60 TS ARCMASTER ® INVERTER ARC WELDER Operating Manual Revision: AA.
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.
! 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. Instruction Manual Number 0-4858 for: ArcMaster 160TS 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.
ARCMASTER® 160TS Table of Contents SECTION 1: SAFETY INSTRUCTIONS AND WARNINGS ........................................................ 1-1 1.01 Arc Welding Hazards ........................................................................................1-1 1.02 Principal Safety Standards ................................................................................1-4 1.03 Precautions De Securite En Soudage A L’arc ....................................................1-5 1.
ARCMASTER® 160TS SECTION 6 :BASIC TIG WELDING GUIDE ........................................................................ 6-1 6.01 Electrode Polarity ..............................................................................................6-1 6.02 Tungsten Electrode Current Ranges ..................................................................6-1 6.03 Tungsten Electrode Types .................................................................................6-1 6.
ARCMASTER® 160TS iv March 31, 2006
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.
ARCMASTER® 160TS 1. Protect yourself and others from flying sparks and hot metal. 2. Do not weld where flying sparks can strike flammable material. WARNING FUMES AND GASES can be hazardous to your health. Welding produces fumes and gases. Breathing these fumes and gases can be hazardous to your health. 3. Remove all flammables within 35 ft (10.7 m) of the welding arc. If this is not possible, tightly cover them with approved covers. 4.
ARCMASTER® 160TS 3. Allow engine to cool before fueling. If possible, check and add fuel to cold engine before beginning job. WARNING 4. Do not overfill tank — allow room for fuel to expand. 5. Do not spill fuel. If fuel is spilled, clean up before starting engine. CYLINDERS can explode if damaged. Shielding gas cylinders contain gas under high pressure. If damaged, a cylinder can explode. Since gas cylinders are normally part of the welding process, be sure to treat them carefully.
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.) NOTE Considerations About Welding And The Effects of Low Frequency Electric and Magnetic Fields The following is a quotation from the General Conclusions Section of the U.S.
ARCMASTER® 160TS 1.03 Precautions De Securite En Soudage A L’arc ! MISE EN GARDE LE SOUDAGE A L’ARC EST DANGEREUX PROTEGEZ-VOUS, AINSI QUE LES AUTRES, CONTRE LES BLESSURES GRAVES POSSIBLES OU LA MORT. NE LAISSEZ PAS LES ENFANTS S’APPROCHER, NI LES PORTEURS DE STIMULATEUR CARDIAQUE (A MOINS QU’ILS N’AIENT CONSULTE UN MEDECIN). CONSERVEZ CES INSTRUCTIONS. LISEZ LE MANUEL D’OPERATION OU LES INSTRUCTIONS AVANT D’INSTALLER, UTILISER OU ENTRETENIR CET EQUIPEMENT.
ARCMASTER® 160TS 4. Portez des vêtements en matériaux ignifuges et durables (laine et cuir) et des chaussures de sécurité. 5. Portez un casque antibruit ou des bouchons d’oreille approuvés lorsque le niveau de bruit est élevé. 7. Ne soudez des tôles galvanisées ou plaquées au plomb ou au cadmium que si les zones à souder ont été grattées à fond, que si l’espace est bien ventilé; si nécessaire portez un respirateur à adduction d’air.
ARCMASTER® 160TS 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.
ARCMASTER® 160TS 6. Réinstallez les capots ou les protecteurs et fermez les portes après des travaux d’entretien et avant de faire démarrer le moteur. 1.05 Principales Normes De Securite Safety in Welding and Cutting, norme ANSI Z49.1, American Welding Society, 550 N.W. LeJeune Rd., Miami, FL 33128. Safety and Health Standards, OSHA 29 CFR 1910, Superintendent of Documents, U.S. Government Printing Office, Washington, D.C. 20402.
ARCMASTER® 160TS SECTION 2: INTRODUCTION AND DESCRIPTION 2.01 How To Use This Manual 2.02 Equipment Identification This Owner’s Manual applies to just specification or part numbers listed on page i. To ensure safe operation, read the entire manual, including the chapter on safety instructions and warnings. Throughout this manual, the words WARNING, CAUTION, and NOTE may appear. Pay particular attention to the information provided under these headings.
