arcmaster® 160 s
160 S
®
ARCMASTER
INVERTER ARC WELDER
Operating Manual
Version No: 1
Issue Date: March 31, 2006
Manual No: 0-4854
Operating Features:
1
SMAW
GTAW
PHASE
50 Hz
60
INVERTER
115
V
230
V
CC DC
WE APPRECIATE YOUR BUSINESS!
Congratulations on your new Thermal Arc® product. We are proud to
have you as our customer and will strive to provide you with the best
service and reliability in the industry. This product is backed by our
extensive warranty and world-wide service network. To locate your
nearest distributor or service agency call 800-752-7621, or visit us
on the web at www.thermalarc.com.
This Operating Manual has been designed to instruct you on the correct
use and operation of your Thermal Arc® product. Your satisfaction with
this product and its safe operation is our ultimate concern. Therefore,
please take the time to read the entire manual, especially the Safety
Precautions. They will help you to avoid potential hazards that may
exist when working with this product.
YOU ARE IN GOOD COMPANY!
The Brand of Choice for Contractors and Fabricators Worldwide.
Thermal Arc® is a Global Brand of Arc Welding Products for Thermadyne
Industries Inc. We manufacture and supply to major welding industry
sectors worldwide including; Manufacturing, Construction, Mining,
Automotive, Aerospace, Engineering, Rural and DIY/Hobbyist.
We distinguish ourselves from our competition through marketleading, dependable products that have stood the test of time. We
pride ourselves on technical innovation, competitive prices, excellent
delivery, superior customer service and technical support, together
with excellence in sales and marketing expertise.
Above all, we are committed to develop technologically advanced
products to achieve a safer working environment within the welding
industry.
!
WARNING
Read and understand this entire Manual and your employer’s safety practices before installing, operating, or
servicing the equipment.
While the information contained in this Manual represents the Manufacturer’s best judgment, the Manufacturer
assumes no liability for its use.
Instruction Manual Number 0-4854 for:
ArcMaster 160 S Inverter Welding Power Supply Part No. 10-3066
Published by:
Thermadyne Industries, Inc.
82 Benning Street
West Lebanon, New Hampshire, USA 03784
(603) 298-5711
www.thermalarc.com
Copyright © 2006 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: March 31, 2006
Record the following information for Warranty purposes:
Where Purchased:
_______________________________
Purchase Date:
_______________________________
Equipment Serial #:
_______________________________
ARCMASTER® 160 S
Table of Contents
SECTION 1:
SAFETY INSTRUCTIONS AND WARNINGS .................................................. 1-1
1.01 Arc Welding Hazards.................................................................................1-1
1.02 Principal Safety Standards ........................................................................1-4
1.03 Precautions de Securite en Soudage A L’Arc ............................................1-5
1.04 Dangers relatifs au soudage à l’arc ...........................................................1-5
1.05 Principales Normes De Securite ...............................................................1-8
SECTION 2:
INTRODUCTION AND DESCRIPTION ......................................................... 2-1
2.01 How To Use This Manual ..........................................................................2-1
2.02 Equipment Identification ...........................................................................2-1
2.03 Receipt Of Equipment ...............................................................................2-1
2.04 Symbol Chart ............................................................................................2-2
2.05 Description................................................................................................2-3
2.06 Functional Block Diagrams........................................................................2-3
2.07 Transporting Methods ...............................................................................2-4
SECTION 3:
INSTALLATION RECOMMENDATIONS ........................................................ 3-1
3.01 Environment..............................................................................................3-1
3.02 Location ....................................................................................................3-1
3.03 Electrical Input Connections......................................................................3-1
3.04 Specifications............................................................................................3-4
3.05 Duty Cycle .................................................................................................3-5
SECTION 4:
OPERATOR CONTROLS ........................................................................ 4-1
4.01 ArcMaster 160 S Controls .........................................................................4-1
4.02 Weld Parameter Descriptions for ArcMaster 160 S ...................................4-2
4.03 Weld Parameters for ArcMaster 160 S ......................................................4-3
4.04 Power Source Features .............................................................................4-4
SECTION 5:
SET-UP FOR SMAW (STICK) AND GTAW (TIG) ............................................. 5-1
SECTION 6:
SEQUENCE OF OPERATION .................................................................... 6-1
6.01 Stick Welding ............................................................................................6-1
6.02 DC Lift TIG Welding ..................................................................................6-1
ii
March 31, 2006
ARCMASTER® 160 S
SECTION 7:
BASIC TIG WELDING GUIDE ................................................................... 7-1
7.01 Electrode Polarity ......................................................................................7-1
7.02 Tungsten Electrode Current Ranges ..........................................................7-1
7.03 Tungsten Electrode Types .........................................................................7-1
7.04 Guide for Selecting Filler Wire Diameter ...................................................7-1
7.05 Shielding Gas Selection ............................................................................7-2
7.06 TIG Welding Parameters for Low Carbon & Low Alloy Steel Pipe .............7-2
7.07 Welding Parameters for Steel....................................................................7-2
SECTION 8:
BASIC ARC WELDING GUIDE .................................................................. 8-1
8.01 Electrode Polarity ......................................................................................8-1
8.02 Effects of Stick Welding Various Materials ................................................8-1
SECTION 9:
ROUTINE MAINTENANCE ..................................................................... 9-1
SECTION 10:
BASIC TROUBLESHOOTING .................................................................. 10-1
10.01 TIG Welding Problems ..........................................................................10-1
10.02 Stick Welding Problems ........................................................................10-3
10.03 Power Source Problems .......................................................................10-4
SECTION 11:
VOLTAGE REDUCTION DEVICE (VRD) ....................................................... 11-1
11.01 VRD Specification .................................................................................11-1
11.02 VRD Maintenance .................................................................................11-1
11.03 Switching VRD On/Off...........................................................................11-2
SECTION 12:
POWER SOURCE ERROR CODES ............................................................ 12-1
SECTION 13:
OPTIONS AND ACCESSORIES ................................................................ 13-1
APPENDIX A:
INTERCONNECT DIAGRAM ................................................................... A-2
March 31, 2006
iii
ARCMASTER® 160 S
iv
March 31, 2006
ARCMASTER® 160 S
SECTION 1:
SAFETY INSTRUCTIONS AND WARNINGS
!
WARNING
PROTECT YOURSELF AND OTHERS FROM POSSIBLE SERIOUS INJURY OR DEATH. KEEP CHILDREN AWAY. PACEMAKER WEARERS KEEP AWAY UNTIL
CONSULTING YOUR DOCTOR. DO NOT LOSE THESE INSTRUCTIONS. READ OPERATING/INSTRUCTION MANUAL BEFORE INSTALLING, OPERATING
OR SERVICING THIS EQUIPMENT.
Welding products and welding processes can cause serious injury or death, or damage to other equipment or property, if the operator does not strictly
observe all safety rules and take precautionary actions.
Safe practices have developed from past experience in the use of welding and cutting. These practices must be learned through study and training before
using this equipment. Some of these practices apply to equipment connected to power lines; other practices apply to engine driven equipment. Anyone
not having extensive training in welding and cutting practices should not attempt to weld.
Safe practices are outlined in the American National Standard Z49.1 entitled: SAFETY IN WELDING AND CUTTING. This publication and other guides to what
you should learn before operating this equipment are listed at the end of these safety precautions. HAVE ALL INSTALLATION, OPERATION, MAINTENANCE,
AND REPAIR WORK PERFORMED ONLY BY QUALIFIED PEOPLE.
1.01 Arc Welding Hazards
10. Ground the workpiece to a good electrical (earth) ground.
11. Do not touch electrode while in contact with the work (ground)
circuit.
12. Use only well-maintained equipment. Repair or replace damaged parts
at once.
WARNING
ELECTRIC SHOCK can kill.
13. In confined spaces or damp locations, do not use a welder with AC
output unless it is equipped with a voltage reducer. Use equipment
with DC output.
14. Wear a safety harness to prevent falling if working above floor level.
15. Keep all panels and covers securely in place.
Touching live electrical parts can cause fatal shocks or
severe burns. The electrode and work circuit is electrically
live whenever the output is on. The input power circuit and
machine internal circuits are also live when power is on. In
semiautomatic or automatic wire welding, the wire, wire reel,
drive roll housing, and all metal parts touching the welding
wire are electrically live. Incorrectly installed or improperly
grounded equipment is a hazard.
1. Do not touch live electrical parts.
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.
2. Wear dry, hole-free insulating gloves and body protection.
3. Insulate yourself from work and ground using dry insulating mats or
covers.
4. Disconnect input power or stop engine before installing or servicing
this equipment. Lock input power disconnect switch open, or remove
line fuses so power cannot be turned on accidentally.
5. Properly install and ground this equipment according to its Owner’s
Manual and national, state, and local codes.
6. Turn off all equipment when not in use. Disconnect power to equipment
if it will be left unattended or out of service.
1. Wear a welding helmet fitted with a proper shade of filter (see ANSI
Z49.1 listed in Safety Standards) to protect your face and eyes when
welding or watching.
2. Wear approved safety glasses. Side shields recommended.
3. Use protective screens or barriers to protect others from flash and
glare; warn others not to watch the arc.
4. Wear protective clothing made from durable, flame-resistant material
(wool and leather) and foot protection.
5. Use approved ear plugs or ear muffs if noise level is high.
7. Use fully insulated electrode holders. Never dip holder in water to cool it
or lay it down on the ground or the work surface. Do not touch holders
connected to two welding machines at the same time or touch other
people with the holder or electrode.
8. Do not use worn, damaged, undersized, or poorly spliced cables.
9. Do not wrap cables around your body.
March 31, 2006
1-1
ARCMASTER® 160 S
1. Protect yourself and others from flying sparks and hot metal.
2. Do not weld where flying sparks can strike flammable material.
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.
3. Remove all flammables within 35 ft (10.7 m) of the welding arc. If this
is not possible, tightly cover them with approved covers.
4. Be alert that welding sparks and hot materials from welding can easily
go through small cracks and openings to adjacent areas.
5. Watch for fire, and keep a fire extinguisher nearby.
1. Keep your head out of the fumes. Do not breath the fumes.
6. Be aware that welding on a ceiling, floor, bulkhead, or partition can
cause fire on the hidden side.
2. If inside, ventilate the area and/or use exhaust at the arc to remove
welding fumes and gases.
7. Do not weld on closed containers such as tanks or drums.
3. If ventilation is poor, use an approved air-supplied respirator.
8. Connect work cable to the work as close to the welding area as practical
to prevent welding current from traveling long, possibly unknown paths
and causing electric shock and fire hazards.
4. Read the Material Safety Data Sheets (MSDSs) and the manufacturer’s
instruction for metals, consumables, coatings, and cleaners.
5. Work in a confined space only if it is well ventilated, or while wearing an
air-supplied respirator. Shielding gases used for welding can displace
air causing injury or death. Be sure the breathing air is safe.
