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November 5, 2003 Manual No. 430429-504

INVERTERARC

WELDER

MODEL 160S DC CCSTICKTIG - Lift Start

OPERATING MANUAL

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CONTENTS

SYMBOL LEGEND ............................................................................................................................................................5STATEMENT OF WARRANTY ........................................................................................................................................61.0 GENERAL INFORMATION.........................................................................................................................................7

1.01 Notes, Cautions and Warnings .................................................................................................................................71.02 Important Safety Precautions....................................................................................................................................71.03 Publications .............................................................................................................................................................81.04 Note, Attention et Avertissement..............................................................................................................................91.05 Precautions De Securite Importantes.......................................................................................................................91.06 Documents De Reference ......................................................................................................................................11

2.0 INTRODUCTION AND DESCRIPTION ...................................................................................................................132.01 Description .............................................................................................................................................................132.02 Functional Block Diagrams ....................................................................................................................................142.03 Transporting Methods.............................................................................................................................................142.04 Installation Recommendations................................................................................................................................15

2.04.01 Environment ..................................................................................................................................................152.04.02 Location.........................................................................................................................................................15

2.05 Electrical Input Connections...................................................................................................................................162.05.01 Electrical Input Requirements .......................................................................................................................162.05.02 Input Power ...................................................................................................................................................182.05.03 High Frequency Introduction.........................................................................................................................192.05.04 High Frequency Interference .........................................................................................................................19

2.06 Specifications .........................................................................................................................................................212.07 Duty Cycle..............................................................................................................................................................22

3.0 OPERATOR CONTROLS ...........................................................................................................................................233.01 P-Wee 160S Controls .............................................................................................................................................233.02 Weld Parameter Description for the 160S ..............................................................................................................253.03 Power Source Features ...........................................................................................................................................26

4.0 SET-UP FOR SMAW (STICK) AND GTAW (TIG) ..................................................................................................275.0 SEQUENCE OF OPERATION....................................................................................................................................28

5.0 Stick Welding ...........................................................................................................................................................295.02 DC LIFT TIG Welding...........................................................................................................................................29

6.0 BASIC TIG WELDING GUIDE..................................................................................................................................316.01 Electrode Polarity ...................................................................................................................................................316.02 Tungsten Electrode Current Ranges .......................................................................................................................316.03 Tungsten Electrode Types ......................................................................................................................................316.04 Guide for Selecting Filler Wire Diameter...............................................................................................................326.05 Shielding Gas Selection..........................................................................................................................................326.06 TIG Welding Parameters for Low Carbon & Low Alloy Steel Pipe ......................................................................326.07 Welding Parameters for Steel .................................................................................................................................33

7.0 Basic Arc Welding Guide.............................................................................................................................................347.01Electrode Polarity ....................................................................................................................................................347.02 Effects of Stick Welding Various Materials ...........................................................................................................34

8.0 ROUTINE MAINTENANCE ......................................................................................................................................369.0 BASIC TROUBLESHOOTING...................................................................................................................................37

9.01 TIG Welding Problems...........................................................................................................................................379.02 Stick Welding Problems .........................................................................................................................................398.03 Power Source Problems..........................................................................................................................................41

10.0 Voltage Reduction Device (VRD)..............................................................................................................................4210.01 VRD Specification................................................................................................................................................4210.02 VRD Maintenance ................................................................................................................................................42

11.0 Power Source Error Codes .........................................................................................................................................4312.0 PARTS LIST ..............................................................................................................................................................45APPENDIX A - INTERCONNECT DIAGRAM...............................................................................................................48APPENDIX B - AUTOMATION ......................................................................................................................................50

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PAGE LEFT INTENTIONALLY BLANK

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SYMBOL LEGEND

Amperage STICK (Shielded Metal ArcSMAW)

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

Slope Function VRD Voltage Reduction DeviceCircuit

Slope W/Repeat Function Negative

Spot Function Positive

Impulse Starting (HighFrequency GTAW)

Gas Input

Touch Start (Lift Start TIGcircuit GTAW)

Gas Output

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STATEMENT OF WARRANTYLIMITED WARRANTY: Thermal Arc®, Inc., A Thermadyne Company, hereafter, “Thermal Arc” warrants to customersof its authorized distributors hereafter “Thermal; Arc” that its products will be free of defects in workmanship ormaterial. Should any failure to conform to this warranty appear within the time period applicable to the Thermal Arcproducts as stated below, Thermal Arc shall, upon notification thereof and substantiation that the product has beenstored, 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, oraccident, correct such defects by suitable repair or replacement, at Thermal Arc’s sole option, of any components or partsof the product determined by Thermal Arc to be defective.

THERMAL ARC MAKES NO OTHER WARRANTY, EXPRESS OR IMPLIED. THIS WARRANTY IS EXCLUSIVEAND IN LIEU OF ALL OTHERS, INCLUDING, BUT NOT LIMITED TO ANY WARRANTY OFMERCHANTABILITY OR FITNESS FOR ANY PARTICULAR PURPOSE.

LIMITATION OF LIABILITY: Thermal Arc shall not under any circumstances be liable for special, indirect orconsequential damages, such as, but not limited to, lost profits and business interruption. The remedies of the Purchaserset forth herein are exclusive and the liability of Thermal Arc with respect to any contract, or anything done in connectiontherewith such as the performance or breach thereof, or from the manufacture, sale, delivery, resale, or use of any goodscovered by or furnished by Thermal Arc whether arising out of contract, negligence, strict tort, or under any warranty, orotherwise, shall not, except as expressly provided herein, 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 anyother warranty.

PURCHASER'S RIGHTS UNDER THIS WARRANTY ARE VOID IF REPLACEMENT PARTS OR ACCESSORIESARE USED WHICH IN THERMAL ARC’S SOLE JUDGEMENT MAY IMPAIR THE SAFETY OR PERFORMANCEOF ANY THERMAL ARC PRODUCT.

PURCHASER'S RIGHTS UNDER THIS WARRANTY ARE VOID IF THE PRODUCT IS SOLD TO PURCHASER BYNON-AUTHORIZED PERSONS.

The warranty is effective for the time stated below beginning on the date that the authorized distributor delivers theproducts to the Purchaser. Notwithstanding the foregoing, in no event shall the warranty period extend more than thetime stated plus one year from the date Thermal Arc delivered the product to the authorized distributor.

POWER SUPPLIES POWER SUPPLIES & WIRE FEEDERS LABOR

MAIN POWER MAGNETICS (STATIC & ROTATING) 3 YEAR 3 YEARORIGINAL MAIN POWER RECTIFIER 3 YEAR 3 YEARPOWER SWITCHING SEMI-CONDUCTORS & CONTROL PC BOARD 3 YEAR 3 YEAR

ALL OTHER CIRCUITS AND COMPONENTS INCLUDING 1 YEAR 1 YEARBUT NOT LIMITED TO, CONTACTORS, RELAYS,SOLENOIDS, PUMPS, SWITCHES, MOTORS

ENGINES: ENIGINES ARE NOT WARRANTED BY THERMAL ARC, ALTHOUGH MOST ARE WARRANTED BY THEENGINE MANUFACTURER, SEE THE ENGINE MANUFACTURES WARRANTY FOR DETAILS.

CONSOLES, CONTROL EQUIPMENT, HEAT 1 YEAR 1 YEAREXCHANGES, AND ACCESSORY EQUIPMENT

PLASMA TORCH AND LEADS, AND REMOTE CONTROLS 180 DAYS 180 DAYSREPAIR/REPLACEMENT PARTS 90 DAYS 90 DAYS

Warranty repairs or replacement claims under this limited warranty must be submitted to Thermal Arc by an authorizedThermal Arc repair facility within thirty (30) days of purchaser’s notice of any Warranty Claim. No transportation costsof any kind will be paid under this warranty. Transportation charges to send products to an authorized warranty repairfacility shall be the responsibility of the Purchaser. All returned goods shall be at the Purchaser’s risk and expense. Thiswarranty supersedes all previous Thermal Arc warranties.