ARCMASTER® 160TS 2.04 Symbol Chart Note that only some of these symbols will appear on your model. On Single Phase Wire Feed Function Off Three Phase Wire Feed Towards Workpiece With Output Voltage Off.
ARCMASTER® 160TS 2.05 Description The Thermal Arc™ ArcMaster 160TS is a self contained single-phase DC arc welding power source 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 Welding-Sloped (GTAW-S), and Shielded Metal Arc Welding (SMAW) processes.
ARCMASTER® 160TS 2.07 Transporting Methods • Location These units are equipped with a handle for carrying purposes. Be sure to locate the welder according to the following guidelines: ! • In areas free from moisture and dust. 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.
ARCMASTER® 160TS NOTE Refer to figure 3 and: TThis unit is equipped with a 115 VAC (NEMA 5-15) plug modeled on the two-conductor with earth power cable that is connected at the welding power source for single phase electrical input power. For 230 VAC operation, have a qualified person install according to applicable codes, and instructions. Do not connect an input (WHITE or BLACK) conductor to the ground terminal. Do not connect the ground (GREEN) conductor to an input line terminal. 1.
ARCMASTER® 160TS • Input Power Each unit incorporates an INRUSH circuit and input voltage sensing circuit. When the MAIN CIRCUIT SWITCH is turned on, the inrush circuit provides a pre-charging of the input capacitors. SCR’s in the Power Control Assembly (PCA) will turn on after the input capacitors have charged to full operating voltage (after approximately 5 seconds). NOTE Note the available input power. Damage to the PCA could occur if 460VAC or higher is applied.
ARCMASTER® 160TS 2.
ARCMASTER® 160TS 2.10 Duty Cycle The duty cycle of a welding power source is the percentage of a ten (10) minute period that it can be operated at a given output without causing overheating and damage to the unit. If the welding amperes decrease, the duty cycle increases. If the welding amperes are increased beyond the rated output, the duty cycle will decrease.
ARCMASTER® 160TS SECTION 3: OPERATOR CONTROLS 3.01 ArcMaster 160TS Controls Figure 4 – ArcMaster 160TS Power Source 1. Control Knob 2. Remote Control Socket This control sets the selected weld parameter, rotating it clockwise increases the parameter and is indicated on the digital meter. Pushing the knob inward displays the actual welding voltage. The 8 pin Remote Control Socket is used to connect remote current control devices to the welding Power Source.
ARCMASTER® 160TS 6. ON/OFF Switch 3. Positive Terminal This switch connects the Primary supply voltage to the inverter when in the ON position. This enables the Power Supply. Welding current flows from the Power Source via heavy duty Dinse type terminal. It is essential, however, that the male plug is inserted and turned securely to achieve a sound electrical connection. ! 4. Negative Terminal Welding current flows from the Power Source via heavy duty Dinse type terminal.
ARCMASTER® 160TS 3.
ARCMASTER® 160TS Parameter PRE-FLOW HOT START INITIAL CUR. UP SLOPE PEAK CUR. WELD Description This parameter operates in TIG modes only and is used to get 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.
ARCMASTER® 160TS 3.04 Weld Parameters for ArcMaster 160TS Weld Parameter PRE-FLOW HOT START INITIAL CUR. UP SLOPE PEAK CUR. WELD CUR SPOT TIME PULSE WIDTH PULSE FREQ. DOWN SLOPE CRATER CUR. POST-FLOW Factory Incremental Parameter Range Setting Unit STICK 0.0 to 1.0 sec 0.1 sec 0.1 sec No 0 to 70A 20A 1A Yes 1 to 160A 30A 1A No 0 to 15 sec 1 sec 0.1 sec No 1 to 160A 120A 1A No 1 to 160A 230V 80A 1A Yes 1 to 85A 115V 80A 1A Yes 0.5 to 5.0 sec 2 sec 0.1 sec No 15 to 80% 50% 1% No 0.5 to 500Hz 100.
ARCMASTER® 160TS 3.
