�� ���m �h� w��k ����. �� ���u

�an n�� m�v� �h�m, p������ �h�m w��h fi��p���� ��v���.

LEAD WARNING

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.)

NOTE

Considerations About Welding And The Effects of Low

Frequency Electric and Magnetic Fields

Th� ��ll�w�ng �� a qu��a���n ���m �h� G�n��al C�n�lu���n� ������n ��

�h� U.�. C�ng����, O�fi�� �� T��hn�l�g�� A�����m�n�, B��l�g��al E������

�� P�w�� F��qu�n��� El������ & Magn���� F��ld� - Ba�kg��und Pap��,

OTA-BP-E-63 (Wa�h�ng��n, DC: U.�. G�v��nm�n� P��n��ng O�fi��, Ma��

1989): “...�h��� �� n�w a v���� la�g� v�lum� �� ����n��fi� find�ng� ba��d

�n �xp���m�n�� a� �h� ��llula� l�v�l and ���m ��ud��� w��h an�mal� and p��pl� wh��h �l�a�l�� ���abl��h �ha� l�w ���qu�n��� magn���� fi�ld�

�n���a�� w��h, and p��du�� �hang�� �n, b��l�g��al ������m�. Wh�l� m���

�� �h�� w��k �� �� v���� h�gh qual����, �h� ���ul�� a�� ��mpl�x. Cu���n�

����n��fi� und����and�ng d��� n�� ���� all�w u� �� �n���p��� �h� �v�d�n��

�n a ��ngl� ��h���n� ��am�w��k. Ev�n m��� ��u���a��ng, �� d��� n��

���� all�w u� �� d�aw d�fin��� ��n�lu���n� ab�u� qu�����n� �� p����bl�

���k �� �� ����� �l�a� ����n��-ba��d adv��� �n ���a��g��� �� m�n�m�z�

�� av��d p���n��al ���k�.”

T� ��du�� magn���� ���ld� �n �h� w��kpla��, u�� �h� ��ll�w�ng p����du���.

1. K��p �abl�� �l��� ��g��h�� b�� �w����ng �� �ap�ng �h�m.

2. A��ang� �abl�� �� �n� ��d� and awa�� ���m �h� �p��a���.

3. D� n�� ���l �� d�ap� �abl� a��und �h� b�d��.

4. K��p w�ld�ng p�w�� ��u��� and �abl�� a� �a� awa�� ���m b�d�� a� p�a����al.

!

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.

K��p ALL appa�a�u� �l�an and ���� �� g��a��, ��l and ��h�� flammabl�

�ub��an���.

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.

�a����� �n���u����n�

SAFETY INSTRUCTIONS

D Personal Protection

Ga� flam�� p��du�� �n��a��d �ad�a���n wh��h ma�� hav� a ha�m�ul ������

�n �h� �k�n and ��p���all�� �n �h� �����. ��l��� g�ggl�� �� a ma�k w��h

��mp���d l�n���, �had�d 4 �� da�k��, �� p������ ���u� ����� ���m �nju��� and p��v�d� g��d v���b�l���� �� �h� w��k.

Alwa��� w�a� p�������v� gl�v�� and flam�-������an� �l��h�ng �� p������ �k�n and �l��h�ng ���m �pa�k� and �lag. K��p ��lla��, �l��v��, and p��k��� bu���n�d. DO NOT ��ll up �l��v�� �� �u�� pan��.

Wh�n w��k�ng �n a n�n-w�ld�ng �� �u���ng �nv���nm�n�, alwa��� w�a�

�u��abl� ���� p��������n �� �a�� �h��ld.

!

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

Th� D�pa��m�n� �� T�an�p���a���n (DOT) app��v�� �h� d���gn and manu�a��u�� �� ���l�nd��� �ha� ��n�a�n ga��� u��d ��� w�ld�ng �� �u�-

��ng �p��a���n�.

1. Pla�� �h� ���l�nd�� (F�gu�� 1-1) wh��� ���u w�ll u�� ��. K��p

�h� ���l�nd�� �n a v�����al p������n. ���u�� �� �� a �a��, wall, w��k b�n�h, p���, ���.

THERMAL ARC 161 S

3. ����� �mp��� ���l�nd��� awa�� ���m �ull ���l�nd���. Ma�k �h�m

“EMPTY” and �l��� �h� ���l�nd�� valv�.

4. NEVER u�� ��mp�����d ga� ���l�nd��� w��h�u� a p����u��

��du��ng ��gula��� a��a�h�d �� �h� ���l�nd�� valv�.

5. �n�p��� �h� ���l�nd�� valv� ��� ��l, g��a��, and damag�d pa���.

!

WARNING

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

6. M�m�n�a��l�� �p�n and �l��� (�all�d “��a�k�ng”) �h� ���l�nd�� valv� �� d��l�dg� an�� du�� �� d��� �ha� ma�� b� p����n� �n �h� valv�.

F�gu�� 1-1: Ga� C��l�nd���

!

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 P-

1 “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. Pla�� �h� valv� p��������n �ap �n �h� ���l�nd�� wh�n�v�� m�v�ng ��, pla��ng �� �n ����ag�, �� n�� u��ng ��. N�v�� d�ag ��

��ll ���l�nd��� �n an�� wa��. U�� a �u��abl� hand ��u�k �� m�v�

���l�nd���.

Manual 0-5073 1-5

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

�a����� �n W�ld�ng and Cu���ng, AN�� ��anda�d Z49.1, ���m Am����an

W�ld�ng ��������, 550 N.W. L�J�un� Rd., M�am�, FL 33126.

�a����� and H�al�h ��anda�d�, O�HA 29 CFR 1910, ���m �up���n��nd�n�

�� D��um�n��, U.�. G�v��nm�n� P��n��ng O�fi��, Wa�h�ng��n, D.C.

20402.

R���mm�nd�d �a�� P�a������ ��� �h� P��pa�a���n ��� W�ld�ng and

Cu���ng �� C�n�a�n��� Tha� Hav� H�ld Haza�d�u� �ub��an���, Am����an

W�ld�ng �������� ��anda�d AW� F4.1, ���m Am����an W�ld�ng ��������,

550 N.W. L�J�un� Rd., M�am�, FL 33126.

Na���nal El������al C�d�, NFPA ��anda�d 70, ���m Na���nal F���

P��������n A�����a���n, Ba������ma��h Pa�k, Qu�n���, MA 02269.

�a�� Handl�ng �� C�mp�����d Ga��� �n C��l�nd���, CGA Pamphl�� P-1,

���m C�mp�����d Ga� A�����a���n, 1235 J�������n Dav�� H�ghwa��,

�u��� 501, A�l�ng��n, VA 22202.

C�d� ��� �a����� �n W�ld�ng and Cu���ng, C�A ��anda�d W117.2, ���m

Canad�an ��anda�d� A�����a���n, ��anda�d� �al��, 178 R�xdal�

B�ul�va�d, R�xdal�, On�a���, Canada M9W 1R3.

�a�� P�a������ ��� O��upa���n and Edu�a���nal E��� and Fa�� P��������n,

AN�� ��anda�d Z87.1, ���m Am����an Na���nal ��anda�d� �n����u��,

1430 B��adwa��, N�w Y��k, NY 10018.

Cu���ng and W�ld�ng P��������, NFPA ��anda�d 51B, ���m Na���nal F���

P��������n A�����a���n, Ba������ma��h Pa�k, Qu�n���, MA 02269.

THERMAL ARC 161 S

1.04 Symbol Chart

N��� �ha� �nl�� ��m� �� �h��� ���mb�l� w�ll app�a� �n ���u� m�d�l.

On Single Phase

Off

Dangerous Voltage

Increase/Decrease

Circuit Breaker

AC Auxiliary Power

Fuse

Amperage

Voltage

Hertz (cycles/sec)

Frequency

Negative

Positive

Direct Current (DC)

Protective Earth

(Ground)

Line

Line Connection

Auxiliary Power

115V 15A

Receptacle Rating-

Auxiliary Power

�a����� �n���u����n�

Three Phase

Three Phase Static

Frequency Converter-

Transformer-Rectifier

Remote

X

%

Duty Cycle

Percentage

Panel/Local

Shielded Metal

Arc Welding (SMAW)

Gas Metal Arc

Welding (GMAW)

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

V

Voltage Input

SAFETY INSTRUCTIONS

Wire Feed Function

Wire Feed Towards

Workpiece With

Output Voltage Off.

