ARCMASTER 160 S Service Manual

ARCMASTER 160 S Service Manual
160 S
ARCMASTER
INVERTER ARC WELDER
Art # A-07082
Service Manual
Version No: AA.03
Operating Features:
Issue Date: June 16, 2006
Manual No.: 0-4894B
WARNINGS
Read and understand this entire Manual and your employer’s safety practices before installing,
operating, or servicing the equipment.
While the information contained in this Manual represents the Manufacturer's best judgement,
the Manufacturer assumes no liability for its use.
160S 460V Arc Master Inverter Arc Welder
Service Manual Number 0-4894B for:
Part Number 10-3090
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: June 16, 2006
Record the following information for Warranty purposes:
Where Purchased:
___________________________________
Purchase Date:
___________________________________
Equipment Serial #:
___________________________________
i
CONTENTS
1 SAFETY INSTRUCTIONS AND WARNINGS
1
2
3
4
5
Arc Welding Hazards. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–1
PRINCIPAL SAFETY STANDARDS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–5
PRECAUTIONS DE SECURITE EN SOUNDAGE A L’ARC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–5
Dangers relatifs au soudage à l’arc . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–6
PRINCIPAL SAFETY STANDARDS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–10
2 INTRODUCTION
1
2
4
5
6
7
How To Use This Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Equipment Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Symbol Chart. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Functional Block Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Transporting Methods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2–1
2–1
2–2
2–3
2–4
2–4
3 INSTALLATION
1
2
3
4
5
6
7
Environment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Location. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Electrical Input Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Electrical Input Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Input Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Duty Cycle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3–1
3–1
3–1
3–1
3–2
3–2
3–3
4 OPERATOR CONTROL
1
2
3
ARC MASTER 160S (460V) Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–1
Weld Parameter Descriptions for ARC MASTER 160S (460V). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–2
Weld Parameters for ARC MASTER 160S (460V) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–3
3. 1 Weld Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–3
4 Power Source Features. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–3
5 SET-UP FOR SMAW (STICK) AND GTAW (TIG) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-1
6 SEQUENCE OF OPERATION
1
2
3
Stick Welding. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–1
Lift TIG Welding. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–1
Panel Lift TIG Welding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–1
7 ROUTINE MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7-1
8 BASIC TROUBLESHOOTING
1
2
3
TIG Welding Problems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8–1
Stick Welding Problems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8–2
Power Source Problems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8–4
9 VOLTAGE REDUCTION DEVICE (VRD)
1
2
3
VRD Specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9–1
VRD Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9–1
Switching VRD On/Off . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9–1
10 POWER SOURCE ERROR CODE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10-1
11 ADVANCED TROUBLESHOOTING
1
2
3
4
5
System-Level Fault Isolation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11–1
1. 1 Opening the Enclosure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11–1
Verification and Remedy to the Indicated Error Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11–3
2. 1 E01 “Over-Temperature at the primary side” . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11–3
2. 2 E02 “Over-Temperature at the secondary side”. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11–3
2. 3 E03 “Primary Over-Current Failure” . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11–4
2. 4 E94 “Thermistor malfunction”. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11–4
2. 5 E99 “Initial Power Receiving” . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11–4
Verification and Remedy to Failures without Indication Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11–5
3. 1 “Cooling Fan (FAN1) Failure” (Fan is not rotating.) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11–5
3. 2 “No weld output”. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11–5
3. 3 “Operating Panel Failure” (LED’s do not light properly or welding setting cannot be established). . . . . . . . . . . . . . . .11–6
Fault Isolation Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11–6
4. 1 Preparation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11–6
Verification of the Power Input Circuitry . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11–7
5. 1 Verify the AC input voltage using an AC voltmeter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11–7
5. 2 Power Supply Voltage Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11–8
5. 3 Verification of the Cooling Fan, FAN1, Drive Circuitry . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11–8
5. 4 Verification of the primary Diode (D1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11–9
5. 5 Verification of the secondary Diode (D2, D3). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11–10
5. 6 Verification of the primary IGBT (Q1A-Q4C) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11–10
5. 7 Verification of No-load Voltage (OCV) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11–11
12 MAINTENANCE
1
Subsystem Test and Replacement Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12–1
1. 1 Preparation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12–1
1. 2 Test and Replacement Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12–1
2 Service Tools. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12–3
2. 1 Tools and parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12–3
2. 2 Notes of disassembly and assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12–3
3 Replacement Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12–4
3. 1 PCB1 (WK-5815) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12–4
3. 2 PCB2 (WK-5767), Capacitor C1 and Resistor R1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12–7
3. 3 PCB3 (WK-5854), CT1 “Current Transformer” and T1 “Transformer”) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12–8
3. 4 PCB4 (WK-5765) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12–10
3. 5 PCB5 (WK-5448) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12–11
3. 6 PCB6 (WK-5460) and Q1A-Q2C “Primary IGBT” . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12–12
3. 7 PCB7 (WK-5460) and Q3A-Q4C “Primary IGBT” . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12–13
3. 8 PCB8 (WK-5828) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12–14
3. 9 PCB9 (WK-5827) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12–14
3. 10 PCB10 (WK-5816) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12–15
3. 11 PCB11 (WK-5855) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12–15
3. 12 CON1 “Remote Receptacle” . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12–16
3. 13 D1 “Primary Diode” . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12–17
3. 14 D2, D3 and D4 “Secondary Diode” . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12–17
3. 15 FAN1 “Cooling Fan” . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12–18
3. 16 FCH1 “Reactor” and HCT1 “Hole Current Trans” . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12–19
3. 17 S1 “Switch” . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12–20
3. 18 TH1 “Primary Thermistor” . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12–21
3. 19 TH2 “Secondary Thermistor” . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12–22
APPENDIX 1 PARTS LIST
1
2
Equipment Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A–1
How To Use This Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A–1
APPENDIX 2 CONNECTION WIRING GUIDE
APPENDIX 3 INTERCONNECT DIAGRAM
APPENDIX 4 DIODE TESTING BASICS
160 S INVERTER ARC WELDER
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
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.
WARNING
9. Do not wrap cables around your body.
10. Ground the workpiece to a good electrical (earth) ground.
ELECTRIC SHOCK can kill.
11. Do not touch electrode while in contact with the work (ground)
circuit.
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.
12. Use only well-maintained equipment. Repair or replace damaged
parts at once.
1. Do not touch live electrical parts.
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.
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.
WARNING
ARC RAYS can burn eyes and skin; NOISE can damage
hearing. Arc rays from the welding process produce
intense heat and strong ultraviolet rays that can burn
eyes and skin. Noise from some processes can damage
hearing.
1. Wear a welding helmet fitted with a proper shade of filter (see
ANSI Z49.1 listed in Safety Standards) to protect your face and
eyes when welding or watching.
2. Wear approved safety glasses. Side shields recommended.
June 16, 2006
1-1
160 S INVERTER ARC WELDER
3. Use protective screens or barriers to protect others from flash
and glare; warn others not to watch the arc.
WARNING
4. Wear protective clothing made from durable, flame-resistant
material (wool and leather) and foot protection.
WELDING can cause fire or explosion.
5. Use approved ear plugs or ear muffs if noise level is high.
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.
WARNING
FUMES AND GASES can be hazardous to your health.
1. Protect yourself and others from flying sparks and hot metal.
Welding produces fumes and gases. Breathing these
fumes and gases can be hazardous to your health.
2. Do not weld where flying sparks can strike flammable material.
1. Keep your head out of the fumes. Do not breath the fumes.
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.
2. If inside, ventilate the area and/or use exhaust at the arc to remove
welding fumes and gases.
4. Be alert that welding sparks and hot materials from welding can
easily go through small cracks and openings to adjacent areas.
3. If ventilation is poor, use an approved air-supplied respirator.
5. Watch for fire, and keep a fire extinguisher nearby.
4. Read the Material Safety Data Sheets (MSDSs) and the
manufacturer’s instruction for metals, consumables, coatings, and
cleaners.
6. Be aware that welding on a ceiling, floor, bulkhead, or partition
can cause fire on the hidden side.
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 closed containers such as tanks or drums.
8. Connect work cable to the work as close to the welding area as
practical to prevent welding current from traveling long, possibly
unknown paths and causing electric shock and fire hazards.
9. Do not use welder to thaw frozen pipes.
10. Remove stick electrode from holder or cut off welding wire at
contact tip when not in use.
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.
Eye protection filter shade selector for welding or cutting
(goggles or helmet), from AWS A6.2-73.
Welding or cutting
Torch soldering
Torch brazing
Oxygen Cutting
Light
Medium
Heavy
Gas welding
Light
Medium
Heavy
Shielded metal-arc
1-2
Electrode Size
Filter
2
3 or 4
Under 1 in., 25 mm
1 to 6 in., 25-150 mm
Over 6 in., 150 mm
3 or 4
4 or 5
5 or 6
Under 1/8 in., 3 mm
1/8 to 1/2 in., 3-12 mm
Over 1/2 in., 12 mm
Under 5/32 in., 4 mm
5/32 to 1/4 in.,
Over 1/4 in., 6.4 mm
4 or 5
5 or 6
6 or 8
10
12
14
Welding or cutting
Electrode Size
Gas metal-arc
Non-ferrous base metal
All
Ferrous base metal
All
Gas tungsten arc welding
All
(TIG)
All
Atomic hydrogen welding
All
Carbon arc welding
All
Plasma arc welding
Carbon arc air gouging
Light
Heavy
Plasma arc cutting
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
June 16, 2006
160 S INVERTER ARC WELDER
WARNING
FLYING SPARKS AND HOT METAL can cause injury.
Chipping and grinding cause flying metal. As welds cool,
they can throw off slag.
1. Wear approved face shield or safety goggles. Side shields
recommended.
2. Wear proper body protection to protect skin.
WARNING
2. If used in a closed area, vent engine exhaust outside and away
from any building air intakes.
WARNING
ENGINE FUEL can cause fire or explosion.
Engine fuel is highly flammable.
1. Stop engine before checking or adding fuel.
2. Do not add fuel while smoking or if unit is near any sparks or
open flames.
3. Allow engine to cool before fueling. If possible, check and add
fuel to cold engine before beginning job.
CYLINDERS can explode if damaged.
4. Do not overfill tank — allow room for fuel to expand.
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.
5. Do not spill fuel. If fuel is spilled, clean up before starting engine.
1. Protect compressed gas cylinders from excessive heat, mechanical
shocks, and arcs.
WARNING
MOVING PARTS can cause injury.
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.
Moving parts, such as fans, rotors, and belts can cut fingers and hands
and catch loose clothing.
3. Keep cylinders away from any welding or other electrical circuits.
1. Keep all doors, panels, covers, and guards closed and
securely in place.
4. Never allow a welding electrode to touch any cylinder.
2. Stop engine before installing or connecting unit.
5. Use only correct shielding gas cylinders, regulators, hoses, and
fittings designed for the specific application; maintain them and
associated parts in good condition.
3. Have only qualified people remove guards or covers for
maintenance and troubleshooting as necessary.
6. Turn face away from valve outlet when opening cylinder valve.
4. To prevent accidental starting during servicing, disconnect
negative (-) battery cable from battery.
7. Keep protective cap in place over valve except when cylinder is in
use or connected for use.
5. Keep hands, hair, loose clothing, and tools away from moving
parts.
8. Read and follow instructions on compressed gas cylinders,
associated equipment, and CGA publication P-1 listed in Safety
Standards.
6. Reinstall panels or guards and close doors when servicing
is finished and before starting engine.
!
WARNING
Engines can be dangerous.
WARNING
SPARKS can cause BATTERY GASES TO EXPLODE;
BATTERY ACID can burn eyes and skin.
Batteries contain acid and generate explosive gases.
WARNING
1. Always wear a face shield when working on a battery.
2. Stop engine before disconnecting or connecting battery cables.
ENGINE EXHAUST GASES can kill.
3. Do not allow tools to cause sparks when working on a battery.
Engines produce harmful exhaust gases.
4. Do not use welder to charge batteries or jump start vehicles.
1. Use equipment outside in open, well-ventilated areas.
5. Observe correct polarity (+ and –) on batteries.
June 16, 2006
1-3
160 S INVERTER ARC WELDER
1.02
WARNING
STEAM AND PRESSURIZED HOT COOLANT can burn
face, eyes, and skin.
The coolant in the radiator can be very hot and under
pressure.
1. Do not remove radiator cap when engine is hot. Allow engine to cool.
2. Wear gloves and put a rag over cap area when removing cap.
Principal Safety Standards
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.
3. Allow pressure to escape before completely removing cap.
!
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
Safe Handling of Compressed Gases in Cylinders, CGA Pamphlet P1, 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.
The following is a quotation from the General Conclusions Section of
the U.S. Congress, Office of Technology Assessment, Biological Effects
of Power Frequency Electric & Magnetic Fields - Background Paper,
OTA-BP-E-63 (Washington, DC: U.S. Government Printing Office, May
1989): “...there is now a very large volume of scientific findings based
on experiments at the cellular level and from studies with animals and
people which clearly establish that low frequency magnetic fields
interact with, and produce changes in, biological systems. While most
of this work is of very high quality, the results are complex. Current
scientific understanding does not yet allow us to interpret the evidence
in a single coherent framework. Even more frustrating, it does not yet
allow us to draw definite conclusions about questions of possible risk
or to offer clear science-based advice on strategies to minimize or
avoid potential risks.”