Thermal Arc® is a Registered Trademark of Thermadyne Industries Inc.

Effective April 1, 2002

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1.0 GENERAL INFORMATION1.01 Notes, Cautions and WarningsThroughout this manual, notes, cautions, andwarnings are used to highlight importantinformation. These highlights are categorized asfollows:

NOTE

An operation, procedure, orbackground information whichrequires additional emphasis or ishelpful in efficient operation of thesystem.

CAUTION

A procedure which, if not properlyfollowed, may cause damage to theequipment.

WARNING

A procedure which, if not properlyfollowed, may cause injury to theoperator or others in the operatingarea.

1.02 Important Safety Precautions

WARNING

OPERATION ANDMAINTENANCE OF ARCWELDING EQUIPMENT CAN BEDANGEROUS AND HAZARDOUSTO YOUR HEALTH.

To prevent possible injury, read,understand and follow all warnings,safety precautions and instructionsbefore using the equipment. Call 1-800-462-2782 or your local distributorif you have any questions.

GASES AND FUMES

Gases and fumes produced during the Arcwelding/cutting process can be dangerous andhazardous to your health.

• Keep all fumes and gases from the breathingarea. Keep your head out of the weldingfume plume.

• Use an air-supplied respirator if ventilation isnot adequate to remove all fumes and gases.

• The kinds of fumes and gases from the arcwelding/cutting depend on the kind ofmetal being used, coatings on the metal, andthe different processes. You must be verycareful when cutting or welding any metalswhich may contain one or more of thefollowing:

Antimony Chromium MercuryArsenic Cobalt NickelBarium Copper SeleniumBeryllium Lead SilverCadmium ManganeseVanadium

• Always read the Material Safety Data Sheets(MSDS) that should be supplied with thematerial you are using. These MSDSs willgive you the information regarding the kindand amount of fumes and gases that may bedangerous to your health.

• For information on how to test for fumes andgases in your workplace, refer to item 1 inSubsection 1.03, Publications in this manual.

• Use special equipment, such as water ordown draft welding/cutting tables, tocapture fumes and gases.

• Do not use the welding torch in an areawhere combustible or explosive gases ormaterials are located.

• Phosgene, a toxic gas, is generated from thevapors of chlorinated solvents and cleansers.Remove all sources of these vapors.

ELECTRIC SHOCK

Electric Shock can injure or kill. The arc weldingprocess uses and produces high voltage electricalenergy. This electric energy can cause severe orfatal shock to the operator or others in theworkplace.

• Never touch any parts that are electrically“live” or “hot.”

• Wear dry gloves and clothing. Insulateyourself from the work piece or other partsof the welding circuit.

• Repair or replace all worn or damaged parts.• Extra care must be taken when the workplace

is moist or damp.

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• Install and maintain equipment according toNEC code, refer to item 4 in Subsection 1.03,Publications.

• Disconnect power source before performingany service or repairs.

• Read and follow all the instructions in theOperating Manual.

FIRE AND EXPLOSION

Fire and explosion can be caused by hot slag,sparks, or the arc weld.

• Be sure there is no combustible or flammablematerial in the workplace. Any material thatcannot be removed must be protected.

• Ventilate all flammable or explosive vaporsfrom the workplace.

• Do not cut or weld on containers that mayhave held combustibles.

• Provide a fire watch when working in anarea where fire hazards may exist.

• Hydrogen gas may be formed and trappedunder aluminum workpieces when they arecut underwater or while using a water table.DO NOT cut aluminum alloys underwateror on a water table unless the hydrogen gascan be eliminated or dissipated. Trappedhydrogen gas that is ignited will cause anexplosion.

NOISE

Noise can cause permanent hearing loss. Arcwelding/cutting processes can cause noise levelsto exceed safe limits. You must protect your earsfrom loud noise to prevent permanent loss ofhearing.

• To protect your hearing from loud noise,wear protective ear plugs and/or ear muffs.Protect others in the workplace.

• Noise levels should be measured to be surethe decibels (sound) do not exceed safelevels.

• For information on how to test for noise, seeitem 1 in Subsection 1.03, Publications, inthis manual.

ARC WELDING RAYS

Arc Welding/Cutting Rays can injure your eyesand burn your skin. The arc welding/cuttingprocess produces very bright ultra violet and infrared light. These arc rays will damage your eyesand burn your skin if you are not properlyprotected.

• To protect your eyes, always wear a weldinghelmet or shield. Also always wear safetyglasses with side shields, goggles or otherprotective eye wear.

• Wear welding gloves and suitable clothing toprotect your skin from the arc rays andsparks.

• Keep helmet and safety glasses in goodcondition. Replace lenses when cracked,chipped or dirty.

• Protect others in the work area from the arcrays. Use protective booths, screens orshields.

• Use the shade of lens as recommended inSubsection 1.03, item 4.

1.03 PublicationsRefer to the following standards or their latestrevisions for more information:

1. OSHA, SAFETY AND HEALTH STANDARDS,29CFR 1910, obtainable from theSuperintendent of Documents, U.S.Government Printing Office, Washington, D.C.20402

2. ANSI Standard Z49.1, SAFETY IN WELDINGAND CUTTING, obtainable from the AmericanWelding Society, 550 N.W. LeJeune Rd, Miami,FL 33126

3. NIOSH, SAFETY AND HEALTH IN ARCWELDING AND GAS WELDING ANDCUTTING, obtainable from the Superintendentof Documents, U.S. Government PrintingOffice, Washington, D.C. 20402

4. ANSI Standard Z87.1, SAFE PRACTICES FOROCCUPATION AND EDUCATIONAL EYEAND FACE PROTECTION, obtainable fromAmerican National Standards Institute, 1430Broadway, New York, NY 10018

5. ANSI Standard Z41.1, STANDARD FOR MEN’SSAFETY-TOE FOOTWEAR, obtainable fromthe American National Standards Institute,1430 Broadway, New York, NY 10018

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6. ANSI Standard Z49.2, FIRE PREVENTION INTHE USE OF CUTTING AND WELDINGPROCESSES, obtainable from AmericanNational Standards Institute, 1430 Broadway,New York, NY 10018

7. AWS Standard A6.0, WELDING ANDCUTTING CONTAINERS WHICH HAVEHELD COMBUSTIBLES, obtainable fromAmerican Welding Society, 550 N.W. LeJeuneRd, Miami, FL 33126

8. NFPA Standard 51, OXYGEN-FUEL GASSYSTEMS FOR WELDING, CUTTING ANDALLIED PROCESSES, obtainable from theNational Fire Protection Association,Batterymarch Park, Quincy, MA 02269

9. NFPA Standard 70, NATIONAL ELECTRICALCODE, obtainable from the National FireProtection Association, Batterymarch Park,Quincy, MA 02269

10. NFPA Standard 51B, CUTTING ANDWELDING PROCESSES, obtainable from theNational Fire Protection Association,Batterymarch Park, Quincy, MA 02269

11.CGA Pamphlet P-1, SAFE HANDLING OFCOMPRESSED GASES IN CYLINDERS,obtainable from the Compressed GasAssociation, 1235 Jefferson Davis Highway,Suite 501, Arlington, VA 22202

12. CSA Standard W117.2, CODE FOR SAFETY INWELDING AND CUTTING, obtainable fromthe Canadian Standards Association, StandardsSales, 178 Rexdale Boulevard, Rexdale, Ontario,Canada M9W 1R3

13. NWSA booklet, WELDING SAFETYBIBLIOGRAPHY obtainable from the NationalWelding Supply Association, 1900 Arch Street,Philadelphia, PA 19103

14. American Welding Society Standard AWSF4.1,RECOMMENDED SAFE PRACTICES FORTHE PREPARATION FOR WELDING ANDCUTTING OF CONTAINERS AND PIPINGTHAT HAVE HELD HAZARDOUSSUBSTANCES, obtainable from the AmericanWelding Society, 550 N.W. LeJeune Rd, Miami,FL 33126

15. ANSI Standard Z88.2, PRACTICE FORRESPIRATORY PROTECTION, obtainablefrom American National Standards Institute,1430 Broadway, New York, NY 10018

1.04 Note, Attention et AvertissementDans ce manuel, les mots “note,” “attention,” et“avertissement” sont utilisés pour mettre en reliefdes informations à caractère important. Ces misesen relief sont classifiées comme suit :

NOTE

Toute opération, procédure ourenseignement général sur lequel ilimporte d’insister davantage ou quicontribue à l’efficacité defonctionnement du système.