Welding Gun

Purging Of Gas

Continuous Weld

Mode

Spot Weld Mode

t1

t

Spot Time

Preflow Time

t2

Postflow Time

2 Step Trigger

Operation

Press to initiate wirefeed and welding, release to stop.

4 Step Trigger

Operation

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

t

Burnback Time

IPM

Inches Per Minute

MPM

Meters Per Minute

Art # A-04130

SAFETY INSTRUCTIONS

1.05 Precautions De Securite En Soudage A L’arc

THERMAL ARC 161 S

!

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 EQUIPE-

MENT.

L�� p��du��� �� p���édé� d� ��udag� p�uv�n� �au��� d�� bl���u��� g�av�� �u la m���, d� mêm� qu� d�� d�mmag�� au ����� du ma�é���l �� à la p��p��é�é, �� l’u��l��a��u� n’adhè�� pa� �������m�n� à ��u��� l�� �ègl�� d� �é�u���é �� n� p��nd pa� l�� p�é�au���n� né����a����.

En ��udag� �� ��upag�, d�� p�a��qu�� �é�u���a���� �� ��n� dév�l�ppé�� �u��� à l’�xpé���n�� pa��é�. C�� p�a��qu�� d��v�n� ê��� app����� pa�

é�ud� �u �n��aîn�m�n� avan� d’u��l���� l’�qu�p�m�n�. T�u�� p����nn� n’a��an� pa� �u�v� un �n��aîn�m�n� �n��n��� �n ��udag� �� ��upag� n� d�v�a�� pa� ��n��� d� ��ud��. C���a�n�� p�a��qu�� ��n���n�n� l�� équ�p�m�n�� �a����dé� aux l�gn�� d’al�m�n�a���n al��� qu� d’au���� �’ad�����n� aux g��up�� él�����gèn��.

La n��m� Z49.1 d� l’Am����an Na���nal ��anda�d, �n���ulé� “�AFETY �N WELD�NG AND CUTT�NG” p�é��n�� l�� p�a��qu�� �é�u���a���� à �u�v��.

C� d��um�n� a�n�� qu� d’au���� gu�d�� qu� v�u� d�v���z ��nnaî��� avan� d’u��l���� ��� équ�p�m�n� ��n� p�é��n�é� à la fin d� ��� �n���u����n� d� �é�u���é.

�EULE� DE� PER�ONNE� QUAL�F�EE� DO�VENT FA�RE DE� TRAVAUX D’�N�TALLAT�ON, DE REPARAT�ON, D’ENTRET�EN ET D’E��A�.

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. N� ��u�h�z pa� à d�� p�è��� ��u� ��n���n.

2. P����z d�� gan�� �� d�� vê��m�n�� ���lan��, ���� �� n�n ���ué�.

3 ���l�z-v�u� d� la p�è�� à ��ud�� �� d� la m��� à la ����� au m����n d� �ap�� ���lan�� �u au����.

4. Dé��nn����z la p���� d’al�m�n�a���n d� l’équ�p�m�n� �u a��ê��z l� m���u� avan� d� l’�n��all�� �u d’�n �a��� l’�n������n. Bl�qu�z l� ��mmu�a��u� �n ����u�� �uv��� �u �nl�v�z l�� �u��bl�� d� l’al�m�n�a���n afin d’év���� un� m��� �n ma��h� a���d�n��ll�.

5. V�u�ll�z à �n��all�� ��� équ�p�m�n� �� à l� m����� à la ����� ��l�n l� manu�l d’u��l��a���n �� l�� ��d�� na���naux, p��v�n��aux �� l��aux appl��abl��.

6. A��ê��z ��u� équ�p�m�n� ap�è� u�ag�. C�up�z l’al�m�n�a���n d� l’équ�p�m�n� �’�l ��� h��� d’u�ag� �u �nu��l��é.

7. N’u��l���z qu� d�� p����-él�����d�� b��n ���lé�. N� jama�� pl�ng�� l�� p����-él�����d�� dan� l’�au p�u� l�� ������d��. N� jama�� l�� la����� ��aîn�� pa� ����� �u �u� l�� p�è��� à ��ud��. N� ��u�h�z pa� aux p����-él�����d�� �a����dé� à d�ux ��u���� d� ��u�an� �n mêm� ��mp�. N� jama�� ��u�h�� qu�lqu’un d’au��� av�� l’él�����d�

�u l� p����-él�����d�.

8. N’u��l���z pa� d� �âbl�� él�����qu�� u�é�, �nd�mmagé�, mal ép��-

�é� �u d� ������n ���p p�����.

9. N’�n��ul�z pa� d� �âbl�� él�����qu�� au��u� d� v���� ���p�.

10. N’u��l���z qu’un� b�nn� p���� d� ma��� p�u� la m��� à la ����� d� la p�è�� à ��ud��.

11. N� ��u�h�z pa� à l’él�����d� l���qu’�n ��n�a�� av�� l� ����u�� d�

��udag� (�����).

12. N’u��l���z qu� d�� équ�p�m�n�� �n b�n é�a�. Répa��z �u ��mpla��z au����ô� l�� p�è��� �nd�mmagé��.

13. Dan� d�� ��pa��� ��nfiné� �u m�u�llé�, n’u��l���z pa� d� ��u��� d� ��u�an� al���na���, à m��n� qu’�l ���� mun� d’un �édu���u� d�

��n���n. U��l���z plu�ô� un� ��u��� d� ��u�an� ��n��nu.

14. P����z un ha�na�� d� �é�u���é �� v�u� ��ava�ll�z �n hau��u�.

15. F��m�z ��l�d�m�n� ��u� l�� pann�aux �� l�� �ap���.

AVERTISSEMENT

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.

Manual 0-5073 1-7

THERMAL ARC 161 S

1. P����z un� �a�qu� d� ��ud�u� av�� fil��� ��ula��� d� nuan�� app��p��é� (��n�ul��z la n��m� AN�� Z49 �nd�qué� ��-ap�è�) p�u� v�u� p���ég�� l� v��ag� �� l�� ���ux l���qu� v�u� ��ud�z �u qu� v�u� �b���v�z l’�xé�u���n d’un� ��udu��.

2. P����z d�� lun����� d� �é�u���é app��uvé��. D�� é��an� la�é�aux

��n� ����mmandé�.

3. En��u��z l’a��� d� ��udag� d� ��d�aux �u d� �l����n� p�u� p���ég�� l�� au���� d�� ��up� d’a�� �u d� l’ébl�u����m�n�; av�������z l��

�b���va��u�� d� n� pa� ��ga�d�� l’a��.

4. P����z d�� v�m�n�� �n ma��aux �gn��ug�� �� du�abl�� (la�n� ��

�u��) �� d�� �hau��u��� d� �é�u���é.

5. P����z un �a�qu� an��b�u�� �u d�� b�u�h�n� d’����ll� app��uvé� l���qu� l� n�v�au d� b�u�� ��� él�vé.

AVERTISSEMENT

LES VAPEURS ET LES FUMEES SONT DANGEREUSES

POUR LA SANTE.

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

SAFETY INSTRUCTIONS

1. El��gn�z la �ê�� d�� �umé�� p�u� év���� d� l�� ���p����.

2. A l’�n�é���u�, a��u��z-v�u� qu� l’a��� d� ��udag� ��� b��n v�n��lé�

�u qu� l�� �umé�� �� l�� vap�u�� ��n� a�p��é�� à l’a��.

3. �� la v�n��la���n ��� �nad�qua��, p����z un ���p��a��u� à addu����n d’a�� app��uvé.

4. L���z l�� fi�h�� ��gnalé��qu�� �� l�� ��n��gn�� du �ab���an� ��la��v�� aux mé�aux, aux p��du��� ��n�ummabl��, aux ��vê��m�n�� �� aux p��du��� n������an��.

5. N� ��ava�ll�z dan� un ��pa�� ��nfiné qu� �’�l ��� b��n v�n��lé;

��n�n, p����z un ���p��a��u� à addu����n d’a��. L�� gaz p�������u�� d� ��udag� p�uv�n� dépla��� l’�x��gèn� d� l’a�� �� a�n�� �au��� d�� mala���� �u la m���. A��u��z-v�u� qu� l’a�� ��� p��p�� à la

���p��a���n.