To reduce magnetic fields in the workplace, use the following
procedures:
1. Keep cables close together by twisting or taping them.
2. Arrange cables to one side and away from the operator.
3. Do not coil or drape cable around the body.
4. Keep welding power source and cables as far away from
body as practical.
ABOUT PACEMAKERS:
The above procedures are among those also normally
recommended for pacemaker wearers. Consult your
doctor for complete information.
1-4
June 16, 2006
160 S INVERTER ARC WELDER
1.03
Precautions de Securite en Soudage à 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
AVERTISSEMENT
L’ELECTROCUTION PEUT ETRE MORTELLE.
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 porte-électrodes raccordés à deux sources de courant en
même temps. Ne jamais toucher quelqu’un d’autre avec l’électrode
ou le porte-électrode.
8. N’utilisez pas de câbles électriques usés, endommagés, mal
épissés ou de section trop petite.
9. N’enroulez pas de câbles électriques autour de votre corps.
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.
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.
1. Ne touchez pas à des pièces sous tension.
15. Fermez solidement tous les panneaux et les capots.
2. Portez des gants et des vêtements isolants, secs et non troués.
3
Isolez-vous de la pièce à souder et de la mise à la terre au moyen
de tapis isolants ou autres.
4. Déconnectez la prise d’alimentation de l’équipement ou arrêtez le
moteur avant de l’installer ou d’en faire l’entretien. Bloquez le
commutateur en circuit ouvert ou enlevez les fusibles de
l’alimentation afin d’éviter une mise en marche accidentelle.
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.
June 16, 2006
1-5
160 S INVERTER ARC WELDER
AVERTISSEMENT
AVERTISSEMENT
LE RAYONNEMENT DE L’ARC PEUT BRÛLER LES YEUX
ET LA PEAU; LE BRUIT PEUT ENDOMMAGER L’OUIE.
LES VAPEURS ET LES FUMEES SONT DANGEREUSES
POUR LA SANTE.
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.
Le soudage dégage des vapeurs et des fumées
dangereuses à respirer.
1. Eloignez la tête des fumées pour éviter de les respirer.
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. 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.
2. Portez des lunettes de sécurité approuvées. Des écrans latéraux
sont recommandés.
4. Lisez les fiches signalétiques et les consignes du fabricant relatives aux métaux, aux produits consummables, aux revêtements
et aux produits nettoyants.
3. Entourez l’aire de soudage de rideaux ou de cloisons pour protéger
les autres des coups d’arc ou de l’éblouissement; avertissez les
observateurs de ne pas regarder l’arc.
4. Portez des vêtements en matériaux ignifuges et durables (laine et
cuir) et des chaussures de sécurité.
5. Portez un casque antibruit ou des bouchons d’oreille approuvés
lorsque le niveau de bruit est élevé.
3. Si la ventilation est inadequate, portez un respirateur à adduction
d’air approuvé.
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.
SELECTION DES NUANCES DE FILTRES OCULAIRS POUR LA PROTECTION
DES YEUX EN COUPAGE ET SOUDAGE (selon AWS á 6.2-73)
Dimension d'électrode ou
Epiasseur de métal ou
Intensité de courant
Nuance de
filtre oculaire
Brassage tendre
au chalumeau
toutes conditions
2
Brassage fort
au chalumeau
toutes conditions
3 ou 4
Opération de coupage
ou soudage
Soudage á l'arc sous gaz
avec fil plein (GMAW)
métaux non-ferreux
toutes conditions
11
métaux ferreux
toutes conditions
12
toutes conditions
12
toutes conditions
12
toutes conditions
12
toutes dimensions
12
Oxycoupage
mince
moins de 1 po. (25 mm)
moyen de 1 á 6 po. (25 á 150 mm)
épais
plus de 6 po. (150 mm)
3 ou 4
4 ou 5
5 ou 6
Soudage aux gaz
Dimension d'électrode ou
Nuance de
Epiasseur de métal ou
filtre oculaire
Intensité de courant
Opération de coupage
ou soudage
Soudage á l'arc sous gaz avec
électrode de tungstène (GTAW)
Soudage á l'hydrogène
atomique (AHW)
Soudage á l'arc avec
électrode de carbone (CAW)
Soudage á l'arc Plasma (PAW)
mince
moins de 1/8 po. (3 mm)
moyen de 1/8 á 1/2 po. (3 á 12 mm)
épais
Soudage á l'arc avec
électrode enrobees
(SMAW)
4 ou 5
Gougeage Air-Arc avec
électrode de carbone
5 ou 6
mince
12
plus de 1/2 po. (12 mm)
6 ou 8
épais
14
moins de 5/32 po. (4 mm)
10
5/32 á 1/4 po. (4 á 6.4 mm)
12
mince
moins de 300 amperès
9
plus de 1/4 po. (6.4 mm)
14
moyen
de 300 á 400 amperès
12
plus de 400 amperès
14
Coupage á l'arc Plasma (PAC)
épais
1-6
June 16, 2006
160 S INVERTER ARC WELDER
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 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.
LE SOUDAGE PEUT CAUSER UN INCENDIE OU UNE
EXPLOSION
1. Portez un écran facial ou des lunettes protectrices
approuvées. Des écrans latéraux sont recommandés.
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.
2. Portez des vêtements appropriés pour protéger la peau.
1. Protégez-vous, ainsi que les autres, contre les étincelles et du
métal chaud.
2. Ne soudez pas dans un endroit où des particules volantes ou des
projections peuvent atteindre des matériaux inflammables.
3. Enlevez toutes matières inflammables dans un rayon de 10, 7
mètres autour de l’arc, ou couvrez-les soigneusement avec des
bâches approuvées.
4. Méfiez-vous des projections brulantes de soudage susceptibles
de pénétrer dans des aires adjacentes par de petites ouvertures
ou fissures.
5. Méfiez-vous des incendies et gardez un extincteur à portée de la
main.
6. N’oubliez pas qu’une soudure réalisée sur un plafond, un plancher,
une cloison ou une paroi peut enflammer l’autre côté.
7. Ne soudez pas un récipient fermé, tel un réservoir ou un baril.
8. Connectez le câble de soudage le plus près possible de la zone
de soudage pour empêcher le courant de suivre un long parcours
inconnu, et prévenir ainsi les risques d’électrocution et d’incendie.
AVERTISSEMENT
LES BOUTEILLES ENDOMMAGEES PEUVENT
EXPLOSER
Les bouteilles contiennent des gaz protecteurs sous
haute pression. Des bouteilles endommagées peuvent
exploser. Comme les bouteilles font normalement partie
du procédé de soudage, traitez-les avec soin.
1. Protégez les bouteilles de gaz comprimé contre les sources de
chaleur intense, les chocs et les arcs de soudage.
2. Enchainez verticalement les bouteilles à un support ou à un cadre
fixe pour les empêcher de tomber ou d’être renversées.
3. Eloignez les bouteilles de tout circuit électrique ou de tout soudage.
4. Empêchez tout contact entre une bouteille et une électrode de
soudage.
5. N’utilisez que des bouteilles de gaz protecteur, des détendeurs,
des boyauxs et des raccords conçus pour chaque application
spécifique; ces équipements et les pièces connexes doivent être
maintenus en bon état.
6. Ne placez pas le visage face à l’ouverture du robinet de la bouteille
lors de son ouverture.
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.
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.
AVERTISSEMENT
LES MOTEURS PEUVENT ETRE DANGEREUX
LES GAZ D’ECHAPPEMENT DES MOTEURS PEUVENT
ETRE MORTELS.
Les moteurs produisent des gaz d’échappement nocifs.
June 16, 2006
1-7
160 S INVERTER ARC WELDER
1. Utilisez l’équipement à l’extérieur dans des aires ouvertes et bien
ventilées.
Les accumulateurs contiennent de l’électrolyte acide et
dégagent des vapeurs explosives.
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.
1. Portez toujours un écran facial en travaillant sur un accumu-lateur.
AVERTISSEMENT
LE CARBURANT PEUR CAUSER UN INCENDIE OU UNE
EXPLOSION.
Le carburant est hautement inflammable.
2. Arrêtez le moteur avant de connecter ou de déconnecter des câbles
d’accumulateur.
3. N’utilisez que des outils anti-étincelles pour travailler sur un
accumulateur.
4. N’utilisez pas une source de courant de soudage pour charger
un accumulateur ou survolter momentanément un véhicule.
5. Utilisez la polarité correcte (+ et –) de l’accumulateur.
1. Arrêtez le moteur avant de vérifier le niveau e carburant ou de
faire le plein.
2. Ne faites pas le plein en fumant ou proche d’une source d’étincelles
ou d’une flamme nue.
AVERTISSEMENT
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.
LA VAPEUR ET LE LIQUIDE DE REFROIDISSEMENT
BRULANT SOUS PRESSION PEUVENT BRULER LA
PEAU ET LES YEUX.
4. Ne faites pas le plein de carburant à ras bord: prévoyez de l’espace
pour son expansion.
Le liquide de refroidissement d’un radiateur peut être
brûlant et sous pression.
5. Faites attention de ne pas renverser de carburant. Nettoyez tout
carburant renversé avant de faire démarrer le moteur.
1. N’ôtez pas le bouchon de radiateur tant que le moteur n’est pas
refroidi.
AVERTISSEMENT
DES PIECES EN MOUVEMENT PEUVENT CAUSER DES
BLESSURES.
Des pièces en mouvement, tels des ventilateurs, des
rotors et des courroies peuvent couper doigts et mains,
ou accrocher des vêtements amples.
1. Assurez-vous que les portes, les panneaux, les capots et les
protecteurs soient bien fermés.
2. Avant d’installer ou de connecter un système, arrêtez le moteur.
3. Seules des personnes qualifiées doivent démonter des protecteurs
ou des capots pour faire l’entretien ou le dépannage nécessaire.
4. Pour empêcher un démarrage accidentel pendant l’entretien,
débranchez le câble d’accumulateur à la borne négative.
5. N’approchez pas les mains ou les cheveux de pièces en
mouvement; elles peuvent aussi accrocher des vêtements amples
et des outils.
6. Réinstallez les capots ou les protecteurs et fermez les portes après
des travaux d’entretien et avant de faire démarrer le moteur.
AVERTISSEMENT
DES ETINCELLES PEUVENT FAIRE EXPLOSER UN
ACCUMULATEUR; L’ELECTROLYTE D’UN ACCUMULATEUR PEUT BRULER LA PEAU ET LES YEUX.
1-8
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.
1.05
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.
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.
June 16, 2006
2 INTRODUCTION
1 How To Use This Manual
2 Equipment Identification
This Service Manual applies to just specification or
part numbers listed on page i.
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.
To ensure safe operation, read the entire manual,
including the chapter on safety instructions and
warnings.
Throughout this manual, the words WARNING,
CAUTION, and NOTE may appear. Pay particular
attention to the information provided under these
headings. These special annotations are easily
recognized as follows:
WARNING
A WARNING gives information regarding possible
personal injury.
CAUTION
A CAUTION refers to possible equipment damage.
NOTE
A NOTE offers helpful information concerning certain operating procedures.
Additional copies of this manual may be purchased
by contacting Thermal Arc at the address and
phone number in your area listed in the inside back
cover of this manual. Include the Service 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
2–1
160S
2 INTRODUCTION
3 Symbol Chart
Note that only some of these symbols will appear on your model.
Amperage
STICK
(Shielded Metal Arc SMAW)
Voltage
Pulse Current Function
Hertz (frequency)
Spot Time (GTAW)
t
SEC
Seconds
Remote Control
(Panel/Remote)
%
Percent
Remote Function
DC (Direct Current)
Arc Control (SMAW)
AC (Alternating Current)
t2
Standard Function
t1
VRD
Slope Function
Gas Post-Flow
Gas Pre-Flow
Voltage Reduction Device
Circuit
Slope W/Repeat Function
Negative
Spot Function
Positive
Impulse Starting
(High Frequency GTAW)
Gas Input
Touch Start
(Lift Start TIG circuit GTAW)
Gas Output
2–2
160S (460V)
2 INTRODUCTION
5 Description
The Thermal ArcTM Model 160S (460V) 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 a
lift 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
(V)
OCV
10V
5A
160A
(A)
25A
STICK Process
160A
(A)
LIFT TIG Process
Figure 2-1: Model 160S (460V) 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.
2–3
160S (460V)
2 INTRODUCTION
6 Functional Block Diagrams
Figure 2-2 illustrates the functional block diagram of the 160S (460V)-power supply.
Input
Power
Main
Circuit
Switch
Input
Diode
Filter
Capacitor
DC Power
Primary
Voltage
Sensor
IGBT
Inverter
Themal
Detector
Main
Transformers
(T1)
Output
Diodes
Thermal
Detector
Hall Current
Transformer
(HCT1)
To each control circuit
+/-15VDC +18VDC
+24VDC +5VDC
Trouble
Sensing
Circuit
Thermal
Sensor
Circuit
Drive
Circuit
Primary
Circuit
Sensor
Torch Control
Connection
(CON1)
Stick Mode
VRD
Sensing
Circuit
Lift Tig Mode
Output Short
Sensing
Circuit
Sequence
Control
Current
Adjustment
Circuit
Reference
Adjustment &
Mode select Switch
Panel Circuit Board
Figure 2-2: 160S (460V) Model Functional Block Diagram
7 Transporting Methods
These units are equipped with a strap 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 strap 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
Output
Inductor
Fan Control
Circuit
Fan
3 INSTALLATION
1 Environment
3 Electrical Input Connec-
INSTALLATION
tions
The ARC MASTER 160S (460V) is designed for
use in adverse environments.