ATTENTION

Toute procédure pouvant résulterl’endommagement du matériel en casde non-respect de la procédure enquestion.

AVERTISSEMENT

Toute procédure pouvant provoquerdes blessures de l’opérateur ou desautres personnes se trouvant dans lazone de travail en cas de non-respectde la procédure en question.

1.05 Precautions De SecuriteImportantes

AVERTISSEMENT

L’OPÉRATION ET LAMAINTENANCE DU MATÉRIELDE SOUDAGE À L’ARC AU JETDE PLASMA PEUVENTPRÉSENTER DES RISQUES ETDES DANGERS DE SANTÉ.

Il faut communiquer aux opérateurs etau personnel TOUS les dangerspossibles. Afin d’éviter les blessurespossibles, lisez, comprenez et suiveztous les avertissements, toutes lesprécautions de sécurité et toutes lesconsignes avant d’utiliser le matériel.Composez le + 1-800-462-2782 ouvotre distributeur local si vous avezdes questions.

FUMÉE et GAZ

La fumée et les gaz produits par le procédé de jetde plasma peuvent présenter des risques et desdangers de santé.

• Eloignez toute fumée et gaz de votre zone derespiration. Gardez votre tête hors de laplume de fumée provenant du chalumeau.

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• Utilisez un appareil respiratoire àalimentation en air si l’aération fournie nepermet pas d’éliminer la fumée et les gaz.

• Les sortes de gaz et de fumée provenant del’arc de plasma dépendent du genre de métalutilisé, des revêtements se trouvant sur lemétal et des différents procédés. Vous devezprendre soin lorsque vous coupez ou soudeztout métal pouvant contenir un ou plusieursdes éléments suivants:

antimoine cadmium mercureargent chrome nickelarsenic cobalt plombbaryum cuivre séléniumbéryllium manganèsevanadium

• Lisez toujours les fiches de données sur lasécurité des matières (sigle américain“MSDS”); celles-ci devraient être fourniesavec le matériel que vous utilisez. Les MSDScontiennent des renseignements quant à laquantité et la nature de la fumée et des gazpouvant poser des dangers de santé.

• Pour des informations sur la manière detester la fumée et les gaz de votre lieu detravail, consultez l’article 1 et les documentscités à la page 5.

• Utilisez un équipement spécial tel que destables de coupe à débit d’eau ou à courantdescendant pour capter la fumée et les gaz.

• N’utilisez pas le chalumeau au jet de plasmadans une zone où se trouvent des matièresou des gaz combustibles ou explosifs.

• Le phosgène, un gaz toxique, est généré par lafumée provenant des solvants et desproduits de nettoyage chlorés. Elimineztoute source de telle fumée.

CHOC ELECTRIQUELes chocs électriques peuvent blesser ou mêmetuer. Le procédé au jet de plasma requiert etproduit de l’énergie électrique haute tension. Cetteénergie électrique peut produire des chocs graves,voire mortels, pour l’opérateur et les autrespersonnes sur le lieu de travail.

• Ne touchez jamais une pièce “sous tension”ou “vive”; portez des gants et des vêtementssecs. Isolez-vous de la pièce de travail ou desautres parties du circuit de soudage.

• Réparez ou remplacez toute pièce usée ouendommagée.

• Prenez des soins particuliers lorsque la zonede travail est humide ou moite.

• Montez et maintenez le matérielconformément au Code électrique nationaldes Etats-Unis. (Voir la page 5, article 9.)

• Débranchez l’alimentation électrique avanttout travail d’entretien ou de réparation.

• Lisez et respectez toutes les consignes duManuel de consignes.

INCENDIE ET EXPLOSIONLes incendies et les explosions peuvent résulterdes scories chaudes, des étincelles ou de l’arc deplasma. Le procédé à l’arc de plasma produit dumétal, des étincelles, des scories chaudes pouvantmettre le feu aux matières combustibles ouprovoquer l’explosion de fumées inflammables.

• Soyez certain qu’aucune matière combustibleou inflammable ne se trouve sur le lieu detravail. Protégez toute telle matière qu’il estimpossible de retirer de la zone de travail.

• Procurez une bonne aération de toutes lesfumées inflammables ou explosives.

• Ne coupez pas et ne soudez pas lesconteneurs ayant pu renfermer des matièrescombustibles.

• Prévoyez une veille d’incendie lors de touttravail dans une zone présentant des dangersd’incendie.

• Le gas hydrogène peut se former ous’accumuler sous les pièces de travail enaluminium lorsqu’elles sont coupées sousl’eau ou sur une table d’eau. NE PAS couperles alliages en aluminium sous l’eau ou surune table d’eau à moins que le gashydrogène peut s’échapper ou se dissiper.Le gas hydrogène accumulé explosera sienflammé.

RAYONS D’ARC DE PLASMA

Les rayons provenant de l’arc de plasma peuventblesser vos yeux et brûler votre peau. Le procédé àl’arc de plasma produit une lumière infra-rouge etdes rayons ultra-violets très forts. Ces rayons d’arcnuiront à vos yeux et brûleront votre peau si vousne vous protégez pas correctement.

• Pour protéger vos yeux, portez toujours uncasque ou un écran de soudeur. Porteztoujours des lunettes de sécurité munies de

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parois latérales ou des lunettes de protectionou une autre sorte de protection oculaire.

• Portez des gants de soudeur et un vêtementprotecteur approprié pour protéger votrepeau contre les étincelles et les rayons del’arc.

• Maintenez votre casque et vos lunettes deprotection en bon état. Remplacez toutelentille sale ou comportant fissure ourognure.

• Protégez les autres personnes se trouvant surla zone de travail contre les rayons de l’arcen fournissant des cabines ou des écrans deprotection.

• Respectez le teint de lentille recommandédans le article 4, page 5.

• Hydrogen gas may be present underaluminum workpieces during the cuttingprocess when being cut underwater or usinga water table. DO NOT cut aluminumunderwater or on a water table unless thehydrogen gas can be eliminated as thehydrogen gas may detonate.

BRUIT

Le bruit peut provoquer une perte permanente del’ouïe. Les procédés de soudage à l’arc de plasmapeuvent provoquer des niveaux sonoressupérieurs aux limites normalement acceptables.Vous dú4ez vous protéger les oreilles contre lesbruits forts afin d’éviter une perte permanente del’ouïe.

• Pour protéger votre ouïe contre les bruitsforts, portez des tampons protecteurs et/oudes protections auriculaires. Protégezégalement les autres personnes se trouvantsur le lieu de travail.

• Il faut mesurer les niveaux sonores afind’assurer que les décibels (le bruit) nedépassent pas les niveaux sûrs.

• Pour des renseignements sur la manière detester le bruit, consultez l’article 1, page 5.