6. Do not weld in locations near degreasing, cleaning, or spraying
operations. The heat and rays of the arc can react with vapors to form
highly toxic and irritating gases.
7. Do not weld on coated metals, such as galvanized, lead, or cadmium
plated steel, unless the coating is removed from the weld area, the
area is well ventilated, and if necessary, while wearing an air-supplied
respirator. The coatings and any metals containing these elements can
give off toxic fumes if welded.
9. Do not use welder to thaw frozen pipes.
10. Remove stick electrode from holder or cut off welding wire at contact
tip when not in use.
WARNING
FLYING SPARKS AND HOT METAL can cause injury.
Chipping and grinding cause flying metal. As welds cool,
they can throw off slag.
1. Wear approved face shield or safety goggles. Side shields
recommended.
WARNING
2. Wear proper body protection to protect skin.
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.
Welding or cutting
Torch soldering
Torch brazing
Oxygen Cutting
Light
Medium
Heavy
Gas welding
Light
Medium
Heavy
Shielded metal-arc
1-2
Eye protection filter shade selector for welding or cutting
(goggles or helmet), from AWS A6.2-73.
Electrode Size
Filter
Welding or cutting
Electrode Size
2
Gas metal-arc
3 or 4
Non-ferrous base metal
All
Ferrous base metal
All
Under 1 in., 25 mm
3 or 4
Gas tungsten arc welding
All
1 to 6 in., 25-150 mm
4 or 5
(TIG)
All
Over 6 in., 150 mm
5 or 6
Atomic hydrogen welding
All
Carbon arc welding
All
Under 1/8 in., 3 mm
4 or 5
Plasma arc welding
1/8 to 1/2 in., 3-12 mm 5 or 6
Carbon arc air gouging
Over 1/2 in., 12 mm
6 or 8
Light
Under 5/32 in., 4 mm
10
Heavy
5/32 to 1/4 in.,
12
Plasma arc cutting
Over 1/4 in., 6.4 mm
14
Light Under 300 Amp
Medium 300 to 400 Amp
Heavy Over 400 Amp
Filter
11
12
12
12
12
12
12
14
9
12
14
March 31, 2006
ARCMASTER® 160 S
3. Allow engine to cool before fueling. If possible, check and add fuel to
cold engine before beginning job.
WARNING
4. Do not overfill tank — allow room for fuel to expand.
5. Do not spill fuel. If fuel is spilled, clean up before starting engine.
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.
WARNING
MOVING PARTS can cause injury.
1. Protect compressed gas cylinders from excessive heat, mechanical
shocks, and arcs.
2. Install and secure cylinders in an upright position by chaining them to
a stationary support or equipment cylinder rack to prevent falling or
tipping.
3. Keep cylinders away from any welding or other electrical circuits.
4. Never allow a welding electrode to touch any cylinder.
5. Use only correct shielding gas cylinders, regulators, hoses, and fittings
designed for the specific application; maintain them and associated
parts in good condition.
6. Turn face away from valve outlet when opening cylinder valve.
7. Keep protective cap in place over valve except when cylinder is in use
or connected for use.
Moving parts, such as fans, rotors, and belts can cut fingers and hands
and catch loose clothing.
1. Keep all doors, panels, covers, and guards closed and securely
in place.
2. Stop engine before installing or connecting unit.
3. Have only qualified people remove guards or covers for
maintenance and troubleshooting as necessary.
4. To prevent accidental starting during servicing, disconnect
negative (-) battery cable from battery.
5. Keep hands, hair, loose clothing, and tools away from moving
parts.
6. Reinstall panels or guards and close doors when servicing is
finished and before starting engine.
8. Read and follow instructions on compressed gas cylinders, associated
equipment, and CGA publication P-1 listed in Safety Standards.
!
WARNING
WARNING
SPARKS can cause BATTERY GASES TO EXPLODE; BATTERY
ACID can burn eyes and skin.
Engines can be dangerous.
Batteries contain acid and generate explosive gases.
1. Always wear a face shield when working on a battery.
WARNING
2. Stop engine before disconnecting or connecting battery cables.
3. Do not allow tools to cause sparks when working on a battery.
ENGINE EXHAUST GASES can kill.
4. Do not use welder to charge batteries or jump start vehicles.
5. Observe correct polarity (+ and –) on batteries.
Engines produce harmful exhaust gases.
1. Use equipment outside in open, well-ventilated areas.
2. If used in a closed area, vent engine exhaust outside and away from
any building air intakes.
WARNING
WARNING
ENGINE FUEL can cause fire or explosion.
STEAM AND PRESSURIZED HOT COOLANT can burn face,
eyes, and skin.
The coolant in the radiator can be very hot and under
pressure.
Engine fuel is highly flammable.
1. Do not remove radiator cap when engine is hot. Allow engine to cool.
1. Stop engine before checking or adding fuel.
2. Do not add fuel while smoking or if unit is near any sparks or open
flames.
March 31, 2006
2. Wear gloves and put a rag over cap area when removing cap.
3. Allow pressure to escape before completely removing cap.
1-3
ARCMASTER® 160 S
!
1.02 Principal Safety Standards
WARNING
This product, when used for welding or cutting, produces
fumes or gases which contain chemicals know to the State of
California to cause birth defects and, in some cases, cancer.
(California Health & Safety code Sec. 25249.5 et seq.)
NOTE
Considerations About Welding And The Effects of Low
Frequency Electric and Magnetic Fields
The following is a quotation from the General Conclusions Section of the
U.S. Congress, Office of Technology Assessment, Biological Effects of Power
Frequency Electric & Magnetic Fields - Background Paper, OTA-BP-E-63
(Washington, DC: U.S. Government Printing Office, May 1989): “...there
is now a very large volume of scientific findings based on experiments at
the cellular level and from studies with animals and people which clearly
establish that low frequency magnetic fields and interact with, and produce
changes in, biological systems. While most of this work is of very high
quality, the results are complex. Current scientific understanding does
not yet allow us to interpret the evidence in a single coherent framework.
Even more frustrating, it does not yet allow us to draw definite conclusions
about questions of possible risk or to offer clear science-based advice on
strategies to minimize or avoid potential risks.”
Safety in Welding and Cutting, ANSI Standard Z49.1, from American Welding
Society, 550 N.W. LeJeune Rd., Miami, FL 33126.
Safety and Health Standards, OSHA 29 CFR 1910, from Superintendent of
Documents, U.S. Government Printing Office, Washington, D.C. 20402.
Recommended Safe Practices for the Preparation for Welding and Cutting
of Containers That Have Held Hazardous Substances, American Welding
Society Standard AWS F4.1, from American Welding Society, 550 N.W.
LeJeune Rd., Miami, FL 33126.
National Electrical Code, NFPA Standard 70, from National Fire Protection
Association, Batterymarch Park, Quincy, MA 02269.
Safe Handling of Compressed Gases in Cylinders, CGA Pamphlet P-1, from
Compressed Gas Association, 1235 Jefferson Davis Highway, Suite 501,
Arlington, VA 22202.
Code for Safety in Welding and Cutting, CSA Standard W117.2, from
Canadian Standards Association, Standards Sales, 178 Rexdale Boulevard,
Rexdale, Ontario, Canada M9W 1R3.
Safe Practices for Occupation and Educational Eye and Face Protection,
ANSI Standard Z87.1, from American National Standards Institute, 1430
Broadway, New York, NY 10018.
Cutting and Welding Processes, NFPA Standard 51B, from National Fire
Protection Association, Batterymarch Park, Quincy, MA 02269.
To reduce magnetic fields in the workplace, use the following
procedures.
1. Keep cables close together by twisting or taping them.
2. Arrange cables to one side and away from the operator.
3. Do not coil or drape cable around the body.
4. Keep welding power source and cables as far away from body
as practical.
ABOUT PACEMAKERS:
The above procedures are among those also normally
recommended for pacemaker wearers. Consult your doctor
for complete information.
1-4
March 31, 2006
ARCMASTER® 160 S
1.03 Precautions De Securite En Soudage A L’arc
!
MISE EN GARDE
LE SOUDAGE A L’ARC EST DANGEREUX
PROTEGEZ-VOUS, AINSI QUE LES AUTRES, CONTRE LES BLESSURES GRAVES POSSIBLES OU LA MORT. NE LAISSEZ PAS LES ENFANTS S’APPROCHER,
NI LES PORTEURS DE STIMULATEUR CARDIAQUE (A MOINS QU’ILS N’AIENT CONSULTE UN MEDECIN). CONSERVEZ CES INSTRUCTIONS. LISEZ LE
MANUEL D’OPERATION OU LES INSTRUCTIONS AVANT D’INSTALLER, UTILISER OU ENTRETENIR CET EQUIPEMENT.
Les produits et procédés de soudage peuvent sauser des blessures graves ou la mort, de même que des dommages au reste du matériel et à la propriété,
si l’utilisateur n’adhère pas strictement à toutes les règles de sécurité et ne prend pas les précautions nécessaires.
En soudage et coupage, des pratiques sécuritaires se sont développées suite à l’expérience passée. Ces pratiques doivent être apprises par étude ou
entraînement avant d’utiliser l’equipement. Toute personne n’ayant pas suivi un entraînement intensif en soudage et coupage ne devrait pas tenter de
souder. Certaines pratiques concernent les équipements raccordés aux lignes d’alimentation alors que d’autres s’adressent aux groupes électrogènes.
La norme Z49.1 de l’American National Standard, intitulée “SAFETY IN WELDING AND CUTTING” présente les pratiques sécuritaires à suivre. Ce document
ainsi que d’autres guides que vous devriez connaître avant d’utiliser cet équipement sont présentés à la fin de ces instructions de sécurité.
SEULES DES PERSONNES QUALIFIEES DOIVENT FAIRE DES TRAVAUX D’INSTALLATION, DE REPARATION, D’ENTRETIEN ET D’ESSAI.
1.04 Dangers relatifs au soudage à l’arc
Ne jamais toucher quelqu’un d’autre avec l’électrode ou le porteélectrode.
8. N’utilisez pas de câbles électriques usés, endommagés, mal épissés
ou de section trop petite.
9. N’enroulez pas de câbles électriques autour de votre corps.
AVERTISSEMENT
L’ELECTROCUTION PEUT ETRE MORTELLE.
Une décharge électrique peut tuer ou brûler gravement.
L’électrode et le circuit de soudage sont sous tension dès
la mise en circuit. Le circuit d’alimentation et les circuits
internes de l’équipement sont aussi sous tension dès la mise
en marche. En soudage automatique ou semi-automatique
avec fil, ce dernier, le rouleau ou la bobine de fil, le logement
des galets d’entrainement et toutes les pièces métalliques
en contact avec le fil de soudage sont sous tension. Un
équipement inadéquatement installé ou inadéquatement
mis à la terre est dangereux.
1. Ne touchez pas à des pièces sous tension.
10. N’utilisez qu’une bonne prise de masse pour la mise à la terre de la
pièce à souder.