WARNING
Examples of environments with increased adverse
conditions are :
ELECTRIC SHOCK can kill; SIGNIFICANT DC
VOLTAGE is present after removal of input power.
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;
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.
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, or
4 Electrical Input Require-
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.
ments
Operate the welding power source from a singlephase 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 any
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.
Environments with adverse conditions do not
include places where electrically conductive parts
are in the near vicinity of the operator.
2 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.
Do not connect an input (BROWN or BLUE) conductor to the ground terminal.
 In areas, free from oil, steam and corrosive
gases.
Do not connect the ground (GREEN) conductor to
an input line terminal.
 In areas, not subjected to abnormal vibration or
shock.
Refer to figure 3 and:
 In areas, not exposed to direct sunlight or rain.
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 3-1 and Table 3-2 as a guide to select
line fuses for the disconnect switch.
 Place at a distance of 12" (304.79mm) or more
from walls or similar that could restrict natural
airflow for cooling.
WARNING
Thermal Arc advises that this equipment be electrically connected by a qualified electrician.
3–1
160S (460V)
Input Voltage
460 VAC
3 INSTALLATION
Minimum Current & Duty Cycle
Primary
Supply Lead Primary
Current
Model
Size
TIG
STICK
(Factory Circuit Size
(Vin/Amps)
Fitted)
Fuse Size
40 Amps
Table 3-1: Electrical Input Connections
NOTE
460/12
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).
ARC
MASTER 12/3 AWG
160S
minimum
(460V)
[email protected]
40%
-
Weiding Power Supply
Ground
Terminal
[email protected]
100%
460/19
-
[email protected]
40%
Table 3-2: 460V Primary Current Circuit sizes to
achieve maximum current
Ground
Conductor
Line Disconnect
Switch
The ARC MASTER 160S (460V) is designed for
use with a generator as an input power source.
Contact an accredited Thermal Arc service agent
for the proper sizing and set-up recommendations
of a generator power source system. As a general
rule, depending on the type of generator used, the
generator capacity should be twice the maximum
rating of the welder.
Line
Fuse
Primary
Power Cable
6 Duty Cycle
Figure 3-1: Electrical input connections
5 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. At this point,
the Bus Voltages are checked and the welder is
enabled after the input capacitors have charged to
full operating voltage (after approximately 5 seconds).
NOTE
Note the available input power. Damage to the
welder could occur if 575VAC or higher is applied.
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
The following 460V Primary Current recommendations are required to obtain the maximum
welding current and duty cycle from this welding
equipment:
Continually exceeding the duty cycle ratings can
cause damage to the welding power source and
will void the manufacturer’s warranty.
3–2
160S (460V)
3 INSTALLATION
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.
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.
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.
7 Specifications
Parameter
Rated Output
Amperes
Volts
Duty Cycle
TIG
Duty Cycle
STICK
Output Current TIG
Range
STICK
Open Circuit Voltage
Dimensions
Width
Height
Length
Weight
[email protected] Load
Output Amperes
Output Volts
Duty Cycle
KVA
KW
[email protected] Load
KVA
KW
Input Volts Single Phase
460V
160S (460V)
460VAC
160
27
40%
160A / 17V @ 40%
130A / 16V @ 60%
100A / 14V @ 100%
160A / 27V @ 40%
130A / 25V @ 60%
100A / 24V @ 100%
5 - 160
5 - 160
65V
5.12" (130mm)
10.24" (260mm)
14.17" (360mm)
19.84 lb. 9.0 kg
460V
160A
27V
40%
8.7
5.2
0.5
0.3
Amperage Draw
@Rated Load
19
No Load
1.6
3–3
160S (460V)
PAGE LEFT INTENTIONALLY BLANK
3–4
3 INSTALLATION
4 OPERATOR CONTROL
1. Control Knob:
This control sets the selected weld parameter,
rotating it clockwise increases the parameter
that is indicated on the digital meter. Pushing
the knob inward displays the actual welding
voltage.
1 ARC MASTER 160S (460V)
Controls
2. Remote Control Socket:
The 8 pin Remote Control Socket is used to
connect remote current control devices to the
welding Power Source. To make connections,
align keyway, insert plug, and rotate threaded
collar fully clockwise.
2
260
1
4
3
15
GND
2
130
1
12345678
5
4
3
8
7
6
Front view 8-Socket Receptacle
6
5k
Ohms
Figure 4-2: 8-Socket Receptacle
Socket
Pin
320
5
Function
1
Earth (Ground).
2
Torch Switch Input (24V) to
(connect pins 2 & 3 to turn on welding current).
3
Torch Switch Input (0V) to energize weld
current
(connect pins 2 & 3 to turn on welding current).
4
Connect pin 4 to pin 8 to instruct machine that
a remote current control device is connected
(12V DC supply).
5
5k ohm (maximum) connection to 5k ohm
remote control potentiometer.
6
Zero ohm (minimum) connection to 5k ohm
remote control potentiometer.
7
Wiper arm connection to 5k ohm remote control
potentiometer.
8
Connect pin 4 to pin 8 to instruct machine that
a remote current control device is connected
(0V).
Table 4-1: Socket Pin Functions
Figure 4-1: ARC MASTER 160S (460V) Power Source
4–1
160S (460V)
4 OPERATOR CONTROL
2 Weld Parameter Descrip-
3. Positive Terminal:
Welding current flows from the Power Source
via heavy duty Dinse type terminal (25 mm).
It is essential, however, that the male plug
is inserted and turned securely to achieve a
sound electrical connection.
tions for ARC MASTER 160S
(460V)
4. Negative Terminal:
Welding current flows from the Power Source
via heavy duty Dinse type terminal (25 mm).
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.
Figure 4-3: ARC MASTER 160S (460V) Front Panel with Parameter
Description
5. ON/OFF Dinse Switch:
This switch connects the Primary supply voltage to the inverter when in the ON position.
This enables the Power Supply.
Parameter
Description
This parameter operates in STICK weld
mode and is used to improve the start
HOT START characteristics for stick electrodes. e.g.
low hydrogen electrodes. It sets the peak
start current on top of the (WELD) current.
WARNING
When the welder is connected to the Primary supply voltage, the internal electrical components
may be at 460V potential with respect to earth.
A
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.
6. Input Cable:
The input cable connects the Primary supply
voltage to the equipment.
LIFT TIG mode of operation.
LED “ON” - LIFT TIG mode of operation:
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.
LED Blinks - PANEL LIFT TIG mode of
operation:
This is a Lift TIG mode which operates
when the torch switch is pressed
continuously. A remote control device is
not necessary in this operation mode.
The arc will start easily when the electrode
of a torch is shorted with the welded
object or material.
STICK Mode of operation.
Table 4-2: Weld Parameter Descriptions for ARC MASTER 160S (460V)
4–2
160S (460V)
4 OPERATOR CONTROL
3 Weld Parameters for ARC
Feature
MASTER 160S (460V)
 For the selected weld parameter,
3.1 Weld Parameters
Weld Mode
Parameter
Range
Factory
Setting
Unit
STICK
LIFT
TIG
HOT
START
0 to 70A
20A
1A
Yes
No
WELD
CURRENT
5 to 160A
80A
1A
Yes
Yes
ARC
0 to 100%
CONTROL
10%
1%
Yes
No
Weld
Parameter
Control Knob
Self
Diagnosis
Using Error
Codes
Table 4-3: Weld Parameters for ARC MASTER 160S
(460V)
Description
New Digital
Control
 Almost all welding parameters are
Touch Panel
Switches
 Touch switches eliminate mechani-
Front Control
Cover
 Protects front panel controls.
adjustable.
cal damage.
 Displays selected weld parameter
value.
Digital Meter
 Displays weld current when welding.
 Displays weld current for 20 seconds
after weld has been completed.
 A selected weld parameter value can
be adjusted at any time even while
welding.
ON/OFF
switch
rotating the knob clockwise
increases the parameter.
 Rotating the knob counterclockwise
decreases the parameter.
 A selected weld parameter value can
be adjusted at any time even while
welding.
 Pushing the knob in displays actual
arc voltage.
 An error code is displayed on the
Digital Meter when a problem occurs
with Primary supply voltage or internal component problems. Refer to
troubleshooting guide.
Table 4-4: Power Source Features
4 Power Source Features
Feature
Description
 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.
Voltage
Reduction
 VRD fully complies to IEC 60974-1.
Device (VRD)  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.
4–3
160S (460V)
PAGE LEFT INTENTIONALLY BLANK
4–4
4 OPERATOR CONTROL
5 SET-UP FOR SMAW (STICK) AND GTAW (TIG)
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.
CAUTION
Remove any packaging material prior to use.
Do not block the air vents at the front or rear or
sides of the Welding Power Source.
CAUTION
DO NOT change the Weld Mode or Weld Process
Mode until after POST-FLOW time has finished.
Figure 5-1: 160S (460V) Set-up
5–1
160S (460V)
5 SET-UP FOR SMAW (STICK) AND GTAW (TIG)
PAGE LEFT INTENTIONALLY BLANK
5–2
6 SEQUENCE OF OPERATION
NOTE
1 Stick Welding
SEQUENCE OF OPERATION
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 the
Symbols Table located in the front of the manual
for Symbol descriptions.
 Connect work lead to negative terminal.
 Connect electrode lead to positive terminal.
 Switch machine on.
 Set weld current.
 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.
1
Commence welding.
5
2 Lift TIG Welding
2
3
 Connect work lead to positive terminal.
 Connect TIG torch to negative terminal.
 Switch machine on.
 Set WELD current.
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.
4
Figure 6-1: 160S (460V) Front Panel
1. Scroll Buttons - used to select the parameters
to be set. The LED’s show which function is
being adjusted on the weld sequence graph.
2. Digital LED display - Welding amperage and
parameter values are displayed in this window.
Internal warnings such as over temperature
and primary input current too high are signaled
to the operator by a warning sound and error
message on the screen.
Commence welding.
3 Panel Lift TIG Welding
3. Control knob - allows the operator to adjust the
output amperage within the entire range of the
power source also used to set each parameter
value. Pushing the knob inward displays the
actual welding voltage.
 Connect work lead to positive terminal
 Connect TIG torch to negative terminal
 Switch welder on
4. Process Button - This button selects between
STICK. Lift TIG or Panel Lift TIG mode.
 Select “Panel Lift TIG” mode. A LED of “Lift TIG”
mode blinks when the button is pushed again at
the “Lift TIG” mode. The machine is in “Panel
Lift TIG” mode when the “Lift TIG” mode LED blinks.
5. 8 pin remote control receptacle for connecting
remote devices. A remote control device is
required for use during LIFT TIG operation.
See section 4.1, section 2 “Remote Control
Socket”, for complete details of the remote
device.
 Set WELD current.
NOTE
If the power supply was turned off while the “Panel
Lift TIG” mode was blinking at the end of the previous operation, the machine will start in “Lift TIG
mode” (LED “ON”) for safety. In order to establish
the “Panel Lift TIG” mode again, press the Process
Button until the LED starts to blink.
6–1
160S (460V)
NOTE
No connection to a remote control device is necessary. During the Panel Lift TIG operation, it operates under the condition where the torch switch is
pressed continuously.
Use the Scroll Buttons to move to the parameter to
be set. The LED will show which function is being
adjusted on the weld sequence graph. Use the
control knob to adjust each parameter.
 Set WELD current.
Commence welding.
6–2
6 SEQUENCE OF OPERATION
7 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.
ROUTINE MAINTENANCE
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 Section 11.01.01, "Opening the Enclosure" in
this manual.
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.
7–1
Warning!
Disconnect input power before maintaining.
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
7-2
Maintain more often
if used under severe
conditions
8 BASIC TROUBLESHOOTING
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.
1 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 bead buildup 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.
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.
A Electrode is connected to the '+' terminal.
A Connect the electrode to the '-' terminal.
A Electrode contaminated through contact
with work piece or filler rod material.
B Gas contaminated with air.
A Clean the electrode by grinding off the
contaminates.
B Check gas lines for cuts and loose fitting
or change gas cylinder.
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.
8 Electrode melts or
A No gas flowing to welding region.
oxidizes when an arc is B Torch is clogged with dust.
struck.
C Gas hose is cut.
D Gas passage contains impurities.
E Gas regulator turned off.
F Torch valve is turned off.
G The electrode is too small for the welding
current.
9 Poor weld finish.
Inadequate shielding gas.
8–1
160S (460V)
Description
10 Arc flutters during TIG
welding.
Possible Cause
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
B
C
12 Arc start is not smooth. A
B
C
D
E
8 BASIC TROUBLESHOOTING
Remedy
A Select the right size electrode. Refer to
Basic TIG Welding guide.
B Refer Basic TIG Welding Guide for ways
to reduce arc flutter.
