160 TS ARCMASTER® Service Manual

160 TS ARCMASTER® Service Manual
160 TS
®
ARCMASTER
INVERTER ARC WELDER
Service Manual
Revision: AB
Issue Date: June 16, 2006
Manual No: 0-4881B
Operating Features:
1
GTAW
SMAW
PHASE
50 Hz
60
INVERTER
115
V
230
V
DC CC
WE APPRECIATE YOUR BUSINESS!
Congratulations on your new Thermal Arc® product. We are proud to
have you as our customer and will strive to provide you with the best
service and reliability in the industry. This product is backed by our
extensive warranty and world-wide service network. To locate your
nearest distributor or service agency call 800-752-7621, or visit us
on the web at www.thermalarc.com.
This Operating Manual has been designed to instruct you on the correct
use and operation of your Thermal Arc® product. Your satisfaction with
this product and its safe operation is our ultimate concern. Therefore,
please take the time to read the entire manual, especially the Safety
Precautions. They will help you to avoid potential hazards that may
exist when working with this product.
YOU ARE IN GOOD COMPANY!
The Brand of Choice for Contractors and Fabricators Worldwide.
Thermal Arc® is a Global Brand of Arc Welding Products for Thermadyne
Industries Inc. We manufacture and supply to major welding industry
sectors worldwide including; Manufacturing, Construction, Mining,
Automotive, Aerospace, Engineering, Rural and DIY/Hobbyist.
We distinguish ourselves from our competition through marketleading, dependable products that have stood the test of time. We
pride ourselves on technical innovation, competitive prices, excellent
delivery, superior customer service and technical support, together
with excellence in sales and marketing expertise.
Above all, we are committed to develop technologically advanced
products to achieve a safer working environment within the welding
industry.
!
WARNINGS
Read and understand this entire Manual and your employer’s safety practices before installing, operating,
or servicing the equipment.
While the information contained in this Manual represents the Manufacturer’s best judgment, the
Manufacturer assumes no liability for its use.
Service Manual Number 0-4881B for:
ArcMaster 160 TS Inverter Welding Power Supply Part No. 10-3067
Published by:
Thermadyne Industries, Inc.
82 Benning Street
West Lebanon, New Hampshire, USA 03784
(603) 298-5711
www.thermalarc.com
Copyright © 2006, 2007, 2008 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:
Revision AB Date:
June 16, 2006
June 5, 2008
Record the following information for Warranty purposes:
Where Purchased:
_______________________________
Purchase Date:
_______________________________
Equipment Serial #:
_______________________________
i
CONTENTS
SECTION 1: SAFETY INSTRUCTIONS AND WARNINGS....................................................................................................3
1.01 Arc Welding Hazards ...........................................................................................................................................3
1.02 PRINCIPAL SAFETY STANDARDS .......................................................................................................................7
1.03 PRECAUTIONS DE SECURITE EN SOUNDAGE A L’ARC.......................................................................................8
1.04 Dangers relatifs au soudage à l’arc ......................................................................................................................8
1.05 PRINCIPAL SAFETY STANDARDS .....................................................................................................................12
SECTION 2: INTRODUCTION ..........................................................................................................................................13
2.01 How To Use This Manual....................................................................................................................................13
2.02 Equipment Identification.....................................................................................................................................13
2.04 Symbol Chart......................................................................................................................................................14
2.05 Description .........................................................................................................................................................15
2.06 Functional Block Diagrams .................................................................................................................................16
2.07 Transporting Methods ........................................................................................................................................16
SECTION 3: INSTALLATION ..........................................................................................................................................17
3.01 Environment .......................................................................................................................................................17
3.02 Location .............................................................................................................................................................17
3.03 Electrical Input Connections ............................................................................................................................... 17
3.04 Electrical Input Requirement............................................................................................................................... 18
3.05 Input Power........................................................................................................................................................19
3.06 High Frequency Introduction ..............................................................................................................................19
3.07 High Frequency Interference............................................................................................................................... 20
3.08 Duty Cycle ..........................................................................................................................................................20
3.09 Specifications .....................................................................................................................................................21
SECTION 4: OPERATOR CONTROLS .............................................................................................................................23
4.01 ARC MASTER 160TS Controls............................................................................................................................23
4.02 Weld Process selection for 160TS ......................................................................................................................25
4.03 Weld Parameter Descriptions for ARC MASTER 160TS ......................................................................................26
4.04 Weld Parameters for ARC MASTER 160TS .........................................................................................................29
4.05 Power Source Features.......................................................................................................................................30
SECTION 5: SET-UP FOR SMAW (STICK) AND GTAW (TIG)..........................................................................................31
SECTION 6: SEQUENCE OF OPERATION........................................................................................................................32
6.01 Stick Welding .....................................................................................................................................................33
6.02 HF TIG & Lift TIG Welding ..................................................................................................................................33
6.03 Slope Mode Sequence ........................................................................................................................................34
6.04 Slope Mode with repeat sequence ......................................................................................................................34
6.05 Pulse Controls ....................................................................................................................................................35
SECTION 7: ROUTINE MAINTENANCE...........................................................................................................................36
SECTION 8: BASIC TROUBLESHOOTING.......................................................................................................................38
8.01 TIG Welding Problems........................................................................................................................................38
8.02 Stick Welding Problems .....................................................................................................................................41
8.03 Power Source Problems .....................................................................................................................................44
SECTION 9: VOLTAGE REDUCTION DEVICE (VRD)..........................................................................................46
9.01 VRD Specification...............................................................................................................................................46
9.02 VRD Maintenance ...............................................................................................................................................46
9.03 Switching VRD On/Off ........................................................................................................................................49
SECTION 10: POWER SOURCE ERROR CODE .....................................................................................................50
1
CONTENTS
SECTION 11: ADVANCED TROUBLE SHOOTING............................................................................................... 52
11.01 System-Level Fault Isolation ............................................................................................................................ 52
1. Opening the Enclosure ....................................................................................................................................... 53
11.02 Verification and Remedy to the Indicated Error Codes ..................................................................................... 56
1. E01 “Over-Temperature at the primary side”...................................................................................................... 57
2. E02 “Over-Temperature at the secondary side”.................................................................................................. 57
3. E03 “Primary Over-Current Failure” .................................................................................................................. 58
4. E94 “Thermistor malfunction”............................................................................................................................ 58
5. E99 “Initial Power Receiving”............................................................................................................................. 58
11.03 Verification and Remedy to Failures without Indication Codes .........................................................................59
1. “Cooling Fan (FAN1) Failure” (Fan is not rotating.).............................................................................................59
2. “Gas Valve Failure” (No Gas flow through unit)..................................................................................................59
3. “No Weld Output” .............................................................................................................................................. 60
4. “Operating Panel Failure” (LED’s do not light properly or welding setting cannot be established.)..................... 61
5. “High Frequency Output Failure” (Unit does not generate High Frequency.)....................................................... 61
11.04 Fault Isolation Tests ......................................................................................................................................... 62
11.05 Verification of the Power Input Circuitry........................................................................................................... 63
1. Verification of the AC input voltage using an AC voltmeter................................................................................. 63
2. Verification of the Power Supply Voltage ........................................................................................................... 65
3. Verification of the Cooling Fan, FAN1, Drive Circuitry......................................................................................... 67
4. Verification of the Gas Valve, SOL1, Drive Circuitry............................................................................................ 68
5. Verification of the primary Diode (D1)................................................................................................................69
6. Verification of the secondary Diode (D2, D3) ..................................................................................................... 70
7. Verification of the primary IGBT (Q1A-Q4C)....................................................................................................... 71
8. Verification of No-load Voltage (OCV) ................................................................................................................ 72
9. Output Load Test ............................................................................................................................................... 73
SECTION 12: MAINTENANCE ................................................................................................................................ 74
12.01 Maintenance List.............................................................................................................................................. 74
12.02 Service Tools ................................................................................................................................................... 77
12.03 Replacement Procedure ................................................................................................................................... 78
1. PCB1 (WK-5466) and Primary Diode D1............................................................................................................ 78
2. PCB2 (WK-5467), Capacitor C1 and Resistor R1 ............................................................................................... 81
3. PCB3 (WK-5609) and T1 “Transformer” ............................................................................................................ 82
4. PCB4 (WK-5449) ............................................................................................................................................... 83
5. PCB5 (WK-5448) ............................................................................................................................................... 84
6. PCB6 (WK-5460) and Q1A-Q2C “Primary IGBT” ................................................................................................ 85
7. PCB7 (WK-5460) and Q3A-Q4C “Primary IGBT” ................................................................................................ 86
8. D2 and D3 “Secondary Diode” ........................................................................................................................... 86
9. C.C. “Coupling Coil”* and FCH1 “Reactor” *160TS only ................................................................................... 87
10. CT1 “Hole Current Trans”................................................................................................................................. 88
11. FAN1 “Cooling Fan” .........................................................................................................................................89
12. HF UNIT1 “High Frequency Unit” *160TS only................................................................................................ 90
13. SOL1 “Solenoid GAS Valve” *160TS only ....................................................................................................... 90
14. S1 “Switch” ..................................................................................................................................................... 91
15. CON1 “Remote Receptacle” ............................................................................................................................. 92
16. TH1 “Primary Thermistor” ............................................................................................................................... 93
17. TH2 “Secondary Thermistor” ........................................................................................................................... 93
APPENDIX A: PARTS LIST ....................................................................................................................................... 95
APPENDIX B: CONNECTION WIRING GUIDE.................................................................................................... 100
1. Connection Guide................................................................................................................................................. 100
2. Connection Wire List............................................................................................................................................ 101
APPENDIX C: CONNECTION DIAGRAM ............................................................................................................. 103
APPENDIX D: DIODE TESTING BASICS............................................................................................................... 105
2
ARCMASTER 160TS
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 outline in the American National Standard Z49.1 entitled: SAFETY IN WELDING AND CUTTING. This
publication and other guides to what you should learn before operating this equipment are listed at the end of these safety
precautions. HAVE ALL INSTALLATION, OPERATION, MAINTENANCE, AND REPAIR WORK PERFORMED ONLY BY
QUALIFIED PEOPLE.
1.01 Arc Welding Hazards
WARNING
5.
Properly install and ground this equipment according
to its Owner’s Manual and national, state, and local
codes.
6.
Turn off all equipment when not in use. Disconnect
power to equipment if it will be left unattended or out
of service.
7.
Use fully insulated electrode holders. Never dip holder
in water to cool it or lay it down on the ground or the
work surface. Do not touch holders connected to two
welding machines at the same time or touch other
people with the holder or electrode.
8.
Do not use worn, damaged, undersize, or poorly
spliced cables.
9.
Do not wrap cables around your body.
ELECTRIC SHOCK can kill
Touching live electrical parts can cause fatal shocks or
severe burns. The electrode and work circuit is
electrically live whenever the output is on. The input
power circuit and machine internal circuits are also
live when power is on. In semiautomatic or automatic
wire welding, the wire, wire reel, drive roll housing,
and all metal parts touching the welding wire are
electrically live. Incorrectly installed or improperly
grounded equipment is a hazard.
1.
Do not touch live electrical parts.
2.
Wear dry, hole-free insulating gloves and body
protection.
3.
4.
10. Ground the workpiece to a good electrical (earth)
ground.
11. Do not touch electrode while in contact with the work
(ground) circuit.
Insulate yourself from work and ground using dry
insulating mats or covers.
12. Use only well-maintained equipment. Repair or
replace damaged parts at once.
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.
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.
3
ARCMASTER 160TS
14. Wear a safety harness to prevent falling if working
above fool level.
WARNING
15. Keep all panels and covers securely in place.
FUMES AND GASES can be hazardous your health.
Welding produces fumes and gases. Breathing these
fumes and gases can be hazardous to your health.
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 eyes and skin.
Noise from some processes can damage hearing.
1.
2.
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.
Wear approved safety glasses. Side shields
recommended.
1.
Keep your head out of the fumes. Do not breath the
fumes.
2.
If inside, ventilate the area and/or use exhaust at the
arc to remove welding fumes and gases.
3.
If ventilation is poor, use an approved air-supplied
respirator.
4.
Read the Material Safety Data Sheets (MSDSs) and
the manufacturer’s instruction for metals,
consumables, coatings, and cleaners.
5.
Work in a 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.
3.
Use protective screens or barriers to protect others
from flash and flare; warn others not to watch the arc.
4.
Wear protective clothing made from durable, flameresistant material (wool and lather) and foot
protection.
5.
Use approved ear plugs or ear muffs if noise level is
high.
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
Electrode Size
Filter
Welding or cutting
2
3 or 4
Gas metal-arc
Non-ferrous base metal
Ferrous base metal
Gas tungsten arc welding
(TIG)
Atomic hydrogen welding
Carbon arc welding
Plasma arc welding
Carbon arc air gouging
Light
Heavy
Plasma arc cutting
Light
Medium
Heavy
Under 1 in., 25mm
1 to 6 in., 25-150mm
Over 6 in., 150mm
3 or 4
4 or 5
5 or 6
Under 1/8 in., 3mm
1/8 to 1/2 in., 3-12mm
Over 1/2 in., 12mm
Under 5/32 in., 4mm
5/32 to 1/4 in.,
Over 1/4 in., 6.4mm
4 or 5
5 or 6
6 or 8
10
12
14
4
Electrode Size
Filter
All
All
All
All
All
All
11
12
12
12
12
12
12
14
Under 300 Amp
300 to 400 Amp
Over 400 Amp
9
12
14
ARCMASTER 160TS
6.
7.
Do not weld in locations near degreasing, cleaning, or
spraying operations. The heat and rays of the arc can
react with vapors to from highly toxic and irritating
gases.
WARNING
FLYING SPARKS AND HOT METAL can cause injury.
Chipping and grinding cause flying metal. As weld
cool, they can throw off slag.
Do not weld on coated metals, such as galvanized,
lead, or cadmium plated steel, unless the coating is
removed from the weld area, the area is well ventilated,
and if necessary, while wearing an air-supplied
respirator. The coatings and any metals containing
these elements can give off toxic fumes if welded.
1.
Wear approved face shield or safety goggles. Side
shields recommended.
2.
Wear proper body protection to protect skin.
WARNING
WARNING
1.
WELDING can cause fire or explosion.
CYLINDERS can explode if damaged.
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.
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.
Protect yourself and others from flying sparks and hot
metal.
2.
Do not weld where flying sparks can strike flammable
material.
3.
Remove all flammables within 35 ft (10.7m) of the
welding arc. If this is not possible, tightly cover them
with approved covers.
1.
Protect compressed gas cylinders from excessive heat,
mechanical shocks, and arcs.
2.
Install and secure cylinders in an upright position by
chaining them to a stationary support or equipment
cylinder rack to prevent falling or tipping.
3.
Keep cylinders away from any welding or other
electrical circuits.
4.
Never allow a welding electrode to touch any cylinder.
5.
Use only correct shielding gas cylinders, regulators,
hoses, and fittings designed for the specific
application; maintain them and associated parts in
good condition.
4.
Be alert that welding sparks and hot materials from
welding can easily go through small cracks and
openings to adjacent areas.
5.
Watch for fire, and keep a fire extinguisher nearby.
6.
Be aware that welding on a ceiling, floor, bulkhead, or
partition can cause fire on the hidden side.
6.
Turn face away from valve outlet when opening
cylinder valve.
7.
Do not weld on closed containers such as tanks or
drums.
7.
Keep protective cap in place over valve except when
cylinder is in use or connected for use.
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.
8.