11. Ne touchez pas à l’électrode lorsqu’en contact avec le circuit de
soudage (terre).
12. N’utilisez que des équipements en bon état. Réparez ou remplacez
aussitôt les pièces endommagées.
13. Dans des espaces confinés ou mouillés, n’utilisez pas de source de
courant alternatif, à moins qu’il soit muni d’un réducteur de tension.
Utilisez plutôt une source de courant continu.
14. Portez un harnais de sécurité si vous travaillez en hauteur.
15. Fermez solidement tous les panneaux et les capots.
AVERTISSEMENT
2. Portez des gants et des vêtements isolants, secs et non troués.
3. Isolez-vous de la pièce à souder et de la mise à la terre au moyen de
tapis isolants ou autres.
LE RAYONNEMENT DE L’ARC PEUT BRÛLER LES YEUX ET LA
PEAU; LE BRUIT PEUT ENDOMMAGER L’OUIE.
4. Déconnectez la prise d’alimentation de l’équipement ou arrêtez
le moteur avant de l’installer ou d’en faire l’entretien. Bloquez le
commutateur en circuit ouvert ou enlevez les fusibles de l’alimentation
afin d’éviter une mise en marche accidentelle.
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.
5. Veuillez à installer cet équipement et à le mettre à la terre selon le
manuel d’utilisation et les codes nationaux, provinciaux et locaux
applicables.
6. Arrêtez tout équipement après usage. Coupez l’alimentation de
l’équipement s’il est hors d’usage ou inutilisé.
7. N’utilisez que des porte-électrodes bien isolés. Ne jamais plonger les
porte-électrodes dans l’eau pour les refroidir. Ne jamais les laisser
traîner par terre ou sur les pièces à souder. Ne touchez pas aux porteélectrodes raccordés à deux sources de courant en même temps.
March 31, 2006
1. Portez une casque de soudeur avec filtre oculaire de nuance appropriée
(consultez la norme ANSI Z49 indiquée ci-après) pour vous protéger
le visage et les yeux lorsque vous soudez ou que vous observez
l’exécution d’une soudure.
2. Portez des lunettes de sécurité approuvées. Des écrans latéraux sont
recommandés.
3. Entourez l’aire de soudage de rideaux ou de cloisons pour protéger
les autres des coups d’arc ou de l’éblouissement; avertissez les
observateurs de ne pas regarder l’arc.
1-5
ARCMASTER® 160 S
4. Portez des vêtements en matériaux ignifuges et durables (laine et cuir)
et des chaussures de sécurité.
5. Portez un casque antibruit ou des bouchons d’oreille approuvés lorsque
le niveau de bruit est élevé.
7. Ne soudez des tôles galvanisées ou plaquées au plomb ou au cadmium
que si les zones à souder ont été grattées à fond, que si l’espace est
bien ventilé; si nécessaire portez un respirateur à adduction d’air.
Car ces revêtements et tout métal qui contient ces éléments peuvent
dégager des fumées toxiques au moment du soudage.
AVERTISSEMENT
AVERTISSEMENT
LES VAPEURS ET LES FUMEES SONT DANGEREUSES POUR
LA SANTE.
LE SOUDAGE PEUT CAUSER UN INCENDIE OU UNE
EXPLOSION
Le soudage dégage des vapeurs et des fumées dangereuses
à respirer.
1. Eloignez la tête des fumées pour éviter de les respirer.
2. A l’intérieur, assurez-vous que l’aire de soudage est bien ventilée ou
que les fumées et les vapeurs sont aspirées à l’arc.
3. Si la ventilation est inadequate, portez un respirateur à adduction d’air
approuvé.
4. Lisez les fiches signalétiques et les consignes du fabricant relatives aux
métaux, aux produits consummables, aux revêtements et aux produits
nettoyants.
5. Ne travaillez dans un espace confiné que s’il est bien ventilé; sinon,
portez un respirateur à adduction d’air. Les gaz protecteurs de soudage
peuvent déplacer l’oxygène de l’air et ainsi causer des malaises ou la
mort. Assurez-vous que l’air est propre à la respiration.
6. Ne soudez pas à proximité d’opérations de dégraissage, de nettoyage
ou de pulvérisation. La chaleur et les rayons de l’arc peuvent réagir
avec des vapeurs et former des gaz hautement toxiques et irritants.
L’arc produit des étincellies et des projections. Les particules
volantes, le métal chaud, les projections de soudure et
l’équipement surchauffé peuvent causer un incendie et
des brûlures. Le contact accidentel de l’électrode ou du
fil-électrode avec un objet métallique peut provoquer des
étincelles, un échauffement ou un incendie.
1. Protégez-vous, ainsi que les autres, contre les étincelles et du métal
chaud.
2. Ne soudez pas dans un endroit où des particules volantes ou des
projections peuvent atteindre des matériaux inflammables.
3. Enlevez toutes matières inflammables dans un rayon de 10, 7 mètres
autour de l’arc, ou couvrez-les soigneusement avec des bâches
approuvées.
4. Méfiez-vous des projections brulantes de soudage susceptibles de
pénétrer dans des aires adjacentes par de petites ouvertures ou
fissures.
5. Méfiez-vous des incendies et gardez un extincteur à portée de la
main.
SELECTION DES NUANCES DE FILTRES OCULAIRS POUR LA PROTECTION
DES YEUX EN COUPAGE ET SOUDAGE (selon AWS á 8.2-73)
Opération de coupage
ou soudage
Brassage tendre
au chalumeau
Brassage fort
au chalumeau
Dimension d'électrode ou
Nuance de
Epiasseur de métal ou
filtre oculaire
Intensité de courant
toutes conditions
3 ou 4
métaux non-ferreux
toutes conditions
11
métaux ferreux
toutes conditions
12
2 ou 3
Soudage á l'arc sous gaz avec
électrode de tungstène (GTAW)
toutes conditions
12
toutes conditions
12
toutes conditions
12
toutes dimensions
12
moins de 1 po. (25 mm)
plus de 6 po. (150 mm)
4 ou 5
5 ou 6
Soudage aux gaz
mince
Soudage á l'hydrogène
atomique (AHW)
Soudage á l'arc avec
électrode de carbone (CAW)
Soudage á l'arc Plasma (PAW)
moins de 1/8 po. (3 mm)
moyen de 1/8 á 1/2 po. (3 á 12 mm)
épais plus de 1/2 po. (12 mm)
Soudage á l'arc avec
électrode enrobees
moins de 5/32 po. (4 mm)
(SMAW)
5/32 á 1/4 po. (4 á 6.4 mm)
plus de 1/4 po. (6.4 mm)
1-6
Soudage á l'arc sous gaz
avec fil plein (GMAW)
2
moyen de 1 á 6 po. (25 á 150 mm)
épais
Dimension d'électrode ou
Nuance de
Epiasseur de métal ou
filtre oculaire
Intensité de courant
toutes conditions
Oxycoupage
mince
Opération de coupage
ou soudage
4 ou 5
5 ou 6
6 ou 8
10
12
14
Gougeage Air-Arc avec
électrode de carbone
mince
épais
12
14
Coupage á l'arc Plasma (PAC)
mince
moyen
moins de 300 amperès
de 300 á 400 amperès
9
12
épais
plus de 400 amperès
14
March 31, 2006
ARCMASTER® 160 S
6. N’oubliez pas qu’une soudure réalisée sur un plafond, un plancher, une
cloison ou une paroi peut enflammer l’autre côté.
7. Ne soudez pas un récipient fermé, tel un réservoir ou un baril.
8. Connectez le câble de soudage le plus près possible de la zone de
soudage pour empêcher le courant de suivre un long parcours inconnu,
et prévenir ainsi les risques d’électrocution et d’incendie.
9. Ne dégelez pas les tuyaux avec un source de courant.
10. Otez l’électrode du porte-électrode ou coupez le fil au tube-contact
lorsqu’inutilisé après le soudage.
11. Portez des vêtements protecteurs non huileux, tels des gants en cuir,
une chemise épaisse, un pantalon revers, des bottines de sécurité et
un casque.
AVERTISSEMENT
LES ETINCELLES ET LES PROJECTIONS BRULANTES
PEUVENT CAUSER DES BLESSURES.
Le piquage et le meulage produisent des particules
métalliques volantes. En refroidissant, la soudure peut
projeter du éclats de laitier.
1. Portez un écran facial ou des lunettes protectrices approuvées. Des
écrans latéraux sont recommandés.
2. Portez des vêtements appropriés pour protéger la peau.
AVERTISSEMENT
LES BOUTEILLES ENDOMMAGEES PEUVENT EXPLOSER
Les bouteilles contiennent des gaz protecteurs sous haute
pression. Des bouteilles endommagées peuvent exploser.
Comme les bouteilles font normalement partie du procédé
de soudage, traitez-les avec soin.
1. Protégez les bouteilles de gaz comprimé contre les sources de chaleur
intense, les chocs et les arcs de soudage.
2. Enchainez verticalement les bouteilles à un support ou à un cadre fixe
pour les empêcher de tomber ou d’être renversées.
3. Eloignez les bouteilles de tout circuit électrique ou de tout soudage.
4. Empêchez tout contact entre une bouteille et une électrode de
soudage.
5. N’utilisez que des bouteilles de gaz protecteur, des détendeurs, des
boyauxs et des raccords conçus pour chaque application spécifique;
ces équipements et les pièces connexes doivent être maintenus en
bon état.
6. Ne placez pas le visage face à l’ouverture du robinet de la bouteille
lors de son ouverture.
7. Laissez en place le chapeau de bouteille sauf si en utilisation ou lorsque
raccordé pour utilisation.
8. Lisez et respectez les consignes relatives aux bouteilles de gaz
comprimé et aux équipements connexes, ainsi que la publication P-1
de la CGA, identifiée dans la liste de documents ci-dessous.
March 31, 2006
AVERTISSEMENT
LES MOTEURS PEUVENT ETRE DANGEREUX
LES GAZ D’ECHAPPEMENT DES MOTEURS PEUVENT ETRE
MORTELS.
Les moteurs produisent des gaz d’échappement nocifs.
1. Utilisez l’équipement à l’extérieur dans des aires ouvertes et bien
ventilées.
2. Si vous utilisez ces équipements dans un endroit confiné, les fumées
d’échappement doivent être envoyées à l’extérieur, loin des prises d’air
du bâtiment.
AVERTISSEMENT
LE CARBURANT PEUR CAUSER UN INCENDIE OU UNE
EXPLOSION.
Le carburant est hautement inflammable.
1. A r r ê t e z l e m o t e u r a v a n t d e v é r i f i e r l e n i v e a u e
carburant ou de faire le plein.
2. Ne faites pas le plein en fumant ou proche d’une source d’étincelles
ou d’une flamme nue.
3. Si c’est possible, laissez le moteur refroidir avant de faire le plein de
carburant ou d’en vérifier le niveau au début du soudage.