6. N� ��ud�z pa� à p��x�m��é d’�pé�a���n� d� dég�a���ag�, d� n������ag� �u d� pulvé���a���n. La �hal�u� �� l�� �a���n� d� l’a�� p�uv�n�

�éag�� av�� d�� vap�u�� �� ���m�� d�� gaz hau��m�n� ��x�qu�� ��

�����an��.

7. N� ��ud�z d�� �ôl�� galvan��é�� �u plaqué�� au pl�mb �u au

�adm�um qu� �� l�� z�n�� à ��ud�� �n� é�é g�a��é�� à ��nd, qu�

�� l’��pa�� ��� b��n v�n��lé; �� né����a��� p����z un ���p��a��u� à addu����n d’a��. Ca� ��� ��vê��m�n�� �� ��u� mé�al qu� ��n���n�

��� élém�n�� p�uv�n� dégag�� d�� �umé�� ��x�qu�� au m�m�n� du ��udag�.

SELECTION DES NUANCES DE FILTRES OCULAIRS POUR LA PROTECTION

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

Opé�a���n d� ��upag�

�u ��udag�

D�m�n���n d'él�����d� �u

Ep�a���u� d� mé�al �u

�n��n���é d� ��u�an�

Nuan�� d� fil��� ��ula���

Opé�a���n d� ��upag�

�u ��udag�

D�m�n���n d'él�����d� �u

Ep�a���u� d� mé�al �u

�n��n���é d� ��u�an�

Nuan�� d� fil���

��ula���

B�a��ag� ��nd�� au �halum�au

B�a��ag� ���� au �halum�au

Ox����upag� m�n��

��u��� ��nd����n�

��u��� ��nd����n� m��n� d� 1 p�. (25 mm) m����n d� 1 á 6 p�. (25 á 150 mm)

épa�� plu� d� 6 p�. (150 mm)

��udag� aux gaz m�n�� m��n� d� 1/8 p�. (3 mm) m����n d� 1/8 á 1/2 p�. (3 á 12 mm)

��udag� á l'a�� av��

él�����d� �n��b���

(�MAW)

épa�� plu� d� 1/2 p�. (12 mm) m��n� d� 5/32 p�. (4 mm)

5/32 á 1/4 p�. (4 á 6.4 mm) plu� d� 1/4 p�. (6.4 mm)

2

3 �u 4

2 �u 3

4 �u 5

5 �u 6

4 �u 5

5 �u 6

6 �u 8

10

12

14

��udag� á l'a�� ��u� gaz av�� fil pl��n (GMAW) mé�aux n�n-�����ux mé�aux �����ux

��udag� á l'a�� ��u� gaz av��

él�����d� d� �ung��èn�

(GTAW)

��udag� á l'h��d��gèn� a��m�qu� (AHW)

��udag� á l'a�� av��

él�����d� d� �a�b�n� (CAW)

��udag� á l'a�� Pla�ma (PAW)

G�ug�ag� A��-A�� av��

él�����d� d� �a�b�n� m�n��

épa��

C�upag� á l'a�� Pla�ma (PAC) m�n�� m����n

épa��

��u��� ��nd����n�

��u��� ��nd����n�

��u��� ��nd����n�

��u��� ��nd����n�

��u��� ��nd����n�

��u��� d�m�n���n� m��n� d� 300 amp��è� d� 300 á 400 amp��è� plu� d� 400 amp��è�

9

12

14

11

12

12

12

12

12

12

14

�a����� �n���u����n�

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. P���ég�z-v�u�, a�n�� qu� l�� au����, ��n��� l�� é��n��ll�� �� du mé�al �haud.

2. N� ��ud�z pa� dan� un �nd���� �ù d�� pa����ul�� v�lan��� �u d�� p��j�����n� p�uv�n� a����nd�� d�� ma�é��aux �nflammabl��.

3. Enl�v�z ��u��� ma��è��� �nflammabl�� dan� un �a���n d� 10, 7 mè���� au��u� d� l’a��, �u ��uv��z-l�� ���gn�u��m�n� av�� d�� bâ�h�� app��uvé��.

4. Méfi�z-v�u� d�� p��j�����n� b�ulan��� d� ��udag� �u���p��bl�� d� péné���� dan� d�� a���� adja��n��� pa� d� p������ �uv���u���

�u fi��u���.

5. Méfi�z-v�u� d�� �n��nd��� �� ga�d�z un �x��n���u� à p���é� d� la ma�n.

6. N’�ubl��z pa� qu’un� ��udu�� �éal��é� �u� un pla��nd, un plan�h��, un� �l����n �u un� pa��� p�u� �nflamm�� l’au��� �ô�é.

7. N� ��ud�z pa� un �é��p��n� ���mé, ��l un �é���v��� �u un ba��l.

8. C�nn����z l� �âbl� d� ��udag� l� plu� p�è� p����bl� d� la z�n� d� ��udag� p�u� �mpê�h�� l� ��u�an� d� �u�v�� un l�ng pa�-

��u�� �n��nnu, �� p�év�n�� a�n�� l�� ���qu�� d’él������u���n �� d’�n��nd��.

9. N� dég�l�z pa� l�� �u��aux av�� un ��u��� d� ��u�an�.

10. O��z l’él�����d� du p����-él�����d� �u ��up�z l� fil au �ub�-��n�a�� l���qu’�nu��l��é ap�è� l� ��udag�.

11. P����z d�� v�m�n�� p�������u�� n�n hu�l�ux, ��l� d�� gan�� �n

�u��, un� �h�m��� épa����, un pan�al�n ��v���, d�� b����n�� d�

�é�u���é �� un �a�qu�.

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. P����z un é��an �a��al �u d�� lun����� p����������� app��uvé��. D�� é��an� la�é�aux ��n� ����mmandé�.

2. P����z d�� vê��m�n�� app��p��é� p�u� p���ég�� la p�au.

AVERTISSEMENT

LES BOUTEILLES ENDOMMAGEES PEUVENT EX-

PLOSER

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. P���ég�z l�� b�u���ll�� d� gaz ��mp��mé ��n��� l�� ��u���� d�

�hal�u� �n��n��, l�� �h��� �� l�� a��� d� ��udag�.

2. En�ha�n�z v�����al�m�n� l�� b�u���ll�� à un �upp��� �u à un �ad�� fix� p�u� l�� �mpê�h�� d� ��mb�� �u d’ê��� ��nv���é��.

3. El��gn�z l�� b�u���ll�� d� ��u� ����u�� él�����qu� �u d� ��u� ��udag�.

4. Empê�h�z ��u� ��n�a�� �n��� un� b�u���ll� �� un� él�����d� d�

��udag�.

5. N’u��l���z qu� d�� b�u���ll�� d� gaz p�������u�, d�� dé��nd�u��, d�� b���aux� �� d�� �a����d� ��nçu� p�u� �haqu� appl��a���n

�pé��fiqu�; ��� équ�p�m�n�� �� l�� p�è��� ��nn�x�� d��v�n� ê��� ma�n��nu� �n b�n é�a�.

6. N� pla��z pa� l� v��ag� �a�� à l’�uv���u�� du ��b�n�� d� la b�u���ll� l��� d� ��n �uv���u��.

7. La����z �n pla�� l� �hap�au d� b�u���ll� �au� �� �n u��l��a���n �u l���qu� �a����dé p�u� u��l��a���n.

8. L���z �� ���p����z l�� ��n��gn�� ��la��v�� aux b�u���ll�� d� gaz

��mp��mé �� aux équ�p�m�n�� ��nn�x��, a�n�� qu� la publ��a���n

P-1 d� la CGA, �d�n��fié� dan� la l���� d� d��um�n�� ��-d����u�.

AVERTISSEMENT

LES MOTEURS PEUVENT ETRE DANGEREUX

LES GAZ D’ECHAPPEMENT DES MOTEURS PEUVENT

ETRE MORTELS.

L�� m���u�� p��du���n� d�� gaz d’é�happ�m�n� n�����.

1. U��l���z l’équ�p�m�n� à l’�x�é���u� dan� d�� a���� �uv����� �� b��n v�n��lé��.

2. �� v�u� u��l���z ��� équ�p�m�n�� dan� un �nd���� ��nfiné, l��

�umé�� d’é�happ�m�n� d��v�n� ê��� �nv���é�� à l’�x�é���u�, l��n d�� p����� d’a�� du bâ��m�n�.

AVERTISSEMENT

LE CARBURANT PEUR CAUSER UN INCENDIE OU UNE

EXPLOSION.