Read and follow instructions on compressed gas
cylinders, associated equipment, and CGA publication
P-1 listed Safety Standards.
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.
5
ARCMASTER 160TS
6.
WARNING
Reinstall panels or guards and close doors when
servicing is finished and before starting engine.
Engines can be dangerous.
WARNING
SPARKS can cause BATTERY GASES TO EXPLODE;
BATTERY ACID can burn eyes and skin.
WARNING
Batteries contain acid and generate explosive gases.
1. Always ware a face shield when working on a battery.
ENGINE EXHAUST GASES can kill.
Engines produce harmful exhaust gases.
1. Use equipment outside in open, well-ventilated areas.
2.
Stop engine before disconnecting or connecting
battery cables.
2.
3.
Do not allow tools to cause sparks when working on a
battery.
4.
Do not use welder to charge batteries or jump start
vehicles.
5.
Observe correct polarity (+ and -) on batteries.
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 fuse is highly flammable.
1.
Stop engine before checking or adding fuel.
2.
Do not add fuel while smoking or if unit is near any
sparks or open flames.
3.
Allow engine to cool before fueling. If possible, check
and add fuel to cold engine before beginning job.
4.
Do not overfill tank – allow room for fuel to expand.
5.
Do not spill fuel. If fuel is spilled, clean up before
stating engine.
WARNING
STEAM AND PRESSURIZED HOT COOLANT can burn
face , eyes,and skin.
The coolant in the radiator can be very hot and under
pressure.
1.
Do not remove radiator cap when engine is hot. Allow
engine to cool.
2.
Wear gloves and put a rag over cap area when
removing cap.
3.
Allow pressure to escape before completely removing
cap.
WARNING
MOVING PARTS can cause injury.
Moving parts, such as fans, rotors, and belts can cut
fingers and hands and catch loose clothing.
1. Keep all doors, panels, covers, and guards closed and
securely in place.
2.
Stop engine before installing or connecting unit.
3.
Have only qualified people remove guards or covers
for maintenance and troubleshooting as necessary.
4.
To prevent accidental starting during servicing,
disconnect negative (-) battery cable from battery.
5.
Keep hands, hair, loose clothing, and tools away from
moving parts.
6
ARCMASTER 160TS
1.02 PRINCIPAL SAFETY STANDARDS
WARNING
This product, when used for welding or cutting,
produces fumes or gases which contain chemicals
know to the State of California to cause birth defects
and, in some cases, cancer. (California Health &
Safety code sec. 25249.5 et seq.)
Safety in Welding and Cutting, ANSI Standard Z49.1, from
the American Welding Society, 550 N.W. LeJeune Rd.,
Miami, FL 33126.
Safety and Health Standards, OSHA, 29CFR 1910, SAFETY
AND HEALTH STANDARDS, obtainable from
Superintendent of Documents, U.S. Government Printing
Office, Washington, D.C. 20402.
NOTE
Considerations About Welding And The Effects of Low
Frequency Electric and Magnetic Fields.
Recommended Safe Practices for the Preparation for
Welding and Cutting of Containers That Have Held
Hazardous Substances, American Welding Society
Standard AWSF4.1, obtainable from the American Welding
Society, 550 N.W. LeJeune Rd, Miami, FL 33126.
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-E63 (Washington, DC; U.S. Government Printing Office,
MAY 1989): “…there is now a very large volume of
scientific findings based on experiment at the cellular level
and from studies with animals and people which clearly
establish that low frequency magnetic fields and interact
with, and produce changes in, biological systems. While
most of this work is of very high quality, the results are
complex. Current scientific understanding does not yet
allow us to interpret the evidence in a single coherent
framework. Even more frustrating, it does not yet allow us
to draw definite conclusions about questions of possible
risk or to offer clear science-based advice on strategies to
minimize or avoid potential risk.”
National Electrical Code, NFPA Standard 70, obtainable
from the National Fire Protection Association,
Batterymarch Park, Quincy, MA 02269.
Safe Handling of Compressed Gases in Cylinders, CGA
Pamphlet P-1, obtainable from the Compressed Gas
Association, 1235 Jefferson Davis Highway, Suite 501,
Arlington, VA 22202.
Code for Safety in Welding and Cutting, CSA Standard
W117.2, obtainable from the Canadian Standards
Association, Standards Sales, 178 Rexdale Boulevard,
Rexdale, Ontario, Canada M9W 1R3.
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.
Safe Practices for Occupation and Educational Eye and
Face Protection, ANSI Standard Z87.1, obtainable from
American National Standards Institute, 1430 Broadway,
New York, NY 10018.
Cutting and Welding Processes, NFPA Standard 51B,
obtainable from the National Fire Protection Association,
Batterymarch Park, Quincy, MA 02269.
ABOUT PACEMAKERS:
The above procedures are among those also
normaly recommended for pacemaker
wearers. Consult your doctor for complete
information.
7
ARCMASTER 160TS
1.03 PRECAUTIONS DE SECURITE EN SOUNDAGE A L’ARC
MISE EN GARD
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 meme 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 entrainement 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 REPARTION,
D’ENTRETIEN ET D’ESSAI
l’entretien. Bloquez le commutateur en circuit ouvert
ou enlevez les fusibles de l’alimentation afin d’éviter
une mise en marche accidentelle.
1.04 Dangers relatifs au soudage à l’arc
5.
Veuillez à installer cet équipement et à le mettre à la
terre selon le manuel d’utilisation et les codes
nationaux, provinciaux et locaux applicables.
6.
Arrêtez tout équipement après usage. Coupez
l’alimentation de l’équipement s’il est hors d’usage ou
inutilisé.
7.
N’utilisez que des porte-électrodes bien isolés. Ne
jamais plonger les porte-électrodes dans l’eau pour
les refroidir. Ne jamais les laisser traîner par terre ou
sur les pièces à souder. Ne touchez pas aux
porteelectrodes raccordes 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 cables électriques usés,
endommagés, mal épissés ou de section trop petite.
AVERTISSEMENT
L’ELECTROCUTION PEUT ETRE MORTELLE.
Une décharge électrique peut tuer ou brûler
gravement. L’électrode et le circuit de soudage
sont sous tension dès la mise en circuit. Le
circuit d’alimentation et les circuits internes
de l’équipement sont aussi sous tension dés
la mise en marche. En soudage automatique
ou semi-automatique avec fil, ce dernier, le
rouleau ou la bobine de fil, le logement des
galets d’entrainement et toutes les pièces
métalliques en contact avec le fil de soudage
sont sous tension. Un équipement inadéquatement
installé ou inadéquatement
mis à la terre est dangereux.
1.
2.
3.
4.
9.
N’enroulez pas de câbles électriques autour de votre
corps.
10. N’utilisez qu’une bonne prise de masse pour la mise à
la terre de la pièce à souder.
11. Ne touchez pas à l’électrode lorsqu’en contact avec le
circuit de soudage (terre).
Ne touchez pas à des pièces sous tension.
Portez des gants et des vêtements isolants, secs et
non troués.
Isolez-vous de la pièce à souder et de la mise à la
terre au moyen de tapis isolants ou autres.
Déconnectez la prise d’alimentation de l’équipement
ou arrêtez le moteur avant de l’installer ou d’en faire
12. N’utilisez que des équipements en bon état. Réparez
ou remplacez aussitôt les pièces endommagées.
13. Dans des espaces confinés ou mouilles, n’utilisez pas
de source de courant alternatif, à moins qu’il soit
8
ARCMASTER 160TS
yeux lorsque vous soudez ou que vous observez
l’exécution d’une soudure.
muni d’un réducteur de tension. Utilisez plutôt une
source de courant continu.
14. Portez un harnais de sécurité si vous travaillez en
hauteur.
2.
Portez des lunettes de sécurité approuvées. Des
écrans latéraux sont recommandés.
15. Fermez solidement tous les panneaux et les capots.
3.
Entourez l’aire de soudage de rideaux ou de cloisons
pour protéger les autres des coups d’arc ou de
l’éblouissement; avertissez les observateurs de ne pas
regarder l’arc.
4.
Portez des vêtements en matériaux ignifuges et
durables (laine et cuir) et des chaussures de sécurité.
5.
Portez un casque antibruit ou des bouchons d’oreille
approuvés lorsque le niveau de bruit est élevé.
AVERTISSEMENT
LE RAYONNEMENT DE L’ARC PEUT BRÛLER LES
YEUX ET LA PEAU; LE BRUIT PEUT ENDOMMAGER
L’OUIE.
L’arc de soudage produit une chaleur et des
rayons ultraviolets intenses, susceptibles de
brûler les yeux et la peau. Le bruit causé par
certains procédés peut endommager l’ouïe.
1.
AVERTISSEMENT
LES VAPEURS ET LES FUMEES SONT
DANGEREUSES POUR LA SANTE.
Le soudage dégage des vapeurs et des fumées
dangereuses à respirer.
Portez une casque de soudeur avec filtre oculaire de
nuance appropriee (consultez la norme ANSI Z49
indiquee ci-aprés) pour vous protéger le visage et les
Opération de
coupage ou soudage
Brassage tender au
chalumeau
Brassage fort au
chalumeau
Oxycoupage
SELECTION DES NUANCES DE FILTRES OCULAIRS POUR LA PROTECTION
DES YEUX EN COUPAGE ET SOUDAGE (selon AWS à 6.2-73)
Nuance
Dim ension d’électrode ou
Dim ension d’électrode ou
Opération de coupage ou soudage
de filter
Epiasseur de métal ou
Epiasseur de métal ou
oculaire
Intensité de courant
Intensité de courant
Soudage á l'arc sous gaz avec fil
Toutes conditions
2
plein (GMAW)
Toutes conditions
3 ou 4
mince
moins de 1 po. (25mm)
3 ou 4
moyen
de 1 à 6 po. (25 à 150mm)
4 ou 5
plus de 6 po. (150mm)
5 ou 6
épais
Soudage auxgaz
mince
moyen
épais
Soudage á l'arc avec
électrode enrobes
(SMAW)
moins de 1/8 po. (3mm)
de 1/8 à 1/2 po.
(3 à 12mm)
plus de 1/2 po. (12mm)
4 ou 5
métaux non-ferreux
Toutes conditions
11
métaux ferreux
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)
Gougeage Air-Arc avec
électrode de carbone
Toutes conditions
12
Toutes conditions
12
Toutes conditions
12
Toutes conditions
12
Toutes conditions
12
5 ou 6
mince
6 ou 8
épais
monis de 5/32 po. (4mm)
10
5/32 à 1/4 po. (4 à 6.4mm)
plus de 1/4 po. (6.4mm)
12
14
1.
Eloignez la tete des fumées pour éviter de les respirer.
2.
A l’intérieur, assurez-vous que l’aire de soudage est
bien ventilée ou que les fumees et les vapeurs sont
aspirées à l’arc.
Nuance
de filter
oculaire
12
Coupage á l'arc Plasma (PAC)
mince
moyen
épais
3.
9
14
monis de 300 amperés
de 300 á 400 amperés
plus de 300 amperés
Si la ventilation est inadequate, portez un respirateur à
adduction d’air approuvé.
9
12
14
ARCMASTER 160TS
4.
5.
6.
7.
Lisez les fiches signalétiques et les consignes du
fabricant relatives aux métaux, aux produits
consummables, aux revêtements et aux produits
nettoyants.
Ne travaillez dans un espace confiné que s’il est bien
ventilé; sinon, portez un respirateur a 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 a la
respiration.
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.
6.
N’oubliez pas qu’une soudure réalisée sur un plafond,
un plancher, une cloison ou une paroi peut enflammer
l’autre côté.
7.
Ne soudez pas un récipient fermé, tel un réservoir ou
un baril.
8.
Connectez le câble de soudage le plus près possible
de la zone de soudage pour empêcher le courant de
suivre un long parcours inconnu, et prévenir ainsi les
risques d’électrocution et d’incendie.
9.
Ne dégelez pas les tuyaux avec un source de courant.
10. Otez l’électrode du porte-électrode ou coupez le fil au
tube-contact lorsqu’inutilisé après le soudage.
11. Portez des vêtements protecteurs non huileux, tels
des gants en cuir, une chemise épaisse, un pantalon
revers, des bottines de sécurité et un casque.
Ne soudez des tôles galvanisées ou plaquées au
plomb ou au cadmium que si les zones à souder ont
été grattées à fond, que si l’espace est bien ventilé; si
nécessaire portez un respirateur à adduction d’air. Car
ces revêtements et tout métal qui contient ces
éléments peuvent dégager des fumées toxiques au
moment du soudage.
AVERTISSEMENT
LES 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.
AVERTISSEMENT
LE SOUDAGE PEUT CAUSER UN INCENDIE OU UNE
EXPLOSION.
L’arc produit des étincellies et des projections. Les
particules volantes, le métal chaud, les projections de
soudure et l’équipement surchauffé peuvent causer un
incendie et des brûlures. Le contact accidentel de
l’électrode ou du fil-électrode avec un objet métallique
peut provoquer des étincelles, un échauffement ou
un incendie.
1.
Portez un écran facial ou des lunettes protectrices
approuvées. Des écrans latéraux sont recommandés.
2.
Portez des vêtements appropriés pour protéger la
peau.
AVERTISSEMENT
1.
Protégez-vous, ainsi que les autres, contre les
étincelles et du métal chaud.
LES BOUTEILLES
EXPLOSER.
2.
Ne soudez pas dans un endroit où des particules
volantes ou des projections peuvent atteindre des
matériaux inflammables.
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.
3.
Enlevez toutes matières inflammables dans un rayon
de 10, 7 mètres autour de l’arc, ou couvrez-les
soigneusement avec des bâches approuvées.
1.
Protégez les bouteilles de gaz comprimé contre les
sources de chaleur intense, les chocs et les arcs de
soudage.
Méfiez-vous des projections brulantes de soudage
susceptibles de pénétrer dans des aires adjacentes
par de petites ouvertures ou fissures.
2.
Enchainez verticalement les bouteilles à un support ou
à un cadre fixe pour les empêcher de tomber ou d’être
renversées.
4.
5.
Méfiez-vous des incendies et gardez un extincteur à
portée de la main.
10
ENDOMMAGEES
PEUVENT
ARCMASTER 160TS
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.
5.
Faites attention de ne pas renverser de carburant.
Nettoyez tout carburant renversé avant de faire
démarrer le moteur.
AVERTISSEMENT
DES PIECES EN MOUVEMENT PEUVENT CAUSER
DES BLESSURES.
Des pièces en
mouvement, tels des ventilateurs, des rotors et des
courroies peuvent couper doigts et mains, ou
accrocher des vêtements amples.
6.
Ne placez pas le visage face à l’ouverture du robinet
de la bouteille lors de son ouverture.
7.
Laissez en place le chapeau de bouteille sauf si en
utilisation ou lorsque raccordé pour utilisation.
1.
Assurez-vous que les portes, les panneaux, les capots
et les protecteurs soient bien fermés.
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.
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
LES MOTEURS PEUVENT ETRE DANGEREUX LES
GAZ D’ECHAPPEMENTDES MOTEURS PEUVENT ETRE
MORTELS.
Les moteurs produisent des gaz d’échappement nocifs.
1.
2.
Utilisez l’équipement à l’extérieur dans des aires
ouvertes et bien ventilées.
Si vous utilisez ces équipements dans un endroit
confiné, les fumées d’échappement doivent être
envoyées à l’extérieur, loin des prises d’air du
bâtiment.