4. Ne faites pas le plein de carburant à ras bord: prévoyez de l’espace
pour son expansion.
5. Faites attention de ne pas renverser de carburant. Nettoyez tout
carburant renversé avant de faire démarrer le moteur.
AVERTISSEMENT
DES PIECES EN MOUVEMENT PEUVENT CAUSER DES
BLESSURES.
Des pièces en mouvement, tels des ventilateurs, des rotors et
des courroies peuvent couper doigts et mains, ou accrocher
des vêtements amples.
1. Assurez-vous que les portes, les panneaux, les capots et les protecteurs
soient bien fermés.
2. Avant d’installer ou de connecter un système, arrêtez le moteur.
3. Seules des personnes qualifiées doivent démonter des protecteurs ou
des capots pour faire l’entretien ou le dépannage nécessaire.
4. Pour empêcher un démarrage accidentel pendant l’entretien,
débranchez le câble d’accumulateur à la borne négative.
5. N’approchez pas les mains ou les cheveux de pièces en mouvement;
elles peuvent aussi accrocher des vêtements amples et des outils.
1-7
ARCMASTER® 160 S
6. Réinstallez les capots ou les protecteurs et fermez les portes après
des travaux d’entretien et avant de faire démarrer le moteur.
1.05 Principales Normes De Securite
Safety in Welding and Cutting, norme ANSI Z49.1, American Welding Society,
550 N.W. LeJeune Rd., Miami, FL 33128.
Safety and Health Standards, OSHA 29 CFR 1910, Superintendent of
Documents, U.S. Government Printing Office, Washington, D.C. 20402.
AVERTISSEMENT
DES ETINCELLES PEUVENT FAIRE EXPLOSER UN
ACCUMULATEUR; L’ELECTROLYTE D’UN ACCUMU-LATEUR
PEUT BRULER LA PEAU ET LES YEUX.
Les accumulateurs contiennent de l’électrolyte acide et
dégagent des vapeurs explosives.
1. Portez toujours un écran facial en travaillant sur un accumu-lateur.
2. Arrêtez le moteur avant de connecter ou de déconnecter des câbles
d’accumulateur.
3. N’utilisez que des outils anti-étincelles pour travailler sur un
accumulateur.
4. N’utilisez pas une source de courant de soudage pour charger un
accumulateur ou survolter momentanément un véhicule.
Recommended Safe Practices for the Preparation for Welding and Cutting
of Containers That Have Held Hazardous Substances, norme AWS F4.1,
American Welding Society, 550 N.W. LeJeune Rd., Miami, FL 33128.
National Electrical Code, norme 70 NFPA, National Fire Protection
Association, Batterymarch Park, Quincy, MA 02269.
Safe Handling of Compressed Gases in Cylinders, document P-1,
Compressed Gas Association, 1235 Jefferson Davis Highway, Suite 501,
Arlington, VA 22202.
Code for Safety in Welding and Cutting, norme CSA W117.2 Association
canadienne de normalisation, Standards Sales, 276 Rexdale Boulevard,
Rexdale, Ontario, Canada M9W 1R3.
Safe Practices for Occupation and Educational Eye and Face Protection,
norme ANSI Z87.1, American National Standards Institute, 1430 Broadway,
New York, NY 10018.
Cutting and Welding Processes, norme 51B NFPA, National Fire Protection
Association, Batterymarch Park, Quincy, MA 02269.
5. Utilisez la polarité correcte (+ et –) de l’accumulateur.
AVERTISSEMENT
LA VAPEUR ET LE LIQUIDE DE REFROIDISSEMENT BRULANT
SOUS PRESSION PEUVENT BRULER LA PEAU ET LES YEUX.
Le liquide de refroidissement d’un radiateur peut être brûlant
et sous pression.
1. N’ôtez pas le bouchon de radiateur tant que le moteur n’est pas
refroidi.
2. Mettez des gants et posez un torchon sur le bouchon pour l’ôter.
3. Laissez la pression s’échapper avant d’ôter complètement le
bouchon.
1-8
March 31, 2006
ARCMASTER® 160 S
SECTION 2:
INTRODUCTION AND DESCRIPTION
2.01 How To Use This Manual
2.02 Equipment Identification
This Owner’s Manual applies to just specification or part
numbers listed on page i.
To ensure safe operation, read the entire manual, including
the chapter on safety instructions and warnings.
Throughout this manual, the words WARNING, CAUTION, and
NOTE may appear. Pay particular attention to the information
provided under these headings. These special annotations are
easily recognized as follows:
The unit’s identification number (specification or part number),
model, and serial number usually appear on a nameplate
attached to the control panel. In some cases, the nameplate
may be attached to the rear panel. Equipment which does
not have a control panel such as gun and cable assemblies is
identified only by the specification or part number printed on
the shipping container. Record these numbers on the bottom
of page i for future reference.
!
2.03 Receipt Of Equipment
WARNING
A WARNING gives information regarding possible
personal injury.
CAUTION
A CAUTION refers to possible equipment
damage.
NOTE
A NOTE offers helpful information concerning
certain operating procedures.
Additional copies of this manual may be purchased by
contacting Thermal Arc at the address and phone number in
your area listed in the inside back cover of this manual. Include
the Owner’s Manual number and equipment identification
numbers.
Electronic copies of this manual can also be downloaded at
no charge in Acrobat PDF format by going to the
Thermal Arc web site listed below and clicking on the
Literature Library link:
http://www.thermalarc.com
March 31, 2006
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.
Move the equipment to the installation site before un-crating
the unit. Use care to avoid damaging the equipment when
using bars, hammers, etc., to un-crate the unit.
2-1
ARCMASTER® 160 S
2.04 Symbol Chart
Note that only some of these symbols will appear on your model.
On
Single Phase
Wire Feed Function
Off
Three Phase
Wire Feed Towards
Workpiece With
Output Voltage Off.
Dangerous Voltage
Three Phase Static
Frequency ConverterTransformer-Rectifier
Welding Gun
Increase/Decrease
Remote
Purging Of Gas
Duty Cycle
Continuous Weld
Mode
Percentage
Spot Weld Mode
Circuit Breaker
AC Auxiliary Power
2-2
Spot Time
Fuse
Panel/Local
Amperage
Shielded Metal
Arc Welding (SMAW)
Voltage
Gas Metal Arc
Welding (GMAW)
Hertz (cycles/sec)
Gas Tungsten Arc
Welding (GTAW)
Frequency
Air Carbon Arc
Cutting (CAC-A)
Negative
Constant Current
Positive
Constant Voltage
Or Constant Potential
Direct Current (DC)
High Temperature
Protective Earth
(Ground)
Fault Indication
Line
Arc Force
IPM
Inches Per Minute
Line Connection
Touch Start (GTAW)
MPM
Meters Per Minute
Auxiliary Power
Variable Inductance
Receptacle RatingAuxiliary Power
V
Voltage Input
t
Preflow Time
t1
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
Disturbance In
Ground System
Art # A-04130
115V 15A
X
%
March 31, 2006
ARCMASTER® 160 S
2.05 Description
The Thermal Arc™ ArcMaster 160 S is a self contained single-phase DC arc welding power sources with Constant Current
(CC) output characteristics. This unit is equipped with a Digital Volt/Amperage Meter and lift arc starter, and high-frequency
arc starter for use with Gas Tungsten Arc Welding (GTAW), and Shielded Metal Arc Welding (SMAW) processes. The power
source is totally enclosed in an impact resistant, flame resistant and non-conductive plastic case.
(V)
OCV
Art # A-05037
(V)
OCV
18V
10V
5A
160A 210A
(A)
25A
STICK PROCESS
LIFT-TIG PROCESS
160A
(A)
Figure 1 - ArcMaster 160 S Volt-Ampere curve
NOTE
Volt-Ampere curves show the maximum Voltage and Amperage output capabilities of the welding power source.
Curves of other settings will fall between the curves shown.
2.06 Functional Block Diagrams
Figure 2 illustrates the functional block diagram of the 160 S-power supply.
Input
Power
Main
Circuit
Switch
Input
Diode
Filter
Capacitor
DC Power
Primary
Voltage
Sensor
IGBT
Inverter
Themal
Detector
Hall Current
Output
Diodes
Transformer
(HCT1)
Output
Inductor
To each control circuit
+/-12VDC +18VDC
+24VDC +5VDC
Trouble
Sensing
Circuit
Torch Control
Connection
(CON1)
Main
Transformers
(T1)
Thermal
Sensor
Circuit
Drive
Circuit
Stick Mode Lift Tig Mode
VRD
Output Short
Sensing
Sensing
Circuit
Circuit
Primary
Circuit
Sensor
Sequence
Control
Fan Control
Circuit
Fan
Current
Reference
Adjustment
Adjustment &
Circuit
Mode select Switch
Panel Circuit Boad
Figure 2-2: 160 S Functional Block Diagram
March 31, 2006
2-3
ARCMASTER® 160 S
2.07 Transporting Methods
These units are equipped with a handle for carrying
purposes.
!
WARNING
ELECTRIC SHOCK can kill. DO NOT TOUCH
live electrical parts. Disconnect input power
conductors from de-energized supply line before
moving the welding power source.
!
WARNING
FALLING EQUIPMENT can cause serious personal
injury and equipment damage.
Lift unit with handle on top of case.
Use handcart or similar device of adequate capacity.
If using a fork lift vehicle, place and secure unit on a proper
skid before transporting.
2-4
March 31, 2006
ARCMASTER® 160 S
SECTION 3:
INSTALLATION RECOMMENDATIONS
3.03 Electrical Input Connections
3.01 Environment
The ArcMaster 160 S is designed for use in adverse
environments.
Examples of environments with increased adverse conditions
are a. In locations in which freedom of movement is restricted,
so that the operator is forced to perform the work in a
cramped (kneeling, sitting or lying) position with physical
contact with conductive parts,
b. In locations which are fully or partially limited by
conductive elements, and in which there is a high risk
of unavoidable or accidental contact by the operator,
c. In wet or damp hot locations where humidity or
perspiration considerably reduces the skin resistance
of the human body and the insulation properties of
accessories.
Environments with adverse conditions do not include places
where electrically conductive parts are in the near vicinity of
the operator, which can cause increased hazard, have been
insulated.
3.02 Location
Be sure to locate the welder according to the following
guidelines:
• In areas free from moisture and dust.
• Ambient temperature between 0 degrees C to 40
degrees C.
• In areas free from oil, steam and corrosive gases.
• In areas not subjected to abnormal vibration or shock.
• In areas not exposed to direct sunlight or rain.
• Place at a distance of 12” (304.79mm) or more from
walls or similar that could restrict natural irflow for
cooling.
!
WARNING
Thermal Arc advises that this equipment be
electrically connected by a qualified electrician.
March 31, 2006
!
WARNING
ELECTRIC SHOCK can kill; SIGNIFICANT DC
VOLTAGE is present after removal of input
power.
DO NOT TOUCH live electrical parts.