Le carburant est hautement inflammable.

1. A���z l� m���u� avan� d� v�fi�� l� n�v�au � �a�bu�an� �u d�

�a��� l� pl��n.

Manual 0-5073 1-9

THERMAL ARC 161 S

2. N� �a���� pa� l� pl��n �n �uman� �u p���h� d’un� ��u��� d’é��n��ll��

�u d’un� flamm� nu�.

3. �� �’��� p����bl�, la����z l� m���u� ������d�� avan� d� �a��� l� pl��n d� �a�bu�an� �u d’�n vé��fi�� l� n�v�au au débu� du ��udag�.

4. N� �a���� pa� l� pl��n d� �a�bu�an� à �a� b��d: p�év����z d� l’��pa�� p�u� ��n �xpan���n.

5. Fa���� a���n���n d� n� pa� ��nv����� d� �a�bu�an�. N�������z ��u�

�a�bu�an� ��nv���é avan� d� �a��� déma���� l� m���u�.

SAFETY INSTRUCTIONS

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’ô��z pa� l� b�u�h�n d� �ad�a��u� �an� qu� l� m���u� n’��� pa�

������d�.

2. M����z d�� gan�� �� p���z un ����h�n �u� l� b�u�h�n p�u� l’ô���.

3. La����z la p������n �’é�happ�� avan� d’ô��� ��mplè��m�n� l� b�u�h�n.

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. A��u��z-v�u� qu� l�� p�����, l�� pann�aux, l�� �ap��� �� l�� p�������u�� ����n� b��n ���mé�.

2. Avan� d’�n��all�� �u d� ��nn����� un �����èm�, a��ê��z l� m���u�.

3. ��ul�� d�� p����nn�� qual�fié�� d��v�n� dém�n��� d�� p�������u��

�u d�� �ap��� p�u� �a��� l’�n������n �u l� dépannag� né����a���.

4. P�u� �mpê�h�� un déma��ag� a���d�n��l p�ndan� l’�n������n, déb�an�h�z l� �âbl� d’a��umula��u� à la b��n� néga��v�.

5. N’app���h�z pa� l�� ma�n� �u l�� �h�v�ux d� p�è��� �n m�uv�m�n�; �ll�� p�uv�n� au��� a�����h�� d�� vê��m�n�� ampl�� �� d��

�u��l�.

6. Ré�n��all�z l�� �ap��� �u l�� p�������u�� �� ���m�z l�� p����� ap�è� d�� ��avaux d’�n������n �� avan� d� �a��� déma���� l� m���u�.

AVERTISSEMENT

DES ETINCELLES PEUVENT FAIRE EXPLOSER UN ACCU-

MULATEUR; 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. P����z ��uj�u�� un �an �a��al �n ��ava�llan� �u� un a��umu-la-

��u�.

2. A��ê��z l� m���u� avan� d� ��nn����� �u d� dé��nn����� d�� �âbl�� d’a��umula��u�.

3. N’u��l���z qu� d�� �u��l� an��-é��n��ll�� p�u� ��ava�ll�� �u� un a�-

�umula��u�.

4. N’u��l���z pa� un� ��u��� d� ��u�an� d� ��udag� p�u� �ha�g�� un a��umula��u� �u �u�v�l��� m�m�n�aném�n� un véh��ul�.

5. U��l���z la p�la���é �������� (+ �� –) d� l’a��umula��u�.

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

L�� �pé�a���n� d� ��udag� u��l���n� l� ��u �u la ��mbu����n ��mm� �u��l d� ba��. C� p������u� ��� ��è� u��l� quand �l ��� ��������m�n� ��n��ôlé.

1. La z�n� d��� ��mp����� un ��l �gn��ugé.

2. L�� é�abl�� �u �abl�� u��l��é� p�ndan� l�� �pé�a���n� d�

��udag� d��v�n� av��� un ��v�m�n� �gn��ug�.

3. U��l���z d�� é��an� �é����an�� à la �hal�u� �u �n ma�é��au app��uvé p�u� p���ég�� l�� �l����n� p���h�� �u l� ��l vulné�abl� d�� é��n��ll�� �� du mé�al �haud.

4. Ga�d�z un �x��n���u� app��uvé du b�n ���p� �� d� la b�nn� �a�ll� dan� la z�n� d� ��ava�l. �n�p����z-l� �égul�è��m�n� p�u� v�u� a��u��� qu’�l ��� �n é�a� d� ��n����nn��. App��n�z à v�u� �n

���v��.

5. Enl�v�z ��u� l�� ma��aux ��mbu���bl�� d� la z�n� d� ��ava�l.

�� v�u� n� p�uv�z pa� l�� �nl�v��, p���ég�z-l�� av�� un� ��uv��

�gn��ug�.

�a����� �n���u����n�

SAFETY INSTRUCTIONS

!

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.

Ga�d�z TOUS l�� appa���l� p��p��� �� �x�mp�� d� g�a����, hu�l� �u au���� �ub��an��� �nflammabl��.

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

L�� flamm�� d� gaz p��du���n� un� �ad�a���n �n��a��ug� qu� p�u� av��� un ����� né�a��� �u� la p�au, �� pa����ul�è��m�n� �u� l�� ���ux. Ch�����-

��z d�� lun����� �u un ma�qu� av�� d�� v����� ���mpé� a���mb��� au n�v�au 4 �u plu� ��mb��, p�u� p���ég�� v�� ���ux d�� d�mmag��

�� ga�d�� un� b�nn� v���b�l��é �u� l� ��ava�l.

P����z �n p��man�n�� d�� gan�� d� p��������n �� d�� v�m�n��

�gn��ug�� p�u� la p��������n d� la p�au �� d�� v�m�n�� ��n��� l��

é��n��ll�� �� l� la�����. Ga�d�z ��l, man�h�� �� p��h�� b�u��nné�. �l n�

�au� pa� ��m�n��� v�� man�h�� �u l�� pan�al�n� à ��v���.

Quand v�u� ��ava�ll�z dan� un �nv���nn�m�n� n�n déd�é au ��udag�

�u d�upag�, p����z ��uj�u�� un� p��������n d�� ���ux app��p���

�u un ma�qu� �a��al.

THERMAL ARC 161 S

!

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

L� Dépa���m�n� d�� T�an�p���� amé���a�n (DOT) app��uv� la ��n��p-

���n �� la �ab���a���n d�� b�u���ll�� qu� ��n���nn�n� l�� gaz u��l��é� p�u� l�� �pé�a���n� d� ��udag� �u d� dé��upag�.

1. Pla��z la b�u���ll� (L� ��héma 1) là �ù �ll� ���a u��l��é�. Ga�d�z-la

�n p������n v�����al�. F�x�z-la �u� un �ha���� un� �l����n, un é�abl�,

���.

L� ��héma 1-1: C��l�nd��� d� 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.

2. Pla��z l� b�u�h�n d� p��������n d� vann� �u� la b�u���ll�

à �haqu� ���� qu� v�u� la dépla��z �u n� l’u��l���z pa�. N�

�a���� jama�� gl����� �u ��ul�� d’au�un� man�è�� l�� b�u���ll��.

U��l���z un d�abl� app��p��é p�u� l�� dépla���.

3. En���p���z l�� b�u���ll�� v�d�� à l’é�a�� d�� b�u���ll�� pl��n��.

Ma�qu�z-l�� “V�DE” �� �����m�z l�u� vann�.

4. N’u��l���z JAMAIS d�� b�u���ll�� d� gaz ��mp��mé �an� un

�égula��u� d� p������n �n �é��� �u� la vann� d� b�u���ll�.

5. �n�p����z la vann� d� b�u���ll� p�u� �� dé������ d� l’hu�l� �u d� la g�a����, �u dè� p�è��� �nd�mmagé��.

Manual 0-5073 1-11

THERMAL ARC 161 S

!

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. Ouv��z �� ���m�z m�m�n�aném�n� la vann� d� la b�u���ll�, dél�g�an� a�n�� d’év�n�u l��� p�u���è��� �u �al��é�. qu� p�u�-

�a��n� �� p��n��� dan� la vann�.

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

�a����� �n W�ld�ng and Cu���ng, n��m� AN�� Z49.1, Am����an W�ld�ng

��������, 550 N.W. L�J�un� Rd., M�am�, FL 33128.