AVERTISSEMENT
AVERTISSEMENT
DES ETINCELLES PEUVENT FAIRE EXPLOSER UN
ACCUMULATEUR; L’ELECTROLYTE D’UN ACCUMULATEUR PEUT BRULER LA PEAU ET LES YEUX.
Les accumulateurs contiennent de l’électrolyte acide et
dégagent des vapeurs explosives.
LE CARBURANT PEUR CAUSER UN INCENDIE OU
UNE EXPLOSION.
Le carburant est
hautement inflammable.
1.
2.
3.
4.
Arrêtez le moteur avant de vérifier le niveau e
carburant ou de faire le plein.
Ne faites pas le plein en fumant ou proche d’une
source d’étincelles ou d’une flamme nue.
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.
Ne faites pas le plein de carburant à ras bord:
prévoyez de l’espace pour son expansion.
11
1.
Portez toujours un écran facial en travaillant sur un
accumu-lateur.
2.
Arrêtez le moteur avant de connecter ou de
déconnecter des câbles d’accumulateur.
3.
N’utilisez que des outils anti-étincelles pour travailler
sur un accumulateur.
ARCMASTER 160TS
4.
5.
N’utilisez pas une source de courant de soudage pour
charger
un
accumulateur
ou
survolter
momentanément un véhicule.
1.05 PRINCIPAL SAFETY STANDARDS
Safety in Welding and Cutting, ANSI Standard Z49.1, from the
American Welding Society, 550 N.W. LeJeune Rd., Miami, FL
33126.
Utilisez la polarité correcte (+ et –) de l’accumulateur.
Safety and Health Standards, OSHA, 29CFR 1910, SAFETY AND
HEALTH STANDARDS, obtainable from Superintendent of
Documents, U.S. Government Printing Office, Washington, D.C.
20402.
AVERTISSEMENT
Recommended Safe Practices for the Preparation for Welding
and Cutting of Containers That Have Held Hazardous Substances,
American Welding Society Standard AWSF4.1, obtainable from
the American Welding Society, 550 N.W. LeJeune Rd, Miami, FL
33126.
LA VAPEUR ET LE LIQUIDE DE REFROIDISSEMENT
BRULANT SOUS PRESSION PEUVENT BRULER LA
PEAU ET LES YEUX.
Le liquide de refroidissement d’un radiateur peut être
brûlant et sous pression.
1.
N’ôtez pas le bouchon de radiateur tant que le moteur
n’est pas refroidi.
2.
Mettez des gants et posez un torchon sur le bouchon
pour l’ôter.
Laissez la pression s’échapper avant d’ôter
complètement le bouchon.
3.
National Electrical Code, NFPA Standard 70, obtainable from the
National Fire Protection Association, Batterymarch Park, Quincy,
MA 02269.
Safe Handling of Compressed Gases in Cylinders, CGA Pamphlet
P-1, obtainable from the Compressed Gas Association, 1235
Jefferson Davis Highway, Suite 501, Arlington, VA 22202.
Code for Safety in Welding and Cutting, CSA Standard W117.2,
obtainable from the 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, obtainable from American
National Standards Institute, 1430 Broadway, New York, NY
10018.
Cutting and Welding Processes, NFPA Standard 51B, obtainable
from the National Fire Protection Association, Batterymarch Park,
Quincy, MA 02269.
12
ARCMASTER 160TS
SECTION 2:
INTRODUCTION
2.02 Equipment Identification
The unit’s identification number (specification or
part number), model, and serial number usually
appear on a nameplate attached to the control
panel. In some cases, the nameplate may be
attached to the rear panel. Equipment which
does not have a control panel such as gun and
cable assemblies is identified only by the
specification or part number printed on the
shipping container. Record these numbers on
the bottom of page i for future reference.
2.01 How To Use This Manual
This Service Manual applies to just specification
or part numbers listed on page i.
To ensure safe operation, read the entire manual,
including the chapter on safety instructions and
warnings.
Throughout this manual, the words WARNING,
CAUTION, and NOTE may appear. Pay particular
attention to the information provided under these
headings. These special annotations are easily
recognized as follows:
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
13
ARCMASTER 160TS
2.04 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)
SEC
Seconds
Remote Control (Panel/Remote)
%
Percent
Remote Function
DC (Direct Current)
Arc Control (SMAW)
AC (Alternating Current
Gas Post-Flow
Standard Function
Gas Pre-Flow
VRD
Slope Function
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
14
ARCMASTER 160TS
2.05 Description
The Thermal Arc™ Model 160TS 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, gas
control valve, built in Sloper and Pulser, lift arc starter, and high-frequency arc starter for use with Gas
Tungsten Arc Welding (GTAW), Gas Tungsten Arc Welding-Pulsed (GTAW-P) Gas Tungsten Arc WeldingSloped (GTAW-S), and Shielded Metal Arc Welding (SMAW) processes. The power source is totally
enclosed in an impact resistant, flame resistant and non-conductive plastic case.
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.
(V)
(V)
OCV
OCV
10V
25A
200A
(A)
LIFT TIG Process
5A
HF TIG Process
(V)
OCV
5A
160A
(A)
STICK Process
Figure 2-1: Model 160TS Volt-Ampere curve
15
160A
(A)
ARCMASTER 160TS
2.06 Functional Block Diagrams
Figure 2-2 illustrates the functional block diagram of the 160TS-power supply.
Input
Power
Main
Circuit
Switch
Input
Diode
Filter
Capacitor
DC Power
Primary
Voltage
Sensor
IGBT
Inverter
Themal
Detector
Main
Transformers
(T1)
Hall Current
Output
Diodes
Transformer
(HCT1)
Output
Inductor
To each control circuit
+/-12VDC +18VDC
+24VDC +5VDC
Trouble
Sensing
Circuit
Thermal
Sensor
Circuit
HF Unit
Control
Circuit
Drive
Circuit
Coupling
Coil
Stick Mode Lift Tig Mode
VRD
Output Short
Sensing
Sensing
Circuit
Circuit
Primary
Circuit
Sensor
High
Frequency
Unit
Sequence
Control
Torch Control
Connection
(CON1)
Current
Reference
Adjustment
Adjustment &
Circuit
Mode select Switch
Fan Control
Circuit
Fan
Gas Control
Circuit
Solenoid
Panel Circuit Boad
Figure 2-2: 160TS Model Functional Block Diagram
2.07 Transporting Methods
These units are equipped with a handle for carrying purposes.
WARNING
ELECTRIC SHOCK can kill.
DO NOT TOUCH live electrical parts.
Disconnect input power conductors from de-energized supply line before moving the welding
power source.
WARNING
FALLING EQUIPMENT can cause serious personal injury and equipment damage.
Lift unit with handle on top of case.
Use handcart or similar device of adequate capacity.
If using a fork lift vehicle, place and secure unit on a proper skid before transporting.
16
ARCMASTER 160TS
・ Place at a distance of 12" (304.79mm) or
more from walls or similar boundaries that
could restrict natural airflow for cooling.
SECTION 3:
INSTALLATION
3.01 Environment
The ARC MASTER 160TS is designed for use in
adverse environments.
WARNING
Examples of environments with increased
adverse conditions are:
Thermal Arc advises that this equipment be
electrically connected by a qualified
electrician.
a. In locations in which freedom of movement
is restricted, so that the operator is forced
to perform the work in a cramped (kneeling,
sitting or lying) position with physical
contact with conductive parts;
b. In locations which are fully or partially
limited by conductive elements, and in
which there is a high risk of unavoidable or
accidental contact by the operator, or
c. In wet or damp hot locations where
humidity or perspiration considerably
reduces the skin resistance of the human
body and the insulation properties of
accessories.
Environments with adverse conditions do not
include places where electrically conductive
parts are in the near vicinity of the operator,
which can cause increased hazard, have been
insulated.
3.03 Electrical Input Connections
WARNING
ELECTRIC SHOCK can kill; SIGNIFICANT DC
VOLTAGE is present after removal of input
power.
DO NOT TOUCH live electrical parts.
SHUT DOWN welding power source, disconnect
input
power
employing
lockout/tagging
procedures. Lockout/tagging procedures consist
of padlocking line disconnect switch in open
position, removing fuses from fuse box, or
shutting off and red-tagging circuit breaker or
other disconnecting device.
3.02 Location
Be sure to locate the welder according to the
following guidelines:
・ In areas, free from moisture and dust.
・ Ambient temperature between 0 degrees C
to 40 degrees C.
・ In areas, free from oil, steam and corrosive
gases.
・ In areas, not subjected to abnormal
vibration or shock.
・ In areas, not exposed to direct sunlight or
rain.
17
ARCMASTER 160TS
for single phase electrical input power. For direct
wiring installation have a qualified person install
according to all applicable codes and instructions for
single and three phase electrical input power.
3.04 Electrical Input Requirement
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.
Do not connect an input (WHITE or BLACK)
conductor to the ground terminal.
Do not connect the ground (GREEN) conductor
to an input line terminal.
Refer to figure 3-1 and:
1. Connect end of ground (GREEN) conductor
to a suitable ground. Use a grounding
method that complies with all applicable
electrical codes.
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.
2. Connect ends of line 1 (BLACK) and line 2
(WHITE) input conductors to a de-energized
line disconnect switch.
Note
This unit is equipped with a 250 VAC (NEMA 6-50P)
plug molded on the two-conductor with earth power
cable that is connected at the welding power source
3. Use Table 1 and Table 2 as a guide to select
line fuses for the disconnect switch.
Input Voltage
Fuse Size
115V
75 Amps
230V
75 Amps
Table 3-1: Electrical Input Connections
Note
Fuse size is based on not more than 200 percent of the rated input amperage of the welding
power source (Based on Article 630, National Electrical Code).
Figure 3-1: Electrical Input Connections
18
ARCMASTER 160TS
3.05 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 (approximately 5 seconds).
Note
Note the available input power. Damage to the welder could occur if 460VAC or higher is
applied.
The following 208-230V Primary Current recommendations are required to obtain the maximum welding
current and duty cycle from this welding equipment:
Model
ARC
MASTER
160TS
Primary Supply
Lead Size
(Factory Fitted)
Minimum Primary
Current Circuit Size
(Vin/Amps)
12/3 AWG
minimum
115/23
208/28
230/25
115/40
208/44
230/39
Current & Duty Cycle
TIG
STICK
85 @ 100%
85 @ 100%
160 @ 35%
-
160 @ 35%
Table 3-2: 208-230V Primary Current Circuit sizes to achieve maximum current
The ARC MASTER 160TS 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.
3.06 High Frequency Introduction
WARNING: Explosives
The high frequency section of this machine
has an output similar to a radio transmitter.
The machine should NOT be used in the
vicinity of blasting operations due to the
danger of premature firing.
The importance of correct installation of high
frequency welding equipment cannot be overemphasized. Interference due to high frequency
initiated or stabilized arc is almost invariably
traced to improper installation. The following
information is intended as a guide for personnel
installing high frequency welding machines.
WARNING: Computers
It is also possible that operation close to computer
installations may cause computer malfunction.
19
ARCMASTER 160TS
3.07 High Frequency Interference
3.08 Duty Cycle
Interference may be transmitted by a high
frequency initiated or stabilized arc welding
machine in the following ways:
1. Direct Radiation: Radiation from the machine
can occur if the case is metal and is not
properly grounded. It can occur through
apertures such as open access panels. The
shielding of the high frequency unit in the
Power Source will prevent direct radiation if
the equipment is properly grounded.
2. Transmission via the Supply Lead: Without
adequate shielding and filtering, high
frequency energy may be fed to the wiring
within the installation (mains) by direct
coupling. The energy is then transmitted by
both radiation and conduction. Adequate
shielding and filtering is provided in the Power
Source.
3. Radiation from Welding Leads: Radiated
interference from welding leads, although
pronounced in the vicinity of the leads,
diminishes rapidly with distance. Keeping
leads as short as possible will minimize this
type of interference. Looping and suspending
of leads should be avoided where possible.
4. Re-radiation from Unearthed Metallic
Objects: A major factor contributing to
interference is re-radiation from unearthed
metallic objects close to the welding leads.
Effective grounding of such objects will
prevent re-radiation in most cases.
The duty cycle of a welding power source is the
percentage of a ten (10) minute period that it can
be operated at a given output without causing
overheating and damage to the unit. If the
welding amperes decrease, the duty cycle
increases. If the welding amperes are increased
beyond the rated output, the duty cycle will
decrease.
WARNING
Exceeding the duty cycle ratings will cause
the thermal overload protection circuit to
become energized and shut down the output
until the unit has cooled to normal operating
temperature.
CAUTION
Continually exceeding the duty cycle ratings
can cause damage to the welding power
source and will void the manufactures
warranty.
NOTE
Due to variations that can occur in
manufactured products, claimed
performance, voltages, ratings, all capacities,
measurements, dimensions and weights
quoted are approximate only. Achievable
capacities and ratings in use and operation
will depend upon correct installation, use,
applications, maintenance and service.
20
ARCMASTER 160TS
3.09 Specifications
Parameter
Rated Output
Amperes
Volts
Duty Cycle
Duty Cycle
TIG
STICK
Output Current
TIG
Range
STICK
Open Circuit Voltage
Dimensions
Width
Height
Length
Weight
Output @ Rated Load
Output Amperes
Output Volts
Duty Cycle
KVA
KW
Output @ No Load
KVA
KW
Input Volts Single Phase
208V
230V
160TS
115VAC
230VAC
85
160
23
27
100%
35%
160A / 17V @ 35%
230VAC
130A / 15V @ 60%
230VAC
100A / 14V @ 100%
230VAC
85A / 13V @ 100%
115VAC
160A / 27V @ 35%
230VAC
130A / 25V @ 60%
230VAC
100A / 24V @ 100%
230VAC
85A / 23V @ 100%
115VAC
1 – 160 (230V), 1 – 85 (115V)
1 – 160 (230V), 1 – 85 (115V)
65V
5.12” (130mm)
10.24” (260mm)
12.60” (320mm)
17.63 lb. 8.0 kg
115V
230V
85A
160A
23V
27V
100%
35%
4.4
8.7
2.4
5.2
0.5
0.3
Amperage Draw @ Rated Load
44
39
No Load Amps
2.2
1.6
Thermal Arc continuously strives to produce the best product possible and therefore reserves the right to change, improve or revise the
specifications or design of this or any product without prior notice. Such updates or changes do not entitle the buyer of equipment previously
sold or shipped to the corresponding changes, updates, improvements or replacement of such items.
The values specified in the table above are optimal values, your values may differ. Individual equipment may differ from the above
specifications due to in part, but not exclusively, to any one or more of the following; variations or changes in manufactured components,
installation location and conditions and local power grid supply conditions.
21
ARCMASTER 160TS
SECTION 4:
OPERATOR CONTROLS
4.01 ARC MASTER 160TS Controls
7
6
2
1
5
4
3
8
Figure 4-1: ARC MASTER 160TS Power Source
Socket Pin
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
2
3
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.
4
GND
2
1
12345678
5
4
3
8
7
6
Fr ont view 8- Socket Receptacl e
5k Ohms
Function
Earth (Ground)
Torch Switch Input (24V) to
(connect pins 2 & 3 to turn on
welding current)
Torch Switch Input (0V) to energize
weld current
(connect pins 2 & 3 to turn on
welding current)
Connect pin 4 to pin 8 to instruct
machine that a remote current control
device is connected (12V DC supply)
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)
Figure 4-2: 8-Socket Receptacle
Table 4-1: Socket Pin Functions
23
ARCMASTER 160TS
3. Positive Terminal: Welding current flows
from the Power Source via heavy duty Dinse
type terminal (Size 25mm Dinse). It is
essential, however, that the male plug is
inserted and turned securely to achieve a
sound electrical connection.