SHUT DOWN welding power source, disconnect input power
employing lockout/tagging procedures. Lockout/tagging
procedures consist of padlocking line disconnect switch in
open position, removing fuses from fuse box, or shutting
off and red-tagging circuit breaker or other disconnecting
device.
• Electrical Input Requirements
Operate the welding power source from a single-phase 50/60
Hz, AC power supply. The input voltage must match one of the
electrical input voltages shown on the input data label on the
unit nameplate. Contact the local electric utility for information
about the type of electrical service available, how proper
connections should be made, and inspection required.
The line disconnect switch provides a safe and convenient
means to completely remove all electrical power from the
welding power supply whenever necessary to inspect or
service the unit.
NOTE
This unit is equipped with a 115 VAC (NEMA 5-15)
plug modeled on the two-conductor with earth
power cable that is connected at the welding
power source for single phase electrical input
power. For 230 VAC operation, have a qualified
person install according to applicable codes, and
instructions.
Do not connect an input (WHITE or BLACK) conductor to the
ground terminal.
Do not connect the ground (GREEN) conductor to an input
line terminal.
3-1
ARCMASTER® 160 S
Refer to figure 3 and:
1. Connect end of ground (GREEN) conductor to a suitable ground. Use a grounding method that complies with all applicable
electrical codes.
2. Connect ends of line 1 (BLACK) and line 2 (WHITE) input conductors to a de-energized line disconnect switch.
3. Use Table 1 and Table 2 as a guide to select line fuses for the disconnect switch.
Input Voltage
Fuse Size
115 V
40 Amps
208-230 V
45 Amps
Table 1 - Electrical Input Connections
NOTE
Fuse size is based on not more than 200 percent of the rated input amperage of the welding power source (Based
on Article 630, National Electrical Code).
Figure 3 - Electrical Input Connections
• Input Power
Each unit incorporates an INRUSH circuit and input voltage sensing circuit. When the MAIN CIRCUIT SWITCH is turned on, the
inrush circuit provides a pre-charging of the input capacitors. SCR’s in the Power Control Assembly (PCA) will turn on after the
input capacitors have charged to full operating voltage (after approximately 5 seconds).
NOTE
Note the available input power. Damage to the PCA could occur if 460VAC or higher is applied.
The following 115/208-230V Primary Current recommendations are required to obtain the maximum welding current and duty
cycle from this welding equipment:
Minimum Primary
Current & Duty Cycle
Model
Current Circuit Size
TIG
STICK
(Vin/Amps)
115/23
85A @ 100%
208/28
160A @ 35%
230/25
ArcMaster 160 S
12/3 AWG minimum
115/40
85A @ 100%
208/44
160A @ 35%
230/39
Table 2 – 115/208-230V Primary Current Circuit sizes to achieve maximum current
Primary Supply Lead Size
(Factory Fitted)
3-2
March 31, 2006
ARCMASTER® 160 S
3.04 Specifications
Parameter
Rated Output
Amperes
Volts
Duty Cycle
Duty Cycle
TIG
STICK
Output Current
TIG
Range
STICK
Open Circuit Voltage
Dimensions
Width
Height
Length
Weight
160 S
115VAC
230VAC
85
160
23
27
100%
35%
160A / 17V @ 35%
230VAC
130A / 15V @ 60%
230VAC
100A / 14V @ 100%
230VAC
85A / 13V @ 100%
115VAC
160A / 27V @ 35%
230VAC
130A / 25V @ 60%
230VAC
100A / 24V @ 100%
230VAC
85A / 23V @ 100%
115VAC
5 – 160 (230V), 5 – 85 (115V)
5 – 160 (230V), 5 – 85 (115V)
65V
5.12” (130mm)
10.24” (260mm)
12.60” (320mm)
18.95 lbs. (8.6 kg)
Output @ Rated Load
Rated Input Voltage
Single Phase 115VAC
Single phase 230VAC
Output Amperes
85A
160A
Output Volts
23V
27V
100%
35%
KVA
4.4
8.7
KW
2.4
5.2
Duty Cycle
Output @ No Load
0.5
KVA
KW
0.3
Input Volts Single Phase
Amperage Draw @ Rated Load
No Load
115V
40
2.2
230V
39
1.6
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.
March 31, 2006
3-3
ARCMASTER® 160 S
3.05 Duty Cycle
The duty cycle of a welding power source is the percentage
of a ten (10) minute period that it can be operated at a given
output without causing overheating and damage to the unit.
If the welding amperes decrease, the duty cycle increases. If
the welding amperes are increased beyond the rated output,
the duty cycle will decrease.
!
WARNING
Exceeding the duty cycle ratings will cause the
thermal overload protection circuit to become
energized and shut down the output until the unit
has cooled to normal operating temperature.
CAUTION
Continually exceeding the duty cycle ratings can
cause damage to the welding power source and
will void the manufacturer’s warranty.
NOTE
Due to variations that can occur in manufactured
products, claimed performance, voltages, ratings,
all capacities, measurements, dimensions and
weights quoted are approximate only. Achievable
capacities and ratings in use and operation will
depend upon correct installation, use, applications,
maintenance and service.
3-4
March 31, 2006
SECTION 4:
OPERATOR CONTROLS
ARCMASTER® 160 S
4.01 ArcMaster 160 S Controls
Figure 4 – ArcMaster 160 S Power Source
the digital meter. Pushing the knob inward displays the
actual welding voltage.
2. Remote Control Socket
1. Control Knob
This control sets the selected weld parameter, rotating it
clockwise increases the parameter and is indicated on
Gnd.
2
12345678
1
5
4
3
8
7
6
The 8 pin Remote Control Socket is used to connect
remote current control devices to the welding Power
Source. To make connections, align keyway, insert plug,
and rotate threaded collar fully clockwise.
5k Ohms
Front view of 8-Socket Receptacle
Sock et Pin
1
2
3
4
5
6
7
8
March 31, 2006
Function
Earth (Ground)
Torch Switch Input (24V) to energize weld current.
(connect pins 2 & 3 to turn on welding current)
Torch Switch Input (0V) to energize weld current
(connect pins 2 & 3 to turn on welding current)
Connect pin 4 to pin 8 to instruct machine that a remote current control device is
connected (12V DC supply)
5k ohm (maximum) connection to 5k ohm remote control potentiometer
Zero ohm (minimum) connection to 5k ohm remote control potentiometer
Wiper arm connection to 5k ohm remote control potentiometer
Connect pin 4 to pin 8 to instruct machine that a remote current control device is
connected (0V)
4-1
ARCMASTER® 160 S
3. Positive Terminal
5. ON/OFF Switch
Welding current flows from the Power Source via heavy
duty Dinse type terminal. It is essential, however, that
the male plug is inserted and turned securely to achieve
a sound electrical connection.
This switch connects the Primary supply voltage to the
inverter when in the ON position. This enables the Power
Supply.
!
4. Negative Terminal
Welding current flows from the Power Source via heavy
duty Dinse type terminal. It is essential, however, that
the male plug is inserted and turned securely to achieve
a sound electrical connection.
CAUTION
Loose welding terminal connections can cause
overheating and result in the male plug being
fused in the bayonet terminal.
WARNING
When the welder is connected to the Primary
supply voltage, the internal electrical components
maybe at 240V potential with respect to earth.
6. Input Cable
The input cable connects the Primary supply voltage to
the equipment.
4.02 Weld Parameter Descriptions for ArcMaster 160 S
Figure 4-3: ArcMaster 160 S Front Panel with Parameter Description
Parameter
HOT START
A
Description
This parameter operates in STICK weld mode and is used to improve the start characteristics
for stick electrodes. e.g. low hydrogen electrodes. It sets the peak start current on top of
the (WELD) current.
Weld Current (Amperage)- sets the STICK and TIG WELD current.
ARC CONTROL - This parameter provides a suitable short circuit current in STICK welding
to improve electrode sticking and arc stability.
LIFT TIG mode of operation. A remote control device is required for use during LIFT TIG
operation. See section 3.01, section 2 “Remote Control Socket”, for complete details of
the remote device.
STICK Mode of operation.
Table 3 – Weld Parameter Descriptions for ArcMaster 160 S
4-2
March 31, 2006
ARCMASTER® 160 S
4.03 Weld Parameters for ArcMaster 160 S
Weld Mode
Weld
Parameter
HOT START
Parameter Range
0 to 70A
WELD CUR
ARC CONTROL
5 to 85A 115V
5 to 160A 230V
Factory
Setting
20A
Incremental
Unit
1A
STICK
Yes
LIFT TIG
No
80A
1A
Yes
Yes
Yes
No
0 to 100%
10%
1%
Table 4 – Weld Parameters for ArcMaster 160 S
4.04 Power Source Features
Feature
New Digital Control
Touch Panel Switches
Front Control Cover
•
•
•
•
Description
Almost all welding parameters are adjustable
Touch switches eliminate mechanical damage
Protects front panel controls
Displays selected weld parameter value
• Displays weld current when welding
Digital Meter
ON/OFF switch
Voltage Reduction Device (VRD)
(shipped de-activated, Field Capable)
see Section 11 for Activation Instructions
• Displays weld current for 20 seconds after weld has been
completed
• A selected weld parameter value can be adjusted at any time
even while welding
• Primary voltage Supply ON/OFF switch located on rear panel
Reduces the OCV when the power supply is not in use. Eliminates the
need for add on voltage reducers and has no effect on arc starting.
• VRD fully complies to IEC 60974-1
• When Stick mode is selected the green VRD light is ON when
not welding and red when welding.
• When in TIG modes VRD is off.
• For the selected weld parameter, rotating the knob clockwise
increases the parameter
Control Knob
• Rotating the knob counterclockwise decreases the parameter
• A selected weld parameter value can be adjusted at any time
even while welding
• Pushing the knob in displays actual arc voltage.
Self Diagnosis Using Error Codes
March 31, 2006
• An error code is displayed on the Digital Meter when a problem
occurs with Primary supply voltage or internal component
problems. Refer to troubleshooting guide.
4-3
ARCMASTER® 160 S
4-4
March 31, 2006
ARCMASTER® 160 S
SECTION 5:
SET-UP FOR SMAW (STICK) AND GTAW (TIG)
Conventional operating procedures apply when using the Welding Power Source, i.e. connect work lead directly to work piece
and electrode lead is used to hold electrode. Wide safety margins provided by the coil design ensure that the Welding Power
Source will withstand short-term overload without adverse effects. The welding current range values should be used as a guide
only. Current delivered to the arc is dependent on the welding arc voltage, and as welding arc voltage varies between different
classes of electrodes, welding current at any one setting would vary according to the type of electrode in use. The operator
should use the welding current range values as a guide, then finally adjust the current setting to suit the application.
!
WARNING
Before connecting the work clamp to the work
and inserting the electrode in the electrode
holder make sure the Primary power supply is
switched off.