1.06 Documents De ReferenceConsultez les normes suivantes ou les révisions lesplus récentes ayant été faites à celles-ci pour deplus amples renseignements :

1. OSHA, NORMES DE SÉCURITÉ DUTRAVAIL ET DE PROTECTION DE LASANTÉ, 29CFR 1910, disponible auprès du

Superintendent of Documents, U.S.Government Printing Office, Washington,D.C. 20402

2. Norme ANSI Z49.1, LA SÉCURITÉ DESOPÉRATIONS DE COUPE ET DESOUDAGE, disponible auprès de la SociétéAméricaine de Soudage (American WeldingSociety), 550 N.W. LeJeune Rd., Miami, FL33126

3. NIOSH, LA SÉCURITÉ ET LA SANTÉ LORSDES OPÉRATIONS DE COUPE ET DESOUDAGE À L’ARC ET AU GAZ,disponible auprès du Superintendent ofDocuments, U.S. Government PrintingOffice, Washington, D.C. 20402

4. Norme ANSI Z87.1, PRATIQUES SURESPOUR LA PROTECTION DES YEUX ET DUVISAGE AU TRAVAIL ET DANS LESECOLES, disponible de l’Institut Américaindes Normes Nationales (American NationalStandards Institute), 1430 Broadway, NewYork, NY 10018

5. Norme ANSI Z41.1, NORMES POUR LESCHAUSSURES PROTECTRICES, disponibleauprès de l’American National StandardsInstitute, 1430 Broadway, New York, NY10018

6. Norme ANSI Z49.2, PRÉVENTION DESINCENDIES LORS DE L’EMPLOI DEPROCÉDÉS DE COUPE ET DE SOUDAGE,disponible auprès de l’American NationalStandards Institute, 1430 Broadway, NewYork, NY 10018

7. Norme A6.0 de l’Association Américaine duSoudage (AWS), LE SOUDAGE ET LACOUPE DE CONTENEURS AYANTRENFERMÉ DES PRODUITSCOMBUSTIBLES, disponible auprès de laAmerican Welding Society, 550 N.W.LeJeune Rd., Miami, FL 33126

8. Norme 51 de l’Association Américaine pourla Protection contre les Incendies (NFPA),LES SYSTEMES À GAZ AVECALIMENTATION EN OXYGENE POUR LESOUDAGE, LA COUPE ET LES PROCÉDÉSASSOCIÉS, disponible auprès de la NationalFire Protection Association, BatterymarchPark, Quincy, MA 02269

9. Norme 70 de la NFPA, CODE ELECTRIQUENATIONAL, disponible auprès de laNational Fire Protection Association,Batterymarch Park, Quincy, MA 02269

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10. Norme 51B de la NFPA, LES PROCÉDÉSDE COUPE ET DE SOUDAGE, disponibleauprès de la National Fire ProtectionAssociation, Batterymarch Park, Quincy, MA02269

11. Brochure GCA P-1, LA MANIPULATIONSANS RISQUE DES GAZ COMPRIMÉS ENCYLINDRES, disponible auprès del’Association des Gaz Comprimés(Compressed Gas Association), 1235Jefferson Davis Highway, Suite 501,Arlington, VA 22202

12. Norme CSA W117.2, CODE DE SÉCURITÉPOUR LE SOUDAGE ET LA COUPE,disponible auprès de l’Association desNormes Canadiennes, Standards Sales, 178Rexdale Boulevard, Rexdale, Ontario,Canada, M9W 1R3

13. ivret NWSA, BIBLIOGRAPHIE SUR LASÉCURITÉ DU SOUDAGE, disponible

auprès de l’Association Nationale deFournitures de Soudage (National WeldingSupply Association), 1900 Arch Street,Philadelphia, PA 19103

14. Norme AWSF4.1 de l’AssociationAméricaine de Soudage,RECOMMANDATIONS DE PRATIQUESSURES POUR LA PRÉPARATION À LACOUPE ET AU SOUDAGE DECONTENEURS ET TUYAUX AYANTRENFERMÉ DES PRODUITS DANGEREUX, disponible auprès de la American WeldingSociety, 550 N.W. LeJeune Rd., Miami, FL33126

15. Norme ANSI Z88.2, PRATIQUES DEPROTECTION RESPIRATOIRE, disponibleauprès de l’American National StandardsInstitute, 1430 Broadway, New York, NY10018

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2.0 INTRODUCTION AND DESCRIPTION2.01 DescriptionThe Thermal Arc™ Model P-Wee 160S is a self contained single-phase DC arc welding power sourcewith Constant Current (CC) output characteristics. This unit is equipped with a Digital Volt/AmperageMeter and lift arc starter, for use with Gas Tungsten Arc Welding (GTAW) and Shielded Metal ArcWelding (SMAW) processes. The power source is totally enclosed in an impact resistant, flame resistantand non-conductive plastic case.

160A5A (A)

(V)

OCV

18V

210A

160A

STICK Process LIFT-TIG Process

Figure 1. Model 160S Volt-Ampere curve

Note 1Volt-Ampere curves show the maximum Voltage and Amperage output capabilities of thewelding power source. Curves of other settings will fall between the curves shown.

160A25A (A)

(V)

OCV

10V

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2.02 Functional Block Diagrams

Figure 2 illustrates the functional block diagram of the 160S-power supply.

Figure 2. Model 160S Functional Block Diagram

2.03 Transporting Methods

These units are equipped with a handle for carrying purposes.

WARNING 1

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

WARNING 2

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.

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2.04 Installation Recommendations

2.04.01 Environment

The P-Wee 160S is designed for use in hazardous environments.

Examples of environments with increased hazardous environments are -a. In locations in which freedom of movement is restricted, so that the operator is forced

to perform the work in a cramped (kneeling, sitting or lying) position with physicalcontact with conductive parts;

b. In locations which are fully or partially limited by conductive elements, and in whichthere 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 theskin resistance of the human body and the insulation properties of accessories.

Environments with hazardous environments do not include places where electrically conductiveparts in the near vicinity of the operator, which can cause increased hazard, have beeninsulated.

2.04.02 Location

Be sure to locate the welder according to the following guidelines:

• In areas, free from moisture and dust. • Ambient temperature between 0 degrees Cto 40 degrees C.

• In areas, free from oil, steam andcorrosive gases.

• In areas, not subjected to abnormalvibration or shock.

• In areas, not exposed to direct sunlight orrain.

• Place at a distance of 12” (304.79mm) ormore from walls or similar that couldrestrict natural airflow for cooling.

WARNING 3

Thermal Arc advises that this equipment be electrically connected by a qualifiedelectrician.

16

2.05 Electrical Input Connections

WARNING 4

ELECTRIC SHOCK can kill; SIGNIFICANT DC VOLTAGE is present after removal ofinput power.

DO NOT TOUCH live electrical parts.SHUT DOWN welding power source, disconnect input power employing lockout/taggingprocedures. Lockout/tagging procedures consist of padlocking line disconnect switch in openposition, removing fuses from fuse box, or shutting off and red-tagging circuit breaker or otherdisconnecting device.

2.05.01 Electrical Input Requirements

Operate the welding power source from a single-phase 50/60 Hz, AC power supply. The inputvoltage must match one of the electrical input voltages shown on the input data label on the unitnameplate. Contact the local electric utility for information about the type of electrical serviceavailable, how proper connections should be made, and inspection required.

The line disconnect switch provides a safe and convenient means to completely remove allelectrical power from the welding power supply whenever necessary to inspect or service the unit.

Note 2These units are equipped with a two-conductor with earth power cable that is connected atthe welding power source end for single phase electrical input power.

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.

17

Refer to figure 3 and:

1. Connect end of ground (GREEN) conductor to a suitable ground. Use a grounding method thatcomplies with all applicable electrical codes.