�a����� and H�al�h ��anda�d�, O�HA 29 CFR 1910, �up���n��nd�n�

�� D��um�n��, U.�. G�v��nm�n� P��n��ng O�fi��, Wa�h�ng��n, D.C.

20402.

R���mm�nd�d �a�� P�a������ ��� �h� P��pa�a���n ��� W�ld�ng and

Cu���ng �� C�n�a�n��� Tha� Hav� H�ld Haza�d�u� �ub��an���, n��m�

AW� F4.1, Am����an W�ld�ng ��������, 550 N.W. L�J�un� Rd., M�am�,

FL 33128.

Na���nal El������al C�d�, n��m� 70 NFPA, Na���nal F��� P��������n

A�����a���n, Ba������ma��h Pa�k, Qu�n���, MA 02269.

�a�� Handl�ng �� C�mp�����d Ga��� �n C��l�nd���, d��um�n� P-1,

C�mp�����d Ga� A�����a���n, 1235 J�������n Dav�� H�ghwa��, �u���

501, A�l�ng��n, VA 22202.

C�d� ��� �a����� �n W�ld�ng and Cu���ng, n��m� C�A W117.2 A�����a���n

�anad��nn� d� n��mal��a���n, ��anda�d� �al��, 276 R�xdal� B�ul�va�d,

R�xdal�, On�a���, Canada M9W 1R3.

�a�� P�a������ ��� O��upa���n and Edu�a���nal E��� and Fa�� P�����-

���n, n��m� AN�� Z87.1, Am����an Na���nal ��anda�d� �n����u��, 1430

B��adwa��, N�w Y��k, NY 10018.

Cu���ng and W�ld�ng P��������, n��m� 51B NFPA, Na���nal F��� P�����-

���n A�����a���n, Ba������ma��h Pa�k, Qu�n���, MA 02269.

SAFETY INSTRUCTIONS

�a����� �n���u����n�

SAFETY INSTRUCTIONS

1.09 Graphique de Symbole

Seulement certains de ces symboles apparaîtront sur votre modèle.

Sous Tension

Hors Tension

Mono Phasé

Tension dangereuse

Augmentez/Diminuer

Disjoncteur

Source AC Auxiliaire

Fusible

Intensité de Courant

Tension

Hertz (cycles/sec)

Fréquence

Négatif

Positif

Courant Continue (DC)

Terre de Protection

Trois Phasé

Tri-Phase Statique

Fréquence Convertisseur

Transformateur-Redresseur

Distant

X

%

Facteur de Marche

Pourcentage

Panneau/Local

Soudage Arc Electrique

Avec Electrode Enrobé

(SMAW)

Soudage á L’arc Avec

Fil Electrodes Fusible

(GMAW)

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

Ligne

Connexion de la Ligne

Source Auxiliaire

115V 15A

Classement de Prise-

Source Auxiliaire

Manual 0-5073

V

Tension

1-13

THERMAL ARC 161 S

Déroulement du Fil

Alimentation du Fil Vers la Pièce de Fabrication

Hors Tension

Torch de

Soudage

Purge Du Gaz

Mode Continu de

Soudure

Soudure Par Point

t1

t

Duréc du Pulse

Durée de Pré-Dèbit

t2

Durée de Post-Dèbit

Détente à 2-Temps

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

Détente à 4-Temps

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

t

Probléme de Terre

IPM

Pouces Par Minute

MPM

Mètres Par Minute

Art # A-07639

Th�� pag� l��� blank �n��n���nall��.

INTRODUCTION THERMAL ARC 161 S

SECTION 2:

INTRODUCTION

2.04 Description 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:

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.

!

WARNING

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

2.05 Transportation Methods

CAUTION

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

NOTE

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

2.02 Equipment Identification

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.

!

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.

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.

2.06 Duty Cycle

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.

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

2.07 Specifications

INTRODUCTION

Power Source Part Number

Mains Power

Nominal Supply Voltage

Number of Phases

Input Voltage Range

Nominal Supply Frequency

Effective Input Current (l1eff)

Maximum Input Current (l1 max)

Single Phase Generator Requirements [Continuous rating at nominal supply voltage with maximum output for STICK (SMAW) welding]

Welding Output

Welding Current Range

Nominal DC Open Circuit Voltage (OCV)

Welding Output, 104º F (40º C), 10 min.

(Quoted figures refer to STICK (SMAW) output)

AC 115V

Single Phase

AC 104- 127V

50/60 Hz

16.7 Amps

∆ 27.3 Amps

4 KVA

W1003600

AC 208/230V

Single Phase

AC 187- 253V

50/60 Hz

12.7 Amps

∆ 25 Amps

6 KVA

Rated Input Current (A)

for STICK (SMAW) Welding

Rated Input Current (A)

for LIFT TIG (GTAW) Welding

Rated Output for STICK (SMAW) Welding

Rated Output for LIFT TIG (GTAW) Welding

Duty Cycle (%)

Welder Type

Output Terminal Type

Classification

Protection Class

Standards

10 - 110 Amps

71V

100A @ 35%, 24.0V

80A @ 60%, 23.2V

60A @ 100%, 22.4V

27.3A

Io = 100A @ 24.0V

19A

Io = 110A @ 14.4V

24.0V, 100A @ 35%

14.4V, 110A @ 50%

35% @ 100A

10 - 160 Amps

71V

160A @ 30%, 26.4V

100A @ 60%, 24.0V

80A @ 100%, 23.2V

26.4V, 160A @ 30%

16.4V, 160A @ 30%

30% @ 160A

Inverter Power Source

Heavy Duty Dinse

TM

50

25A

Io = 160A @ 26.4V

15.5A

Io = 160A @ 16.4V

IP23S

EN 60974-1

EN50199

Fan Cooled Cooling Method

Dimensions and Weight

Welding Power Source Mass

Welding Power Source Dimensions (Height x Width x Depth)

17.4 lb. (7.9 kg)

H 9.0” x W 5.3” x D 15.5”

(H230mm x W135mm x D393mm)

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)

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

THERMAL ARC 161 S INSTALLATION

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

115V

208-230V

Circuit Breaker or Fuse Size

30A

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.

208-230V, 50A, 1Ø

Welding Power Supply

120 V, 20A, 1Ø

The Adapters enable connection to all these power outlets

120 V, 15A, 1Ø

Primary Power Cable

Art# A-09862

Figure 3-1: Electrical Input Connections

Installation

INSTALLATION

Input Power

THERMAL ARC 161 S

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

Thermal Arc

161 S

Primary Supply Lead

Size (Factory Fitted)

Minimum Primary

Current Circuit Size

(Vin/Amps)

115V/27.3A

Current & Duty Cycle

LIFT TIG (GTAW) STICK (SMAW)

12 AWG (3.3mm²)

115V/20A

208-230V/25A

-

110A @ 50%

-

208-230V/15A 160A @ 30%

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

100A @ 35%

-

160A @ 30%

-

Manual 0-5073

THERMAL ARC 161 S

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.

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

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

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

INSTALLATION

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.

THERMAL ARC 161 S

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

THERMAL ARC 161 S

3.06 STICK (SMAW) Setup

Set Process Selection

Switch to SMAW (Stick)

Negative Output

Terminal

(Dinse™ 50)

Set Welding Current as specified by the

Electrode Manufacturer.

Positive Output

Terminal

(Dinse™ 50)

INSTALLATION

Art #: A-09878

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

STICK (SMAW) Mode Sequence of Operation

CAUTION

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.

NOTE

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. 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

3.07 LIFT TIG (GTAW) Setup

Set Process Selection

Switch to GTAW (Lift TIG).

THERMAL ARC 161 S

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

Negative

Output

Terminal

(Dinse™ 50)

Set Welding Current as specified by the

Electrode Manufacturer.

Positive Output

Terminal

(Dinse™ 50)

Art #: A-09880

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

LIFT TIG (GTAW) Sequence of Operation

CAUTION

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

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.

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

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

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

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

NOTE

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.

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.

Manual 0-5073

THERMAL ARC 161 S

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.

INSTALLATION

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

DO NOT use a regulator 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.

Figure 3-4: Victor CS Regulator

!

WARNING

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

NOTE

Regulators purchased with open 1/8”, 1/4”,

3/8”, or 1/2” NPT ports must be assembled to their intended system.

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

INSTALLATION

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.

THERMAL ARC 161 S

9. Slowly and carefully open the cylinder valve

(Figure 3-6) until the maximum pressure shows on the high pressure gauge.