ARCMASTER® 160TS SECTION 4: SET-UP FOR SMAW (STICK) AND GTAW (TIG) Conventional operating procedures apply when using the Welding Power Source, i.e. connect work lead directly to work piece and electrode lead is used to hold electrode. Wide safety margins provided by the coil design ensure that the Welding Power Source will withstand short-term overload without adverse effects. The welding current range values should be used as a guide only.
ARCMASTER® 160TS 4-2 March 31, 2006
ARCMASTER® 160TS SECTION 5: 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 Symbols Table located in the front of the manual for Symbol descriptions. 7 1 2 6 8 3 4 5 Figure 7 - 160TS Front Panel 1. Pulse function – Pressing this button enables the TIG 5.01 Stick Welding current pulse functions. • Connect work lead to negative terminal 2.
ARCMASTER® 160TS 5.02 HF TIG & Lift TIG Welding • Set POST-FLOW time • Set WELD current • Connect work lead to positive terminal • Set POST-FLOW time Slope Mode Parameters if required • Connect TIG torch to negative terminal • Switch machine on • Set INITIAL CUR current • Set WELD current. • Connect remote control device. A remote control device is required for use during LIFT TIG and HF TIG operation. See section 3.01, section 2 “Remote Control Socket”, for complete details of the remote device.
ARCMASTER® 160TS Pulse Controls (Pulse Width) (Pulse Frequency) (Peak Current) (Base) Back ground Current The Pulse controls are used primarily to control heat input. Pulse offers a number of advantages as follows: 1) Control puddle – size and fluidity (especially out of position). 2) Increase penetration 3) Travel speed control 4) Better consistent quality 5) Distortion on lighter or thinner materials. Pulse-current provides a system in which the welding current continuously changes between two levels.
ARCMASTER® 160TS 5-4 March 31, 2006
ARCMASTER® 160TS SECTION 6: BASIC TIG WELDING GUIDE 6.01 Electrode Polarity Connect the TIG torch to the - / TORCH terminal and the work lead to the + / WORK terminal for direct current straight polarity. Direct current straight polarity is the most widely used polarity for DC TIG welding. It allows limited wear of the electrode since 70% of the heat is concentrated at the work piece. 6.02 Tungsten Electrode Current Ranges Electrode Diameter DC Current (Amps) 0.040” (1.0mm) 30 – 60 1/16” (1.
ARCMASTER® 160TS 6.05 Shielding Gas Selection Alloy Shielding Gas Aluminium & alloys Welding Argon Carbon Steel Welding Argon Stainless Steel Welding Argon Nickel Alloy Welding Argon Copper Welding Argon Titanium Welding Argon Table 10 – Shielding gas selection 6.06 TIG Welding Parameters for Low Carbon & Low Alloy Steel Pipe Electrode Type & Diameter Current Range DC Amperes Filler Rod for Root Pass Thoriated 2% 3/32” (2.4 mm) 120 - 170 Yes Thoriated 2% 3/32” (2.
ARCMASTER® 160TS SECTION 7: BASIC ARC WELDING GUIDE 7.01 Electrode Polarity Cast Iron Stick electrodes are generally connected to the ‘+’ terminal and the work lead to the ‘−’ terminal but if in doubt consult the electrode manufacturers literature. 7.02 Effects of Stick Welding Various Materials Most types of cast iron, except white iron, are weldable. White iron, because of its extreme brittleness, generally cracks when attempts are made to weld it.
ARCMASTER® 160TS 7-2 March 31, 2006
ARCMASTER® 160TS SECTION 8: 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.
ARCMASTER® 160TS Warning! Disconnect input power before maintaining. Maintain more often if used under severe conditions Each Use Visual check of torch Consumable parts Visual check of regulator and pressure Weekly Visually inspect the torch body and consumables Visually inspect the cables and leads.
ARCMASTER® 160TS SECTION 9: 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.
ARCMASTER® 160TS 9. Description Poor weld finish. Possible Cause Inadequate shielding gas. 10. Arc flutters during TIG welding. A. B. 11. Welding arc can not be established. A. B. C. 12. Arc start is not smooth. A. B. C. D. E. Remedy Increase gas flow or check gas line for gas flow problems. Tungsten electrode is too large for A. Select the right size electrode. Refer the welding current. to Basic TIG Welding guide. Absence of oxides in the weld B. Refer Basic TIG Welding Guide for ways pool.