Figure 5-1: 160 S Set-up
March 31, 2006
5-1
ARCMASTER® 160 S
5-2
March 31, 2006
SECTION 6:
SEQUENCE OF OPERATION
ARCMASTER® 160 S
NOTE: Scroll Buttons are used to select the parameters to be set. The LED’s show which
function is being adjusted on the weld sequence graph. Refer to Symbols Table located in
the front of the manual for Symbol descriptions.
5
1
2
3
Figure 7-1: 160 S Front Panel
4
1. Scroll Buttons– used to select the parameter to be set. 3. Control Knob– allows the operator to adjust the output
The LED’s show which function is being adjusted on the
amperage within the entire range of the power source,
weld sequence graph.
also used to set each parameter value. Pushing the knob
inward displays the actual welding voltage.
2. Digital LED display– Welding amperage and parameter
values are displayed in this window. Internal warnings 4. Process Button- This button selects between STICK or
such as over temperature, low or high input voltage
LIFT TIG mode.
applied are signaled to the operator by a warning sound
5. 8 pin remote control receptacle for connecting remote
and error message on the screen.
device. A remote control device is required for use during
LIFT TIG operation. See section 4.01, section Remote
2“
Control Socket”, for complete details of the remote
device.
6.01 Stick Welding
6.02 DC Lift TIG Welding
• Connect work lead to negative terminal
• Connect work lead to positive terminal
• Connect electrode lead to positive terminal
• Connect TIG torch to negative terminal
• Switch machine on
• Switch machine on
• Connect remote control device if required
Use the Scroll Buttons to move to the parameter to be set.
The LED will show which function is being adjusted on the
weld sequence graph. Use the control knob to adjust each
parameter.
• Set HOT START
• Set WELDcurrent
• Set Arc Control
Commence welding
March 31, 2006
• Set WELDcurrent.
• Connect remote control device. A remote control device
is required for use during LIFT TIG operation. See
section 4.01, section 2 Remote
“
Control Socket
”, for
complete details of the remote device.
Use the Scroll Buttons to move to the parameter to be set.
The LED will show which function is being adjusted on the
weld sequence graph. Use the control knob to adjust each
parameter.
• Set WELDtime
Commence welding
6-1
ARCMASTER® 160 S
6-2
March 31, 2006
ARCMASTER® 160 S
SECTION 7:
BASIC TIG WELDING GUIDE
7.01 Electrode Polarity
Connect the TIG torch to the - / TORCH terminal and the work lead to the + / WORK terminal for direct current straight polarity.
Direct current straight polarity is the most widely used polarity for DC TIG welding. It allows limited wear of the electrode since
70% of the heat is concentrated at the work piece.
7.02 Tungsten Electrode Current Ranges
Electrode Diameter
DC Current (Amps)
0.040” (1.0mm)
30 – 60
1/16” (1.6mm)
60 – 115
3/32” (2.4mm)
100 – 165
1/8” (3.2mm)
135 – 200
5/32” (4.0mm)
190 – 280
3/16” (4.8mm)
250 – 340
Table 4 – Current ranges for varies tungsten electrode sizes
7.03 Tungsten Electrode Types
Electrode Type
(Ground Finish)
Thoriated 2%
Ceriated 2%
Welding Application
Features
DC welding of mild steel, stainless Excellent arc starting, Long life, High
steel and copper.
current carrying capacity.
DC welding of mild steel, stainless Longer life, More stable arc, Easier
steel, copper, aluminium,
starting, Wider current range,
magnesium and their alloys
Narrower more concentrated arc.
Table 5 – Tungsten electrode types
Color
Code
Red
Grey
7.04 Guide for Selecting Filler Wire Diameter
DC Current Range
Filler Wire Diameter
(Amps)
1/16” (1.6 mm)
20 - 90
3/32” (2.4 mm)
65 - 115
1/8” (3.2 mm)
100 - 165
3/16” (4.8 mm)
200 - 350
Table 6 – Filler wire selection guide
NOTE
The filler wire diameter specified in Table 9 is a guide only, other diameter wires may be used according to the
welding application.
March 31, 2006
7-1
ARCMASTER® 160 S
7.05 Shielding Gas Selection
Alloy
Shielding Gas
Aluminium & alloys
Welding Argon
Carbon Steel
Welding Argon
Stainless Steel
Welding Argon
Nickel Alloy
Welding Argon
Copper
Welding Argon
Titanium
Welding Argon
Table 7 – Shielding gas selection
7.06 TIG Welding Parameters for Low Carbon & Low Alloy Steel Pipe
Electrode Type &
Diameter
Thoriated 2%
3/32” (2.4 mm)
Current Range DC
Amperes
120 - 170
Filler Rod for
Root Pass
Yes
Thoriated 2%
3/32” (2.4 mm)
100 - 160
Yes
Thoriated 2%
3/32” (2.4 mm)
90 - 130
No
Joint Preparation
Table 8– TIG welding parameters for low carbon & low alloy steel pipe
7.07 Welding Parameters for Steel
Base Metal
Thickness
0.040”
1.0mm
0.045”
1.2mm
1/16”
1.6mm
1/8”
3.2mm
3/16”
4.8mm
¼”
6.4mm
7-2
DC Current for
Mild Steel
35-45
40-50
45-55
50-60
60-70
70-90
80-100
90-115
115-135
140-165
160-175
170-200
DC Current
Tungsten
Filler Rod
for Stainless
Electrode
Diameter
Steel
Diameter
(if required)
20-30
0.040”
1/16”
25-35
1.0mm
1.6mm
30-45
0.040”
1/16”
35-50
1.0mm
1.6mm
40-60
1/16”
1/16”
50-70
1.6mm
1.6mm
65-85
1/16”
3/32”
90-110
1.6mm
2.4mm
100-125
3/32”
1/8”
125-150
2.4mm
3.2mm
135-160
1/8”
5/32”
160-180
3.2mm
4.0mm
Table 9 – DC TIG welding parameters
Argon Gas
Flow Rate
Liters/min
5-7
5-7
7
7
10
10
Joint Type
Butt/Corner
Lap/ Fillet
Butt/Corner
Lap/ Fillet
Butt/Corner
Lap/ Fillet
Butt/Corner
Lap/ Fillet
Butt/Corner
Lap/ Fillet
Butt/Corner
Lap/ Fillet
March 31, 2006
ARCMASTER® 160 S
SECTION 8:
BASIC ARC WELDING GUIDE
8.01 Electrode Polarity
Cast Iron
Stick electrodes are generally connected to the ‘+’ terminal
and the work lead to the ‘−’ terminal but if in doubt consult
the electrode manufacturers literature.
8.02 Effects of Stick Welding Various
Materials
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
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.
Metals being joined
Electrode
Mild steel
6013
Mild steel
7014
Cast iron
99% Nickel
Stainless steel
Copper, Bronze, Brass, etc.
High Alloy Steels,
Dissimilar Metals,
Crack Resistance.
All Hard-To-Weld Jobs.
318L-16
Bronze
5.7
ERCUSI-A
312-16
The most important factor is the high rate of heat
conductivity of copper, making preheating of heavy
sections necessary to give proper fusion of weld and
base metal.
Types of Electrodes
Arc Welding electrodes are 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 and all will
work on even the most basic of welding machines.
Comments
Ideal electrodes for all general purpose work.
Features include out standing operator appeal,
easy arc starting and low spatter.
All positional electrode for use on mild and
galvanized steel furniture, plates, fences,
gates, pipes and tanks etc. Especially suitable
for vertical-down welding.
Suitable for joining all cast irons except white
cast iron.
High corrosion resistance. Ideal for dairy work,
etc. On stainless steels.
Easy to use electrode for marine fittings, water
taps and valves, water trough float arms, etc.
Also for joining copper to steel and for bronze
overlays on steel shafts.
It will weld most problematical jobs such as
springs, shafts, broken joins mild steel to
stainless and alloy steels.
Not suitable for Aluminum.
Table 10 - Types of Electrodes
March 31, 2006
8-1
ARCMASTER® 160 S
8-2
March 31, 2006
ARCMASTER® 160 S
SECTION 9:
ROUTINE MAINTENANCE
The only routine maintenance required for the power supply is a thorough cleaning and inspection, with the frequency depending
on the usage and the operating environment.
!
WARNING
Disconnect primary power at the source before
opening the enclosure. Wait at least two minutes
before opening the enclosure to allow the primary
capacitors to discharge.
To clean the unit, open the enclosure (please refer to the 160 S Service Manual P/N 430429-513) and use a vacuum cleaner to
remove any accumulated dirt and dust. The unit should also be wiped clean, if necessary; with solvents that are recommended
for cleaning electrical apparatus.
CAUTION
Do not blow air into the power supply during
cleaning. Blowing air into the unit can cause
metal particles to interfere with sensitive electrical
components and cause damage to the unit.
March 31, 2006
9-1
ARCMASTER® 160 S
Warning!
Disconnect input power before maintaining.
Maintain more often
if used under severe
conditions
Each Use
Visual check of torch
Consumable parts
Visual check of
regulator and pressure
Weekly
Visually inspect the torch
body and consumables
Visually inspect the
cables and leads.
Replace as needed
3 Months
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.
Art # A-07331
9-2
March 31, 2006
ARCMASTER® 160 S
SECTION 10:
BASIC TROUBLESHOOTING
!
WARNING
There are extremely dangerous voltages and power levels present inside this product. Do not attempt to open or
repair unless you are an Accredited Thermal Arc Service Agent and you have had training in power measurements
and troubleshooting techniques.
If major complex subassemblies are faulty, then the Welding Power Source must be returned to an Accredited Thermal Arc
Service Agent for repair.
The basic level of troubleshooting is that which can be performed without special equipment or knowledge.
10.01 TIG Welding Problems
Weld quality is dependent on the selection of the correct consumables, maintenance of equipment and proper welding
technique.
1.
2.
3.
4.
5.
6.
7.
Description
Excessive beard build-up or poor
penetration or poor fusion at
edges of weld.
Weld bead too wide and flat or
undercut at edges of weld or
excessive burn through
Weld bead too small or insufficient
penetration or ripples in bead are
widely spaced apart
Weld bead too wide or excessive
bead build up or excessive penetration in butt joint
Uneven leg length in fillet joint
Electrode melts when arc is
struck.
Dirty weld pool.
A.
March 31, 2006
Possible Cause
Welding current is too low
Remedy
Increase weld current and/or faulty
joint preparation
Welding current is too high
Decrease weld current
Travel speed too fast
Reduce travel speed
Travel speed too slow
Increase travel speed
Wrong placement of filler rod
Re-position filler rod
Electrode is connected to the ‘+’
Connect the electrode to the ‘−’
terminal.
terminal.
Electrode contaminated through A. Clean the electrode by grinding off
contact with work piece or filler rod
the contaminates.
material.
B. Gas contaminated with air.
B. Check gas lines for cuts and loose
fitting or change gas cylinder.
10-1
ARCMASTER® 160 S
8.
Description
Electrode melts or oxidizes when
an arc is struck.