Work clamp is not connected to the work
A Connect the work clamp to the work piece
piece or the work/torch leads are not
or connect the work/torch leads to the
connected to the right welding terminals.
right welding terminals.
Torch lead is disconnected.
B Connect it to the '-' terminal.
Gas flow incorrectly set, cylinder empty or C Select the right flow rate, change
the torch valve is off.
cylinders or turn torch valve on.
Tungsten electrode is too large for the
A Select the right size electrode. Refer to
welding current.
Basic TIG Welding Guide.
The wrong electrode is being used for the B Select the right electrode type. Refer to
welding job.
Basic TIG Welding Guide.
Gas flow rate is too high.
C Select the correct rate for the welding job.
Refer to Basic TIG Welding Guide.
Incorrect shielding gas is being used.
D
Select
the right shielding gas. Refer to
Poor work clamp connection to work piece.
Basic TIG Welding Guide.
E Improve connection to work piece.
Table 8-1: TIG Welding Problems
2 Stick Welding Problems
Description
1 Gas pockets or voids in
weld metal (Porosity).
Possible Cause
Remedy
A Electrodes are damp.
B Welding current is too high.
A Dry electrodes before use.
B Reduce welding current.
C Surface impurities such as oil, grease,
paint, etc.
C Clean joint before welding.
2 Crack occurring in weld A Rigidity of joint.
metal soon after
B Insufficient throat thickness.
solidification
C Cooling rate is too high.
commences.
A Redesign to relieve weld joint of severe
stresses or use crack resistance
electrodes.
B Travel slightly slower to allow greater
build up in throat.
C Preheat plate and cool slowly.
3 A gap is left by failure
of the weld metal to fill
the root of the weld.
A Welding current is too low.
A Increase welding current.
B Electrode too large for joint.
C Insufficient gap.
B Use smaller diameter electrode.
C Allow wider gap.
D Incorrect sequence.
D Use correct build-up sequence.
Incorrect sequence
Insufficient gap
Figure 8-1: Example of insufficient gap or incorrect sequence
8–2
160S (460V)
8 BASIC TROUBLESHOOTING
Description
Possible Cause
Remedy
4 Portions of the weld run A Small electrodes used on heavy cold
do not fuse to the
plate.
surface of the metal or B Welding current is too low.
edge of the joint.
C Wrong electrode angle.
D Travel speed of electrode is too high.
E Scale or dirt on joint surface.
A Use larger electrodes and pre-heat the
plate.
B Increase welding current.
C Adjust angle so the welding arc is
directed more into the base metal.
D Reduce travel speed of electrode.
E Clean surface before welding.
Lack of fusion caused by dirt,
electrode angle incorrect, rate
of travel too high
Lack of inter-run Fusion
Lack of side fusion, scale
dirt, small electrode,
amperage too low
Lack of Root Fusion
Figure 8-2: Example of lack of fusion
Description
Possible Cause
Remedy
5 Non-metallic particles
are trapped in the weld
metal (slag inclusion).
A Non-metallic particles may be trapped in
undercut from previous run.
B Joint preparation too restricted.
C Irregular deposits allow slag to be
trapped.
D Lack of penetration with slag trapped
beneath weld bead.
E Rust or mill scale is preventing full fusion.
A If bad undercut is present, clean slag out
and cover with a run from a smaller
diameter electrode.
B Allow for adequate penetration and room
for cleaning out the slag.
C If very bad, chip or grind out irregularities.
F Wrong electrode for position in which
welding is done.
D Use smaller electrode with sufficient
current to give adequate penetration. Use
suitable tools to remove all slag from
corners.
E Clean joint before welding.
F Use electrodes designed for position in
which welding is done, otherwise proper
control of slag is difficult.
Table 8-2: STICK Welding Problems
Not cleaned, or
incorrect electrode
Slag trapped in
undercut
Slag trapped in root
Figure 8-3: Examples of slag inclusion
8–3
160S (460V)
8 BASIC TROUBLESHOOTING
3 Power Source Problems
Description
Possible Cause
1 The welding arc cannot
be established.
A The Primary supply voltage has not been
switched ON.
B The Welding Power Source switch is
switched OFF.
C Loose connections internally.
Defective control circuit.
2 Maximum output
welding current can not
be achieved with
nominal Mains supply
voltage.
3 Welding current
reduces when welding.
Remedy
A Switch ON the Primary supply voltage.
B Switch ON the Welding Power Source.
C Have an Accredited Thermal Arc Service
Agent repair the connection.
Have an Accredited Thermal Arc Service
Agent inspect then repair the welder.
A Loose welding cable connections.
B Incorrect welding cable size.
A Tighten all welding cable
C Improper input connections.
D Poor electrode condition.
B Use proper size and type of cable.
connections.
C Refer to Section 2.05 Electrical Input
Requirements.
E Wrong welding polarity.
D Replace electrode.
E Verify output torch connections.
Table 8-3: Power Source Problems
8–4
9 VOLTAGE REDUCTION DEVICE (VRD)
1 VRD Specification
Description
ARC MASTER
160S (460V)
VRD Open
Circuit Voltage
15.3 to 19.8V
VRD
Resistance
148 to 193
ohms
VRD Turn
OFF Time
0.2 to 0.3
seconds
If this equipment is used in a location or an environment with a high risk of electrocution then the
above tests should be carried out prior to entering
this location.
VOLTAGE REDUCTION DEVICE (VRD)
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.
3 Switching VRD On/Off
Switch the machine Off.
A) Remove the clear plastic cover from the control
panel (see Figure 9-1).
 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.
Table 9-1: VRD Specification
 Remove the control’s clear plastic cover.
2 VRD Maintenance
Routine inspection and testing (power source):
An inspection of the power source, an insulation
resistance test and an earth resistance test should
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.
Figure 9-1: VRD ON/OFF Step A
B) Remove four mounting screws from the control
panel (see Figure 9-2).
NOTE
A transportable power source is any equipment
that is not permanently connected and fixed in the
position in which it is operated.
1
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.
1
2
1
Description
IEC 60974-1 Requirements
VRD Open Circuit Voltage Less than 20V; at Vin=460V
VRD Turn ON Resistance
Less than 200 ohms
VRD Turn OFF Time
Less than 0.3 seconds
1
Table 9-2: Periodic Tests
Figure 9-2: VRD ON/OFF Step B,C
9–1
160S (460V)
C) Access the VRD control by gently prying back
the front panel controls to reveal the VRD on/off
potentiometer (see Figure 9-3).
CAUTION
Do not pull back the front panel with excessive
force as this will unplug the control PCB. Plugging
the control PCB back into the front panel controls
can only be achieved by removing the side covers.
Figure 9-3: VRD ON/OFF Step D
D) Turning the VRD ON/OFF (see Figure 9-3).
 To turn VRD ON:
rotate 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 9-1.
 To turn VRD OFF:
rotate the trim potentiometer (VR1) on the display
PCB fully counter clockwise.
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.
9–2
9 VOLTAGE REDUCTION DEVICE (VRD)
10 POWER SOURCE ERROR CODE
POWER SOURCE ERROR CODE
Description
1 E01 error code displayed
Temperature sensor TH1
(protects IGBTs) is
greater than 80°C for
about 1 second.
2 E02 error code displayed
Temperature sensor TH2
(protects secondary
diodes) is greater than
80°C for about 1 second.
Possible Cause
Remedy
A Let Power Source cool
down then keep within its
duty cycle.
B Have an Accredited
Thermal Arc Service Agent
investigate.
C Air flow is restricted by
vents being blocked.
C Unblock vents then let
Power Source cool down.
A The Welding Power
Source’s duty cycle has
been exceeded.
B Fan ceases to operate.
A Let Power Source cool
down then keep within its
duty cycle.
B Have an Accredited
Thermal Arc Service.
C Agent investigate. Unblock
vents then let Power
Source cool down.
Weld current ceases.
Buzzer sounds
constantly.
Fan operates at max
speed.E02 resets when
TH2 decreases to 70oC
for about 30 seconds.
A Reduce length of welding
arc.
Weld current ceases.
Buzzer sounds
constantly.
Switch machine off then
on to reset E03 error.
C Air flow is restricted by
vents being blocked.
3 E03 error code displayed A Primary current is too
Primary (input) current too
high because welding arc
high.
is too long.
B Mains supply voltage is
more than 10% below
nominal voltage.
4 E94 error code displayed
Temperature sensor TH1
for IGBTs or sensor TH2
for secondary diodes are
open circuit.
5 E99 error code displayed.
Main supply (input)
voltage has been turned
off but control circuit has
power from the
primary capacitors.
Remarks
A The Welding Power
Source’s duty cycle has
been exceeded.
B Fan ceases to operate.
B Have an Accredited
Thermal Arc Service Agent
or a qualified electrician
check for low Mains
voltage.
Have an Accredited
Thermal Arc Service Agent
check or replace the
temperature sensors.
The Welding Power
Source’s temperature
sensors have
malfunctioned.
A Main on/off switchon
machine hasturned off.
B Main supply (input)
voltage has been turned
off.
C Main supply (input)
voltage is up to a
dangerously high level.
D Main supply (input)
voltage is down to a
dangerously low level.
Weld current ceases.
Buzzer sounds
constantly.
Fan operates at max
speed.E01 resets when
TH1 decreases to 70oC
for about 30 seconds.
Weld current ceases.
Buzzer sounds
constantly.
Switch machine off.
A Main on/off switch on.
_
Weld current ceases.
Buzzer soundsconstantly.
B Have an Accredited Thermal Must Switch Machine
offthen on to reset
Arc Service Agent or a
E99error.
qualified electrician check
the Mains voltage & fuses.
Error code
E99 automatically will
reset when the voltage
returns within the proper
D Have a Thermal Arc Service range.
Agent or a qualified
electrician check the Mains
voltage & fuses.
C Have a Thermal Arc Service
Agent or a qualified
electrician check the Mains
voltage & fuses.
Table 10-1: Power Source Error Codes
10 – 1
160S (460V)
10 POWER SOURCE ERROR CODE
PAGE LEFT INTENTIONALLY BLANK
10 – 2
11 ADVANCED TROUBLESHOOTING
If you are here, all of the troubleshooting suggestions in Section 8 Basic Troubleshooting have
either failed to resolve the faulty operation or have
indicated that one or more of the subsystems
within the power supply are defective. This section
provides the information needed to take live measurements on the various subsystems within the
power supply, and replace those subsystems that
prove faulty.
ADVANCED TROUBLESHOOTING
1 System-Level Fault Isolation
If none of the suggestions provided in Section 7
have solved the problem or corrected the faulty
operation, the next step is to isolate one or more of
the internal subassemblies that may be defective.
CAUTION
Perform all steps in each procedure, in sequence.
Skipping portions of procedures, or performing
steps out of sequence can result in damage to the
unit, and possible injury, or worse, to the operator.
CAUTION
Troubleshooting and repairing this unit is a process, which should be undertaken only by those
familiar with high voltage/high power electronic
equipment.
1.1 Opening the Enclosure
WARNING
There are extremely dangerous voltage and power
levels present inside this unit. Do not attempt to
diagnose or repair unless you have training in
power electronics, measurement and troubleshooting techniques.
Under no circumstances are field repairs to be
attempted on printed circuit boards or other subassemblies of this unit. Evidence of unauthorized
repairs will void the factory warranty. If a subassembly is found to be defective by executing any of
the procedures in this Service Manual, the subassembly should be replaced with a new one. The
faulty subassembly should then be returned to
Thermal Arc through established procedures.
WARNING
Disconnect primary power at the source before disassembling the power supply. Frequently review
the "Principle Safety Standards" in section 1.02.
Be sure the operator is equipped with proper
gloves, clothing and eye and ear protection. Make
sure no part of the operator's body comes into contact with the work piece or any internal components
while the unit is activated.
1) Verify that the switch of power supply and the
switch on switchboard (distribution panel) are
all OFF.
OFF
Figure 11-1: Switch OFF
CAUTION
The capacitors inside the power supply will slowly
discharged after you turn off the switch of the
power supply or the switch at the breaker box (distribution panel). Wait at least 5 minutes for the discharge to complete.
2) Remove all screws and nuts on the side covers.
Figure 11-2: Remove screws
11 – 1
160S (460V)
3) Loosen the screws on the front panel and the
rear panel by turning them approximately two
turns CCW.
11 ADVANCED TROUBLESHOOTING
5) Remove the side covers.
Figure 11-5: Remove Side covers
6) Remove protection cover sheet by removing
the plastic tabs.
Figure 11-3: Loosen screws
1
NOTE
DO NOT remove the screws completely.
2
1
4) Pull the front panel slightly forward and pull the
rear panel slightly backward. The interlocking
hooks of the side case covers can now be disengaged from the front and rear panels.
1
1
Figure 11-6: Remove PCB cover
NOTE
When you re-assemble the parts, conduct the
above process backwards.
Figure 11-4: Loosen front and rear panels
11 – 2
160S (460V)
11 ADVANCED TROUBLESHOOTING
2 Verification and Remedy to
cleanings.
c) Verify the operation of the cooling fan, FAN1,
and replace it if necessary.
the Indicated Error Codes
 Verify the condition of FAN1. Verify that there
are no broken or cracked fan blades and that
FAN1 is not producing any abnormal sounds.