ARCMASTER® 160TS Figure 8 – Example of insufficient gap or incorrect sequence 4. Portions of the weld run A. Small electrodes used on heavy A Use larger electrodes and pre-heat the do not fuse to the surface cold plate. . plate. of the metal or edge of the B. Welding current is too low. B. Increase welding current joint. C. Wrong electrode angle. C. Adjust angle so the welding arc is directed more into the base metal D. Travel speed of electrode is too D. Reduce travel speed of electrode high. E.
ARCMASTER® 160TS 9.03 Power Source Problems Description Possible Cause Remedy 1. The welding arc cannot be A. The Primary supply voltage has not A. Switch ON the Primary supply voltage. established been switched ON. B. The Welding Power Source switch B. Switch ON the Welding Power Source. is switched OFF. C. Loose connections internally. C. Have an Accredited Thermal Arc Service Agent repair the connection. 2.
ARCMASTER® 160TS SECTION 10: VOLTAGE REDUCTION DEVICE (VRD) 10.01 VRD Specification Description VRD Open Circuit Voltage VRD Resistance ArcMaster 160TS 15.3 to 19.8V 148 to 193 ohms VRD Turn OFF Time 0.2 to 0.3 seconds Notes Open circuit voltage between welding terminals The required resistance between welding terminals to turn ON the welding power The time taken to turn OFF the welding power once the welding current has stopped 10.
ARCMASTER® 160TS 10.03 Switching VRD On/Off Switch the machine Off. a) Remove the clear plastic cover from the control panel (see Figure 11). • Lift up the cover so it rests on the top of the unit. • Place a small flat bladed screw driver between the cover hinge on the front panel. • Gently lift the cover hinge out of the front cover mounting hole. • Remove the control’s clear plastic cover. Figure 11 VRD ON/OFF Step A b) Remove four mounting screws from the control panel (see Figure 12).
ARCMASTER® 160TS d) Turning the VRD ON/OFF (see Figure 13). • To turn VRD ON: rote the trim potentiometer (VR1) on the display PCB fully clockwise. • When VRD is turned ON check that it operates as per VRD Specifications on page 5-13. • To turn VRD OFF: rote the trim potentiometer (VR1) on the display PCB fully counter • clockwise. ! 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.
ARCMASTER® 160TS 10-4 March 31, 2006
March 31, 2006 E11 error code displayed Over Primary supply (input) voltage at primary capacitors is exceeded for one second E12 error code displayed Under mains supply (input) voltage primary capacitors is reduced for one second E93 error code displayed Memory chip (EEPROM) on control PCB can not read/write weld parameters E94 error code displayed Temperature sensor TH1 for IGBT’s is an open circuit.
ARCMASTER® 160TS APPENDIX A: INTERCONNECT DIAGRAM (serial numbers xxxxxxA103067 and earlier) A-2 March 31, 2006
ARCMASTER® 160TS March 31, 2006 A-3
ARCMASTER® 160TS APPENDIX B: INTERCONNECT DIAGRAM (serial numbers xxxxxxA103067 and later) B-2 March 31, 2006
ARCMASTER® 160TS March 31, 2006 B-3
ARCMASTER® 160TS APPENDIX C: OPTIONS AND ACCESSORIES PRODUCT DESCRIPTION Carry Case Accommodates the power supply, regulator, stick work lead, TIG torch & accy. kit Stick Kit 90924 Work clamp with 15’ #4 cable, and stick electrode with 15’ #4 cable TIG Kit 600288 Includes regulator/flowgauge, 12.
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.
WARRANTY SCHEDULE This information applies to Thermal Arc products that were purchased in the USA and Canada. April 2006 ENGINE DRIVEN WELDERS W ARRANTY P ERIOD Scout, Raider, Explorer Original Main Power Stators and Inductors .................................................................................. 3 years LABOR 3 years Original Main Power Rectifiers, Control P.C. Boards ...................................................................
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: sales@thermalarc.
World Headquarters Thermadyne Holdings Corporation Suite 300, 16052 Swingley Ridge Road Telephone: (636) 728-3000 Fascimile: (636) 728-3010 Email: sales@thermalarc.com www.thermalarc.