2. Connect ends of line 1 (BLACK) and line 2 (WHITE) input conductors to a de-energized linedisconnect switch.

3. Use Table 1 and Table 2 as a guide to select line fuses for the disconnect switch.

Input Voltage Fuse Size115 VAC 40 Amps

208-230 VAC 45 Amps

Table 1 Electrical Input Connections

Note 3Fuse size is based on not more than 200 percent of the rated input amperage of the welding powersource (Based on Article 630, National Electrical Code).

Figure 3. Electrical Input Connections

18

2.05.02 Input Power

Each unit incorporates an INRUSH circuit and input voltage sensing circuit. When the MAINCIRCUIT SWITCH is turned on, the inrush circuit provides a pre-charging of the input capacitors.SCR’s in the Power Control Assembly (PCA) will turn on after the input capacitors have chargedto full operating voltage (after approximately 5 seconds).

Note 4Note the available input power. Damage to the PCA could occur if 460VAC or higher isapplied.

The following 115/230V Primary Current recommendations are required to obtain themaximum welding current and duty cycle from this welding equipment:

Current & Duty CycleModelPrimary Supply

Lead Size(Factory Fitted)

Minimum PrimaryCurrent Circuit Size

(Vin/Amps) TIG STICK115/22 85A @ 100% -208/25 -230/23 160A @ 35% -115/38 - 85A @ 100%208/42 -

P-Wee 160S 12/3 AWGminimum

230/38 - 160A @ 35%

Table 2 – 115/230V Primary Current Circuit sizes to achieve maximum current

19

2.05.03 High Frequency Introduction

The importance of correct installation of high frequency welding equipment cannot be over-emphasized. Interference due to high frequency initiated or stabilized arc is almost invariablytraced to improper installation. The following information is intended as a guide for personnelinstalling high frequency welding machines.

WarningExplosives

The high frequency section of this machine has an output similar to a radio transmitter. Themachine should NOT be used in the vicinity of blasting operations due to the danger ofpremature firing.

ComputersIt is also possible that operation close to computer installations may cause computermalfunction.

2.05.04 High Frequency Interference

Interference may be transmitted by a high frequency initiated or stabilized arc weldingmachine in the following ways:

Direct RadiationRadiation from the machine can occur if the case is metal and is not properly grounded. Itcan occur through apertures such as open access panels. The shielding of the high frequencyunit in the Power Source will prevent direct radiation if the equipment is properly grounded.

Transmission via the Supply LeadWithout adequate shielding and filtering, high frequency energy may be fed to the wiringwithin the installation (mains) by direct coupling. The energy is then transmitted by bothradiation and conduction. Adequate shielding and filtering is provided in the Power Source.

Radiation from Welding LeadsRadiated 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 typeof interference. Looping and suspending of leads should be avoided where possible.

Re-radiation from Unearthed Metallic ObjectsA major factor contributing to interference is re-radiation from unearthed metallic objectsclose to the welding leads. Effective grounding of such objects will prevent re-radiation inmost cases.

20


21

2.06 SpecificationsParameter 160SRated OutputAmperesVoltsDuty Cycle

115VAC 230VAC85 16023 26100% 35%

Duty Cycle TIG 160A / 16V @ 35% 230VAC130A / 15V @ 60% 230VAC100A / 14V @ 100% 230VAC85A / 13V @ 100% 115VAC

STICK 160A / 26V @ 35% 230VAC130A / 25V @ 60% 230VAC100A / 24V @ 100% 230VAC85A/23V @ 100% 115VAC

Output Current TIG 5 – 160 (230V), 5 - 85 (115V)Range STICK 5 – 160 (230V), 5 – 85 (115V)Open Circuit Voltage 64VDimensionsWidthHeightLength

5.12” (130mm)10.24” (260mm)12.60” (320mm)

Weight 18.95 lb. 8.6 kgOutput @ Rated LoadOutput AmperesOutput VoltsDuty CycleKVAKW

115V 230V85A 160A23V 26V100% 35%4.4 8.72.4 5.2

Output @ No LoadKVAKW

0.20.1

Input Volts Single Phase115V208V230V

Amperage Draw @ Rated Load384238

No Load1.51.11.0

Thermal Arc continuously strives to produce the best product possible and therefore reserves the right to change, improve or revise thespecifications or design of this or any product without prior notice. Such updates or changes do not entitle the buyer of equipmentpreviously sold or shipped to the corresponding changes, updates, improvements or replacement of such items.

22

2.07 Duty Cycle

The duty cycle of a welding power source is the percentage of a ten (10) minute period that it canbe operated at a given output without causing overheating and damage to the unit. If the weldingamperes decrease, the duty cycle increases. If the welding amperes are increased beyond therated output, the duty cycle will decrease.

WARNING 5

Exceeding the duty cycle ratings will cause the thermal overload protection circuit tobecome energized and shut down the output until the unit has cooled to normal operatingtemperature.

CAUTION 1

Continually exceeding the duty cycle ratings can cause damage to the welding powersource and will void the manufactures warranty.

NOTE 5Due to variations that can occur in manufactured products, claimed performance, voltages, ratings,all capacities, measurements, dimensions and weights quoted are approximate only. Achievablecapacities and ratings in use and operation will depend upon correct installation, use, applications,maintenance and service.

23

Gnd.1 2 3 4 5 6 7 8

2 15 4 3

8 7 6

5k Ohms

Front view of 8-Socket Receptacle

3.0 OPERATOR CONTROLS3.01 P-Wee 160S Controls

Figure 4 – P-Wee 160S Power Source1 Control Knob

This control sets the selected weld parameter, rotating it clockwise increases the parameterand is indicated on the digital meter. Pushing the knob inward displays the actual weldingvoltage.

2 Remote Control SocketThe 8 pin Remote Control Socket is used to connect remote current control devices to thewelding Power Source. To make connections, align keyway, insert plug, and rotate threadedcollar fully clockwise.

24

Socket Pin Function1 Earth (Ground)2 Torch Switch Input (24V) to energize weld current.

(connect pins 2 & 3 to turn on welding current)3 Torch Switch Input (0V) to energize weld current

(connect pins 2 & 3 to turn on welding current)4 Connect pin 4 to pin 8 to instruct machine that a remote current control

device is connected (12V DC supply)5 5k ohm (maximum) connection to 5k ohm remote control potentiometer6 Zero ohm (minimum) connection to 5k ohm remote control

potentiometer7 Wiper arm connection to 5k ohm remote control potentiometer8 Connect pin 4 to pin 8 to instruct machine that a remote current control

device is connected (0V)

3 Positive TerminalWelding current flows from the Power Source via heavy duty Dinse type terminal. It isessential, however, that the male plug is inserted and turned securely to achieve a soundelectrical connection.

4 Negative TerminalWelding current flows from the Power Source via heavy duty Dinse type terminal. It isessential, however, that the male plug is inserted and turned securely to achieve a soundelectrical connection.

CAUTION 2

Loose welding terminal connections can cause overheating and result in the male plugbeing fused in the bayonet terminal.

5 ON/OFF SwitchThis switch connects the Primary supply voltage to the inverter when in the ON position.This enables the Power Supply.

WARNING 6

When the welder is connected to the Primary supply voltage, the internal electricalcomponents maybe at 230V potential with respect to earth.

6 Input CableThe input cable connects the Primary supply voltage to the equipment.

25

3.02 Weld Parameter Description for the 160S

Figure 5. P-Wee 160S Front Panel with Parameter Description

Parameter Description

HOT STARTThis parameter operates in STICK weld mode and is used to improve thestart characteristics for stick electrodes. e.g. low hydrogen electrodes. Itsets 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 currentin STICK welding to improve electrode sticking and arc stability.LIFT TIG mode of operation. A remote control device is required for useduring LIFT TIG operation. See section 3.01, section 2 “Remote ControlSocket”, for complete details of the remote device.STICK Mode of operation.