Possible Cause
A. No gas flowing to welding region.
B. Torch is clogged with dust.
C. Gas hose is cut.
D. Gas passage contains impurities.
9.
Poor weld finish.
E. Gas regulator turned off.
F. Torch valve is turned off.
G. The electrode is too small for the
welding current.
Inadequate shielding gas.
Remedy
A. Check the gas lines for kinks or
breaks and gas cylinder contents.
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.
Increase gas flow or check gas line
for gas flow problems.
A. Select the right size electrode. Refer
to Basic TIG Welding guide.
B. Refer Basic TIG Welding Guide for
ways to reduce arc flutter.
A. Connect the work clamp to the work
piece or connect the work/torch leads
to the right welding terminals.
10. Arc flutters during TIG welding.
A. Tungsten electrode is too large for
the welding current.
B. Absence of oxides in the weld pool.
11. Welding arc can not be
established.
A. Work clamp is not connected to
the work piece or the work/torch
leads are not connected to the right
welding terminals.
B. Torch lead is disconnected.
B. Connect it to the ‘−‘ terminal.
C. Gas flow incorrectly set, cylinder C. Select the right flow rate, change
empty or the torch valve is off.
cylinders or turn torch valve on.
A. Tungsten electrode is too large for A. Select the right size electrode.
the welding current.
Refer to Section 7, Basic TIG
Welding Guide.
B. The wrong electrode is being used B. Select the right electrode type.
for the welding job
Refer to Section 7, Basic TIG
Welding Guide.
C. Gas flow rate is too high.
C. Select the correct rate for the
welding job.
Refer to Section 7, Basic TIG
Welding Guide.
D. Incorrect shielding gas is being D. Select the right shielding gas.
used.
Refer to Section 7, Basic TIG
Welding Guide.
E. Poor work clamp connection to work E. Improve connection to work piece.
piece.
12. Arc start is not smooth.
10-2
March 31, 2006
ARCMASTER® 160 S
10.02 Stick Welding Problems
Description
1. Gas pockets or voids in weld metal
(Porosity).
2. Crack occurring in weld metal soon
after solidification commences
A.
B.
C.
A.
Possible Cause
Electrodes are damp.
Welding current is too high.
Surface impurities such as oil,
grease, paint, etc.
Rigidity of joint.
B. Insufficient throat thickness.
3. A gap is left by failure of the weld
metal to fill the root of the weld.
C. Cooling rate is too high.
A. Welding current is too low.
B. Electrode too large for joint.
C. Insufficient gap.
D. Incorrect sequence.
Remedy
A. Dry electrodes before use.
B. Reduce welding current.
C. Clean joint before welding.
A. Redesign to relieve weld joint
of severe stresses or use crack
B. resistance electrodes.
Travel slightly slower to allow
C. greater build up in throat.
Preheat plate and cool slowly.
A. Increase welding current
B. Use smaller diameter
electrode.
C. Allow wider gap.
D. Use correct build-up sequence.
Figure 8 – Example of insufficient gap or incorrect sequence
4. Portions of the weld run do not fuse A . Small electrodes used on heavy A . Use larger electrodes and pre-heat
to the surface of the metal or edge
cold plate.
the plate.
of the joint.
B Welding current is too low.
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 D. Reduce travel speed of electrode
high.
E. Scale or dirt on joint surface.
E. Clean surface before welding.
Figure 9 – Example of lack of fusion
March 31, 2006
10-3
ARCMASTER® 160 S
5. Non-metallic parti cles are A. Non-metallic particles may be trapped A. If bad undercut is present, clean slag
trapped in the weld metal
in undercut from previous run.
out and cover with a run from a smaller
(slag inclusion).
diameter electrode.
B. Joint preparation too restricted.
B. Allow for adequate penetration and room
for cleaning out the slag.
C. Irregular deposits allow slag to be C. I f v e r y b a d , c h i p o r g r i n d o u t
trapped.
irregularities.
D. Lack of penetration with slag trapped D. Use smaller electrode with sufficient
beneath weld bead.
current to give adequate penetration.
Use suitable tools to remove all slag
from corners.
E. Rust or mill scale is preventing full E. Clean joint before welding.
fusion.
F. Wrong electrode for position in which F. Use electrodes designed for position in
welding is done.
which welding is done, otherwise proper
control of slag is difficult.
Figure 10 – Examples of slag inclusion
10.03 Power Source Problems
Description
Possible Cause
1. The welding arc cannot be A. The Primary supply voltage has not A .
established
been switched ON.
B. The Welding Power Source switch B.
is switched OFF.
C. Loose connections internally.
C.
2. Maximum output welding current
can not be achieved with nominal
Mains supply voltage.
3. Welding current reduces when
welding
10-4
Defective control circuit
Poor work lead connection to the
work piece.
Remedy
Switch ON the Primar y supply
voltage.
Switch ON the Welding Power Source.
Have an Accredited Thermal Arc Service
Agent repair the connection.
Have an Accredited Thermal Arc Service
Agent inspect then repair the welder.
Ensure that the work lead has a
positive electrical connection to the
work piece.
March 31, 2006
ARCMASTER® 160 S
SECTION 11:
VOLTAGE REDUCTION DEVICE (VRD)
11.01 VRD Specification
Description
VRD Open Circuit Voltage
ArcMaster 160 S
15.3 to 19.8V
VRD Resistance
148 to 193 ohms
VRD Turn OFF Time
0.2 to 0.3 seconds
Notes
Open circuit voltage between welding terminals
The required resistance between welding
terminals to turn ON the welding power
The time taken to turn OFF the welding power
once the welding current has stopped
11.02 VRD Maintenance
Routine inspection and testing (power source)
An inspection of the power source, an insulation resistance test and an earth resistance test shall be carried out.
a) For transportable equipment, at least once every 3 months; and
b) For fixed equipment, at least once every 12 months.
The owners of the equipment shall keep a suitable record of the periodic tests.
NOTE
A transportable power source is any equipment that is not permanently connected and fixed in the position in
which it is operated.
In addition to the above tests and specifically in relation to the VRD fitted to this machine, the following periodic tests should
also be conducted by an accredited Thermal Arc service agent.
Description
IEC 60974-1 Requirements
VRD Open Circuit Voltage
Less than 20V; at Vin=115V or 230V
VRD Turn ON Resistance
Less than 200 ohms
VRD Turn OFF Time
Less than 0.3 seconds
If this equipment is used in a location or environment with a high risk of electrocution then the above tests should be carried
out prior to entering this location.
March 31, 2006
11-1
ARCMASTER® 160 S
11.03 Switching VRD On/Off
Switch the machine Off.
a) Remove the clear plastic cover from the control panel (see Figure 11).
• Lift up the cover so it rests on the top of the unit.
• Place a small flat bladed screw driver between the cover hinge on the front panel.
• Gently lift the cover hinge out of the front cover mounting hole.
• Remove the control’s clear plastic cover.
b) Remove four mounting screws from the control panel (see Figure 12).
c) Access the VRD control by gently prying back the front panel controls to reveal the VRD on/off potentiometer (see Figure 12).
d) Turning the VRD ON/OFF (see Figure 13).
• To turn VRD ON: rote the trim potentiometer (VR1) on the display PCB fully clockwise. When VRD is turned ON check
that it operates as per VRD Specifications on page 5-13.
• To turn VRD OFF: rote the trim potentiometer (VR1) on the display PCB fully counter clockwise.
Figure 11-1: VRD ON/OFF Step A
CAUTION
Do not pull back the front panel with excessive force as this will unplug control PCB. Plugging the control PCB back
into the front panel controls can only be achieved by removing the side covers.
11-2
March 31, 2006
ARCMASTER® 160 S
1
1
2
1
1
Figure 11-2: VRD ON/OFF Step B,C
!
WARNING
The VRD ON/OFF trim potentiometer MUST ONLY be positioned fully clockwise OR fully counter clockwise as the
VRD function will be unknown for every other position.
Figure 11-3: VRD ON/OFF Step D
March 31, 2006
11-3
ARCMASTER® 160 S
11-4
March 31, 2006
March 31, 2006
6. E99 error code displayed
Mains supply (input) voltage has been
turned off but control circuit has power
from the primary capacitors.
Table 12-1: Power Source Error Codes
A. Main on/off switch on machine has A. Turn on/off switch on.
been turned off.
B. Mains supply (input) voltage has B. Have an accredited Thermal Arc
been turned off.
Agent or a qualified electrician
check the Mains voltage and
fuses.
Possible Cause
Remedy
A. The Welding Power Source’s duty A . Let Power Source cool down
cycle has been exceeded.
then keep within its duty cycle.
B. Fan ceases to operate.
B. Have an Accredited Thermal Arc
Service Agent investigate.
C. Air flow is restricted by vents being C. Unblock vents then let Power
blocked.
Source cool down.
2. E02 error code displayed
A. The Welding Powe Source’s duty A. Let Power Source cool down
cycle has been exceeded.
then keep within its duty cycle.
Temperature sensor TH2 (protects
o
B. Fan ceases to operate.
B. Have an accredited Thermal Arc
secondary diodes) is greather than 80 C
Service Agent investigate.
for about 1 second
C. Air flow is restricted by vents being C. Unblock vents then let Power
blocked.
Source cool down.
3. E03 error code displayed
A. Primary current is too high because A . Reduce length of welding arc.
Primary (input) current too high
welding arc is too long.
B. Mains supply voltage is more than B. Have an Accredited Thermal
10% below nominal voltage .
Arc Service Agent or a qualified
electrician check for low Mains
voltage.
4. E94 error code displayed
The Welding Power Source’s
Have an Accredited Thermal
temperature sensors have
Arc Service Agent or a qualified
Temperature sensor TH1 for IGBT’s or
electrician check or replace the
malfunctioned.
sensor TH2 for secondary diodes are open
temperature sensors.
circuit.
Description
1. E01 error code displayed
Temperature sensor TH1 (protects IGBTs)
is greater than 80ºC for about 1 second
Weld current ceases.
Buzzer sounds constantly.
Must switch machine off and then
on to reset E99 error code.
Weld current ceases.
Buzzer sounds constantly.
Switch machine off.
Weld current ceases.
Buzzer sounds constantly.
Switch machine off then on to reset
E03 error.
Weld current ceases. Buzzer
sounds constantly.’Fan operates at
max speed.
E02 resets when the TH2 decreases
to 70oC for about 30 seconds
Remarks
Weld current ceases.
Buzzer sounds constantly.
E01 resets when TH1 decreases to
70ºC for about 30 seconds.
ARCMASTER® 160 S
SECTION 12:
POWER SOURCE ERROR CODES
12-1
ARCMASTER® 160 S
12-2
March 31, 2006
ARCMASTER® 160 S
SECTION 13:
OPTIONS AND ACCESSORIES
PRODUCT
Carry Case
PART NO.