4. Negative Terminal: Welding current flows
from the Power Source via heavy duty Dinse
type terminal (Size 25mm Dinse). 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.
5. Gas Outlet: The Gas Outlet is a 5/8 18 UNF
female gas fitting.
6. ON/OFF Switch: This switch connects the
Primary supply voltage to the inverter when in
the ON position. This enables the Power
Supply.
WARNING
When the welder is connected to the Primary
supply voltage, the internal electrical
components may be at 240V potential with
respect to earth.
7. Input Cable: The input cable connects the
Primary supply voltage to the equipment.
8. Gas Inlet: The Gas Inlet is a 5/8 18 UNF
female gas fitting.
24
ARCMASTER 160TS
4.02 Weld Process selection for 160TS
Weld Mode
Weld Process
Selection
STICK
HF
TIG
LIFT
TIG
Yes
Yes
Yes
2T operation in TIG Modes using remote
devices to control contactor & current
No
Yes
Yes
4T operation in TIG Modes with crater fill
using a remote contactor device to control
sequence.
No
Yes
Yes
4T operation in TIG Modes with repeat
operation and crater fill using a remote
contactor device.
No
Yes
No
2T operation spot welding in HF TIG using a
remote contactor device.
No
Yes
Yes
Pulse operation in TIG Modes
Description
STD
SLOPE
REPEAT
SPOT
PULSE ON/OFF
Table 4-2: Weld Process selection verses Weld Mode for 160TS
25
ARCMASTER 160TS
4.03 Weld Parameter Descriptions for ARC MASTER 160TS
Figure 4-3: ARC MASTER 160TS Front Panel with Parameter Description
Parameter
PRE-FLOW
HOT START
Description
This parameter operates in TIG modes only and is used to provide gas to
the weld zone prior to striking the arc, once the torch trigger switch has
been pressed. This control is used to dramatically reduce weld porosity at
the start of a weld.
This parameter operates in all weld modes except Lift TIG mode and is
used to heat up the weld zone in TIG modes or improve the start
characteristics for stick electrodes. e.g. low hydrogen electrodes. It sets
the peak start current on top of the BASE (WELD) current.
e.g. HOT START current = 130 amps when BASE (WELD) = 100 amps &
HOT START = 30 amps
INITIAL CUR.
This parameter operates in SLOPE or REPEAT (4T) TIG modes only and is
used to set the start current for TIG. The Start Current remains on until the
torch trigger switch is released after it has been depressed.
UP SLOPE
This parameter operates in TIG modes only and is used to set the time for
the weld current to ramp up, after the torch trigger switch has been pressed
then released, from INITIAL CUR to PEAK or BASE current
PEAK CUR.
WELD
This parameter sets the PEAK weld current when in PULSE mode
This parameter sets the TIG WELD current in STD, SLOPE, REPEAT and
SPOT modes when PULSE is off. This parameter also sets the STICK weld
current.
BASE
(Background
Current)
SPOT TIME
PULSE WIDTH
This parameter sets the Background current when in Pulse TIG mode.
PULSE FREQ.
This parameter sets the PULSE FREQUENCY when the PULSE is on.
This parameter sets the duration of the SPOT TIME in HF TIG mode only
This parameter sets the percentage on time of the PULSE FREQUENCY for
PEAK weld current when the PULSE is on.
26
ARCMASTER 160TS
Parameter
Description
DOWN SLOPE
This parameter operates in TIG modes only and is used to set the time for
the weld current to ramp down, after the torch trigger switch has been
pressed, to CRATER CUR. This control is used to eliminate the crater that
can form at the completion of a weld.
CRATER CUR.
This parameter operates in SLOPE or REPEAT (4T) TIG modes only and is
used to set the finish current for TIG. The CRATER Current remains on until
the torch trigger switch is released after it has been depressed.
POST-FLOW
This parameter operates in TIG modes only and is used to adjust the post
gas flow time once the arc has extinguished. This control is used to
dramatically reduce oxidation of the tungsten electrode.
The SAVE/LOAD buttons are used to save and retrieve a total number of 5
programs into the 160TS memory.
Table 4-3: Weld Parameter Descriptions for ARC MASTER 160TS
27
ARCMASTER 160TS
Figure 4-4: ARC MASTER 160TS Front Panel with Parameter Description
Parameter
Description
HOT START
This parameter operates in STICK weld mode and is used to improve the
start characteristics for stick electrodes. e.g. low hydrogen electrodes. It
sets the peak start current on top of the (WELD) current.
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.
LIFT TIG mode of operation. A remote control device may be used for use
during LIFT TIG operation. See section 4.01, section 2 “Remote Control
Socket”, for complete details of the remote device.
STICK Mode of operation
Table 4-4: Weld Parameter Descriptions for ARC MASTER 160TS
28
ARCMASTER 160TS
4.04 Weld Parameters for ARC MASTER 160TS
Weld Mode
Weld
Parameter
Parameter
Factory
Incremental
Range
Setting
Unit
STICK
PRE-FLOW
0.0 to 1.0 sec
0 sec
0.1 sec
No
HOT START
0 to 70A
20A
1A
Yes
INITIAL CUR.
1 to 160A
30A
1A
No
UP SLOPE
0 to 15 sec
1 sec
0.1 sec
No
PEAK CUR.
1 to 160A
120A
1A
No
WELD CUR
1 to 160A 230V
80A
1A
Yes
1 to 85A 115V
80A
1A
Yes
SPOT TIME
0.5 to 5.0 sec
2 sec
0.1 sec
No
PULSE WIDTH
15 to 80%
50%
1%
No
PULSE FREQ.
0.5 to 500Hz
100.0Hz
See Table 4-6
No
DOWN SLOPE
0 to 25 sec
3 sec
0.1 sec
No
CRATER CUR.
1 to 160A
30A
1A
No
POST-FLOW
0.0 to 60 sec
10 sec
0.1 sec
No
Table 4-5: Weld Parameters for ARC MASTER 160TS
PULSE FREQ. Range
0.5 to 20Hz
Incremental Unit
0.1Hz
20 to 100Hz
1Hz
100 to 500Hz
5Hz
Table 4-6: PULSE FREQ. Range and Incremental Units
29
HF
TIG
Yes
Yes
Yes
Yes
Yes
Yes
Yes
Yes
Yes
Yes
Yes
Yes
Yes
LIFT
TIG
Yes
No
Yes
Yes
Yes
Yes
Yes
No
Yes
Yes
Yes
Yes
Yes
ARCMASTER 160TS
4.05 Power Source Features
Feature
Description
New Digital Control
• Almost all welding parameters are adjustable
Touch Panel Switches
• Touch switches eliminate mechanical damage
Front Control Cover
• Protects front panel controls
Digital Meter
• Displays selected weld parameter value
• Displays weld current when welding
• Displays weld current for 20 seconds after weld has been completed
• A selected weld parameter value can be adjusted at any time even
while welding
ON/OFF switch
• Primary voltage Supply ON/OFF switch located on rear panel
Save/Load Function
• A total number of 5 programs can be saved into the 160TS memory
SAVE the Current Weld Parameters into Memory
• Press the SAVE button
• Select a memory location by rotating the control knob, 1 to 5 is
displayed on the meter
• After selecting the desired memory location (ie 1 to 5), press the
right scroll button and the machine will give a beep to verify the
weld parameters from the control panel are saved.
LOAD (retrieve) a Program to Control Panel
• Press the LOAD button
• Select a memory location by rotating the control knob, 1 to 5 is
displayed on the meter
• After selecting the desired memory location (ie 1 to 5), press the
right scroll button and the machine will give a beep to verify the
weld parameters from the weld parameters are loaded.
Voltage Reduction Device Reduces the OCV when the power supply is not in use. Eliminates the
need for add on voltage reducers and has no effect on arc starting.
(VRD)
• VRD fully complies to IEC 60974-1
• When Stick mode is selected the green VRD light is ON when not
welding and red when welding.
• When in TIG modes VRD is off.
Control Knob
• For the selected weld parameter, rotating the knob clockwise
increases the parameter
• Rotating the knob counter-clockwise decreases the parameter
• A selected weld parameter value can be adjusted at any time even
while welding
• Pushing the knob in displays actual arc voltage.
Self Diagnosis Using Error
Codes
• 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 4-7: Power Source Features
30
ARCMASTER 160TS
SECTION 5:
SET-UP FOR SMAW (STICK) AND GTAW (TIG)
Conventional operating procedures apply when
using the Welding Power Source, i.e. connect
work lead directly to work piece and electrode
lead is used to hold electrode. Wide safety
margins provided by the coil design ensure that
the Welding Power Source will withstand shortterm 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.
Figure 6-1: 160TS Set-up
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.
31
ARCMASTER 160TS
SECTION 6:
SEQUENCE OF OPERATION
Note
Scroll Buttons are used to select the parameters to be set. The LED’s show which function is
being adjusted on the weld sequence graph. Refer to the Symbols Table located in the front of
the manual for Symbol descriptions.
7
1
2
6
8
3
4
5
Figure 6-1: 160TS Front Panel
1. Pulse function – Pressing this button enables the TIG current pulse functions.
2. Scroll Buttons – used to select the parameter to be set. The LED’s show which function is being
adjusted on the weld sequence graph.
3. Digital LED display – Welding amperage and parameter values are displayed in this window.
Internal warnings such as over temperature, primary input current too high applied are signaled to
the operator by a warning sound and error message on the screen.
4. 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.
5. Process Button - This button selects between STICK, Lift or HF TIG*mode.
6. 8 pin remote control receptacle for connecting remote device.
7. TIG Mode Functions – Pressing this button scrolls through the output TIG function modes
(Standard, Slope, Slope w/repeat, Spot).
8. Save/Load Button – by using the Save & Load buttons the operator can easily save up to 5 welding
parameter program.
32
ARCMASTER 160TS
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.
6.01 Stick Welding
Connect work lead to negative terminal
Connect electrode lead to positive terminal
Switch machine on
Set PRE-FLOW time
Set weld current
Set HOT START current
Connect remote control device if required
Use the Scroll Buttons to move to the parameter
that needs 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 POST-FLOW time
Set WELD current
Set POST-FLOW time
Slope Mode Parameters if required
Set INTIAL CUR current
Set HOT START
Set UP SLOPE time
Set WELD current
Commence welding
Set (WELD) PEAK CUR current
Set BASE current
6.02 HF TIG & Lift TIG Welding
Connect work lead to positive terminal
Set DOWN SLOPE time
Connect TIG torch to negative terminal
Set CRATER CUR current
Pulse Mode parameters if required
Switch machine on
Set PULSE WIDTH % for PEAK CURRENT
Set WELD current.
Set PEAK CURRENT
Connect remote control device. A remote
control device is required for use during LIFT
TIG and HF TIG operation. See section 4.1,
section 2 “Remote Control Socket”, for
complete details of the remote device.
Set PULSE FREQ
Commence welding
33
ARCMASTER 160TS
6.03 Slope Mode Sequence
Switch
Closed
Initial
Current
Switch
Open
Up
Slope
Switch
Closed
Weld Current
Down
Slope
Switch
Open
Final
Current
Postflow
Preflow
Figure 6-3: Slope Mode Sequence
1. To start the Slope sequence, close the remote
switch contacts. Once the welding arc is
established the Power Source will maintain
the initial current setting as long as the remote
switch contacts are closed.
2. Open Remote Switch – current increases to
weld current. Once welding arc has reached
weld current the power source will maintain
weld current as long as the remote switch
contacts are open.
a. In the HF TIG mode, after Preflow time,
High Frequency is present at the torch.
When the torch is positioned close to the
work the welding current will transfer to
the work and establish the arc at the initial
current setting.
3. Close Remote Switch – Welding current
decreases to final current setting. Once final
welding current is reached the power source
will maintain final current setting as long as
the remote switch contacts are closed.
4. Open Remote Switch – Welding arc stops and
post flow begins.
b. In the Lift TIG mode, after Preflow time, Lift
Start current is present at the torch. When
the electrode is touched to the work and
lifted off, the welding arc is established at
the initial current setting.
6.04 Slope Mode with repeat sequence
The repeat function is operated during the down slope cycle of the Slope Sequence and is active
through the down slope period only. During the down slope period by opening the Remote Switch
contacts the current will increase back to weld current. Within the Down Slope period the repeat
function can be operated as many times as desired. To continue the slope cycle and end the slope
sequence, close the remote switch contacts and allow the weld current to reach the final current
setting. Once the final current setting is reached, opening the Remote Switch again will turn off the
welding arc and post flow begins.
34
ARCMASTER 160TS
6.05 Pulse Controls
(Pulse Width)
(Pulse Frequency)
(Peak Current)
(Base)
Background
Current
The Pulse controls are used primarily to control heat input. Pulse offers a number of advantages as
follows:
1)
2)
3)
4)
5)
Control puddle – size and fluidity (especially out of position).
Increase penetration
Travel speed control
Better consistent quality
Decreased distortion on lighter or thinner materials.
Pulse-current provides a system in which the welding current continuously changes between two
levels. During the periods of Peak current, heating and fusion takes place, and during the background
(base) current periods, cooling and solidification take place. Pulse Width is the time in one cycle the
current remains at the peak current setting. Pulse Frequency, measured in Hertz, is the number of
cycles per second the current travels between peak and background current settings. It is as if the
foot rheostat were moved up and down to increase and decrease the welding current on a regular
basis. The faster you move the foot rheostat up and down the faster the frequency.
35
ARCMASTER 160TS
SECTION 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.
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 11.01.1, Opening the Enclosure) and use
a vacuum cleaner to remove any accumulated dirt and dust. The unit should also be wiped clean, if
necessary; with solvents that are recommended for cleaning electrical apparatus.
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.
36
ARCMASTER 160TS
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
Clean
exterior
of power supply
Replace all
broken parts
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
37
Maintain more often
if used under severe
conditions
ARCMASTER 160TS
SECTION 8:
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.
8.01 TIG Welding Problems
Weld quality is dependent on the selection of the correct consumables, maintenance of equipment and
proper welding technique.
Description
Possible Cause
1 Excessive bead
build-up or poor
penetration or poor
fusion at edges of
weld.
Welding current is too low.
Increase weld current and/or
faulty joint preparation.
2 Weld bead too wide
and flat or undercut
at edges of weld or
excessive burn
through.
Welding current is too high.
Decrease weld current.
3 Weld bead too
small or insufficient
penetration or
ripples in bead are
widely spaced
apart.
Travel speed too fast.
Reduce travel speed.
4 Weld bead too wide
or excessive bead
build up or
excessive penetration in butt joint.
Travel speed too slow.
Increase travel speed.
Table 8-1: TIG Welding Problems
38
Remedy
ARCMASTER 160TS
Description
5 Uneven leg length
in fillet joint.
Possible Cause
Wrong placement of filler rod.
6 Electrode melts
A Electrode is connected to the
when arc is struck.
‘+’ terminal.
Remedy
Re-position filler rod.
A Connect the electrode to the
‘−’ terminal.
B WAVE BALANCE is greater
than 50%.
B Reduced WAVE BALANCE to
below 50% or increase the
electrode size.
A Electrode contaminated
through contact with work
piece or filler rod material.
A Clean the electrode by
grinding off the contaminates.
B Gas contaminated with air.
B Check gas lines for cuts and
loose fitting or change gas
cylinder.
A No gas flowing to welding
region.
A Check the gas lines for kinks
or breaks and gas cylinder
contents.