Table 3 – Weld Parameter Descriptions for P-Wee 160SWeld Mode

WeldParameter

ParameterRange

FactorySetting

IncrementalUnit STICK

LIFT TIG

HOT START 0 to 70A 20A 1A Yes NoWELD CUR 5 to 85A 115V

5 to 160A 230V-

80A1A1A

YesYes

YesYes

ARC CONTROL 0 to 100% 10% 1% Yes No

26

3.03 Power Source FeaturesFeature Description

New Digital Control • Almost all welding parameters are adjustableTouch Panel Switches • Touch switches eliminate mechanical damageFront Control Cover • Protects front panel controlsDigital 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 weldingON/OFF switch • Primary voltage Supply ON/OFF switch located

on rear panelVoltage Reduction Device (VRD) Reduces the OCV when the power supply is not in

use. Eliminates the need for add on voltage reducersand has no effect on arc starting.

• VRD fully complies to IEC 60974-1• When Stick mode is selected the green VRD light

is ON when not welding and red when welding.• When in TIG modes VRD is off.

Control Knob • For the selected weld parameter, rotating the knobclockwise increases the parameter

• Rotating the knob counterclockwise decreases theparameter

• A selected weld parameter value can be adjusted atany 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 supplyvoltage or internal component problems. Refer totroubleshooting guide.

27

4.0 SET-UP FOR SMAW (STICK) AND GTAW (TIG)Conventional operating procedures apply when using the Welding Power Source, i.e. connect worklead directly to work piece and electrode lead is used to hold electrode. Wide safety marginsprovided by the coil design ensure that the Welding Power Source will withstand short-termoverload without adverse effects. The welding current range values should be used as a guideonly. Current delivered to the arc is dependent on the welding arc voltage, and as welding arcvoltage varies between different classes of electrodes, welding current at any one setting wouldvary according to the type of electrode in use. The operator should use the welding current rangevalues as a guide, then finally adjust the current setting to suit the application.

Figure 6 – 160S Set-up

WARNING 7

Before connecting the work clamp to thework and inserting the electrode in theelectrode holder make sure the Primarypower supply is switched off.

CAUTION 3Remove any packaging material prior to use.Do not block the air vents at the front or rearor sides of the Welding Power Source.

28

5.0 SEQUENCE OF OPERATION

NOTE: Scroll Buttons are used to select the parameters to be set. TheLED’s show which function is being adjusted on the weld sequence graph.Refer to Symbols Table located in the front of the manual for Symboldescriptions.

Figure 7 160S Front Panel

1. Scroll Buttons – used to select the parameters to be set. The LED’s show which function isbeing adjusted on the weld sequence graph.

2. Digital LED display – Welding amperage and parameter values are displayed in this window.Internal warnings such as over temperature, low or high input voltage applied are signaled to theoperator by a warning sound and error message on the screen.

3. Control knob – allows the operator to adjust the output amperage within the entire range of thepower source also used to set each parameter value. Pushing the knob inward displays the actualwelding voltage.

4. Process Button – This button selects between STICK or Lift TIG mode.5. 8 pin remote control receptacle for connecting remote devices.

3 4

51

2

29

5.0 Stick WeldingConnect work lead to negative terminalConnect electrode lead to positive terminalSwitch machine onConnect remote control device if required

Use the Scroll Buttons to move to the parameter to be set. The LED will show whichfunction is being adjusted on the weld sequence graph. Use the control knob to adjust eachparameter.Set HOT STARTSet WELD currentSet Arc ControlCommence welding

5.02 DC LIFT TIG Welding• Connect work lead to positive terminalConnect TIG torch to negative terminalSwitch machine onSet weld current.• Connect remote control device. A remote control device is required for use during LIFT

TIG operation. See section 3.01, section 2 “Remote Control Socket”, for complete detailsof the remote device.

Use the Scroll Buttons to move to the parameter to be set. The LED will show whichfunction is being adjusted on the weld sequence graph. Use the control knob to adjust eachparameter.Set WELD current

Commence welding

30


31

6.0 BASIC TIG WELDING GUIDE

6.01 Electrode PolarityConnect the TIG torch to the - / TORCH terminal and the work lead to the + / WORKterminal for direct current straight polarity. Direct current straight polarity is the most widelyused polarity for DC TIG welding. It allows limited wear of the electrode since 70% of theheat is concentrated at the work piece.

6.02 Tungsten Electrode Current Ranges

Electrode Diameter DC Current (Amps)

0.040” (1.0mm) 30 – 60

1/16” (1.6mm) 60 – 115

3/32” (2.4mm) 100 – 165

1/8” (3.2mm) 135 – 200

5/32” (4.0mm) 190 – 280

3/16” (4.8mm) 250 – 340

Table 4 – Current ranges for varies tungsten electrode sizes

6.03 Tungsten Electrode Types

Electrode Type(GroundFinish)

Welding Application Features ColorCode

Thoriated 2%DC welding of mild steel,stainless steel and copper.

Excellent arc starting, Longlife, High current carryingcapacity.

Red

Ceriated 2%DC welding of mild steel,stainless steel, copper,aluminium, magnesium andtheir alloys

Longer life, More stable arc,Easier starting, Wider currentrange, Narrower moreconcentrated arc.

Grey

Table 5 – Tungsten electrode types

32

6.04 Guide for Selecting Filler Wire Diameter

Filler Wire Diameter DC Current Range(Amps)

1/16” (1.6 mm) 20 - 90

3/32” (2.4 mm) 65 - 115

1/8” (3.2 mm) 100 - 165

3/16” (4.8 mm) 200-350Table 6 – Filler wire selection guide

NOTE 6

The filler wire diameter specified in Table 6 is a guide only, other diameter wires maybe used according to the welding application

.6.05 Shielding Gas Selection

Alloy Shielding Gas

Aluminium & alloys ArgonCarbon Steel ArgonStainless Steel ArgonNickel Alloy ArgonCopper ArgonTitanium Argon

Table 7 – Shielding gas selection

6.06 TIG Welding Parameters for Low Carbon & Low Alloy Steel Pipe

Electrode Type &Diameter

Current Range DCAmperes

Filler Rod forRoot Pass

Joint Preparation

Thoriated 2%3/32” (2.4 mm) 120 - 170 Yes

Thoriated 2%3/32” (2.4 mm) 100 - 160 Yes

Thoriated 2%3/32” (2.4 mm) 90 - 130 No

Table 8 – TIG welding parameters for low carbon & low alloy steel pipe

33

6.07 Welding Parameters for Steel

Base MetalThickness

DC Currentfor Mild

Steel

DC Currentfor Stainless

Steel

TungstenElectrodeDiameter

Filler RodDiameter

(if required)

Argon GasFlow RateLiters/min

Joint Type

35-45 20-30 Butt/Corner0.040”1.0mm 40-50 25-35

0.040”1.0mm

1/16”1.6mm

5-7Lap/ Fillet

45-55 30-45 Butt/Corner0.045”1.2mm 50-60 35-50

0.040”1.0mm

1/16”1.6mm

5-7Lap/ Fillet

60-70 40-60 Butt/Corner1/16”1.6mm 70-90 50-70

1/16”1.6mm

1/16”1.6mm

7Lap/ Fillet

80-100 65-85 Butt/Corner1/8”3.2mm 90-115 90-110

1/16”1.6mm

3/32”2.4mm

7Lap/ Fillet

115-135 100-125 Butt/Corner3/16”4.8mm 140-165 125-150

3/32”2.4mm

1/8”3.2mm

10Lap/ Fillet

160-175 135-160 Butt/Corner¼”6.4mm 170-200 160-180

1/8”3.2mm

5/32”4.0mm

10Lap/ Fillet

Table 9 – DC TIG welding parameters

34

7.0 Basic Arc Welding Guide7.01Electrode Polarity

Stick electrodes are generally connected to the ‘+’ terminal and the work lead to the ‘−’ terminalbut if in doubt consult the electrode manufacturers literature.