NOTE
The capacitors inside the power supply will slowly
discharge after you turn off the switch of the
power supply or the switch at the breaker box (distribution panel). Wait at least 5 minutes for the discharge to complete and then remove the cases to
continue your inspection and repair (or maintenance) inside the power supply. For the removal
and installation of the case, refer to section Chapter 11-1.1.
 If broken or cracked FAN1 blades, or abnormal sounds are emanating from FAN1,
replace FAN1.
 Refer to section 12.03.15 for the replacement
of FAN1.
 Refer to section 11.05.3 for addition FAN1
tests.
 Verify the operation of the cooling fan and
replace it if the condition of FAN1 is inactive.
Follow the instruction in section 12.03.15
NOTE
During the "Verification/Remedy" procedures
below, follow the alphabetical sequence (a, b, c...)
and proceed with your verification and confirmation.
d) Replace PCB4 (WK-5765) and PCB5 (WK5448).
 Refer to section 12.03.4 and 12.03.5 for the
replacement of PCB4 and PCB5.
NOTE
After you Verify and replace all spare parts and
components, verify that there are no damaged harnesses or connectors, uninstalled or loose screws.
2.2 E02 “Over-Temperature at the
secondary side”
Cause
2.1 E01 “Over-Temperature at the
primary side”
Occurs when an over-temperature condition of the
secondary diodes are detected.
Cause
Occurs when an over-temperature condition of the
primary IGBT is detected.
Verification/Remedy
a) Unit may be in thermal shutdown mode.
 Review the rated duty cycle of the unit per
section 3.06. Exceeding the duty cycle can
damage the unit and void the warranty. Refer
also to section 3.07 for additional information.
b) Verify the ventilating condition.
 Maintain a clear and unobstructed distance
of more than 12 in. in the front and more that
20 in. in the rear of the unit for ventilation purposes.
 Verify and maintain clean, dust free, front and
rear airflow paths. Cleaning and removing
dust from the front and rear panels once
every six months in a normal working environment is recommended. Extremely dusty
environments will require more frequent
11 – 3
Verification/Remedy
a) Unit may be in thermal shutdown mode.
 Review the rated duty cycle of the unit per
section 3.06. Exceeding the duty cycle can
damage the unit and void the warranty. Refer
also to section 3.07 for additional information.
b) Verify the ventilating condition.
 Maintain a clear and unobstructed distance
of more than 12 in. in the front and more that
20 in. in the rear of the unit for ventilation purposes.
 Verify and maintain clean, dust free, front and
rear airflow paths. Cleaning and removing
dust from the front and rear panels once
every six months in a normal working environment is recommended. Extremely dusty
environments will require more frequent
cleanings.
160S (460V)
11 ADVANCED TROUBLESHOOTING
2.4 E94 “Thermistor malfunction”
c) Verify the operation of the cooling fan, FAN1,
and replace it if necessary.
Cause
 Verify the condition of FAN1. Verify that there
are no broken or cracked fan blades and that
FAN1 is not producing and abnormal sounds.
Thermistors for detecting temperature of internal
components have malfunctioned.
 If broken or cracked FAN1 blades or abnormal sounds are emanating from FAN1,
replace FAN1.
Verification/Remedy
a) Verify a secure connection of the harness
wired between CN5-6 on PCB1 (WK-5815)
and Thermistors (TH1, TH2).
 Refer to section 12.03.15 for the replacement
of FAN1.
 Refer to section 11.05.3 for additional FAN1
tests.
 Re-install the harness with a secure connection.
 Verify the operation of the cooling fan and
replace it if the condition of FAN1 is inactive.
Follow the instruction in section 12.03.15.
 Contact the manufacturer if you find any broken connectors or damaged wiring harness.
b) Replace thermistors (TH1, TH2).
d) Replace PCB4 (WK-5765) and PCB5 (WK5448).
 Refer to the page 12-21.
c) Replace PCB5 (WK-5448).
 Refer to section 12.03.4 and 12.03.5 for the
replacement of PCB4 and PCB5.
 Refer to section 12.03.5.
2.5 E99 “Initial Power Receiving”
2.3 E03 “Primary Over-Current Failure”
Cause
Cause
Occurs when excessive current is detected flowing into the primary side of the main transformer.
Verification/Remedy
Occurs when the initial AC power received signal
has not reached the CPU. This error occurs normally during the power “OFF” sequence of the
unit.
Verification/Remedy
a) Confirm the operation of the machine within
the rated specification.
 Refer to the specification data sheet in Section 3.07.
b) Verify the secondary diode (D2, D3 and D4).
 Refer to section 11.05.5 for the test of D2-D4
and section 12.03.14 for the replacement of
D2-D4.
c) Replace the Hall CT, HCT1.
NOTE
Pay special attention to installed direction of HCT1.
The Hall CT will not function properly if installed in
the incorrect direction.
 Refer to section 12.03.16 for the replacement of
HCT1.
a) Verify the connection between "+" terminal of
Primary diode (D1) and PCB1 (WK-5815).
 Verify that there is no omission of a loosening
connected wire between the PCB1 and D1.
 Contact the manufacturer if you find any broken connectors or damaged wire.
b) Verify that there is no omission of a loosening
screws and connected harness with PCB1
(WK-5815).
 Re-install the harness with a secure connection.
 Contact the manufacturer if you find any broken connectors or damaged wiring harness.
 Replace PCB1. Refer to 12.4.
c) Replace PCB4 (WK-5765) and PCB5 (WK5448).
 Refer to sections 12.10 - 12.11 for the
replacement of PCB4 and PCB5.
11 – 4
160S (460V)
11 ADVANCED TROUBLESHOOTING
3 Verification and Remedy to
3.2 “No weld output”
Failures without Indication
Codes
Cause
Occurs when the remote connector (CON1) or
associated circuitry is defective, damaged, or the
TIG torch cable is defective.
Refer to Note2 in Section 11.02.
3.1 “Cooling Fan (FAN1) Failure”
(Fan is not rotating.)
Verification/Remedy
CAUTION
Cause
Occurs when the cooling fan (FAN1) is defective,
damaged or the driving voltage is incorrect.
Verification/Remedy
Read and understand this entire section before
proceeding. Extreme personal harm and test
equipment damage will occur if the procedures are
not performed accurately.
a) Verify the remote connector (CON1).
(Applies to LIFT TIG mode.)
a) Verify the cooling fan, FAN1.
 Inspect the condition of the fan blades and all
peripheral parts. Clean the fan blades and all
peripheral parts if covered with dust. Cleaning and removing dust from the fan blades
once every 6 months in a normal environment is recommended. Extremely dusty environments will require more frequent cleanings.
 Verify a secure between the remote connector (CON1) and the TIG torch cable.
 Verify that there are no wiring harnesses
entangled inside the fan, confirm that the harnesses do not have any brakes in the wire or
damaged connectors.
 Contact the manufacture if you find any broken connectors or damaged wiring harnesses.
 Replace wiring harnesses if you find any broken connectors or damaged wiring harnesses.
 Replace the fan if there are any broken,
cracked or missing fan blades. Refer to the
page 12-18.
b) Verify the wiring harness between the cooling
fan (FAN1) and CN2 on PCB1 (WK-5815).
 Verify a secure connection of the harness to
CN2 on PCB1.
c) Verify the drive circuitry of the cooling fan
(FAN1) on PCB1.
 Verify the drive circuitry of the cooling fan
(FAN1) on PCB1.
 Refer to the page 11-8.
 Replace PCB1 if necessary. Refer to the
page 12-4.
11 – 5
 Verify a secure connection of the harness
and the connections between the remote
connector (CON1) and CN1 on PCB1 (WK5815) are all correct and there are no open
circuits.
 Verify the proper pins-outs of the remote connector at the TIG Torch side. (Refer to section
Operating Manual.)
 Verify that there is no open circuit on the
remote connector at TIG Torch side.
 In equipment for remote control use, Verify
the pin specification of a connector. (Refer to
section Operating Manual.)
b) Verify the condition and connections of the
welding cable, the stick rod holders and the
ground clamp. (Applies to all welding modes.)
 Verify a secure connection of the welding
cable, stick rod holders, ground clamp and
dense connectors and there are no open circuits.
c) Verify the no-load voltage (OCV).
(Applies to STICK mode.)
 Refer to the section “Verification of No-load
voltage (No OCV)” in the page 11-43.
 If performing the “No-Load Voltage Failure”
procedure and it does not rectify the failure,
perform the following tests in the sequence
160S (460V)
below. Replace any defective components
found.
1) Reactor (FCH1)
 Replacement FCH1. Refer to the page
12-19.
2) Transformer (T1)
 Replacement T1. Refer to the page 12-8.
11 ADVANCED TROUBLESHOOTING
4 Fault Isolation Tests
4.1 Preparation
3) Primary IGBT (Q1-Q4)
 Verification. Refer to the page 11-10.
 Replacement. Refer to the page 12-13,
14.
4) Hall C.T. (HCT1)
 Replacement HCT1. Refer to the page
12-8.
3.3 “Operating Panel Failure”
(LED’s do not light properly
or welding setting cannot be
established.)
The following initial conditions must be met prior to
starting any of the procedures in this section.
1) Connect the appropriate input voltage.
(Check the data tag on the rear of the power
supply for the proper input voltage.)
NOTE
Operate at ALL input voltages as noted on the
nameplate on the rear panel when testing the
power supply.
2) Remove the side covers. Refer to section
11.1.1.
3. Close primary power source wall disconnect
switch or circuit breaker.
4) Place power supply MAIN CIRCUIT SWITCH
(S1) on rear of unit in the ON position.
Cause
Occurs when there is a connection failure among
PCB1 (WK-5815), PCB5 (WK-5448), PCB4 (WK5765), PCB9 (WK-5827) and PCB5 or PCB4 or
PCB9 are defective.
Verification/Remedy
a) Verify the harness connection between CN100
on PCB1 (WK-5815) and CN1 on PCB4 (WK5765).
 Verify a secure connection of the harness
and the connections between CN100 on
PCB1 and CN1 on PCB4.
 Contact the manufacturer if you find any broken
connectors or damaged wiring harnesses.
b) Verify the Power Supply Voltage.
 Refer to the section “Power Supply Voltage
Test” on page 11-8.
 Replace PCB9 if necessary. Refer to the
page 12-14.
c) Verify the connection between PCB5 (WK5448) and PCB4 (WK-5765).
 Verify that there is no omission of a loosening
screws and connected harness between the
PCB1 and PCB4.
 Replace PCB5 and PCB4 if necessary. Refer
to pages 12-10 and 12-11.
11 – 6
WARNING
Dangerous voltage and power levels are present
inside this unit. Be sure the operator is equipped
with proper gloves, clothing and eye and ear protection. Make sure no part of the operator's body
comes into contact with the workpiece or any internal components while the unit is activated.
160S (460V)
11 ADVANCED TROUBLESHOOTING
5 Verification of the Power
The location of points U2 and V2 on switch
S1 are indicated in Figure 11-7.
Input Circuitry
CAUTION
Before performing any portion of the procedure
below, make certain the unit is placed in the initial
set up condition as described in section 11.4.1
“Preparation”.
5.1 Verify the AC input voltage
using an AC voltmeter
1) Verify input voltage (Phase-to Phase) using an
AC voltmeter. (The capability of the voltmeter
should be more than 600VAC). Measure the
point between lines U1 and V1 on the input
switch, S1.
4) If this voltage is out of the operating range,
which is ±10% (414~506VAC) of the rated voltage (460V), replace S1 following the process
in section 12.03.17.
5) Verify the rectified output voltage of the primary diode, D1 using a DC voltmeter. The
capability of the voltmeter should be more than
800VDC. Using a DC voltmeter, measure
between the points “+” [+] and “-” [-] on D1.
See Figure 11-8. The measured voltage
should be approximately 1.4 times larger than
input voltage measured in #1 above. Replace
diode D1 if the calculated measurement is not
within the corresponding range (580 ~
708VDC) following the process in section
12.03.13.
The location of points U1 and V1on switch S1
are indicated in Figure 11-7.
+
U1
V1
U2
V2
Figure 11-8: The check points “+” and “-”
Figure 11-7: Check points U1, U2, V1 and V2
2) If the input voltage is out of the operating range
of the unit, which is ±10% (414~506VAC) of
the rated voltage (400V), verify the available
power capacity at the installed site.
If the input voltage is within the operating
range, recheck the input voltage while welding,
as welding may cause the input voltage to
decrease to a value below the operating range
of the unit.
3) Verify input voltage after the input switch (S1)
using an AC voltmeter. The capability of the
voltmeter should be more than 600VAC.
 Using an AC voltmeter, measure between the
points U2 and V2 on the input switch, S1.
11 – 7
6) Verify bus voltage (the voltage of the electrolytic capacitor after rectification) using a DC
voltmeter. The capability of the voltmeter
should be more than 800VDC. Using a DC
voltmeter, measure between the points
TB1(P)[+] and TB3(N)[-] on PCB1 (WK-5815).
Points TB1(P) and TB3(N) can be found on the
parts side of PCB1. See Figure 11-9. The measured voltage should be approximately 1.4
times larger than input voltage measured in #1
above. Replace diode D1 if the calculated
measurement is not within the corresponding
range (580 ~ 708VDC) following the process in
section 12.03.13.