B Torch is clogged with dust.
B Clean torch.
C Gas hose is cut.
C Replace gas hose.
D Gas passage contains
impurities.
D Disconnect gas hose from
torch then raise gas pressure
and blow out impurities.
E Gas regulator turned off.
E Turn on.
F Torch valve is turned off.
F Turn on.
G The electrode is too small for
the welding current.
G Increase electrode diameter
or reduce the welding
current.
H WAVE BALANCE is set above
50%.
H Reduced WAVE BALANCE to
below 50% or increase the
electrode size.
9 Poor weld finish.
Inadequate shielding gas.
Increase gas flow or check
gas line for gas flow
problems.
10 Arc flutters during
TIG welding.
A Tungsten electrode is too
large for the welding current.
A Select the right size electrode.
Refer to Basic TIG Welding
guide.
7 Dirty weld pool.
8 Electrode melts or
oxidizes when an
arc is struck.
B Absence of oxides in the weld B Refer Basic TIG Welding
Guide for ways to reduce arc
pool.
flutter.
Table 8-1 (continued): TIG Welding Problems
39
ARCMASTER 160TS
Description
Possible Cause
Remedy
11 Welding arc can
A Work clamp is not connected A Connect the work clamp to
to the work piece or the
the work piece or connect the
not be established.
work/torch leads are not
work/torch leads to the right
connected to the right welding
welding terminals.
terminals.
12 Arc start is not
smooth.
B Torch lead is disconnected.
B Connect it to the ‘−‘ terminal.
C Gas flow incorrectly set,
cylinder empty or the torch
valve is off.
C Select the right flow rate,
change cylinders or turn
torch valve on.
A Tungsten electrode is too
large for the welding current.
A Select the right size electrode.
Refer to Basic TIG Welding
Guide.
B The wrong electrode is being
used for the welding job.
B Select the right electrode
type. Refer to Basic TIG
Welding Guide.
C Gas flow rate is too high.
C Select the correct rate for the
welding job.
Refer to Basic TIG Welding
Guide.
D Incorrect shielding gas is
being used.
D Select the right shielding gas.
Refer to Basic TIG Welding
Guide.
E Poor work clamp connection
to work piece.
E Improve connection to work
piece.
Table 8-1 (continued): TIG Welding Problems
40
ARCMASTER 160TS
8.02 Stick Welding Problems
Description
1 Gas pockets or
voids in weld
metal (Porosity).
2 Crack occurring in
weld metal soon
after solidification
commences.
Possible Cause
A Electrodes are damp.
B Welding current is too high.
C Surface impurities such as
oil, grease, paint, etc.
A Rigidity of joint.
B
C
3 A gap is left by
A
failure of the weld B
metal to fill the
root of the weld.
C
D
Remedy
A Dry electrodes before use.
B Reduce welding current.
C Clean joint before welding.
A Redesign to relieve weld joint
of severe stresses or use
crack resistance electrodes.
Insufficient throat thickness. B Travel slightly slower to allow
greater build up in throat.
Cooling rate is too high.
C Preheat plate and cool slowly.
Welding current is too low.
A Increase welding current
Electrode too large for joint. B Use smaller diameter
electrode.
Insufficient gap.
C Allow wider gap.
Incorrect sequence.
D Use correct build-up
sequence.
Table 8-2: STICK Welding Problems
Figure 8-1: Example of insufficient gap or incorrect sequence
41
ARCMASTER 160TS
4 Portions of the weld A Small electrodes used on
run do not fuse to
heavy cold plate.
the surface of the
B Welding current is too low.
metal or 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 preheat 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.
Table 8-2 (continued): STICK Welding Problems
Figure 8-2: Example of lack of fusion
42
ARCMASTER 160TS
5 Non-metallic parti- A Non-metallic particles may be A If bad undercut is present,
cles are trapped in
trapped in undercut from
clean slag out and cover with a
run from a smaller diameter
the weld metal (slag
previous run.
electrode.
inclusion).
B Joint preparation too
B Allow for adequate penetration
and room for cleaning out the
restricted.
slag.
C Irregular deposits allow slag C If very bad, chip or grind out
to be trapped.
irregularities.
D Lack of penetration with slag D Use smaller electrode with
sufficient current to give
trapped beneath weld bead.
adequate penetration. Use
suitable tools to remove all
slag from corners.
E Rust or mill scale is
E Clean joint before welding.
preventing full fusion.
F Wrong electrode for position F Use electrodes designed for
position in which welding is
in which welding is done.
done, otherwise proper control
of slag is difficult.
Table 8-2 (continued): STICK Welding Problems
Slag trapped in root
Figure 8-3: Examples of slag inclusion
43
ARCMASTER 160TS
8.03 Power Source Problems
Description
1 The welding arc
cannot be
established.
2 Maximum output
welding current can
not be achieved
with nominal Mains
supply voltage.
3 Welding current
reduces when
welding.
4 No gas flow when
the torch trigger
switch is
depressed.
Possible Cause
Remedy
A The Primary supply voltage
has not been switched ON.
A Switch ON the Primary
supply voltage.
B The Welding Power Source
switch is switched OFF.
B Switch ON the Welding
Power Source.
C Loose connections internally.
C Have an Accredited Thermal
Arc Service Agent repair the
connection
Defective control circuit.
Have an Accredited Thermal
Arc Service Agent repair the
connection
A Loose welding cable
connections.
B Incorrect welding cable size.
A Tighten all welding cable
connections.
C Improper input connections.
C Refer to Section 2.05
Electrical Input
Requirements.
D Poor electrode condition.
E Wrong welding polarity.
D Replace electrode.
A Gas hose is cut.
B Gas passage contains
impurities.
C Gas regulator turned off.
D Torch trigger switch lead is
disconnected or switch/cable
is faulty.
B Use proper size and type of
cable.
E Verify output torch
connections.
A Replace gas hose.
B Disconnect gas hose from
the rear of Power Source
then raise gas pressure and
blow out impurities.
C Turn gas regulator on.
D Reconnect lead or repair
faulty switch/cable.
Table 8-3: Power Source Problems
44
ARCMASTER 160TS
Description
Possible Cause
5 Gas flow won’t shut A Weld Mode (STD, SLOPE,
off.
REPEAT or SPOT) was
changed before POST-FLOW
gas time had finished.
B Gas valve is faulty.
C Gas valve jammed open.
6 The TIG electrode
has been
contaminated due
to the gas flow
shutting off before
the programmed
POST-FLOW time
has elapsed.
D POST-FLOW control is set to
60 sec.
The Weld Process Mode
(STICK, HF TIG or LIFT TIG)
was changed before POSTFLOW gas time had finished.
Remedy
A Strike an arc to complete the
weld cycle.
OR
Switch machine off then on
to reset solenoid valve
sequence.
B Have an Accredited Thermal
Arc Service Agent repair or
replace the gas valve
C Have an Accredited Thermal
Arc Service Agent repair or
replace the gas valve
D Reduce POST-FLOW time.
Do not change Weld
Process Mode before the
POST-FLOW gas time had
finished.
Table 8-3 (continued): Power Source Problems
45
ARCMASTER 160TS
SECTION 9:
VOLTAGE REDUCTION DEVICE (VRD)
9.01 VRD Specification
ARC MASTER
160TS
Description
VRD Open Circuit Voltage
Notes
15.3 to 19.8V
Open circuit voltage between welding
terminals.
VRD Resistance
148 to 193 ohms
The required resistance between welding
terminals to turn ON the welding power.
VRD Turn OFF Time
0.2 to 0.3 seconds The time taken to turn OFF the welding
power once the welding current has
stopped.
Table 9-1: VRD Specification
9.02 VRD Maintenance
Routine inspection and testing (power source):
An inspection of the power source 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.
Note
A transportable power source is any equipment that is not permanently connected and
fixed in the position in which it is operated.
In addition to the above tests and specifically in relation to the VRD fitted to this machine, the
following periodic tests should also be conducted by an accredited Thermal Arc service agent.
Description
IEC 60974-1 Requirements
VRD Open Circuit Voltage
Less than 20V; at Vin=230V
VRD Turn ON Resistance
Less than 200 ohms
VRD Turn OFF Time
Less than 0.3 seconds
Table 9-2: Periodic Tests
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.
The VRD test is shown below:
1) In STICK welding mode, mark and then turn potentiometer VR1 on PCB4 (WK-5449) fully
clockwise and turn on the electric shock protector function (Voltage-Reduction-Device, VRD).
46
ARCMASTER 160TS
2) Verify the no-load voltage (OCV) using a DC voltmeter. (The capability of the voltmeter should
be more than 100VDC.)
3) The normal no-load voltage is approximately 18V.
4) In STICK welding mode, mark and then turn potentiometer VR1 on PCB4 (WK-5449) fully
clockwise and turn off the VRD.
5) Contactor function is put into the state of “ON” by pushing the Function button. Refer to section 6.
WARNING
Electric shock hazard. The unit will generate OCV (Open Circuit Voltage) immediately when
contactor function is put into the state of “ON” by pushing the Function button and enabling
STICK mode.
7) Verify the no-load voltage (OCV) using a DC voltmeter. (The capability of the voltmeter should
be more than 100VDC.)
8) The normal no-load voltage is approximately 65V.
9.03 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.
Remove the control’s clear plastic cover.
Figure 9-1: VRD ON/OFF Step A
47
ARCMASTER 160TS
B) Remove four mounting screws from the control panel (see Figure 9-2).
Figure 9-2: VRD ON/OFF Step B,C
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 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
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ARCMASTER 160TS
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 9.01.
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.
49
ARCMASTER 160TS
SECTION 10:
POWER SOURCE ERROR CODE
Description
Possible Cause
Remedy
1 E01 error code
displayed
Temperature sensor
TH1 (protects
IGBTs) is greater
than 80ºC for about
1 second.
A The Welding Power
Source’s duty cycle
has been exceeded.
A
Let Power Source
Weld current ceases.
cool down then keep Buzzer sounds
within its duty cycle. constantly.
B Fan ceases to
operate.
B
Have an Accredited Fan operates at max
Thermal Arc Service speed.
Agent investigate.
E01 resets when TH1
Unblock vents then decreases to 70ºC
for about 30
let Power Source
seconds.
cool down.
C Air flow is restricted
by vents being
C
blocked.
2 E02 error code
A The Welding Power A
Source’s duty cycle
displayed
Temperature sensor
has been exceeded.
TH2 (protects
B Fan ceases to
B
secondary diodes) is
operate.
greater than 80ºC for
C Air flow is restricted C
about 1 second.
by vents being
blocked.
3 E03 error code
A Primary
A
Transformer current
displayed
is too high because B
Primary Transformer
welding arc is too
current too high.
long.
B Mains supply voltage
is more than 10%
below nominal
voltage .
Let Power Source
Weld current ceases.
cool down then keep Buzzer sounds
within its duty cycle. constantly.
Have an Accredited Fan operates at max
Thermal Arc Service speed.
Agent investigate
Unblock vents then
let Power Source
cool down.
Reduce length of
welding arc.
E02 resets when TH2
decreases to 70ºC
for about 30
seconds.
Weld current ceases.
Buzzer sounds
constantly.
Have an Accredited
Thermal Arc Service Switch machine off
Agent or a qualified then on to reset E03
electrician check for error.
low Mains voltage.
Table 10-3: Power Source Error Codes
50
Remarks
ARCMASTER 160TS
Description
Possible Cause
4 E94 error code
displayed
Temperature sensor
TH1 for IGBTs or
sensor TH2 for
secondary diodes
are open circuit.
Remedy
The Welding Power
Source’s
temperature sensors
have malfunctioned.
5 E99 error code
A Main on/off switch
A
displayed
on machine has been
Mains supply (input)
turned off
B
voltage has been
B Mains supply (input)
turned off but
voltage has been
control circuit has
turned off.
power from the
primary capacitors.
Have an Accredited
Thermal Arc Service
Agent check or
replace the
temperature sensors
Weld current ceases.
Buzzer sounds
constantly.
Switch machine off.
Turn on/off switch
on.
Weld current ceases.
Have an Accredited
Thermal Arc Service
Agent or a qualified
electrician check the
Mains voltage and
fuses.
constantly.
Table 10-3 (continued): Power Source Error Codes
51
Remarks
Buzzer sounds
Must switch machine
off then on to reset
E99 error.
ARCMASTER 160TS
SECTION 11:
ADVANCED TROUBLE SHOOTING
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.
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.
CAUTION
WARNING
Troubleshooting and repairing this
unit is a process, which should be
undertaken only by those familiar
with high voltage/high power
electronic equipment.
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.
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 unauthorizedrepairs 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. Thefaulty subassembly should then be returned toThermal Arc through established
procedures.
11.01 System-Level Fault Isolation
If none of the suggestions provided in Section 8 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.
52
ARCMASTER 160TS
1. Opening the Enclosure
a) Verify that the switch on the power supply and the switch on the switchboard (distribution
panel) are all 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.
b) Remove all screws and nuts on the Side Panel.
Figure 11-2 Remove screws
53
ARCMASTER 160TS
c) Loosen the screws on the Front Panel and the Rear Panel by turning them approximately two
turns CCW.
Figure 11-3 Loosen screws
Note
DO NOT remove the screws completely.
d) 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 Panel and Rear Panel
Figure 11-4 Loosen Front Panel and Rear Panel
54
ARCMASTER 160TS
e) Remove the Side Panel.
Figure 11-5 Remove Side Panel
f) Remove PCB Cover sheet by removing the four clips.
Figure 11-6 Remove PCB Cover
Note
When you re-assemble the parts, conduct the above process backwards.
55
ARCMASTER 160TS
11.02 Verification and Remedy to the Indicated Error Codes
Note
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 and then remove the cases to continue your
inspection and repair (or maintenance) inside the power supply. As for the removal and
installation of the case, refer to section 11.01.1.
Note
During the “Verification/Remedy” procedures below, follow the alphabetical sequence (a, b,
c…) and proceed with your verification and confirmation.
Note
After you Verify and replace all spare parts and components, Verify that there are no
damaged harnesses or connectors, uninstalled or loose screws.
56
ARCMASTER 160TS
1. E01 “Over-Temperature at the primary side”
2. E02 “Over-Temperature at the secondary
side”
Cause:
Occurs when an over-temperature condition
of the primary IGBT is detected.
Cause:
Occurs when an over-temperature condition
of the secondary IGBT and diode are detected.
Verification/Remedy:
a) Unit may be in thermal shutdown mode.
Verification/Remedy:
a) Unit may be in thermal shutdown mode.
Review the rated duty cycle of the unit per
section 3.08. Exceeding the duty cycle can
damage the unit and void the warranty. Refer
also to section 1.06 for additional information.
Review the rated duty cycle of the unit per
section 3.08. Exceeding the duty cycle can
damage the unit and void the warranty.
b) Verify the ventilating condition.
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.
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.
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.
c) Verify the operation of the cooling fan,
FAN1, and replace it if necessary.
c) Verify the operation of the cooling fan,
FAN1, and replace it if necessary.
Verify the condition of FAN1. Verify that there
are no broken or cracked fan blades and that
FAN1 is not producing abnormal sounds.
Verify the condition of FAN1. Verify that there
are no broken or cracked fan blades and that
FAN1 is not producing any abnormal sounds.
If broken or cracked FAN1 blades, or abnormal
sounds are emanating from FAN1, replace FAN1.
If broken or cracked FAN1 blades, or abnormal
sounds are emanating from FAN1, replace FAN1.
Verify the operation of the cooling fan and
replace it if the condition of FAN1 is inactive.