Art # A-09828

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.

!

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.

Art # A-09845

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

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

CAUTION

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.

THERMAL ARC 161 S

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

INSTALLATION

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.

!

WARNING

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.

Installation

OPERATION THERMAL ARC 161 s

SECTION 4:

OPERATION

C�nv�n���nal ����a��ng ���c�du��s a��ly wh�n us�ng �h�

W�ld�ng P�w�� S�u�c�, �.�. c�nn�c� w��k l�ad d���c�ly �� w��k ���c� and �l�c���d� l�ad �s us�d �� h�ld �h� �l�c���d�.

Th� w�ld�ng cu���n� �ang� valu�s sh�uld b� us�d as a gu�d� �nly. Cu���n� d�l�v���d �� �h� a�c �s d���nd�n� �n

�h� w�ld�ng a�c v�l�ag�, and as w�ld�ng a�c v�l�ag� va���s b��w��n d�ff���n� class�s �f �l�c���d�, w�ld�ng cu���n� a� any �n� s����ng w�uld va�y acc��d�ng �� �h� �y�� �f �l�c-

���d� �n us�. Th� ����a��� sh�uld us� �h� w�ld�ng cu���n�

�ang� valu�s as a gu�d� �h�n fin� �un� �h� w�ld�ng cu���n�

�� su�� �h� s��c�fic a��l�ca���n. R�f�� �� �h� �l�c���d� manufac�u��'s l����a�u�� f�� fu��h�� �nf��ma���n.

4.01 Front Panel

Front Panel

Th� w�ld�ng ��w�� s�u�c� �s �����c��d by a s�lf ��-s����ng

�h��m�s�a�. Th� �nd�ca��� w�ll �llum�na�� �f �h� du�y cycl�

�f �h� ��w�� s�u�c� has b��n �xc��d�d. If �h� �v�� H�a� l�gh� �llum�na��s wa�� f�� �h� �v�� H�a� l�gh� �� �x��ngu�sh b�f��� ��sum�ng w�ld�ng.

(A) Process Selection Switch

Sw��ch�s b��w��n LIFT TIG and STICK W�ld�ng m�d�s.

(B) Power On Indicator

Th� P�w�� �N Ind�ca��� �llum�na��s wh�n �h� �N/�FF sw��ch �s �n �h� �N ��s����n and �h� n�m�nal ma�ns v�l�ag� �s ���s�n�.

(C) Fault Indicator

Th� w�ld�ng ��w�� s�u�c� �s �����c��d by a s�lf ��s����ng

�h��m�s�a� and �v�� ���ma�y cu���n� �����c���n d�v�c�s.

W�ld�ng can n�� �ak� �lac� �f �h� Faul� Ind�ca��� l�gh�s u�

�� l�gh�s u� c�n��nu�usly.

Th��m�s�a� P����c���n

If �h� Faul� Ind�ca��� l�gh�s u� �h�n �h� du�y cycl� �f �h�

��w�� s�u�c� has b��n �xc��d�d, L�av� �h� ��w�� �n and wa�� f�� �h� Wa�n�ng Ind�ca��� �� �x��ngu�sh b�f���

��sum�ng w�ld�ng.

�v�� P��ma�y Cu���n� P����c���n

If �h� Faul� Ind�ca��� l�gh�s u� c�n��nu�usly �h�n �h�

���ma�y cu���n� �n�� �h� ma�n ��ansf��m�� has b��n �xc��d�d. Hav� an Acc��d���d Th��mal A�c S��v�c� P��v�d��

�ns��c� �h�n ���a�� �h� w�ld��.

(D) Welding Current Control

Th� w�ld�ng cu���n� �s �nc��as�d by �u�n�ng �h� W�ld

Cu���n� c�n���l kn�b cl�ckw�s� �� d�c��as�d by �u�n�ng

�h� W�ld Cu���n� c�n���l kn�b c�un���cl�ckw�s�. Th� w�ld�ng cu���n� sh�uld b� s�� acc��d�ng �� �h� s��c�fic a��l�ca���n. R�f�� �� �h� �l�c���d� manufac�u��'s l����a�u�� f�� fu��h�� �nf��ma���n.

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

shown)

Th�s sw��ch c�n���ls �h� Ma�ns Su��ly V�l�ag� �� �h�

P�w�� S�u�c�.

(B) Power On

Indicator

(D) Welding

Current

ǂ

Control

(C) Fault

Indicator

(A) Process

Selection

Switch

F�gu�� �-�: Th��mal A�c �6� S C�n���ls

Art# A-09884

Manual 0-5073�

THERMAL ARC 161 S

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 c) Using an extension cable d) Low line mains power voltage

Output Scale for 115V

OPERATION

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 nuisance tripping of the circuit breaker or fuse.

LIFT TIG Mode: A 15 Amp outlet is capable of supplying 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.

Art# A-09752

15 Amp Outlet

20 Amp Outlet

Output Scale for 115V

Output Scale for 230V

Figure 4-2: Current Control

Operation

OPERATION

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.

Metal Being Joined

Mild Steel

Mild Steel

Mild Steel

Mild Steel

Cast Iron

Stainless Steel

THERMAL ARC 161 S

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.

Electrode

E6011

E6013

E7014

Comments

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.

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.

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.

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.

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

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

Manual 0-5073

THERMAL ARC 161 S

4.05 GTAW Electrode Polarity

OPERATION

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

1/16" (1.6mm)

3/32" (2.4mm)

1/8" (3.2mm)

4.07 Tungsten Electrode Current Ranges

Electrode Diameter

.040” (1.0mm)

1/16” (1.6mm)

3/32” (2.4mm)

DC Current (Amps)

20 - 90

65 - 115

100 - 165

DC Current

25 - 85

50 - 160

135 - 235

4.08 Shielding Gas Selection

Alloy

Carbon Steel

Stainless Steel

Nickel Alloy

Copper

Titanium

Shielding Gas

Welding Argon

Welding Argon

Welding Argon

Welding Argon

Welding Argon

4.09 Tungsten Electrode Types

Electrode Type

(Ground Finish)

Welding Application

Thoriated 2%

Ceriated 2%

Features

DC welding of mild steel, stainless steel and copper.

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

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

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

Color Code

Red

Grey

Operation

OPERATION

4.10 TIG Welding Parameters for Steel

DC Current

Base Metal

Thickness

0.040"

(1.0mm)

Electrode

Diameter

0.040"

(1.0mm)

0.045"

(1.22mm)

1/16"

(1.6mm)

1/8"

(3.2mm)

3/16"

(4.8mm)

1/4"

(6.4mm)

35-45

40-50

45-55

50-60

60-70

70-90

80-100

90-115

115-135

140-165

160-175

170-200

20-30

25-35

30-45

35-50

40-60

50-70

65-85

90-110

100-125

125-150

135-160

160-180

0.040"

(1.0mm)

1/16"

(1.6mm)

Filler Rod

Diameter

1/16"

(1.6mm)

1/16"

(1.6mm)

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)

THERMAL ARC 161 S

Argon Gas Flow

Rate

10 CFH

(5 LPM)

13 CFH

(6 LPM)

15 CFH

(7 LPM)

15CFH

(7 LPM)

21CFH

(10 LPM)

21CFH

(10 LPM)

Joint / Type

Butt/Corner

Lap/Filler

Butt/Corner

Lap/Filler

Butt/Corner

Lap/Filler

Butt/Corner

Lap/Filler

Butt/Corner

Lap/Filler

Butt/Corner

Lap/Filler

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

THERMAL ARC 161 S

4.12 Welding Position

OPERATION

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.

Art # A-07687

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

Art A-07691

Figure 4-7: Vertical position, butt weld

Art # A-07688

Figure 4-4: Flat position, gravity fillet weld

Art # A-07689

Figure 4-5: Horizontal position, butt weld

Art # A-07692

Figure 4-8: Vertical position, fillet weld

Art# A-07693

Figure 4-9: Overhead position, butt weld

Art # A-07690

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

Art # A-07694

Figure 4-10: Overhead position, fillet weld

Operation

OPERATION

4.13 Joint Preparations

THERMAL ARC 161 S

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.