7.02 Effects of Stick Welding Various MaterialsHigh tensile and alloy steels

The two most prominent effects of welding these steels are the formation of a hardened zone inthe weld area, and, if suitable precautions are not taken, the occurrence in this zone of under-beadcracks. Hardened zone and under-bead cracks in the weld area may be reduced by using thecorrect electrodes, preheating, using higher current settings, using larger electrodes sizes, shortruns for larger electrode deposits or tempering in a furnace.

Manganese steelsThe effect on manganese steel of slow cooling from high temperatures is to embrittle it. For thisreason it is absolutely essential to keep manganese steel cool during welding by quenching aftereach weld or skip welding to distribute the heat.

Cast IronMost types of cast iron, except white iron, are weldable. White iron, because of its extremebrittleness, generally cracks when attempts are made to weld it. Trouble may also be experiencedwhen welding white-heart malleable, due to the porosity caused by gas held in this type of iron.

Copper and alloysThe most important factor is the high rate of heat conductivity of copper, making preheating ofheavy sections necessary to give proper fusion of weld and base metal.

Types of ElectrodesArc Welding electrodes are classified into a number of groups depending on their applications.There are a great number of electrodes used for specialized industrial purposes which are not ofparticular interest for everyday general work. These include some low hydrogen types for hightensile steel, cellulose types for welding large diameter pipes, etc. The range of electrodes dealtwith in this publication will cover the vast majority of applications likely to be encountered; are alleasy to use and all will work on even the most basic of welding machines.

Metals beingjoined

Electrode Comments

Mild steel 6013 Ideal electrodes for all generalpurpose work. Features include outstanding operator appeal, easy arcstarting and low spatter.

Mild steel 7014 All positional electrode for use onmild and galvanized steel furniture,plates, fences, gates, pipes and tanksetc. Especially suitable for vertical-down welding.

Cast iron 99% Nickel Suitable for joining all cast ironsexcept white cast iron.

Stainless steel 318L-16 High corrosion resistance. Ideal fordairy work, etc. On stainless steels.

35

Metals beingjoined

Electrode Comments

Copper, Bronze,Brass, etc.

Bronze5.7 ERCUSI-A

Easy to use electrode for marinefittings, water taps and valves, watertrough float arms, etc. Also forjoining copper to steel and for bronzeoverlays on steel shafts.

High Alloy Steels,Dissimilar Metals,Crack Resistance.All Hard-To-WeldJobs.

312-16 It will weld most problematical jobssuch as springs, shafts, broken joinsmild steel to stainless and alloysteels.Not suitable for Aluminum.

Table 10 - Types of Electrodes

36

8.0 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 8

Disconnect primary power at the source before opening the enclosure. Wait at least twominutes before opening the enclosure to allow the primary capacitors to discharge.

To clean the unit, open the enclosure (please refer to Section 8.01.01, Opening the Enclosure in the160S Service Manual P/N 430429-513) and use a vacuum cleaner to remove any accumulated dirtand dust. The unit should also be wiped clean, if necessary; with solvents that are recommendedfor cleaning electrical apparatus.

CAUTION 4

Do not blow air into the power supply during cleaning. Blowing air into the unit cancause metal particles to interfere with sensitive electrical components and causedamage to the unit.

37

9.0 BASIC TROUBLESHOOTING

WARNING 9

There are extremely dangerous voltages and power levels present inside this product. Donot attempt to open or repair unless you are an Accredited Thermal Arc Service Agent andyou have had training in power measurements and troubleshooting techniques.

If major complex subassemblies are faulty, then the Welding Power Source must be returned to anAccredited Thermal Arc Service Agent for repair.

The basic level of troubleshooting is that which can be performed without special equipment orknowledge.

9.01 TIG Welding ProblemsWeld quality is dependent on the selection of the correct consumables, maintenance ofequipment and proper welding technique.

Description Possible Cause Remedy

1 Excessive beadbuild-up or poorpenetration or poorfusion at edges ofweld.

Welding current is too low Increase weld current and/orfaulty joint preparation

2 Weld bead toowide and flat orundercut at edgesof weld orexcessive burnthrough

Welding current is too high Decrease weld current

3 Weld bead toosmall orinsufficientpenetration orripples in bead arewidely spacedapart

Travel speed too fast Reduce travel speed

4 Weld bead toowide or excessivebead build up orexcessive penetra-tion in butt joint

Travel speed too slow Increase travel speed

5 Uneven leg lengthin fillet joint

Wrong placement of filler rod Re-position filler rod

6 Electrode meltswhen arc is struck.

A Electrode is connected to the‘+’ terminal.

A Connect the electrode to the‘−’ terminal.

38


7 Dirty weld pool. A Electrode contaminatedthrough contact with workpiece or filler rod material.

A Clean the electrode bygrinding off the contaminates.

B Gas contaminated with air. B Check gas lines for cuts andloose fitting or change gascylinder.

8 Electrode melts oroxidizes when anarc is struck.

A No gas flowing to weldingregion.

A Check the gas lines for kinksor breaks and gas cylindercontents.

B Torch is clogged with dust. B Clean torchC Gas hose is cut. C Replace gas hose.D Gas passage contains

impurities.D Disconnect gas hose from

torch then raise gas pressureand 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.9 Poor weld finish. Inadequate shielding gas. Increase gas flow or check

gas line for gas flowproblems.

10 Arc flutters duringTIG welding.

A Tungsten electrode is toolarge for the welding current.

A Select the right size electrode.Refer to Basic TIG Weldingguide.

B Absence of oxides in theweld pool.

B Refer Basic TIG WeldingGuide for ways to reduce arcflutter.

11 Welding arc cannot be established.

A Work clamp is not connectedto the work piece or thework/torch leads are notconnected to the rightwelding terminals.

A Connect the work clamp tothe work piece or connect thework/torch leads to the rightwelding terminals.

B Torch lead is disconnected. B Connect it to the ‘−‘ terminal.C Gas flow incorrectly set,

cylinder empty or the torchvalve is off.

C Select the right flow rate,change cylinders or turn torchvalve on.

39


12 Arc start is notsmooth.

A Tungsten electrode is toolarge for the welding current.

A Select the right size electrode.Refer to Basic TIG WeldingGuide.

B The wrong electrode is beingused for the welding job

B Select the right electrodetype. Refer to Basic TIGWelding Guide

C Gas flow rate is too high. C Select the correct rate for thewelding job.Refer to Basic TIG WeldingGuide.

D Incorrect shielding gas isbeing used.

D Select the right shielding gas.Refer to Basic TIG WeldingGuide.

E Poor work clamp connectionto work piece.

E Improve connection to workpiece.

9.02 Stick Welding Problems


1 Gas pockets orvoids in weld metal(Porosity).

ABC

Electrodes are damp.Welding current is too high.Surface impurities such asoil, grease, paint, etc.

ABC

Dry electrodes before use.Reduce welding current.Clean joint before welding.

2 Crack occurring inweld metal soonafter solidificationcommences

A

B

C

Rigidity of joint.

Insufficient throat thickness.

Cooling rate is too high.

A

B

C

Redesign to relieve weld jointof severe stresses or use crackresistance electrodes.Travel slightly slower to allowgreater build up in throat.Preheat plate and cool slowly.

3 A gap is left byfailure of the weldmetal to fill theroot of the weld.

AB

C

Welding current is too low.Electrode too large for joint.

Insufficient gap.

AB

C

Increase welding currentUse smaller diameterelectrode.Allow wider gap.

D Incorrect sequence. D Use correct build-up sequence.