Follow the instruction in section 12.03.11.
Verify the operation of the cooling fan and
replace it if the condition of FAN1 is inactive.
Follow the instruction in section 12.03.11.
Refer to section 11.05.3 for addition FAN1 tests.
Refer to section 11.05.3 for additional FAN1
tests.
Refer to section 12.03.11 for the replacement of
FAN1.
Refer to section 12.03.11 for the replacement of
FAN1.
d) Replace PCB4 (WK-5449) and PCB5 (WK5448).
d) Replace PCB4 (WK-5449) and PCB5 (WK5448).
Refer to section 12.03.4, 12.03.5 for the
replacement of PCB4 and PCB5.
Refer to section 12.03.4, 12.03.5 for the
replacement of PCB4 and PCB5.
57
ARCMASTER 160TS
3. E03 “Primary Over-Current Failure”
Verification/Remedy:
a) Verify a secure connection of the harness
wired between CN5-6 on PCB1 (WK-5466)
and Thermistors (TH1, TH2).
Cause:
Occurs when excessive current is detected
flowing into the primary side of the main
transformer.
Re-install the harness with a secure connection.
Contact the manufacturer if you find any broken
connectors or damaged wiring harness.
Verification/Remedy:
a) Verify the operation of the machine within
the rated specification.
b) Replace thermistors (TH1, TH2).
Refer to the specification data sheet in Section
3.09.
Refer to sections 12.16 and 12.17.
c) Replace PCB5 (WK-5448).
b) Verify the secondary diode (D2 and D3).
Refer to section 12.03.5.
Refer to section 11.05.6 for the test of D2 and
D3.
5. E99 “Initial Power Receiving”
Refer to section 12.03.8 for the replacement of
D2 and D3.
Cause:
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.
c) Verify the H.F. unit (HF. UNIT1).
only
Refer to section 12.03.12 for the replacement of
HF.UNIT 1.
Verification/Remedy:
a) Verify the connection between "+" terminal
of Primary diode (D1) and PCB1 (WK5466).
d) Replace the Hall CT, CT1.
Note
Pay special attention to installed direction of
CT1. The Hall CT will not function properly if
installed in the incorrect direction.
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.
Refer to section 12.03.10 for the replacement of
CT1.
b) Verify that there is no omission of a
loosening screws and connected harness
with PCB1 (WK-5466).
4. E94 “Thermistor malfunction”
Re-install the harness with a secure connection.
Contact the manufacturer if you find any broken
connectors or damaged wiring harness.
Cause:
Thermistors for detecting temperature of
internal components have malfunctioned.
Replace PCB1. Refer to section 12.03.1.
c) Replace PCB4 (WK-5449) and PCB5 (WK5448).
Refer to section 12.03.4, 12.03.5 for the
replacement of PCB4 and PCB5.
58
ARCMASTER 160TS
11.03 Verification and Remedy to Failures without Indication Codes
Refer to Note on Section 11.02.
1. “Cooling Fan (FAN1) Failure” (Fan is not
rotating.)
2. “Gas Valve Failure” (No Gas flow through
unit)
Cause:
Occurs when the cooling fan (FAN1) is
defective, damaged or the driving voltage is
incorrect.
Cause:
Occurs when the gas valve (SOL1) is
defective, damaged or the driving voltage is
incorrect.
Verification/Remedy:
a) Verify the cooling fan (FAN1).
Verification/Remedy:
a) Verify that TIG welding is selected on the
welding mode.
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.
Do not change welding modes while welding.
Only change welding modes when the unit is
idle (torch switch OFF).
Verify the setting of Pre-flow and Post-flow on
the front panel. If the Pre-flow or Post-flow time
is set to 0 seconds, change them to higher
setting.
Verify that there are no wiring harnesses
entangled inside the fan, Verify that the
harnesses do not have any breaks in the wire or
damaged connectors.
b) Verify the layout of the gas hose.
Verify that the hose is securely connected into
the fitting at the inlet and the outlet. Verify the
layout of the gas hose so that it is not bent or
kinked. Verify there are no breaks, burns or
holes in the hose.
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 section 12.03.11.
Verify the layout of the TIG torch gas hose and
that the hose adapters are properly connected.
b) Verify the wiring harness between the
cooling fan (FAN1) and CN2 on PCB1
(WK-5466).
c) Verify the wiring harness and connection
of gas valve (SOL1) and CN2 on PCB1
(WK-5466).
Verify a secure connection of the harness to
CN2 on PCB1.
Verify a secure connection of the harness to
CN2 on PCB1.
c) Verify the drive circuitry of the cooling fan
(FAN1) on PCB1.
d) Verify the drive circuitry of the gas valve
(SOL1).
Verify the drive circuitry of the cooling fan
(FAN1) on PCB3.
Refer to section 11.05.3.
Verify the drive circuitry of the gas valve (SOL1).
Replace PCB1 if necessary. Refer to section
12.03.1.
Refer to section 11.05.4.
Replace PCB1, when abnormal. Refer to section
12.03.1.
59
ARCMASTER 160TS
e) Replace PCB4 (WK-5449) and PCB5 (WK5448).
Verify a secure connection of the welding cable,
stick rod holders, ground clamp and dinse
connectors and there are no open circuits.
Refer to section 12.03.4, 12.03.5 for the
replacement of PCB4 and PCB5.
c) Verify the no-load voltage (OCV). (Applies
to STICK, High Frequency TIG (HF TIG)
mode.)
3. “No Weld Output”
When in High Frequency TIG (HF TIG) mode, if
the High Frequency is not generated (present),
refer to “High Frequency Output Failure” in
section 11.03.5.
Refer to the section “Verification of No-load
voltage (OCV)” in section 11.05.8.
If performing the “No-Load Voltage Failure”
procedure does not rectify the failure, perform
the following tests in the sequence below.
Replace any defective components found.
Cause:
Occurs when the remote connector (CON1)
or associated circuitry is defective, damaged,
or the TIG torch cable is defective.
1, Secondary diode (D2-D3)
Verification. Refer to section 11.05.6.
Verification/Remedy:
Replacement. Refer to section 12.03.8.
Caution
2, Coupling coil (C.C.) and Reactor (FCH1)
Replacement C.C. Refer to section
12.03.9.
Read and understand this entire section
before proceeding. Extreme personal harm
and test equipment damage will occur if the
procedures are not performed accurately.
Replacement FCH1. Refer to section
12.03.9.
3, Transformer (T1)
Replacement T1. Refer to section 12.03.3.
a) Verify the remote connector (CON1).
(Applies to LIFT TIG and High Frequency
TIG [HF TIG] mode.)
4, Primary IGBT (Q1A-Q4C)
Verification. Refer to section 11.05.7.
Verify a secure connection between the remote
connector (CON1) and the TIG torch cable.
Replacement. Refer to section 12.03.6,
12.03.7.
Verify a secure connection of the harness and
the connections between the remote connector
(CON1) and CN1 on PCB1 (WK-5466) are all
correct and there are no open circuits.
5, Hall C.T. (CT1)
Replacement CT1. Refer to section
12.03.10.
Contact the manufacture if you find any broken
connectors or damaged wiring harnesses.
Verify the proper pins-outs of the remote
connector at the TIG Torch side. (Refer to
section 4.01.2.)
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 4.01.2.)
b) Verify the condition and connections of
the welding cable, the stick rod holders
and the ground clamp. (Applies to all
welding modes.)
60
ARCMASTER 160TS
4. “Operating Panel Failure” (LED’s do not
light properly or welding setting cannot be
established.)
5. “High Frequency Output Failure” (Unit does
not generate High Frequency.)
Cause:
Occurs when the High Frequency unit
(HF UNIT1) is defective or blown.
Cause:
Occurs when there is a connection failure
among PCB1 (WK-5466), PCB5 (WK-5448),
PCB6 (WK-5449) and PCB1 or PCB5 or PCB6
are defective.
Verification/Remedy:
Caution
Read and understand this entire section
before proceeding. Extreme personal harm
and test equipment damage will occur if the
procedures are not performed accurately.
The unit will generate a High Voltage
component that can cause extreme personal
harm and test equipment damage.Capacitors
installed inside the Welding Power Source
are electrically charged for a while after the
Mains ON/OFF switch or distribution panel
switch has been turned off. Before inspecting
the inside of the Welding Power Source,
leave it for about 5 min. after switching off
power for discharging the capacitors, and
then remove the top and side panels.
Verification/Remedy:
a) Verify the harness connection between
CN101 on PCB1 (WK-5466) and CN1 on
PCB4 (WK-5449).
Verify a secure connection of the harness and
the connections between CN101 on PCB1 and
CN1 on PCB5.
Contact the manufacturer if you find any broken
connectors or damaged wiring harnesses.
b) Verify the connection between PCB5 (WK5448) and PCB4 (WK-5449).
Verify that there are no loose
screws or harness connections between the
PCB4 and PCB5.
Replace PCB4 and PCB5 if necessary. Refer to
section 12.03.5, 12.03.6.
a) Verify the connection between High
Frequency Unit (HF UNIT1) and Coupling
Coil (C.C.).
Verify the connection between the HF UNIT1
and C.C.. Verify that the quick-disconnect
terminals are inserted onto the terminals of HF
UNIT1 (TB5- TB6) correctly and completely.
Verify there are no short circuits, burnt or
broken wires at C.C..
Replace C.C.. Refer to section 12.03.9.
b) Verify the connection between High
Frequency Unit (HF UNIT1) and the current
limiting resistor (R6 on WK5609 PCB3).
Verify that the quick-disconnect terminals are
inserted onto the terminals of HF UNIT1 (TB3TB4) correctly and completely.
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11.04 Fault Isolation Tests
1. Preparation
The following initial conditions must be met
prior to starting any of the procedures in this
section.
a) Connect the appropriate input voltage.
(Check the name plate on the rear of the
power supply for the proper input
voltage.)
Verify there are no short circuits, burnt or
broken wires between the HF UNIT1 and R6 on
WK5609 PCB3. Its resistance can be
measured across pins 1 and 3 of CN3
(PCB3) WK5609.
c) Verify the connection between the
terminals between AC1-AC2 (TB1-TB2).
Verify the connection between AC1-AC2. Verify
that the quick-disconnect terminals are inserted
onto the terminals of HF UNIT1 correctly and
completely.
Note
Operate at all input voltages as noted on
the nameplate on the rear panel when
testing the power supply.
Verify there are no short circuits, burnt or
broken wires between AC1 and AC2.
b) Remove the Side Panel. Refer to the
section 11.01.1.
d) Verify and replace the Gap (GAP) of the
High Frequency Unit (HF UNIT1).
Verify that the GAP is connected to HF UNIT1
correctly and completely.
c) Close primary power source wall
disconnect switch or circuit breaker.
Verify there is no dust or foreign debris between
the space of the GAP.
d) Place power supply MAIN CIRCUIT
SWITCH (S1) on rear of the unit in the ON
position.
If there are any abnormalities observed with the
GAP, replace the GAP.
The gap is set to 1.0mm.
In the case of a gap 1.0mm or more, high
frequency voltage and period increases.
In the case of a gap 1.0mm or less, high
frequency voltage and period decreases.
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 work piece or any internal
components while the unit is activated.
e) Replace the High Frequency (HF UNIT1).
Refer to section 12.03.12.
f) Replace PCB3 (WK-5609).
Refer to section 12.03.3.
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11.05 Verification of the Power 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 11.04.1 "Preparation"
1. Verification of the AC input voltage using an AC voltmeter.
a) 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. The location of points U1 and V1 on switch S1 are indicated in Figure 11-7.
Figure 11-7: Check points U1, U2, V1 and V2
b) If the input voltage is out of the operating range of the unit, which is ± 10% (187 ~ 253VAC) of
the rated voltage (208-230V), 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.
c) 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.
The location of points U2 and V2 on switch S1 are indicated in Figure 11-7.
d) If this voltage is out of the operating range, which is ± 10% (187 ~ 253VAC) of the rated
voltage (208-230), replace S1 following the process in section 12.3.14.
e) Verify the rectified output voltage of the primary diode, D1 using a DC voltmeter. (The
capability of the voltmeter should be more than 400VDC.) Using a DC voltmeter, measure
between the points “+” [+] and “-“ [-] on D1. Points “+” and “-“ are on PCB1 (WK-5466). See
Figure 11-8. The measured voltage should be approximately 1.4 times larger than input voltage
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measured in #1 above. Replace diode D1 if the calculated measurement is not within the
corresponding range (260 ~ 360VDC) following the process in section 12.03.1.
Figure 11-8: The check points “+“ and “-“
f) Verify bus voltage (the voltage of the electrolytic capacitor after rectification) using a DC
voltmeter. (The capability of the voltmeter should be more than 500VDC.) Using a DC
voltmeter, measure between the points TB1(P)[+] and TB3(N)[-] on PCB1 (WK-5466). See
Figure 11-9. Points TB1(P) and TB2(N) can be found on the parts side of PCB2. 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 (260 ~
360VDC) following the process in section 12.03.1.
Figure 11-9: The check points TB1(P) and TB3(N)
g) After the replacement of D1, if the above voltage is still abnormal, replace PCB1 (WK-5466).
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2. Verification of the Power Supply Voltage
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 11.04.1 "Preparation" .
a) 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.
b) On the PCB5 (WK-5448) and PCB4 (WK-5449), measure the voltages according to the
following table. The check points and the reference are obtainable on the solder side of PCB4
(WK-5449). The locations of points are indicated in Figure 11-10.
Figure 11-10: Checkpoints TP0-TP3 on PCB6
Check Point
PCB6
TP1
TP2
TP3
Reference
PCB6
TP0
TP0
TP0
ACCEPTABLE
VALUE
+5VDC
+12VDC
-12VDC
Table 11-1: Checkpoints TP0-TP3 on PCB6
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Figure 11-11: Checkpoints CN2 on PCB1
Check Point
PCB1
Pin 1 on CN2
Reference
PCB1
Pin 2 on CN2
ACCEPTABLE
VALUE
+24VDC
Table 11-2: Checkpoints CN2 on PCB1
c) If any of these voltages are not present or are below a 10% tolerance, replace the PCB1 (WK5466). Refer to section 12.03.1.
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3. Verification of the Cooling Fan, FAN1, Drive 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 11.04.1 "Preparation" .
a) 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 CN11 on PCB1 (WK-5466). The location of
connector CN2 of PCB3 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.
Figure 11-12: Verification of the FAN1
b) Using the measurement taken above, follow the chart below for possible failure modes.
Case 1
Rotating
Voltage measurement.
(PIN1–PIN2 of CN2 on PCB1)
DC 18 ~ 25V
Case 2
Rotating
Below DC 18V
Case 3
Inactive
Below DC 18V
Case 4
Inactive
DC 18 ~ 25V
FAN1 Status
Remedy
FAN1 drive circuit is normal.
Replace PCB1.
Refer to section 12.03.1.
Replace PCB1.
Refer to section 12.03.1.
Perform “Verification of the
Power Supply Voltage”.
Refer to section 11.05.2.
Replace the FAN1.
Refer to section 12.03.11.
Table 11-3: Verification of the FAN1
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At the time of a low output and standby, fan rotation becomes slow.
Therefore, exact voltage measuring becomes impossible.
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 180VAC).
4. Verification of the Gas Valve, SOL1, Drive 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 11.04.1 "Preparation" .
a) Verify the voltage between the PIN3 (Positive [+]) and PIN4 (Negative [-]) of connector CN2 on
PCB1 (WK-5466) while you press the torch switch while in TIG Mode. (The capacity of the
voltmeter should be more than 50VDC.) The location of connector CN2 of PCB1 (WK-5466) is
indicated in Figure 11-13. When you measure the above voltage, do not remove the connector.