Open Square Butt

Joint

Gap varies from

1/16” (1.6mm) to 3/16” (4.8mm)

depending on plate thickness

Single Vee Butt Joint

Not less than

70°

1/16” (1.6mm) max

Single Vee Butt Joint

Not less than

45°

1/16” (1.6mm)

Double Vee Butt Joint

Not less than

70°

1/16” (1.6mm) max

Lap Joint

Fillet Joint

Corner Weld

Tee Joints

(Fillet both sides of the joint)

1/16” (1.6mm)

Edge Joint

Plug Weld Plug Weld

Art # A-07695_AC

Figure 4-11: Typical joint designs for arc welding

Manual 0-5073

THERMAL ARC 161 S

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.

OPERATION

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.

Art # A-07696

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.

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

OPERATION

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

Art # A-07697

THERMAL ARC 161 S

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.

Art # A-07698

Figure 4-14: Weld build up sequence

Art # A-07699

Figure 4-15: Electrode position for HV fillet weld

Manual 0-5073

THERMAL ARC 161 S

Art # A-07700

Art # A-07701

OPERATION

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

Art # A-07702

Figure 4-18: Multi run vertical fillet weld

Art # A-07703

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

OPERATION

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.

Art # A-07704

Figure 4-20: Overhead fillet weld

THERMAL ARC 161 S

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.

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

THERMAL ARC 161 S

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.

Art # A-07705

Figure 4-21: Parent metal expansion

Art # A-07706

D. Presetting

OPERATION

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 4-22: Parent metal contraction

4.22 Overcoming Distortion Effects

There are several methods of minimizing distortion effects.

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.

Art # A-07707

Preheat

Figure 4-23: Principle of presetting

Art # A-07708

B

Weld

C

Preheat

Dotted lines show effect if no preheat is used

Figure 4-24: Reduction of distortion by preheating

Art # A-07709

Figure 4-25: Examples of distortion

Operation

OPERATION

Art # A-07710

Figure 4-26: Welding sequence

Art # A-07711

Figure 4-27: Step back sequence

Art # A-07712

Figure 4-28: Chain intermittent welding

Art # A-07713

Figure 4-29: Staggered intermittent welding

THERMAL ARC 161 S

Manual 0-5073

This Page Intentionally Blank.

SERVICE THERMAL ARC 161 S

5.01 Maintenance and Inspection

SECTION 5:

SERVICE

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.

Warning!

Disconnect input power before maintaining.

Each Use

Maintain more often if used under severe conditions

Visual check of regulator and pressure

Visual check of torch

Consumable parts

Visually inspect the torch body and consumables

Weekly

Visually inspect the cables and leads.

Replace as needed

3 Months

Manual 0-5073

Art # A-08549_AB

Replace all broken parts

Clean exterior of power supply

6 Months

Bring the unit to an authorized

Thermal Arc Service Center to remove any accumulated dirt and dust from the interior.

This may need to be done more frequently under exceptionally dirty conditions.

THERMAL ARC 161 S

5.02 STICK (SMAW) Welding Problems

SERVICE

Description

1. Gas pockets or voids in weld metal

(Porosity).

Possible Cause

A. Electrodes are damp.

B. Welding current is too high.

Remedy

A. Dry electrodes before use.

B. Reduce welding current.

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

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

A. Rigidity of joint.

C. Clean joint before welding

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

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

Art # A-05866_AC

B. Insufficient throat thickness. B. Travel slightly slower to allow greater build up in throat.

C. Cooling rate is too high.

A. Welding current is too low.

B. Electrode too large for joint.

C. Insufficient gap.

C. Preheat plate and cool slowly.

A. Increase welding current

B. Use smaller diameter electrode.

C. Allow wider gap.

Incorrect Sequence

D. Incorrect sequence.

D. Use correct build-up sequence.

Insufficient Gap

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

A. Small electrodes used on heavy cold plate.

B. Welding current is too low.

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

Art # A-05867_AC

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

Lack of inter-run fusion

Lack of root fusion

A

.

Use larger electrodes and preheat the plate.

B. Increase welding current

C. Wrong electrode angle. C. Adjust angle so the welding arc is directed more into the base metal

D. Travel speed of electrode is too high.

D. Reduce travel speed of electrode

E. Clean surface before welding.

E. Scale or dirt on joint surface.

5. Non-metallic particles are trapped in the weld metal (slag inclusion).

A. Non-metallic particles may be trapped in undercut from previous run.

A. If bad undercut is present, clean slag out and cover with a run from a smaller diameter electrode.

B. Joint preparation too restricted. B. Allow for adequate penetration and room for cleaning out the slag.

Not cleaned, or incorrect electrode

Slag trapped in undercut

C. Irregular deposits allow slag to be trapped.

C. If very bad, chip or grind out irregularities.

D. Lack of penetration with slag trapped beneath weld bead.

D. Use smaller electrode with sufficient current to give adequate penetration.

Use suitable tools to remove all slag from corners.

Slag trapped in root

Art # A-05868_AB

E. Rust or mill scale is preventing full fusion.

E. Clean joint before welding.

F. Wrong electrode for position in which welding is done.

F. Use electrodes designed for position in which welding is done, otherwise proper control of slag is difficult.

Service

SERVICE

5.03 TIG Welding Problems

THERMAL ARC 161 S

Weld quality is dependent on the selection of the correct consumables, maintenance of equipment and proper welding technique.

Description

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.

Possible Cause

Welding current is too low

Welding current is too high.

Travel speed too fast.

Remedy

Increase weld current and/or change joint preparation.

Decrease welding current.

Reduce travel speed.

4. Weld bead too wide or excessive bead build up or excessive penetration in butt joint.

5. Uneven leg length in fillet joint.

6. Electrode melts when arc is struck.

7. Dirty weld pool.

8. Poor weld finish.

Travel speed is too slow.

Increase travel speed.

Wrong placement of filler rod.

Re-position filler rod.

Electrode is connected to the "+"

Positive Output Terminal.

Connect the electrode to the

"-" Negative Output Terminal.

A. Electrode contaminated through contact with work piece or filler rod material.

B. Gas contaminated with air.

A. Clean the electrode by grinding contaminates off.

Inadequate shielding gas.

B. Check gas lines for cuts and loose fitting or change gas cylinder.

Increase gas flow or check gas line for problems

9. Arc flutters during TIG welding.

Tungsten electrode is too large for the welding current.

10. W e l d i n g a r c c a n n o t b e established.

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

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.

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

THERMAL ARC 161 S

TIG Welding Problems (Continued)

Description

12. Arc start is not smooth.

SERVICE

Possible Cause

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.

Remedy

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.

D. Incorrect shield gas is being used.

E. Poor work clamp connection to work piece.

E. Improve 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.

5.04 Power Source Problems

Description

1. The welding arc cannot be established.

Possible Cause

A. The Primary supply voltage has not been switched ON.

B. The Welding Power Source switch is switched OFF.

C. Loose connections internally.

Remedy

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 Indicator welding

Indicator to extinguish before resuming

2. The welding arc cannot be established when the

Warning Indicator lights up continuously

3. Maximum output welding current cannot be achieved with nominal Mains supply voltage.

4. Welding current reduces when welding.

The machines duty cycle has been exceeded

Defective control circuit

Poor work lead connection to the work piece.

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

The circuit breaker (or fuse) is under size.

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

The input current to the main transformer has been exceeded.

Have an Accredited Thermal Arc

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 carrying 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

APPENDIX THERMAL ARC 161 S

APPENDIX 1: OPTIONS AND ACCESSORIES

Description

17V style TIG Torch with 12.5ft lead, gas valve, 50mm dinse connection and accessory kit

VICTOR AF210-580 Regulator, Argon-CO2 Flowgauge with 5/8" - 18 UNF connection

Power Adapter-230V,50A Socket (Nema 6-50R) to 115V, 15A Plug (Nema 5-15P)

USA Graphics Auto-Darkening welding helmet, spare cover lens and operating manual

Canadian Graphics Auto-Darkening welding helmet, spare cover lens and operating manual

Claret Color Auto-Darkening welding helmet, spare cover lens and operating manual

Black Graphics Auto-Darkening welding helmet, spare cover lens and operating manual

Part Number

W4012600

0781-4169

W4014000

W4011700

W4011800

W4011900

W4012000

Manual 0-5073 A-1 Appendix

THERMAL ARC 161 S

APPENDIX 2: REPLACEMENT PARTS

APPENDIX

14

15

16

11

12

13

17

18

19

20

21

Item No

1

2

3

4

5

6

9

10

7

8

Description

Handle

Panel,Cover,

Resistor,4 ohm,60W

Rectifier

Thermistor

Control PCB

Main Power PCB

Front Control PCB3

Inductor

Clear Cover Sheet

Front Panel

Front Panel Label

Knob, control, red, 20 ODx6 ID

Rubber Boot

Output Terminal, 50mm dinse

Base Panel

Fan,24V DC

Rear Panel

ON/OFF Switch

Capacitor,10uF,300VAC

Current Sensor,161-201TS

W7003022

W7003062

W7003079

W7003064

W7003020

W7003073

W7003090

W7003054

W7003053

W7003094

W7003076

Part No.