Figure 8 – Example of insufficient gap or incorrectsequence

40

4 Portions of theweld run do notfuse to the surfaceof the metal oredge of the joint.

A

B

Small electrodes used onheavy cold plate.Welding current is too low.

A

B

Use larger electrodes and pre-heat the plate.Increase welding current

C Wrong electrode angle. C Adjust angle so the weldingarc is directed more into thebase metal

D Travel speed of electrode istoo high.

D Reduce travel speed ofelectrode

E Scale or dirt on joint surface. E Clean surface before welding.

Figure 9 – Example of lack of fusion

5 Non-metallic parti-cles are trapped inthe weld metal(slag inclusion).

A Non-metallic particles maybe trapped in undercut fromprevious run.

A If bad undercut is present,clean slag out and cover with arun from a smaller diameterelectrode.

B Joint preparation toorestricted.

B Allow for adequatepenetration and room forcleaning out the slag.

C Irregular deposits allow slagto be trapped.

C If very bad, chip or grind outirregularities.

D Lack of penetration with slagtrapped beneath weld bead.

D Use smaller electrode withsufficient current to giveadequate penetration. Usesuitable tools to remove allslag from corners.

E Rust or mill scale ispreventing full fusion.

E Clean joint before welding.

F Wrong electrode for positionin which welding is done.

F Use electrodes designed forposition in which welding isdone, otherwise proper controlof slag is difficult.

Figure 10 – Examples of slag inclusion

41

8.03 Power Source Problems


1 The welding arccannot beestablished

A

B

The Primary supply voltagehas not been switched ON.The Welding Power Sourceswitch is switched OFF.

A

B

Switch ON the Primary supplyvoltage.Switch ON the WeldingPower Source.

C Loose connections internally. C Have an Accredited ThermalArc Service Agent repair theconnection.

2 Maximum outputwelding current cannot be achievedwith nominalMains supplyvoltage.

Defective control circuit Have an Accredited ThermalArc Service Agent inspectthen repair the welder.

3 Welding currentreduces whenwelding

Poor work lead connection tothe work piece.

Ensure that the work lead hasa positive electricalconnection to the work piece.

4 No gas flow whenthe torch triggerswitch isdepressed.

AB

Gas hose is cut.Gas passage containsimpurities.

AB

Replace gas hose.Disconnect gas hose from therear of Power Source thenraise gas pressure and blowout impurities.

C Gas regulator turned off. C Turn gas regulator on.

42

10.0 Voltage Reduction Device (VRD)

10.01 VRD Specification

Description P-Wee 160S Notes

VRD Open Circuit Voltage 15.3 to 19.8V Open circuit voltage between weldingterminals

VRD Resistance 148 to 193 ohms The required resistance between weldingterminals to turn ON the welding power

VRD Turn OFF Time 0.2 to 0.3 seconds The time taken to turn OFF the weldingpower once the welding current hasstopped

10.02 VRD Maintenance

Routine inspection and testing (power source)An inspection of the power source, an insulation resistance test and an earth resistance testshall be carried out.a) For transportable equipment, at least once every 3 months; andb) For fixed equipment, at least once every 12 months.

The owners of the equipment shall keep a suitable record of the periodic tests.

Note 7

A transportable power source is any equipment that is not permanently connected andfixed 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 serviceagent.

Description IEC 60974-1 RequirementsVRD Open Circuit Voltage Less than 20V; at Vin=115V or 230VVRD Turn ON Resistance Less than 200 ohmsVRD Turn OFF Time Less than 0.3 seconds

If this equipment is used in a hazardous location or environments with a high risk ofelectrocution then the above tests should be carried out prior to entering this location.

43

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ceas

es to

ope

rate

.

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flow

is re

stric

ted

byve

nts b

eing

blo

cked

A B C

Let P

ower

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rce

cool

dow

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en k

eep

with

in it

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ty c

ycle

.H

ave

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gent

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ound

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stan

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hen

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for a

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igh

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Red

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ied

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ow M

ains

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err

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44

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erro

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l.

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gent

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qua

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45

12.0

PAR

TS L

IST

DW

G. N

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pe &

Rat

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No.

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1C

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SS35

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2000

0650

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ith T

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6300

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ted

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uit B

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with

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ted

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ith L

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01

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010

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ith C

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n La

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47

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IST

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tinue

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ng L

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2400

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ning

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utpu

t Ter

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al (f

emal

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252

2699

9025

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10-6

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t Cab

le13

2” 1

2/3S

OW

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W/5

-15P

152

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put C

able

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mp

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153

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eats

ink

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01

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ob26

1560

31

5099

0001

500

10-6

714

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Cap

3015

104

150

9900

0350

010

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ontro

l Cov

er S

heet

N0B

8831

001

N0B

8831

0010

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6Fl

at C

able

(Lon

g)EA

A547

301

1EA

A547

301

10-6

668

Flat

Cab

le (S

hort)

EBA4

2020

01

EBA4

2020

010

-671

7Q

-Pos

t (M

5)EB

A436

000

1EB

A436

000

10-6

674

D-T

Bus

Bar

EBA4

4790

02

EBA4

4790

010

-671

8Q

Bus

Bar

1EB

A448

200

2EB

A448

200

10-6

719

Q B

us B

ar2

(C2E

1)EB

A551

900

1EB

A551

900

10-6

720

Dio

de B

us B

arEB

A508

300

1EB

A508

300

10-6

721

Clip

#74

NAT

UR

AL4

6060

2422

000

10-5

259

Fron

t Cha

ssis

J3C

0092

001

J3C

0092

0010

-672

2R

ear C

hass

isJ3

C01

0800

1J3

C01

0800

10-6

723

Cap

acito

r Cha

ssis

JDA1

1770

01

JDA1

1770

010

-672

4H

F. U

nit C

hass

isJ4

B549

700

1J4

B549

700

10-6

725

Out

put T

erm

inal

(mal

e)TR

AK-S

K10-

252

2699

9025

600

10-1

068

Ope

ratin

g M

anua

l1

4304

29-5

04Se

rvic

e M

anua

l43

0429

-513

48

APPENDIX A - INTERCONNECT DIAGRAM

50

APPENDIX B - AUTOMATION

SLIDE SWITCH SETTING FOR "OK–TO–MOVE". Models 160S/TS

Three slide switches (S1, S2 and S3) are provided on PC Board WK-4977 for automation purposes.This PCB is the units right side main PCB. This PCB can be accessed by removing the side coversby loosening 4 screws on each the front and rear panel, then removing the 4 side panel screws aswell as the 2 handle screws. Carefully pull the front and rear panels outward to release and removethe side cover. Lift up the protective PCB cover sheet from the bottom and the slide switches willbe accessible through a slot in the PCB Board. See figure on next page for details.All units are shipped from the factory with the slide switches set in position "A". This is for normalsemi-automatic operation utilizing a remote device, such as a foot control. The 8-pin remoteoperates as described earlier in this manual.Placing all slide switches in position "B" would be primarily used for automation with an arcestablish relay, remote amperage and contactor. An arc-establish signal is located from pins 4 and 8when in this mode.Placing slide switches S1 and S2 in "B" position and slide switch S3 in "A" position would have theconfiguration of an arc-establish signal and remote contactor, but the unit’s front panel wouldcontrol the amperage.

• Set All "A" position : factory shipping

POSITIONS1 AS2 AS3 A

• Use "OK TO MOVE signal"

POSITIONS1 B BS2 B BS3 B AA/V REMOTE PANEL

S1A COM B

S2A COM B

B

COM

AOK-TO-MOVERELAY

WK-4977

CN6 CON1

1 4

2 8

S3

2

1 4

CN6 CON1

8

Remote : Short 4 to 8Panel : Open

2

1 4

CN6 CON1

8

OK TO MOVERELAY

Max Load:24V 50ma.

51

Figure 11 – Slide Switch Location

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