Conduct the measurement while the connector plug and receptacle are still connected.
Figure 11-13: Verification of the SOL1
b) Using the measurement taken above, follow the chart below for possible failure modes.
Voltage measurement.
(PIN1–PIN2 of CN2 on PCB1)
Case 1
Below DC 18V
Case 2
DC 18 ~ 25V
Remedy
Replace PCB1.
Refer to the page 12-5.
Replace SOL1.
Refer to the page 12-20.
Table 11-4: Verification of the SOL1
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c) 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 180VAC).
5. Verification of the primary Diode (D1)
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 characteristic of the primary diode, D1, using a diode tester.
b) Refer to Table 11-5 and Figure 11-14 for the checkpoints on D1.
COMPONENT
TESTED
Diode of D1
Diode of D1
TERMINALS
Positive lead
Negative 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 11-5: Tester checkpoints for D1
Figure 11-14: Tester checkpoints in the D1 interconnection diagrams
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6. Verification of the secondary Diode (D2, D3)
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 11.04.1 "Preparation" .
a) Verify the characteristic of the secondary diode, D2 and D3, using a diode tester.
b) Refer to Table 11-6 and Figure 11-15 for the checkpoints on D2 and D3.
COMPONENT
TESTED
Diode 1 of D2 and D3
Diode 2 of D2 and D3
TERMINALS
Positive lead
Negative lead
Anode
Cathode
Cathode
Anode
Anode
Cathode
Cathode
Anode
ACCEPTABLE
VALUE
0.2 to 0.3V
Open
0.2 to 0.3V
Open
Table 11-6: Tester checkpoints for D2 and D3
Figure 11-15: Tester checkpoints for D2 and D3
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7. Verification of the primary IGBT (Q1A-Q4C)
CAUTION
Before performing any portion of the procedure below, make certain the unit is placed in the
initial set up condition as described insection 11.04.1 "Preparation".
a) Check whether there are any abnormalities on the appearance of PCB6 and PCB7.
b) Verify the characteristic of the primary IGBT (Q1A-Q4C), using a diode tester.
c) Refer to Table 11-7 and Figure 11-16 for the checkpoints on PCB6 and PCB7.
COMPONENT
TESTED
Collector-Emitter of Q1A
~Q2C with PCB6
Collector-Emitter of Q3A
~Q4C with PCB7
TERMINALS
Positive lead
Negative lead
ACCEPTABLE
VALUE
C
CE
CE
C
Open
0.2 to 0.5V
CE
E
E
CE
Open
0.2 to 0.5V
Table 11-7: Tester checkpoints for Q1A-Q4C
Figure 11-16: Tester checkpoints for Q1A-Q4C
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1) When in HF TIG mode, the unit will
generate high voltage. To prevent
personal harm and test equipment
damage, mark and then remove the
indicated wire from the HF UNIT1 shown
in Figure 11-17. To prevent electric
shock, always wrap the removed wire
with electrical tape or other suitable
insulation.
8. 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 11.04.1 "Preparation" .
a. Verify the no-load voltage in STICK mode.
1) In STICK welding mode, mark and then
turn potentiometer VR1 on PCB4 (WK5449) fully counter-clockwise to turn off
the electric shock protector function
(Voltage-Reduction-Device, VRD). Refer
to section 9.02.
Figure 11-17 Removal and installation from the
HF UNIT1
(To disable the operation of the HF unit.)
WARNING
Electric shock hazard. The unit will
generate OCV immediately when
Process mode is put into the state of
“ON” pushing Process button enabling
STICK mode.
2) Press the Welding mode selection
button to select HF TIG welding mode.
3) While depressing the Torch switch,
verify the OCV using a DC voltmeter.
(The capability of the voltmeter should
be more than 100VDC.) The check point
with a tester is the voltage between
output terminal + and -. In TIG mode, the
OCV ceases 3 seconds after you depress
the torch switch.
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) The normal no-load voltage is
approximately 65V.
b. Verify the no-load voltage (OCV) in High
Frequency TIG mode.
5) Return the setting variable resister (VR1)
to the original position. (Return to the
position recorded by “a. 1)” clause.)
WARNING
Fully clockwise: VRD ON
This welding mode produces high
frequency and high voltage. Extra care
shall be taken to prevent electric shock.
Fully counter-clockwise: VRD OFF
6) Return connection with HF UNIT1 to the
original position.
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g) Slowly turn the Control Knob clockwise
to the maximum of the power supply,
then counter clockwise, back to 1 Amps
as the control returns to its minimum
position. The amperage meter should
indicate a continuous range of Amperes
between the 5 Amps minimum and the
160A maximum.
9. Output Load Test
This test verifies that the output current,
(amperage) controls are functioning
properly. A clamp-type amperage meter or
equivalent meter capable of reading
approximately 160A full-scale will be needed
for this test.
CAUTION
h) Set minimum current (counter
clockwise).
Before performing any portion of the
procedure below, make certain the unit is
placed in the initial set up condition as
described in section 11.04.1 "Preparation" .
i) Press the Welding mode selection
button to select STICK welding mode.
The amperage meter will indicate
approximately 5 Amps.
a) Connect the POSITIVE (+) and
NEGATIVE (-) OUTPUT TERMINALS to a
piece of metal, separated by
approximately three feet (one meter).
WARNING
At this time, some voltage is applied to
the stick electrode holder. Never touch
the current conducting portion of it.
Extra care shall be taken to prevent
electric shock. Further, to prevent the
risk of striking the arc inadvertently,
care shall be taken to keep the work
piece to be welded away from the said
electrode holder.
b) Connect the clamp-on amperage meter
or equivalent to the output loop between
the POSITIVE (+) and NEGATIVE (-)
OUTPUT TERMINALS.
c) Place the power supply MAIN ON/OFF
SWITCH (S1) on the rear of the unit to
the ON position.
j) Slowly turn the Control Knob clockwise
to the maximum of the power supply,
then counter-clockwise, back to 1 Amps
as the control returns to its minimum
position. The amperage meter should
indicate a continuous range of Amperes
between the 5 Amps minimum and the
160A maximum.
d) Select HF TIG mode and DC mode.
WARNING
This welding mode produces high
frequency and high voltage. Extra care
shall be taken to prevent electric shock.
k) Place the power supply MAIN ON/OFF
SWITCH on the rear of the unit to the
OFF position.
e) Select WELD position, press control
knob. Set minimum current
(counterclockwise).
l) Remove the dead short between the
OUTPUT TERMINALS.
f) Depress the torch switch. The amperage
meter will indicate approximately 5 Amps.
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SECTION 12:
MAINTENANCE
12.01 Maintenance List
NO.
1
2
3
4
5
6
7
DWG NO.
PARTS NAME
PCB6(Q1AQ2C)
PCB1
PCB7(Q3AQ4C)
PCB3
PCB4
PCB5
PCB2
Printed Circuit Board (WK-5460)
Primary IGBT
Printed Circuit Board (WK-5466)
REFERENCE
SECTION
12.03.6
12.03.1
PART NO.
W7001516
W7001403
Printed Circuit Board (WK-5460)
12.03.7
W7001516
Printed Circuit Board (WK-5609)
Printed Circuit Board (WK-5449)
Printed Circuit Board (WK-5448)
Printed Circuit Board (WK-5467)
12.03.3
12.03.4
12.03.5
12.03.2
W7001520
W7001412
W7001724
W7001405
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NO.
1
2
3
4
5
6
DWG NO.
C1
R1
T1
HF UNIT
FCH1
C.C.
PARTS NAME
Capacitor
Resistor
Transformer
High Frequency Unit
Reactor
Coupling Coil
75
REFERENCE
SECTION
12.03.2
12.03.2
12.03.3
12.03.12
12.03.9
12.03.9
PART NO.
10-6510
W7001448
W7001501
W7001399
W7001502
W7001384
ARCMASTER 160TS
NO.
1
2
3
4
5
6
7
8
9
10
DWG NO.
S1
D1
FAN1
SOL1
TH1
CON1
D3
D2
TH2
CT1
PARTS NAME
Main ON/OFF Switch
Primary Diode
Cooling Fan
Solenoid Valve
Primary Thermistor
Remote Connector
Secondary Diode
Secondary Diode
Thermistor
Hall Current Trans
76
REFERENCE
PART NO.
SECTION
12.03.14
W7001453
12.03.1
W7001481
12.03.11
10-5227
12.03.13 10-6645
12.03.16
10-5228
12.03.15
10-6627
12.03.8
10-6229
12.03.8
10-6629
12.03.17
10-5228
12.03.10
10-5003
ARCMASTER 160TS
12.02 Service Tools
1. Tools and Parts
The tools and parts to be used for maintenance are shown by icons.
Figure 12-1 Icon of tool
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.
Note
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.
Figure 12-2 Locking type connectors and board supporters
Note
During your maintenance or repair, please cut any tie-wraps necessary. However, after
your maintenance or repair, please re-assemble and tie-wrap all components and wiring
in the same manner as before the maintenance or repair.
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CAUTION
Please note that you remove each connector, grasp and pull out by the connector part only. Do
not pull the harness (cable) part.
12.03 Replacement Procedure
1. PCB1 (WK-5466) and Primary Diode D1
a) Remove the Side Panel. See section “11.01.1”.
b) Remove the screw and three cables. Cut the snap band.
c) Remove the terminal and Disconnect the three connectors CN1 (PCB4), CN101,103 (PCB1).
d) Remove the terminal and Remove the three cables.
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e) Remove the Gas Tube*. Remove the two bolts, two toothed washers, and the terminal.
f) Remove the four screws and the Front Panel.
g) Remove the Gas Tube and the two cables.
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(Continued on next page.)
h) Remove the four screws and the Rear Panel.
i) Remove the four screws and the two cables. Disconnect the eight connectors CN1-8 on the
PCB1.
j) Remove the four screws and Remove the PCB1 unit.
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k) Remove the Primary Diode D1 with the soldering iron from the PCB1.
*Before installing a new diode, apply a uniform coat of silicone compound (Shinetsu Silicone
G-747 or equivalent) on the base.
2. PCB2 (WK-5467), Capacitor C1 and Resistor R1
a) Remove the Side Panel. See section “11.01.1”.
b) Remove the PCB1 and D1. See section “12.03.1”.
c) Remove the PCB6 and PCB7. See section “12.03.6, 12.03.7”.
d) Remove the screw and the cable.
e) Remove the eight screws and the PCB2 unit.
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f) Remove the screw and Remove the Capacitor C1 and Resistor R1 from the PCB2. Remove the
two edge holders and the PCB2 Insulation Sheet from PCB2.
3. PCB3 (WK-5609) and T1 “Transformer”
a) Remove the Side Panel. See section “11.01.1”.
b) Remove the CT1. See section “12.03.10”.
c) Cut the snap band and Remove the cables. Disconnect the three connectors CN1-3 on the
PCB3. Remove the three screws and the three cables. Remove the terminal.
d) Remove the 11 screws and PCB3 unit.
*Take note of the shape of the screw when you replace PCB3.
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e) Remove the two tap of T1 with the soldering iron from the PCB3. Remove the T-D Bus Bar1
and the T-D Bus Bar2. Open the tap of T1 and Remove the four screws. Remove the T1 from
the PCB3.
4. PCB4 (WK-5449)
a) Remove the Side Panel. See section “11.01.1”.
b) Remove the Protection Cover.
c) Remove the Knob Cap. Holding the Knob down, loosen the screw and remove the Knob.
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d) Disconnect the two connectors CN1,3 on the PCB4. Remove the four screws. Pull out the
operation panel and bring it down.
e) Remove the four screws. Remove the PCB4.
5. PCB5 (WK-5448)
a) Remove the Side Panel. See section “11.01.1”.
b) Remove the PCB4. See section “12.03.4”.
c) Remove the three latches of Front Control Cover and then remove the PCB5.
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*When reinstalling the PCB5, engage two latches of Front Control Cover first.
6. PCB6 (WK-5460) and Q1A-Q2C “Primary IGBT”
a) Remove the Side Panel. See section “11.01.1”.
b) Remove the four screws and two IGBT Spring Clips. Remove the cables from edge holder.
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.
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7. PCB7 (WK-5460) and Q3A-Q4C “Primary IGBT”
a) Remove the Side Panel. See section “11.01.1”.
b) Remove the four screws and two IGBT Spring Clips. Remove the cables from edge holder.
c) 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.
8. D2 and D3 “Secondary Diode”
a) Remove the Side Panel. See section “11.01.1”.
b) Remove PCB3 (WK-5569) and T1. See section “12.03.3”.
c) Remove six screws and then detach the D2 and D3.
*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.
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9. C.C. “Coupling Coil”* and FCH1 “Reactor”
a) Remove the Side Panel. See section “11.01.1”.
b) Remove the Gas Tube*. Remove the two bolts, two toothed washers, and the terminal.
c) Remove the four screws and the Front Panel.
d) Remove the screw and then remove the cable. Remove the two terminals from HF. UNIT.
Remove the terminal from PCB3.
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e) Remove the C.C. and FCH1.
10. CT1 “Hole Current Trans”
a) Remove the Side Panel. See section “11.01.1”.
b) Remove the bolts, the spring, and the washer. Remove the three screws and then remove the
Output Bus Bar.
c) Remove the CT1. Disconnect the connector.
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11. FAN1 “Cooling Fan”
a) Remove the Side Panel. See section “11.01.1”.
b) Remove the Gas Tube. Remove the two terminals and Cut the three snap bands.
c) Disconnect the connector CN2 on the PCB1 and Cut the snap band.
d) Remove the four screws and then open the Rear Panel.
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e) Remove the FAN1.
*Do not place the fan in the wrong direction when reinstalling.
12. HF UNIT1 “High Frequency Unit”
a) Remove the Side Panel. See section “11.01.1”.
b) Remove the high frequency gap. Remove the four terminals.
c) Remove the two screws and the two washers. Detach the HF UNIT1.
13. SOL1 “Solenoid GAS Valve”
a) Remove the Side Panel. See section “11.01.1”.
b) Remove the Gas Tube and two terminals.
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c) Remove the C-ring and then detach the SOL1.
*When reinstalling, make sure that the C-ring seats in the solenoid valve groove.
14. S1 “Switch”
a) Remove the Side Panel. See section “11.01.1”.
b) Remove the four screws and the four cables.
c) Remove the two screws and then detach the S1.
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15. CON1 “Remote Receptacle”
a) Remove the Side Panel. See section “11.01.1”.
b) Remove the screw and then three ground cables. Cut the two snap bands.
c) Cut the snap band and disconnect connector CN1 on the PCB1.
d) Open the Panel Protects. Remove the two screws and the CON1.
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16. TH1 “Primary Thermistor”
a) Remove the Side Panel. See section “11.01.1”.
b) Remove the snap band. 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.
17. TH2 “Secondary Thermistor”
a) Remove the Side Panel. See section “11.01.1”.
b) Remove PCB3 unit. See section “12.03.3”.
c) Cut the three snap bands. 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.
93
APPENDIX A:
ARCMASTER 160TS
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: 10-3067
ARC MASTER 160TS
No.
1
2
3
DWG No. Part No.
Description
C1
10-6510
Capacitor, gen 3.1, IPS
C.C.