160S (460V)
11 ADVANCED TROUBLESHOOTING
Test Point
PCB4
TP1
TP2
TP3
TB1
TB3
Reference
PCB4
TP0
TP0
TP0
ACCEPTABLE
VALUE
+5VDC
+12VDC
–12VDC
Table 11-1: Checkpoints TP0-TP3 on PCB4
PCB1(WK-5815)
2
Figure 11-9: The check points TB1(P) and TB3(N)
1
CN2
7) After the replacement of D1, if the above voltage
is still abnormal, replace PCB8 (WK-5828).
5.2 Power Supply Voltage Test
Figure 11-11: Checkpoints CN2 on PCB1
CAUTION
Before performing any portion of the procedure
below, make certain the unit is placed in the initial
set up condition as described in section 11.4.1
“Preparation”.
Test Point
PCB1
PIN 1 on CN2
Reference
PCB1
PIN 2 on CN2
ACCEPTABLE
VALUE
+24VDC
Table 11-2: Checkpoints CN2 on PCB1
1) Verify Power Supply voltage using an DC voltmeter. The capability of the voltmeter should
be more than 50VDC. Operate at all input voltages as noted on the nameplate on the rear
panel when testing the power supply.
2) On the PCB5 (WK-5548) and PCB4 (WK5765), measure the voltages according to the
following table. The check points and the reference are obtainable on the solder side of
PCB4 (WK-5765). The locations of points are
indicated in Figure 11-10.
3) If any of these voltages are not present or are
below a 10% tolerance, replace the PCB9
(WK-5827).
Refer to the page 12-14.
5.3 Verification of the Cooling
Fan, FAN1, Drive Circuitry
1) Verify the condition of the cooling fan, FAN1,
using a DC voltmeter. (The capability of the
voltmeter should be more than 50VDC.) Using
a DC voltmeter, measure between PIN 1 (Positive [+]) and PIN 2 (Negative [-]) of CN2 on
PCB1 (WK-5815) and measure between 1PIN
(Positive [+]) and PIN 2 (Negative [-]) of CN40
on PCB1. The location of connector CN2 and
CN40 of PCB1 is indicated in Figure 11-12.
When you measure the above voltage, do not
remove the connector. Conduct the measurement while the connector plug and receptacle
are still connected.
PCB4 (WK-5765)
TP3
TP2
TP1
CAUTION
Before performing any portion of the procedure
below, make certain the unit is placed in the initial set
up condition as described in section 11.4.1
“Preparation”.
TP0
Figure 11-10: Checkpoints TP0-TP3 on PCB4
11 – 8
160S (460V)
11 ADVANCED TROUBLESHOOTING
 When verifying the voltage, Verify that the AC
input voltage remain within the operating range
of the unit. (The AC input does not drop below
410VAC).
PCB1(WK-5815)
2
CN2
1
5.4 Verification of the primary
Diode (D1)
CN40
CAUTION
2
Before performing any portion of the procedure
below, make certain the unit is placed in the initial
set up condition as described in section 11.4.1
“Preparation”.
1
Figure 11-12: Verification of the FAN1
2) Using the measurement taken above, follow
the chart below for possible failure modes.
FAN1
Status
Voltage measurement.
(PIN 1-PIN 2 of CN2 on
PCB1)
1) Verify the characteristic of the primary diode,
D1, using a diode tester.
Remedy
2) Refer to Table 11-4 and Figure 11-13 for
the checkpoints on D1.
FAN1 drive
circuit is normal.
Replace PCB1.
Case
Rotating
Below DC 18V
Refer to the
2
page 12-4.
Replace PCB9
(WK-5827)
Refer to the
page 12-14.
Below DC 18V
4
and
Perform
PIN 1-2 of CN40 is
“2. Power
Below DC 18V
Supply Voltage
Test”.
Refer to the
Case
page 11-8.
Inactive
3
Replace PCB1
Below DC 18V
4
and
Perform
PIN 1-2 of CN40 “2. Power
is DC 18 ~ 25V Supply Voltage
CN2
Test”.
Removed
DC 18 ~ 25V Replace the
FAN1.
and
PIN 1-2 of CN40 Refer to the
is DC 18 ~ 25V page 12-18.
Replace the
FAN1.
Case
Inactive
DC 18 ~ 25V
Refer to the
4
page 12-18.
Case
Rotating
1
DC 18 ~ 25V
COMPONENT
TESTED
Diode of D1
Diode of D1
TERMINALS
Positive
Negative
lead
lead
1, 2, 3
5
5
1, 2, 3
1, 2, 3
4
4
1, 2, 3
ACCEPTABLE
VALUE
0.3 to 0.5V
Open
Open
0.3 to 0.5V
Table 11-4: Tester checkpoints in the D1
5 4 3 2 1
5
1
2
3
Table 11-3: Verification of the FAN1
 During low output and standby, fan rotation
becomes slow, making exact voltage measuring
impossible.
4
Figure 11-13: Tester checkpoints in the D1 and D1 interconnection diagrams
11 – 9
160S (460V)
5.5 Verification of the secondary
Diode (D2-D4)
11 ADVANCED TROUBLESHOOTING
5.6 Verification of the primary
IGBT (Q1A-Q4C)
CAUTION
CAUTION
Before performing any portion of the procedure
below, make certain the unit is placed in the initial
set up condition as described in section 11.4.1
“Preparation”.
Before performing any portion of the procedure
below, make certain the unit is placed in the initial
set up condition as described in section 11.4.1
“Preparation”.
1) Verify the characteristic of the secondary
diode, D2, D3 and D4, using a diode tester.
1) Check whether there are any abnormalities on
the appearance of PCB6 and PCB7.
2) Verify the characteristic of the primary IGBT
(Q1A-Q4C), using a diode tester.
3) Refer to Table 11-6 and Figure 11-15 for the
checkpoints on PCB6 and PCB7.
2) Refer to Table 11-5 and Figure 11-14 for the
checkpoints on D2, D3 and D4.
TERMINALS
Positive Negative
lead
lead
Anode Cathode
Diode 1 of D2-D4
Cathode Anode
Anode Cathode
Diode 2 of D2-D4
Cathode Anode
COMPONENT
TESTED
ACCEPTABLE
VALUE
0.2 to 0.3V
Open
0.2 to 0.3V
Open
COMPONENT
TESTED
TERMINALS
ACCEPTABLE
Positive Negative
VALUE
lead
lead
Collector-Emitter
of Q1A~Q2C with
PCB6
Collector-Emitter
of Q3A~Q4C with
PCB7
Table 11-5: Tester checkpoints for D2, D3 and D4
C
E
E
C
Open
0.2 to 0.5V
C
E
E
C
Open
0.2 to 0.5V
Table 11-6: Tester checkpoints for Q1A-Q4C
Cathode
Cathode
E C
Anode
Anode
E C
E C
PCB6
E C
E C
E C
Figure 11-14: Tester checkpoints for D2, D3 and D4
PCB7
E C
E C
E C
E C
E C
E C
Figure 11-15: Tester checkpoints for Q1A-Q4C
11 – 10
160S (460V)
11 ADVANCED TROUBLESHOOTING
5.7 Verification of No-load Voltage (OCV)
CAUTION
Before performing any portion of the procedure
below, make certain the unit is placed in the initial
set up condition as described in section 11.4.1
“Preparation”.
a) Verify the no-load voltage in STICK mode.
1) In STICK welding mode, mark and then
turn potentiometer VR1 on PCB4 (WK5765) fully counter-clockwise to turn off
the electric shock protector function (Voltage-Reduction-Device, VRD).
Refer to section 9.03.
WARNING
Electric shock hazard. The unit will generate OCV
immediately when Process mode is put into the
state of "ON" pushing Process button at STICK mode.
2) Verify the no-load voltage using a DC voltmeter. The capability of the voltmeter
should be more than 100VDC.
3) The normal no-load voltage is approximately 65V.
4) Return the setting o f t h e variable resister
(VR1) to the original position.
11 – 11
12 MAINTENANCE
1 Subsystem Test and Replacement Procedures
MAINTENANCE
1.1 Preparation
This section provides specific procedures for verifying the operation and replacement of each subsystem
within the power supply.
Before undertaking any of these procedures, eliminate the obvious first-visually inspect the suspect subsystem for physical damage, overheating, and loose connections.
1.2 Test and Replacement Parts List
9
6
10
4
1
2
7
5
8
3
11
NO.
DWG NO.
PARTS NAME
REFERENCE
PAGE
PART NO.
1
PCB1
Printed Circuit Board (WK-5815)
12 - 4
W7001404
2
PCB2
Printed Circuit Board (WK-5767)
12 - 7
W7001406
3
PCB3
Printed Circuit Board (WK-5854)
12 - 8
W7001410
4
PCB4
Printed Circuit Board (WK-5765)
12 - 10
W7001413
5
PCB5
Printed Circuit Board (WK-5448)
12 - 11
W7001723
6
PCB6 (Q1A-Q2C)
Printed Circuit Board (WK-5460)
12 - 12
W7001516
7
PCB7 (Q3A-Q4C)
Printed Circuit Board (WK-5460)
12 - 13
W7001516
8
PCB8
Printed Circuit Board (WK-5828)
12 - 14
W7001425
9
PCB9
Printed Circuit Board (WK-5827)
12 - 14
W7001426
10
PCB10
Printed Circuit Board (WK-5816)
12 - 15
W7001549
11
PCB11
Printed Circuit Board (WK-5855)
12 - 15
W7001429
12 – 1
160S (460V)
12 MAINTENANCE
10
2
7
12
13
6
1
11
8
3
9
5
4
NO.
DWG NO.
PARTS NAME
REFERENCE
PAGE
PART NO.
1
CON1
Remote Receptacle
12 - 16
W7001550
2
CT1
Current Transformer
12 - 8
W7001552
3
D1
Primary Diode
12 - 16
W7001388
4
D2
Secondary Diode
12 - 17
10-6629
5
D3
Secondary Diode
12 - 17
10-6629
6
D4
Secondary Diode
12 - 17
10-6629
7
FAN1
Cooling Fan
12 - 18
W7001551
8
FCH1
Reactor
12 - 18
W7001502
9
HCT1
Hole Current Trans
12 - 18
10-5003
10
S1
Switch
12 - 20
W7001401
11
T1
Transformer
12 - 8
W7001501
12
TH1
Primary Thermistor
12 - 21
W7001553
13
TH2
Secondary Thermistor
12 - 21
W7001554
12 – 2
160S (460V)
12 MAINTENANCE
2 Service Tools
2.1 Tools and parts
The tools and parts to be used for maintenance are shown by icons.
Spanner
Philips Head
Screwdriver
Long Nose
Pliers
Soldering Copper
(solder)
Snap Band
Silicon
Compound
2.2 Notes of disassembly and assembly
NOTE
When removing the locking type connectors and board supporters, disengage the locking mechanism first
and then disconnect them.
Locking type connectors and board supporters are indicated in this manual using the following symbols;
black star marks for locking connectors and white star marks for locking board supports.
NOTE
During your maintenance or repair, please cut any tie-wraps necessary. However, after your maintenance or
repair, please reassemble and tie-wrap all components and wiring in the same manner as before the maintenance or repair.
CAUTION
Please note that you remove each connector, grasp and pull out by the connector part only. Do not pull the
harness (cable) part.
WARNING
The capacitors inside the power supply will slowly discharged after you turn off the switch of the power supply or the switch at the breaker box (distribution panel). Wait at least 5 minutes for the discharge to complete.
12 – 3
160S (460V)
12 MAINTENANCE
3 Replacement Procedure
3.1 PCB1 (WK-5815) 
1) Remove the Side Panel. [See section “11.01”]
2) Remove the PCB10 (WK-5816). [See section “12.03.14”]
3) Remove the PCB9 (WK-5827). [See section “12.03.13”]
4) Disconnect the five connectors CN1, CN13, CN100, CN103 and CN104 on the PCB1.
CN13
CN103
CN104
CN100
CN1
5) Disconnect the connector CN12 on the PCB1. Remove the screw and then remove the three ground
cables. Remove the two screws and then remove the four cables.
CN12
2
1
3
12 – 4
160S (460V)
12 MAINTENANCE
6) Remove the two bolts, two spring washers and two washers.
7) Remove the four screws and the Front Panel.
1
1
2
1
1
8) Remove the four screws and the Rear Panel.
1
1
2
1
1
12 – 5
160S (460V)
9) Disconnect the 13 connectors on the PCB1.
CN30
CN50
CN14
CN4
CN3
CN6
CN5
CN15
CN40
CN8
CN20
CN2
CN9
10) Remove the six screws and then remove the two cables. Remove the PCB1.
1
1
1
2
11) Remove the eight PCB Supporters from the PCB1.
12 – 6
12 MAINTENANCE
160S (460V)
12 MAINTENANCE
3.2 PCB2 (WK-5767) 
1) Remove the Side Panel. [See section “11.01”]
2) Remove the PCB10 (WK-5816). [See section “12.03.14”]
3) Remove the PCB9 (WK-5827). [See section “12.03. 13”]
4) Remove the PCB1 (WK-5815). [See section “12.03.3”]
5) Remove the PCB6 (WK-5460). [See section “12.03.11”]
6) Remove the PCB7 (WK-5460). [See section “12.03. 12”]
7) Remove the two screws and then remove the two taps of the T1. Remove the Edge Protector.