W7003040

W7003051

W7003055

W7003010

W7003016

W7003057

W7003061

W7003047

W7003089

W7003060

Reference Designator

R1

THC1, THC2

PCB2

PCB1

PCB3

SW1

C1

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

19

18

17

APPENDIX

20

3

4

5

6

7

Art # A-09896

21

16

8

9

THERMAL ARC 161 s

1

2

15

10

11

12

13

14

Manual 0-5073 A-3 Appendix

THERMAL ARC 161 S

APPENDIX 3: SYSTEM SCHEMATIC

APPENDIX

Appendix

Art # A-09897_AC

S D

J9-1

J9-2

S D

S

D

-24V

GND

+15V

IGBT Driver A

IGBT Driver B

GND

Over Current Signal

Over Current Signal

J2-1

J2-2

J2-3

J2-4

J2-5

J2-6

J2-7

J2-8

RED

WHITE

YELLOW

GRAY

BLACK

RED

J1-2

J1-1

J3-1

J3-2

J3-3

J3-4

J3-5

J3-6

J3-7

J3-8

J5-1

J5-2

J6-1

J6-2

J6-3

J6-4

+15V

-15V

Current Feedback

GND

A-4

Front Panel PCB3

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 notification thereof and substantiation that the product has been stored, installed, operated, and maintained in accordance with Thermal

Arc’s specifications, instructions, recommendations and recognized standard industry practice, and not subject to misuse, repair, neglect, alteration, or damage, correct such defects by suitable repair 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, fitness 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 profits 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 fulfillment of thermal’s obligations to purchaser with respect to the product.

This warranty is void, and seller bears no liability hereunder, if purchaser used replacement parts or accessories which, in Thermal Arc’s sole judgment, impaired the safety or performance of any Thermal Arc product. Purchaser’s rights under this 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 1 st

2009 supersedes all previous Thermal Arc warranties. Thermal Arc

®

is a Registered Trademark of Thermal Arc, Inc.

WARRANTY SCHEDULE

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

January 2009

SAFETY EQUIPMENT

Auto-Darkening Welding Helmet (Electronic Lens)

Harness Assembly

W

ARRANTY

P

2 year

ERIOD

1 Month

ENGINE DRIVEN WELDERS

Scout, Raider, Explorer

W

ARRANTY

P

ERIOD

Original Main Power Stators and Inductors..................................................................................................... 3 years

L

ABOR

2 year

1 Month

L

ABOR

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

Engines and associated components are NOT warranted by Thermal Arc, although most are warranted by the engine manufacturer .............................................................................................

1 year

See the Engine Manufactures’ Warranty for

Details

L

ABOR

GMAW/FCAW (MIG) WELDING EQUIPMENT

Fabricator 140; 180; 190, 210, 251, 281; Fabstar 4030;

PowerMaster 350, 350P, 500, 500P; 320SP; 400SP; 500SP; Excelarc 6045.

Wire Feeders; Ultrafeed, Portafeed

W

ARRANTY

P

ERIOD

Original Main Power Transformer and Inductor................................................................................................ 5 years

Original Main Power Rectifiers, Control P.C. Boards, power switch semi-conductors ..................................... 3 years

All other original circuits and components including, but not limited to, relays, switches, contactors, solenoids, fans, electric motors. ..................................................................................................... 1 year

TIG (GTAW) & MULTI-PROCESS INVERTER WELDING EQUIPMENT

160TS, 300TS, 400TS, 185AC/DC, 200AC/DC, 300AC/DC, 400MST, 300MST, 400MSTP

W

ARRANTY

P

ERIOD

3 years

3 years

1 year

L

ABOR

Original Main Power Magnetics ........................................................................................................................ 5 years

Original Main Power Rectifiers, Control P.C. Boards, power switch semi-conductors ..................................... 3 years

All other original circuits and components including, but not limited to, relays, switches, contactors, solenoids, fans, electric motors. ..................................................................................................... 1 year

3 years

3 years

1 year

PLASMA WELDING EQUIPMENT

Ultima 150

W

ARRANTY

P

ERIOD

Original Main Power Magnetics ....................................................................................................................... 5 years

Original Main Power Rectifiers, Control P.C. Boards, power switch semi-conductors .................................... 3 years

Welding Console, Weld Controller, Weld Timer............................................................................................... 3 years

All other original circuits and components including, but not limited to, relays, switches, contactors, solenoids, fans, electric motors, Coolant Recirculator.................................................................... 1 year

STICK (SMAW) WELDING EQUIPMENT

Thermal Arc 95S

W

ARRANTY

P

ERIOD

Original Main Power Magnetics ......................................................................................................................... 1 year

Original Main Power Rectifiers, Control P.C. Boards ......................................................................................... 1 year

All other original circuits and components including, but not limited to, relays, switches, contactors, solenoids, fans,............................................................................................................................... 1 year

161S, 161STL, 201TS

Original Main Power Magnetics

Original Main Power Rectifiers, Control P.C. Boards

All other original circuits and components including, but not limited to, relays, switches, contactors, solenoids, fans

160S, 300S, 400S

3 years

3 years

1 year

Original Main Power Magnetics ........................................................................................................................ 5 years

Original Main Power Rectifiers, Control P.C. Boards ........................................................................................ 3 years

All other original circuits and components including, but not limited to, relays, switches, contactors, solenoids, fans, power switch semi-conductors ............................................................................. 1 year

GENERAL ARC EQUIPMENT W

ARRANTY

P

ERIOD

Water Recirculators ........................................................................................................................................... 1 year

Plasma Welding Torches .................................................................................................................................180 days

Gas Regulators (Supplied with power sources)...............................................................................................180 days

L

ABOR

3 years

3 years

3 years

1 year

L

ABOR

1 year

1 year

1 year

3 years

3 years

1 year

3 years

3 years

1 year

L

ABOR

1 year

180 days

Nil

MIG and TIG Torches (Supplied with power sources) ......................................................................................90 days

Replacement repair parts..................................................................................................................................90 days

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

Nil

Nil

Nil

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

A Global Cutting & Welding Market Leader

W O R L D H E A D Q U A R T E R S : 1 6 0 5 2 S w i n g l e y R i d g e R o a d , S u i t e 3 0 0 • S t . L o u i s , M i s s o u r i 6 3 0 1 7 U . S . A .

THE AMERICAS

Denton, TX USA

U.S. Customer Care

Ph: 1-800-426-1888 (tollfree)

Fax: 1-800-535-0557 (tollfree)

International Customer Care

Ph: 1-940-381-1212

Fax: 1-940-483-8178

Miami, FL USA

Sales Office, Latin America

Ph: 1-954-727-8371

Fax: 1-954-727-8376

Oakville, Ontario, Canada

Canada Customer Care

Ph: 1-905-827-4515

Fax: 1-800-588-1714 (tollfree)

EUROPE

Chorley, United Kingdom

Customer Care

Ph: +44 1257-261755

Fax: +44 1257-224800

Milan, Italy

Customer Care

Ph: +39 0236546801

Fax: +39 0236546840

ASIA/PACIFIC

Cikarang, Indonesia

Customer Care

Ph: 6221-8990-6095

Fax: 6221-8990-6096

Rawang, Malaysia

Customer Care

Ph: +603 6092-2988

Fax: +603 6092-1085

Melbourne, Australia

Australia Customer Care

Ph: 1300-654-674 (tollfree)

Ph: 61-3-9474-2988

Fax: 61-3-9474-7391

International

Ph: 61-3-9474-7508

Fax: 61-3-9474-7488

Shanghai, China

Sales Office

Ph: +86 21-64072626

Fax: +86 21-64483032

Singapore

Sales Office

Ph: +65 6832-8066

Fax: +65 6763-5812

Form No. 0-5073 (12/17/2010) © 2010 Thermadyne Industries, Inc.

www.thermadyne.com

Printed in U.S.A.

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