W7001384 Coil, Coupling, gen 3.1, IPS
CON1
10-6838
Socket, Remote, gen 3.1, IPS
4
CT1
10-5003
Sensor, Current, gen 3.1, IPS
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
D1
D2
D3
FAN1
FCH1
HF UNIT
L1
PCB1
PCB2
PCB3
PCB4
PCB5
PCB6
PCB7
Q1A-1C
Q2A-2C
Q3A-3C
Q4A-4C
R1
R3, R4
S1
W7001481
10-6629
10-6629
10-5227
W7001502
W7001399
10-6633
10-6538
W7001403
W7001405
W7001520
W7001412
W7001724
W7001516
W7001516
W7001445
W7001445
W7001445
W7001445
W7001448
W7001449
W7001453
Diode, gen 3.1, IPS
Diode, gen 3.1, IPS
Diode, gen 3.1, IPS
Fan, gen 3.1, IPS
Inductor, gen 3.1, IPS
HF, Unit, gen 3.1, IPS
HF, Gap, gen 3.1, IPS
Inductor, 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
Resistor, gen 3.1, IPS
Resistor, gen 3.1, IPS
Switch, gen 3.1, IPS
27
SOL1
10-6645
Valve Solenoid, gen 3.1, IPS
28
29
T1
W7001501 Transformer, gen 3.1, IPS
TH1, TH2 10-5228
Thermistor, gen 3.1, IPS
95
Additional Information
SS351206PP1 DC350V 20uF (CAPACITOR)
F3A040600 200A (COUPING COIL)
206433-1 8P with Wiring Assembly (REMOTE
CONNECTOR)
HC-TN200V4B15M 200A 4V (CURRENT
TRANSFORMER)
DF30DB80 (PRIMARY DIODE)
DBA200UA60 (SECONDARY DIODE)
DBA200UA60 (SECONDARY DIODE)
D12T24PS101 (COOLING FAN)
F3A285001 1601200A FCH (REACTOR)
WK-4840 U04 (HIGH FREQUENCY UNIT)
U0A601100
1615MRE (RING CORE)
WK-5466 U03 (D/D PCB)
WK-5467 U01 (MAIN PCB)
WK-5609 U01 (2ND_DIODE PCB)
WK-5449 U01 (CONTROL PCB)
WK-5448 U04-2 (PANEL PCB)
WK-5460 U01 (GATE PCB)
WK-5460 U01 (GATE PCB)
IRGP20B60PD 600V 22A (TRANSISTOR)
IRGP20B60PD 600V 22A (TRANSISTOR)
IRGP20B60PD 600V 22A (TRANSISTOR)
IRGP20B60PD 600V 22A (TRANSISTOR)
ERG3ANJ103 3W 10kW (RESISTOR)
ERG3SJ220H 3W 22Ω (RESISTOR)
DCP-52SR50C-480V 2P-480V (MAIN ON/OFF
SWITCH)
5505NBR1.5 DC24V 11VA/10W with Gas Inlet and
PC4-02 (SOLENOID VALVE)
F3A013701 200A MTR (TRANSFORMER)
ERTA53D203 20KΩ/25°C B=3950K
(THERMISTOR)
QTY.
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
3
3
3
3
1
2
1
1
1
2
160TS 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
72
73
74
Part No.
W7001458
W7001459
W7001457
W7001460
10-6653
10-6791
10-6705
W7001566
W7001512
W7001508
W7001509
10-6732
10-6733
W7001513
W7001511
10-6659
10-5184
10-6660
N/A
W7001484
W7001489
W7001490
W7001488
10-6665
10-6666
W7001565
W7001493
10-5069
W7001496
W7001495
W7001499
W7001500
W7001492
W7001494
W7001374
W7001503
W7001487
W7001504
W7001505
W7001563
W7001498
W7001497
W7001485
10-6681
300x4858
Description
Panel, Front, gen 3.1, IPS
Panel, Rear, gen 3.1, IPS
Label, Side, gen 3.1, IPS
Case, Front Control, gen 3.1, IPS
Cover, Protector, gen 3.1, IPS
Cover, Encoder, gen 3.1, IPS
Cover, PCB, 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, Output, gen 3.1, IPS
Label, Gas Input, gen 3.1, IPS
Label, VRD, gen 3.1, IPS
Label, VRD, gen 3.1, IPS
Outlet, Gas, gen 3.1, IPS
C-Ring, gen 3.1, IPS
Output, Terminal F, gen 3.1, IPS
Input Cable, gen 3.1, IPS
Clamp, Input, gen 3.1, IPS
Heatsink, gen 3.1, IPS
Heatsink, gen 3.1, IPS
Insulated Board, gen 3.1, IPS
Knob, gen 3.1, IPS
Knob Cap, gen 3.1, IPS
Cover, Protector, gen 3.1, IPS
Terminal Sheet, gen 3.1, IPS
Strap, gen 3.1, IPS
Post, 1 (M4-M4), gen 3.1, IPS
Post, Output, gen 3.1, IPS
Bus Bar, T-D1, gen 3.1, IPS
Bus Bar, 2 T-D, gen 3.1, IPS
Bus Bar, CT1, gen 3.1, IPS
Bus Bar, Output, gen 3.1, IPS
Clip, gen 3.1, IPS
Chassis, gen 3.1, IPS
Clip,Spring IGBT, gen 3.1, IPS
Chassis, D1, gen 3.1, IPS
Chassis, C1, gen 3.1, IPS
Support Board, gen 3.1, IPS
Cushion, CT1, gen 3.1, IPS
Cushion, Dust, gen 3.1, IPS
Holder, Edge, gen 3.1, IPS
Hose, Nylon, gen 3.1, IPS
Operating Manual, gen 3.1, IPS
96
Additional Information
E0D004501
E0D004601
E0D004707
E0C341900
E0C303200
EBA514400
E1B550900 (with Caution Label)
N4A932600
N4A785100
N1B029500
N1B029600
N4A040000
N4A040700
N4A918800
N4A598700
E5A925600 (with PC4-02)
TRAK-BE35-70S
132"12/3 SOW BLKW/5-15P
SCLB14A
E1B834200
E1B836800
E1B834100
2621603
3021104
N1B036400
ECA775700
E5A937000
ECA793500 (M4-M4)
ECA790900 (M8-M8)
ECA848700
ECA848800
ECA775600
ECA788600
#74 NATURAL
J4B983800
E1B832400
JEA280400
JEA280600
ECA774900
ECA793900
ECA793800
EH11U
T0425B Nylon Hose L=0.5m
Operating Manual 160TS
QTY.
1
1
2
1
1
1
1
2
2
1
1
1
1
1
1
1
2
2
1
1
2
1
2
1
1
1
4
1
2
2
1
1
1
1
4
1
4
1
1
2
1
1
3
1
1
160TS PARTS LIST
44
39
49
48
32
38
57
36
64
45
26
31
17
33
55
16
53
35
46
54
8
37
3
37
27
43
30
32
40
59
34
73
47
46
47
45
41
38
97
160TS PARTS LIST
13
5
18
56
14
72
56
72
56
56
19
65
24
1
52
66
67
29
50
66
68
52
9
51
69
66
66
69
2
65
25
10
58
7
71
28
11
72
6
15
29
70
4
62
63
61
66
98
APPENDIX 2 CONNECTION WIRING GUIDE
APPENDIX 2 Connection Wiring Guide
CONNECTION WIRING GUIDE
Destination
Destination
A
PCB1
CN1
↔
CON1
B
PCB1
CN2
↔
FAN1
SOL1
C
D
PCB1
PCB1
CN3
CN4
↔
↔
PCB3
CT1
E
F
PCB1
PCB1
CN5
CN6
↔
↔
TH1
TH2
G
H
PCB1
PCB1
CN7
CN8
↔
PCB6
PCB7
CN1
CN1
I
PCB1
CN101
PCB4
CN1
J
K
PCB1
PCB3
CN103
CN2
L
PCB3
CN3
↔
↔
↔
↔
↔
99
CN1
PCB4
CN3
HF UNIT
HF UNIT
160TS CONNECTION WIRING GUIDE
G
J
CN8
I
CN7
B
CN3
CN101
FAN1
H
CN1
CN2
PCB4
CN4
CN3
CON1
CN103
A
CN1
CN5
CN1
CN1
PCB1
CN6
C
PCB6
E
PCB7
F
CT1
PCB3
TH1
D
TH2
SOL1
CN1
CN3
CN2
K
ACT2
ACT1
R2
R1
HF-UNIT
APPENDIX 3 Interconnect Diagram
100
L
ARCMASTER 160TS
CN103-1
CN103-2
CN103-3
CN103-4
CN103-5
CN103-6
CN103-7
CN103-8
CN103-9
CN103-10
CN103-11
CN103-12
CN103-14
CN103-15
CN103-16
CN103-17
CN103-19
CN103-20
CN103-21
CN103-22
CN103-24
CN103-25
CN103-26
CN101-1
CN101-2
CN101-3
CN101-4
CN101-5
CN101-6
CN101-7
CN4-1
CN4-2
CN4-3
CN4-4
CN5-1
CN5-2
CN6-1
CN6-3
CN2-1
CN2-2
CN2-3
CN2-4
CN7-1
CN7-2
CN7-5
CN7-6
CN8-1
CN8-2
CN8-5
CN8-6
PCB7
WK-5460
PCB6
WK-5460
PCB4
WK-5449
PCB3
WK-5609
PCB1
WK-5466
2. Connection Wire List
CN3-1
CN3-2
CN3-3
CN3-4
CN3-5
CN3-6
CN3-7
CN3-8
CN3-9
CN3-10
CN3-11
CN3-12
CN3-14
CN3-15
CN3-16
CN3-17
CN3-19
CN3-20
CN3-21
CN3-22
CN3-24
CN3-25
CN3-26
CN1-1
CN1-2
CN1-3
CN1-4
CN1-5
CN1-6
CN1-7
Device No.
D1+
D1-G
FAN+
FANSOL1(P)
SOL1(N
HCT1-1
HCT1-2
HCT1-3
HCT1-4
FAN+
FANSOL1
SOL1
CN1-1
CN1-2
CN1-5
CN1-6
CN1-5
CN1-6
CN1-1
CN1-2
101
SIGNAL NAME
GND
Output Current Signal
Output Voltage signal
Torch Switch signal
Panel / Remote signal
GND
Potentiometer Max
Potentiometer Wiper
GND
FAN signal
GND
Primary Current signal
GND
Pre-start complete
115V / 230V detect signal
Error signal
Thermal Sensor1
Thermal Sensor1
Thermal Sensor2
Thermal Sensor2
HF signal
Gas signal
Short Detect signal
+12VDC
+5VDC
-12VDC
GND
IGBT Gate signal(E)
IGBT Gate signal(G)
GND
+12VDC
-12VDC
Current signal
GND
Thermal Sensor1
Thermal Sensor1
Thermal Sensor2
Thermal Sensor2
FAN+
FANSOL1 (P)
SOL1 (N)
IGBT Gate signal(E)
IGBT Gate signal(G)
IGBT Gate signal(E)
IGBT Gate signal(G)
IGBT Gate signal(E)
IGBT Gate signal(G)
IGBT Gate signal(E)
IGBT Gate signal(G)
ARCMASTER 160TS
CN1-2
CN1-3
CN1-4
CN1-5
CN1-6
CN1-7
CN1-8
PCB7
WK-5460
CN1-1
CN1-3
CN1-5
CN1-6
CN2-1
CN3-3
PCB6
WK-5460
PCB3
WK-5609
CN3-1
CN3-3
CN3-5
CN3-6
PCB4
WK-5449
PCB1
WK-5466
Connection Wire List (continued)
Device No.
SIGNAL NAME
GND
Short Detect signal
+12VDC
HF signal
HF. UNIT AC2 HF Input Voltage
HF. UNIT AC1 HF Input Voltage
CON1-2
Contactor Control (+12V)
CON1-3
Contactor Control (GND)
CON1-4
Panel / Remote signal
CON1-5
Potentiometer Max
CON1-6
Potentiometer Min (GND)
CON1-7
Potentiometer Wiper
CON1-8
Panel / Remote signal
102
ARCMASTER 160TS
APPENDIX C:
CONNECTION DIAGRAM
PCB2
Main Circuit Board
[WK-5467]
Q1A
TB7
C
C
G
G
E
C
D1
TB1
S1
Line1
E
TB1
TB10
TB11
TB2
TB2
TB3
TB3
TB9
+
Ground
C
PCB6
IGBT Gate
Circuit Board
[WK-5460]
TB8
Line2
+
TB12
E
Q1B
G
E
Q1C
E
Q2A
E
C
TB5
TB6
TB6
C
CN2
1 2 3 4 5 6
1
2
CN5
SOL1
E
CN1
1
2
3
4
Q4A
E
Q2B
Q4B
C
TB5
FAN1
+
-
TB7
E
G
G
G
SIDE CHASSIS 1
G
C
G
-
Q3C TB4
C
PCB7
IGBT Gate
Circuit Board
[WK-5460]
G
C
Q3B
C
G
+
Q3A
G
E
E
Q2C
Q4C
C
CN1
1 2 3 4 5 6
G
E
CN8
CN3
1 2 3 4 5 6
CN7
1
2
3
4
5
6
CN4
1
2
3
1 2 3 4 5 6
CN6
TH2
1
2
3
4
CN101
TH1
1
2
3
4
5
6
7
+
2
8
1
5
4
7
6
3
1
2
3
4
5
6
7
8
CN1
SIDE CHASSIS 1
PCB1
Control Source
Circuit Board
[WK-5466]
CN103
CON1
(Front View)
1 2 3 4 5 6 7 8
1
2
3
4
5
6
7
8
: Case Ground
: Contactor Control 1/+24VDC
: Contactor Control 2/GND
: +12VDC Supply
: Potentiometer Maximum
: Potentiometer Minimum (GND)
: Amperage Control Wiper 0-10VDC
: Remote Installed =12VDC
103
ARCMASTER 160TS
PCB3
2nd Diode
Circuit Board
[WK-5609]
D2
T1
CT1
TO1
TB1
1 2
3 4
TB3
TB5
+Output
Terminal
TB7
+12
-12
IS
GND
TB4
D3
TB2
TB6
SIDE CHASSIS 2
C1
FCH1
CN3
C.C.
CC2
1 2 3
R1
CC1
CN2
1 2 3
R1
R2
HF UNIT
CN1
1 2 3 4 5 6
PCB4
Control
Circuit Board
[WK-5449]
CN2
CN2
PCB5
Panel
Circuit Board
[WK-5448]
CN3
1
2
3
4
5
6
7
CN1
+12
-12
IS
GND
104
AC1
AC2
TO2
-Output
Terminal
ARCMASTER 160TS
APPENDIX D:
DIODE TESTING BASICS
Testing of diode modules requires a digital
Volt/Ohmmeter that has a diode test scale.
1. Locate the diode module to be tested.
2. Remove cables from mounting studs on
diodes to isolate them within the module.
VR
3. Set the digital volt/ohm meter to the diode
test scale.
Anode
Cathode
Figure D-1 Forward bias diode test
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 1). A properly functioning diode will
conduct in the forward bias direction, and
will indicate between 0.3 and 0.9 volts.
VR
6. To check the diode in the reverse bias
direction, reverse the meter leads (refer to
figure 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".
cables
to
the
COM
A
Reverse Bias
Diode Not Conducting
Cathode
7. If any diode in the module tests as faulty,
replace the diode module.
all
A
Forward Bias
Diode Conducting
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.
8. Reconnect
terminals.
COM
Anode
Figure D-2 Reverse bias diode tes
proper
105
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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