2
1
8) Remove the eight screws and the PCB2.
1
1
1
1
2
12 – 7
160S (460V)
12 MAINTENANCE
9) Remove the two edge holders and the PCB2 Insulation Sheet from the PCB2.
3.3 PCB3 (WK-5854), CT1 “Current Transformer” and T1 “Transformer”)
1) Remove the Side Panel. [See section “11.01”]
2) Remove the PCB8 (WK-5828). [See section “12.03.13”]
3) Remove the PCB11 (WK-5855). [See section “12.03. 14”]
4) Cut the snap band and Disconnect the connector CN9 on the PCB1. Pull the connector from the Edge
Protector and coating clip.
1
2
CN9
3
5) Remove the two screws and then remove the two taps of T1. Cut the snap band and Remove the CT1.
2
1
3
1
12 – 8
160S (460V)
12 MAINTENANCE
6) Remove the screw and four terminals. Remove the Edge Protector from the PCB3.
1
3
2
7) Remove the six screws and six Posts. Remove the PCB3 unit.
1
1
2
1
1
8) Remove the two taps of T1 with the soldering iron from the PCB3. Remove the T-D Bus Bar1 and the TD Bus Bar2. Open the tap of T1 and Remove the four screws. Remove the T1 from the PCB3.
4
2
3
1
5
12 – 9
160S (460V)
12 MAINTENANCE
3.4 PCB4 (WK-5765) 
1) Remove the Side Panel. [See section “11.01”]
2) Remove the Protection Cover.
2
2
3
1
3) Remove the Knob Cap. Holding the Knob down, loosen the screw and remove the Knob.
2
3
1
4) Disconnect the three connectors CN1, CN3 and CN4 on the PCB4. Remove the four screws. Pull out the
operation panel and bring it down.
CN3
CN1
2
CN4
2
3
1
2
2
12 – 10
160S (460V)
12 MAINTENANCE
5) Remove the four screws. Remove the PCB4.
1
1
1
2
1
3.5 PCB5 (WK-5448) 
1) Remove the Side Panel. [See section “11.01”]
2) Remove the PCB4 (WK-5765). [See section “12.03.4”"]
3) Remove the three latches of Front Control Cover and then remove the PCB5.
1
1
2
 When reinstalling the PCB5, engage two latches of Front Control Cover first.
1
2
12 – 11
160S (460V)
12 MAINTENANCE
3.6 PCB6 (WK-5460) and Q1A-Q2C “Primary IGBT” 
1) Remove the Side Panel. [See section ”11.01”]
2) Remove the four screws and two IGBT Spring Clips. Remove the cables from edge holder.
2
1
1
3) Disconnect the connector CN1 on the PCB6. Cut the lead of the Q1A-Q2C.
 Remember to install new Silicone Rubber Sheets where silicone compound (Shinetsu Silicone G-747 or
equivalent) was spread when reinstalling the PCB6. Spread the silicone compound on IGBT.
1
CN1
2
2
3
12 – 12
160S (460V)
12 MAINTENANCE
3.7 PCB7 (WK-5460) and Q3A-Q4C “Primary IGBT” 
1) Remove the Side Panel. [See section “11.01”]
2) Remove the four screws and two IGBT Spring Clips. Remove the cables from edge holder.
2
1
1
3) Disconnect the connector CN1 on the PCB6. Cut the lead of the Q3-Q4C.
 Remember to install new Silicone Rubber Sheets where silicone compound (Shinetsu Silicone G-747 or
equivalent) was spread when reinstalling the PCB7. Spread the silicone compound on IGBT.
1
CN1
2
2
3
12 – 13
160S (460V)
12 MAINTENANCE
3.8 PCB8 (WK-5828) 
1) Remove the Side Panel. [See section “11.01”]
2) Remove the four screws and then open the Rear Panel.
1
1
2
1
1
3) Disconnect the connector CN1 on the PCB8. Remove the six screws and then remove two cables.
Remove the PCB8.
CN1
1
2
3
2
3.9 PCB9 (WK-5827) 
1) Remove the Side Panel. [See section “11.01”]
2) Disconnect the six connectors on the PCB9. Remove the four PCB Supporters and then remove the
PCB9.
CN40
1
CN30 CN7
CN50
CN20
1
CN15
2
1
12 – 14
160S (460V)
12 MAINTENANCE
3.10 PCB10 (WK-5816) 
1) Remove the Side Panel. [See section “11.01”]
2) Disconnect the four connectors CN10, CN11, CN17 and CN100 on the PCB10. Remove the four PCB
Supporters and then remove the PCB10.
1
CN101
CN11
1
CN17
CN10
1
3.11 PCB11 (WK-5855) 
1) Remove the Side Panel. [See section “11.01”]
2) Disconnect the two connectors CN1 and CN2 on the PCB11 and Remove the five screws. Remove the
PCB11.
2
1
CN2
3
2
12 – 15
CN1
1
160S (460V)
3.12 CON1 “Remote Receptacle” 
1) Remove the Side Panel. [See section “11.01”]
2) Remove the screw and then remove the three ground cables. Cut the two snap bands.
1
2
CON1
CN12
3) Cut the snap band and remove the connector CN1 on the PCB1.
1
CN1
2
4) Open the Panel Protects. Remove the two screws and the CON1.
1
2
12 – 16
12 MAINTENANCE
160S (460V)
12 MAINTENANCE
3.13 D1 “Primary Diode” 
1) Remove the Side Panel. [See section “11.01”]
2) Remove the four terminals and two screws. Remove the D1.
 Before installing a new diode, apply a uniform coat of silicone compound (Shinetsu Silicone G-747 or
equivalent) on the base.
2
AC (White)
1
2
AC (Red)
DC - (Blue)
DC+ (Brown)
3.14 D2, D3 and D4 “Secondary Diode” 
1) Remove the Side Panel. [See section “11.01”]
2) Remove PCB8 (WK-5828). [See section “12.03.13”]
3) Remove PCB11 (WK-5855). [See section “12.03.14”]
4) Remove PCB3 (WK-5854). [See section “12.03.3”]
5) Remove the bolt, the spring washer, and the washer. Remove the four screws and two Posts. Remove
the Output Bus Bar.
2
3
2
1
12 – 17
160S (460V)
12 MAINTENANCE
6) Remove six screws and then detach the D2, D3 and D4.
 Do not have the wrong direction of the diodes when reinstalling.
 Before installing a new diode, apply a uniform coat of silicone compound (Shinetsu Silicone G-747 or
equivalent) on the base.
1
2
1
3.15 FAN1 “Cooling Fan” 
1) Remove the Side Panel. [See section “11.01”]
2) Remove the four screws and then open the Rear Panel.
1
1
2
1
1
3) Disconnect the connector CN2 on the PCB1. Remove the FAN1.
 Be sure that the fan is facing in the correct direction when reinstalling.
1
CN2
2
12 – 18
160S (460V)
12 MAINTENANCE
3.16 FCH1 “Reactor” and HCT1 “Hole Current Trans” 
1) Remove the Side Panel. [See section “11.01”]
2) Remove the two bolts, two spring washers, and the two washers.
3) Remove the four screws and the Front Panel.
1
1
2
1
1
4) Remove the screw and then remove the cable. Disconnect the connector from the HCT1.
1
2
12 – 19
160S (460V)
12 MAINTENANCE
5) Cut the snap band. Remove the HCT1.
1
2
6) Disconnect the connector CN2 on the PCB11. Pull out the cable from the coating crip. Remove the
FCH1.
3
CN2
2
1
3.17 S1 “Switch” 
1) Remove the Side Panel. [See section “11.01”]
2) Remove the four screws and the six cables.
12 – 20
160S (460V)
12 MAINTENANCE
3) Remove the two screws and then detach the S1.
3.18 TH1 “Primary Thermistor” 
1) Remove the Side Panel. [See section “11.01”]
2) Cut the three snap bands and disconnect the connector CN5 on the PCB1. Remove the screw and then
detach the TH1. Before installing a new Thermistor, apply a uniform coat of silicone compound (Shinetsu
Silicone G-747 or equivalent) on the base.
1
2
3
12 – 21
CN5
160S (460V)
12 MAINTENANCE
3.19 TH2 “Secondary Thermistor” 
1) Remove the Side Panel. [See section “11.01”]
2) Remove PCB11 (WK-5855). [See section “12.03.10”]
3) Remove the four screws and two Posts.
4) Cut the three snap bands and disconnect the connector CN6 on the PCB1. Remove the screw and then
detach the TH1. Before installing a new Thermistor, apply a uniform coat of silicone compound (Shinetsu
Silicone G-747 or equivalent) on the base.
2
1
4
3
12 – 22
APPENDIX 1 PARTS LIST
1 Equipment Identification
All identification numbers as described in the Introduction chapter must be furnished when ordering parts or
making inquiries. This information is usually found on the nameplate attached to the equipment. Be sure to
include any dash numbers following the Part or Assembly numbers.
2 How To Use This Parts List
The Parts List is a combination of an illustration and a corresponding list of parts which contains a breakdown of the equipment into assemblies, subassemblies, and detail parts. All parts of the equipment are listed
except for commercially available hardware, bulk items such as wire, cable, sleeving, tubing, etc., and permanently attached items which are soldered, riveted, or welded to other parts. The part descriptions may be
indented to show part relationships. To determine the part number, description, quantity, or application of an
item, simply locate the item in question from the illustration and refer to that item number in the corresponding Parts List.
PART NUMBER:
ARC MASTER 160S (460V) 10-3090
No.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
DWG No.
CON1
CT1
D1
D2-4
FAN1
FCH1
HCT1
PCB1
PCB2
PCB3
PCB4
PCB5
PCB6-7
PCB8
PCB9
PCB10
PCB11
Q1A-1C
Q2A-2C
Q3A-3C
Q4A-4C
S1
T1
TH1
TH2
Part No.
W7001550
W7001552
W7001388
10-6629
W7001551
W7001502
10-5003
W7001404
W7001406
W7001410
W7001413
W7001723
W7001516
W7001425
W7001426
W7001549
W7001429
W7001444
W7001444
W7001444
W7001444
W7001401
W7001501
W7001553
W7001554
W7001557
W7001558
W7001464
W7001460
Description
Socket, Remote, gen 3.1, IPS
Transformer, gen 3.1, IPS
Diode, gen 3.1, IPS
Diode, gen 3.1, IPS
Fan, gen 3.1, IPS
Inductor, gen 3.1, IPS
Sensor, Current, gen 3.1, IPS
PCB, gen 3.1, IPS
PCB, gen 3.1, IPS
PCB, gen 3.1, IPS
PCB, gen 3.1, IPS
PCB, gen 3.1, IPS
PCB, gen 3.1, IPS
PCB, gen 3.1, IPS
PCB, gen 3.1, IPS
PCB, gen 3.1, IPS
PCB, gen 3.1, IPS
Transistor, gen 3.1, IPS
Transistor, gen 3.1, IPS
Transistor, gen 3.1, IPS
Transistor, gen 3.1, IPS
Switch, gen 3.1, IPS
Transformer, gen 3.1, IPS
Thermistor, gen 3.1, IPS
Thermistor, gen 3.1, IPS
Panel, Front, gen 3.1, IPS
Panel, Rear, gen 3.1, IPS
Label, Side, gen 3.1, IPS
Cover, Front, gen 3.1, IPS
1
Additional Information
206433-1 8P (with Wiring Assembly)
F2A503001
DF20AA160
DBA200UA60
D12T24PS103 DC 24V
F3A285001 160/200A FCH
HC-TN200V4B15M 200A 4V
WK-5815 U01 INTERFACE PCB
WK-5767 U01 MAIN PCB
WK-5854 U01 TRANS PCB
WK-5765 U01 CONTROL PCB
WK-5448 U17-1 PANEL PCB
WK-5460 U01PRIMARY GATE PCB
WK-5828 U01PRECHARGE PCB
WK-5827 U01CONTROL SOURCE PCB
WK-5816 U01GATE DRIVE PCB
WK-5855 U01 SNUBBER PCB
IRGP20B60PD 600V 22A
IRGP20B60PD 600V 22A
IRGP20B60PD 600V 22A
IRGP20B60PD 600V 22A
DCP-52SR50AMS-480V 2P-480V
F3A013701 200A MAIN TR
ERTA53D203 20K"/25o C
ERTA53D203 20K"/25o C
E0D004501
E0D004601
E0D007503
E0C341900
QTY.
1
1
1
3
1
1
1
1
1
1
1
1
2
1
1
1
1
3
3
3
3
1
1
1
1
1
1
2
1
160S (460V) PARTS LIST
No. DWG No.
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
45
46
47
48
49
50
51
52
53
54
55
56
57
58
59
60
61
62
63
64
65
66
67
68
69
70
71
Part No.