DESCRIPTION
600304
Accommodates the power supply, regulator, stick work lead, TIG torch &
accessory kit
Stick Kit
90924A
Work clamp with 15’ #4 cable, and stick electrode with 15’ #4 cable
TIG Kit
600288
Includes regulator/flowgauge, 12.5ft 150 Amp TIG torch with valve,
accessory kit includes 1 ea of 0040”x7”, 1/16”x7”, 3/32”x7” 2% Tungsten
with collet & collet bodies, 1 ea 1/4”, 5/16”, 3/8” alumina cup, 15’ cable
with clamp & T25 dinse plug
W4009101 Includes regulator/flowgauge, 12.5ft 150 Amp TIG torch with valve and rotary
amperage control, accessory kit includes 1 ea of 0.040”x7”, 1/16”x7”,
3/32”x7” 2% Tungsten with collet & collet bodies, 1 ea 1/4”, 5/16”, 3/8”
alumina cup, 15’ cable with clamp & T25 dinse plug
Dinse Connector
10-1068
T25mm Dinse style male plug
Adaptor
10-4003
8-pin male to 14-pin female (6”)
Hand Held Pendant
10-4014
Includes contactor On/Off switch and current control with 25ft cable
and 8-pin male plug
Foot Control
10-4015
Contactor On/Off and current control with 15ft cable and 8-pin male plug
10-4016
Contactor On/Off and current control with 25ft cable and 8-pin male plug
Extension Cable
10-4017
3ft with 8-pin male plug and 8-pin female cable receptacle
10-4018
15ft with 8-pin male plug and 8-pin female cable receptacle
10-4019
25ft with 8-pin male plug and 8-pin female cable receptacle
10-4020
50ft with 8-pin male plug and 8-pin female cable receptacle
10-4021
75ft with 8-pin male plug and 8-pin female cable receptacle
Torch Switch On/Off
10-4006
15ft torch mounted with 8-pin male plug
10-4007
25ft torch mounted with 8-pin male plug
Torch Switch On/Off w/current 10-4008
15ft torch mounted with 8-pin male plug - adapts to 5/8”-7/8” torch
control
10-4009
15ft torch mounted with 8-pin male plug - adapts to 7/8”-1-1/8” torch
handle
10-4010
15ft torch mounted with 8-pin male plug - adapts to 1-1/8”-1-3/8” torch
handle
10-4011
25ft torch mounted with 8-pin male plug - adapts to 5/8”-7/8” torch
10-4012
25ft torch mounted with 8-pin male plug - adapts to 7/8”-1-1/8” torch
handle
10-4013
25ft torch mounted with 8-pin male plug - adapts to 1-1/8”-1-3/8” torch
handle
600296
Rotary amperage control 5k 15’ velcro for TD8
600297
Rotary amperage control 5k 25’ velcro for TD8
March 31, 2006
13-1
ARCMASTER® 160 S
PCB2
Main Circuit Board
[WK-5467]
Q1A
TB7
C
C
G
E
G
E
C
Q1B
Q3A
Q3B
C
D1
G
E
+
TB1
S1
Line1
TB10
TB11
TB2
TB9
C
PCB6
IGBTGate
TB2 Circuit Board
[WK-5460]
TB8
Line2
+
TB12
Q1C
Q2A
FAN1
+
Q2B
1
2
3
4
CN2
1
2
Q4B
C
TB5
TB6
C
CN1
CN5
-
Q4A
G
E
G
E
TB6
TB7
C
G
E
C
SIDE CHASSIS 1
G
E
TB3
-
TB5
Q3CTB4
C
PCB7
IGBTGate
Circuit Board
[WK-5460]
G
E
C
TB3
+
Ground
TB1
G
E
G
E
G
E
Q2C
Q4C
C
CN1
1 2 3 4 5 6
1 2 3 4 5 6
1 2 3 4 5 6
1 2 3 4 5 6
CN7
CN7
G
E
CN3
1
2
3
4
5
6
CN4
1
2
3
CN6
TH2
1
2
3
4
CN101
TH1
1
2
3
4
5
6
7
+
PCB1
Control Source
Circuit Bord
[WK-5466]
2
8
1
5
4
7
6
3
1
2
3
4
5
6
7
8
CN1
SIDE CHASSIS 1
1 2 3 4 5 6 7 8
CN103
CON1
(Front View)
1 : Case Ground
2 : Contactor Control 1/+24VDC
3 : Contactor Control 2/GND
4 : +12VDC Supply
5 : Potentiometer Maximum
6 : Potentiometer Minimum(GND)
7 : Amperage Control Wiper 0-10VDC
8 : Remote Installed =12VDC
A-2
March 31, 2006
ARCMASTER® 160 S
PCB3
2nd Diode
Circuit Board
[WK-5468]
D2
T1
CT1
TO1
TB1
12
34
TB3
+Output
Terminal
TB5
TB7
D3
TB2
+12
-12
IS
GND
TB4
TB6
SIDE CHASSIS 2
C1
FCH1
R1
TO2
-Output
Terminal
CN1
1 2 3 4 5 6
1
2
3
4
5
6
7
CN1
+12
-12
IS
GND
PCB4
Control
Circuit Board
[WK-5449]
CN2
CN2
CN3
PCB5
Panel
Circuit Board
[WK-5448]
March 31, 2006
A-3
LIMITED WARRANTY
This information applies to Thermal Arc products that were purchased in the USA and Canada.
April 2006
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 April 1st 2006
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.
April 2006
ENGINE DRIVEN WELDERS
W ARRANTY P ERIOD
Scout, Raider, Explorer
Original Main Power Stators and Inductors .................................................................................. 3 years
LABOR
3 years
Original Main Power Rectifiers, Control P.C. Boards ................................................................... 3 years
3 years
All other original circuits and components including, but not limited to, relays,
switches, contactors, solenoids, fans, power switch semi-conductors .......................................... 1 year
1 year
Engines and associated components are NOT warranted by Thermal Arc, although
most are warranted by the engine manufacturer ............................................................. See the Engine Manufactures Warranty for
Details
GMAW/FCAW (MIG) WELDING EQUIPMENT
W ARRANTY P ERIOD
LABOR
Fabricator 131, 181; 190, 210, 251, 281; Fabstar 4030;
PowerMaster 350, 350P, 500, 500P; Excelarc 6045.
Wire Feeders; Ultrafeed, Portafeed
Original Main Power Transformer and Inductor............................................................................ 5 years
3 years
Original Main Power Rectifiers, Control P.C. Boards, power switch semi-conductors ................. 3 years
3 years
All other original circuits and components including, but not limited to, relays,
switches, contactors, solenoids, fans, electric motors................................................................... 1 year
1 year
GTAW (TIG) & MULTI-PROCESS INVERTER WELDING EQUIPMENT
W ARRANTY P ERIOD
LABOR
160TS, 300TS, 400TS, 185AC/DC, 200AC/DC, 300AC/DC, 400GTSW, 400MST,
300MST, 400MSTP
Original Main Power Magnetics.................................................................................................... 5 years
3 years
Original Main Power Rectifiers, Control P.C. Boards, power switch semi-conductors ................. 3 years
3 years
All other original circuits and components including, but not limited to, relays,
switches, contactors, solenoids, fans, electric motors................................................................... 1 year
1 year
PLASMA WELDING EQUIPMENT
W ARRANTY P ERIOD
LABOR
Ultima 150
Original Main Power Magnetics.................................................................................................... 5 years
3 years
Original Main Power Rectifiers, Control P.C. Boards, power switch semi-conductors ................. 3 years
3 years
Welding Console, Weld Controller, Weld Timer ........................................................................... 3 years
3 years
All other original circuits and components including, but not limited to, relays,
switches, contactors, solenoids, fans, electric motors, Coolant Recirculator. ............................... 1 year
1 year
SMAW (Stick) WELDING EQUIPMENT
W ARRANTY P ERIOD
LABOR
Dragster 85
Original Main Power Magnetics..................................................................................................... 1 year
1 year
Original Main Power Rectifiers, Control P.C. Boards .................................................................... 1 year
1 year
All other original circuits and components including, but not limited to, relays,
switches, contactors, solenoids, fans, power switch semi-conductors .......................................... 1 year
1 year
160S, 300S, 400S
Original Main Power Magnetics.................................................................................................... 5 years
3 years
Original Main Power Rectifiers, Control P.C. Boards ................................................................... 3 years
3 years
All other original circuits and components including, but not limited to, relays,
switches, contactors, solenoids, fans, power switch semi-conductors .......................................... 1 year
1 year
GENERAL ARC EQUIPMENT
W ARRANTY P ERIOD
LABOR
Water Recirculators ....................................................................................................................... 1 year
1 year
Plasma Welding Torches.............................................................................................................180 days
180 days
Gas Regulators (Supplied with power sources) ..........................................................................180 days
Nil
MIG and TIG Torches (Supplied with power sources)..................................................................90 days
Replacement repair parts .............................................................................................................90 days
Nil
Nil
MIG, TIG and Plasma welding torch consumable items................................................................... Nil
Nil
GLOBAL CUSTOMER SERVICE CONTACT INFORMATION
Thermadyne USA
Thermadyne Asia Sdn Bhd
2800 Airport Road
Denton, Tx 76207 USA
Telephone: (940) 566-2000
800-426-1888
Fax: 800-535-0557
Email: [email protected]
Lot 151, Jalan Industri 3/5A
Rawang Integrated Industrial Park - Jln Batu Arang
48000 Rawang Selangor Darul Ehsan
West Malaysia
Telephone: 603+ 6092 2988
Fax : 603+ 6092 1085
Thermadyne Canada
Cigweld, Australia
2070 Wyecroft Road
Oakville, Ontario
Canada, L6L5V6
Telephone: (905)-827-1111
Fax: 905-827-3648
71 Gower Street
Preston, Victoria
Australia, 3072
Telephone: 61-3-9474-7400
Fax: 61-3-9474-7510
Thermadyne Europe
Thermadyne Italy
Europe Building
Chorley North Industrial Park
Chorley, Lancashire
England, PR6 7Bx
Telephone: 44-1257-261755
Fax: 44-1257-224800
OCIM, S.r.L.
Via Benaco, 3
20098 S. Giuliano
Milan, Italy
Tel: (39) 02-98 80320
Fax: (39) 02-98 281773
Thermadyne, China
Thermadyne International
RM 102A
685 Ding Xi Rd
Chang Ning District
Shanghai, PR, 200052
Telephone: 86-21-69171135
Fax: 86-21-69171139
2070 Wyecroft Road
Oakville, Ontario
Canada, L6L5V6
Telephone: (905)-827-9777
Fax: 905-827-9797
World Headquarters
Thermadyne Holdings Corporation
Suite 300, 16052 Swingley Ridge Road
St. Louis, MO 63017
Telephone: (636) 728-3000
Fascimile: (636) 728-3010
Email: [email protected]
www.thermalarc.com
Was this manual useful for you? yes no
Thank you for your participation!

* Your assessment is very important for improving the work of artificial intelligence, which forms the content of this project

Download PDF

advertisement