W7001559
W7001556
10-6791
W7001555
10-5069
W7001514
W7001512
W7001508
W7001509
W7001513
W7001511
10-6710
10-6711
N/A
10-6712
W7001489
W7001527
10-6714
10-6715
W7001540
W7001524
W7001495
10-6606
W7001532
W7001533
W7001535
W7001493
10-5259
W7001536
W7001537
W7001487
W7001538
W7001529
W7001530
W7001531
W7001534
W7001525
W7001528
W7001526
W7001485
W7001488
N/A
300X4820
Description
Cover, Rear, gen 3.1, IPS
Cover, Protector, gen 3.1, IPS
Cover, Encoder, gen 3.1, IPS
Cover, PCB, gen 3.1, IPS
Strap, gen 3.1, IPS
Label, Name, gen 3.1, IPS
Label, Side, gen 3.1, IPS
Label, 1 Warning, gen 3.1, IPS
Label, 2 Warning, gen 3.1, IPS
Label, VRD, gen 3.1, IPS
Label, VRD, gen 3.1, IPS
Label, Output, gen 3.1, IPS
Output, Terminal, gen 3.1, IPS
Input Cable, gen 3.1, IPS
Clamp, Input, gen 3.1, IPS
Heatsink, 1, gen 3.1, IPS
Heatsink, 2, gen 3.1, IPS
Knob, gen 3.1, IPS
Knob Cap, gen 3.1, IPS
Cover, Protector, gen 3.1, IPS
Post, gen 3.1, IPS
Post, Output (M8-M8),gen 3.1,IPS
Support, PCB, gen 3.1, IPS
Label, 2 Warning, gen 3.1, IPS
Bus Bar, 2 T-D, gen 3.1, IPS
Bus Bar, Output, gen 3.1, IPS
Sheet, terminal, gen 3.1, IPS
Clip, gen 3.1, IPS
Chassis, gen 3.1, IPS
PCB, gen 3.1, IPS
Clip,Spring IGBT, gen 3.1, IPS
Chassis,PCB8, gen 3.1, IPS
Insulation Sheet, gen 3.1, IPS
Insulation Sheet, gen 3.1, IPS
Insulation Sheet, gen 3.1, IPS
Insulation Sheet, gen 3.1, IPS
Edge Protect, gen 3.1, IPS
Hole closed sheet,gen 3.1, IPS
Clip, Coating, gen 3.1, IPS
Holder, Edge, gen 3.1, IPS
Insulation Plate, gen 3.1, IPS
Output, Terminal, gen 3.1, IPS
Operating Manual, gen 3.1, IPS
2
Additional Information
JFA359601
E1B500700
EBA514400
E2B002400 (with Caution Label)
E5A937000
N4A932400 (160S)
N4A785100
N1B029500
N1B029600
N4A918800
N4A598700
N4A057700
TRAK-BE10-25
SOOW AWG12X3C
SCLB18A
E1B834200
E2B121300
2615603
3015104
N1B036300
BSB410
ECA790900
KGLS-14S
EDA957800
EDA957900
EEA007000
ECA775700
#74 NATURAL
J3C477000
JFA164700
E1B832400
JFA538700
EDA624600
EDA839100
EDA839200
EDA965800
C30SG16A
EBA710900
CS-6
EH11U
E1B834100
TRAK-SK10-25
QTY.
1
1
1
1
1
2
2
1
1
1
1
1
2
1
1
2
1
1
1
1
8
2
8
1
1
1
4
4
1
2
4
1
1
1
1
1
2
2
4
2
2
2
1
160S (460V) PARTS LIST
40
44
43
37
28
34
33
30
36
22
57
27
29
49
67
47
12
48
32
11
39
1
35
5
51
38
31
42
35
41
67
42
51
26
28
36
3
160S (460V) PARTS LIST
8
15
16
63
64
52
52
56
13
66
19
13
56
18
69
68
56
69
9
21
20
62
58
70
60
60
59
59
24
6
A
60
45
46
60
70
61
4 4
2
23
25
66
54
55
50
65
58
10
3
53
50
17
14
A
7
4
68
APPENDIX 2 CONNECTION WIRING GUIDE
APPENDIX 2 Connection Wiring Guide
Connection Wiring Guide
Destination
Destination
A
PCB1
CN1
↔
CON1
B
C
PCB1
PCB1
CN2
CN3
↔
↔
FAN1
PCB11
D
E
PCB1
PCB1
CN4
CN5
↔
↔
HCT1
TH1
F
G
PCB1
PCB1
CN6
CN8
↔
↔
TH2
PCB8
H
I
PCB1
PCB1
CN9
CN15
↔
↔
CT1
PCB9
CN15
J
PCB1
CN20
↔
PCB9
CN20
K
L
PCB1
PCB1
CN30
CN40
↔
↔
PCB9
PCB9
CN30
CN40
M
PCB1
PCB1
CN50
CN100
↔
PCB9
CN50
CN101
CN103
↔
PCB4
CN1
O
PCB10
PCB1
↔
PCB4
CN3
P
Q
PCB1
PCB6
CN104
CN1
↔
↔
PCB4
PCB10
CN4
CN10
R
S
PCB7
PCB9
CN1
CN7
↔
↔
PCB10
PCB10
CN11
CN17
T
PCB11
CN2
↔
FCH1
N
5
CN1
CN1
160S (460V) Connection Wiring Guide
S
Q
R
CN40
CN10
CN1
CN3
K
PCB7
CN4
PCB9
L
M
CN30
CN15
CN40
PCB4
O
CN20
CN50
PCB10
CN101
P
CN7
CN17
CN11
CN1
N
CN30
I
CON1
C
J
CT2
FAN1
D
A
CN15
CN1
CN4
E
TH1
F
CN50
CN5
FCH1
PCB6
CN20
CN3
CN6
B
TH2
CN8
CN103
CN1
CN104
T
PCB1
G
CN9
CN100
PCB8
H
CT1
PCB11
CN2
CN2
CN1
APPENDIX 3 Interconnect Diagram
6
CN1
APPENDIX 3 INTERCONNECT DIAGRAM
PCB8
Precharge
Circuit
Board
[WK-5828]
TB1
1
2
3
4
PCB2
Main
Circuit Board
[WK-5767]
Q1A
C
D1
+
G
E
C
TB1
TB1
TB2
PCB7
IGBT Gate
TB2 Circuit
Board
[WK-5460]
TB2
Line2
Ground
TB3
+
1
2
EA
+
CN12
TB5
G
E
C
PCB6 G
E
Q1C IGBT Gate
Circuit C
Board
[WK-5460] G
E
Q2A
C
G
E
EB
CN5
TH2
1
2
1
2
3
CN6
TH1
Q2C
G
E
C
Q4C
TB9
TB9
G
E
G
E
CN1
1 2 5 6
1 2 5 6
1 2 5 6
1 2 5 6 7
CN11
CN10
PCB10
Gate Drive
Circuit Board
[WK-5816]
CN17
1 2
EA
CON1
(Front View)
1 2 3 4 5 6 7 8
1 : Case Ground
2 : Contactor Control 1/+24VDC
3 : Contactor Control 2/GND
4 : +12VDC Supply
5 : Potentiometer Maximum
6 : Potentiometer Minimum (GND)
CN15
3
1
2
3
1
2
1
2
CN20
6
CN15
7
1 2
1
2
3
CN20
8
1
4
1
2
3
4
5
6
7
8
9
10
CN1
2
TB7
Q4A
FAN1
+
1
2
3
5
Q3C
Q4B
TB6
CN2
-
Q3B
G
E
C
TB6
SIDE CHASSIS
TB4
Q2B
CN1
REAR PANEL
Q3A
G
E
C
G
E
C
TB5
G
E
C
Q1B
C
TB3
C
CN101
S1
Line1
CN14
CN1
1
2
1
2
3
4
CN8
Interconnect Diagram
PCB1
Interface
Circuit Board
[WK-5815]
7 : Amperage Control Wiper 0-10VDC
8 : Remote Installed =12VDC
7
CN7
PCB9
Control Source
Circuit Board
[WK-5827]
CN30
CN50
CN40
1 2 3 4
1 2 3
1 2 3 4 5
1 2 3 4
1 2 3
1 2 3 4 5
CN30
CN50
CN40
9
8
7
6
5
4
3
2
1
160S (460V) Connection Wiring Guide
PCB11
Snubber
Circuit
Board
[WK-5855]
TB4
PCB3
Transformer
Circuit Board
[WK-5854]
D2
T1
TB5
TO1
TB1
+Output
Terminal
TB1
EB
TB3
CN2
D3
TB4
2
1
CT1
TB2
FCH1
HCT1
D4
CT1
CT2
4
TB3
+12
-12
IS
GND
123
TB2
CN1
PCB4
Control
Circuit Board
[WK-5765]
6
5
4
3
2
1
CN2
CN2
PCB5
Panel
Circuit Board
[WK-5448]
EA
CN1
9
8
7
6
5
4
3
2
1
TO2
CN3
CN4
CN100
PCB1
Interface
Circuit Board
[WK-5815]
CN103
GND
CN103
4 3 2 1
+12
-12
IS
CT1
CT2
1 2 3
1 2 3
1 2
1 2 3 4
1 2 3 4
1 2
CN104
CN9
CN4
CN3
CN13
8
-Output
Terminal
APPENDIX 4 DIODE TESTING BASICS
DIODE Testing Basic
Testing of diode modules requires a digital Volt/
Ohmmeter that has a diode test scale.
APPENDIX 4 DIODE Testing Basic
1. Locate the diode module to be tested.
2. Remove cables from mounting studs on diodes
to isolate them within the module.
3. Set the digital volt/ohm meter to the diode test
scale.
4. Using figure 1 and 2, check each diode in the
module. Each diode must be checked in both
the forward bias (positive to negative) and
reverse bias (negative to positive) direction.
VR
COM
A
Forward Bias
Diode Conducting
5. To check the diode in the forward bias direction, connect the volt/ohm meter positive lead
to the anode (positive, +) of the diode and the
negative lead to the cathode (negative, –) of
the diode (refer to Figure 13-1). A properly
functioning diode will conduct in the forward
bias direction, and will indicate between 0.3
and 0.9 volts.
Anode
Cathode
Figure 13-1: Forward bias diode test
6. To check the diode in the reverse bias direction, reverse the meter leads (refer to Figure
13-1). A properly functioning diode will block
current flow in the reverse bias direction, and
depending on the meter function, will indicate
an open or "OL".
7. If any diode in the module tests as faulty,
replace the diode module.
8. Reconnect all cables to the proper terminals.
VR
COM
Reverse Bias
Diode Not Conducting
Cathode
Anode
Figure 13-2: Reverse bias diode test
9
A
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
WARRANTY PERIOD
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,
1 year
switches, contactors, solenoids, fans, power switch semi-conductors.......................................... 1 year
Engines and associated components are NOT warranted by Thermal Arc, although
most are warranted by the engine manufacturer .............................................................
See the Engine’s Warranty for Details
GMAW/FCAW (MIG) WELDING EQUIPMENT
WARRANTY PERIOD
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
Original Main Power Rectifiers, Control P.C. Boards, power switch semi-conductors ................. 3 years
All other original circuits and components including, but not limited to, relays,
switches, contactors, solenoids, fans, electric motors................................................................... 1 year
GTAW (TIG) & MULTI-PROCESS INVERTER WELDING EQUIPMENT
WARRANTY PERIOD
160TS, 300TS, 400TS, 185AC/DC, 200AC/DC, 300AC/DC, 400GTSW, 400MST,
300MST, 400MSTP
Original Main Power Magnetics.................................................................................................... 5 years
Original Main Power Rectifiers, Control P.C. Boards, power switch semi-conductors ................. 3 years
All other original circuits and components including, but not limited to, relays,
switches, contactors, solenoids, fans, electric motors................................................................... 1 year
PLASMA WELDING EQUIPMENT
WARRANTY PERIOD
Ultima 150
Original Main Power Magnetics.................................................................................................... 5 years
Original Main Power Rectifiers, Control P.C. Boards, power switch semi-conductors ................. 3 years
Welding Console, Weld Controller, Weld Timer ........................................................................... 3 years
All other original circuits and components including, but not limited to, relays,
switches, contactors, solenoids, fans, electric motors, Coolant Recirculator. ............................... 1 year
SMAW (Stick) WELDING EQUIPMENT
WARRANTY PERIOD
Dragster 85
Original Main Power Magnetics..................................................................................................... 1 year
Original Main Power Rectifiers, Control P.C. Boards .................................................................... 1 year
All other original circuits and components including, but not limited to, relays,
switches, contactors, solenoids, fans, power switch semi-conductors .......................................... 1 year
160S, 300S, 400S
Original Main Power Magnetics.................................................................................................... 5 years
Original Main Power Rectifiers, Control P.C. Boards ................................................................... 3 years
All other original circuits and components including, but not limited to, relays,
switches, contactors, solenoids, fans, power switch semi-conductors .......................................... 1 year
GENERAL ARC EQUIPMENT
WARRANTY PERIOD
Water Recirculators ....................................................................................................................... 1 year
Plasma Welding Torches.............................................................................................................180 days
Gas Regulators (Supplied with power sources) ..........................................................................180 days
LABOR
1 year
LABOR
1 year
180 days
Nil
MIG and TIG Torches (Supplied with power sources)..................................................................90 days
Replacement repair parts .............................................................................................................90 days
MIG, TIG and Plasma welding torch consumable items...................................................................Nil
Nil
Nil
Nil
3 years
3 years
1 year
LABOR
3 years
3 years
1 year
LABOR
3 years
3 years
3 years
1 year
LABOR
1 year
1 year
1 year
3 years
3 years
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
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