61 S THERMAL ARC ® Inverter Arc Welder Art# A-10380 Operating Manual Revision: AB Issue Date: February 6, 2012 Operating Features: 3163339 Manual No.
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! WARNINGS Read and understand this entire Manual and your employer’s safety practices before installing, operating, or servicing the equipment. While the information contained in this Manual represents the Manufacturer’s best judgement, the Manufacturer assumes no liability for its use. Operating Manual Number 0-5199 for: Thermal Arc 161 S Power Source Arc Welder Thermal Arc 161 S System with Stick Kit & Case Thermal Arc 161 S System with Stick/TIG Kit & Case Part No. W1003606 Part No.
TABLE OF CONTENTS SECTION 1: SAFETY INSTRUCTIONS AND WARNINGS........................................................ 1-1 1.01 1.02 1.03 1.04 1.05 Arc Welding Hazards........................................................................................ 1-1 General Safety Information for Victor CS Regulator........................................... 1-4 Principal Safety Standards............................................................................... 1-6 Symbol Chart................................
TABLE OF CONTENTS SECTION 4: OPERATION............................................................................................ 4-1 4.01 4.02 4.03 4.04 4.05 4.06 4.07 4.08 4.09 4.10 4.11 4.12 4.13 4.14 4.15 4.16 4.17 4.18 4.19 4.20 4.21 4.22 Front Panel...................................................................................................... 4-1 Welding Current Control Explanation............................................................... 4-2 STICK (SMAW) Electrode Polarity..............
Thermal Arc 161S Stick System Part Number W1003608 • Thermal Arc 161S power supply in toolbox • Tweco electrode holder, 13ft (4m) lead • Tweco ground clamp, 10ft (3.1m) lead • 4 GP 1/8" (3.2mm) dia stick electrodes • 230V to 115V adapter • Product family overview DVD • Operating manual Art# A-10378 Thermal Arc 161S TIG/Stick System Part Number W1003609 • Thermal Arc 161 S power supply in toolbox • 17V TIG torch, 12.5ft (3.
SAFETY INSTRUCTIONS THERMAL ARC 161 S SECTION 1: SAFETY INSTRUCTIONS AND WARNINGS ! WARNING PROTECT YOURSELF AND OTHERS FROM POSSIBLE SERIOUS INJURY OR DEATH. KEEP CHILDREN AWAY. PACEMAKER WEARERS KEEP AWAY UNTIL CONSULTING YOUR DOCTOR. DO NOT LOSE THESE INSTRUCTIONS. READ OPERATING/INSTRUCTION MANUAL BEFORE INSTALLING, OPERATING OR SERVICING THIS EQUIPMENT.
THERMAL ARC 161 S SAFETY INSTRUCTIONS 7. Do not weld on coated metals, such as galvanized, lead, or cadmium plated steel, unless the coating is removed from the weld area, the area is well ventilated, and if necessary, while wearing an air-supplied respirator. The coatings and any metals containing these elements can give off toxic fumes if welded. 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.
SAFETY INSTRUCTIONS THERMAL ARC 161 S 6. Be aware that welding on a ceiling, floor, bulkhead, or partition can cause fire on the hidden side. ! 7. Do not weld on closed containers such as tanks or drums. 8. Connect work cable to the work as close to the welding area as practical to prevent welding current from traveling long, possibly unknown paths and causing electric shock and fire hazards. WARNING Engines can be dangerous. 9. Do not use welder to thaw frozen pipes. 10.
THERMAL ARC 161 S SAFETY INSTRUCTIONS 1. Keep cables close together by twisting or taping them. 2. Arrange cables to one side and away from the operator. WARNING SPARKS can cause BATTERY GASES TO EXPLODE; BATTERY ACID can burn eyes and skin. 3. Do not coil or drape cable around the body. 4. Keep welding power source and cables as far away from body as practical. Batteries contain acid and generate explosive gases. ! 1. Always wear a face shield when working on a battery. 2.
SAFETY INSTRUCTIONS C THERMAL ARC 161 S Ventilation ! ! WARNING Cylinders are highly pressurized. Handle with care. Serious accidents can result from improper handling or misuse of compressed gas cylinders DO NOT drop the cylinder, knock it over, or expose it to excessive heat, flames or sparks. DO NOT strike it against other cylinders. Contact your gas supplier or refer to CGA P-1 “Safe Handling of Compressed Gases in Containers” publication.
THERMAL ARC 161 S SAFETY INSTRUCTIONS 1.03 Principal Safety Standards Safety in Welding and Cutting, ANSI Standard Z49.1, from American Welding Society, 550 N.W. LeJeune Rd., Miami, FL 33126. Safety and Health Standards, OSHA 29 CFR 1910, from Superintendent of Documents, U.S. Government Printing Office, Washington, D.C. 20402. Recommended Safe Practices for the Preparation for Welding and Cutting of Containers That Have Held Hazardous Substances, American Welding Society Standard AWS F4.
SAFETY INSTRUCTIONS THERMAL ARC 161 S 1.04 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.
THERMAL ARC 161 S SAFETY INSTRUCTIONS 1.05 Declaration Of Conformity Manufacturer: Thermadyne Corporation Address: 82 Benning Street West Lebanon, New Hampshire 03784 USA The equipment described in this manual has been designed to all applicable aspects and regulations of the ‘Low Voltage Directive’ (2006/95 EC) and to the National legislation for the enforcement of this Directive.
INTRODUCTION tHERMAL ARC 161 S 2.01 How to Use This Manual SECTION 2: INTRODUCTION This Manual usually applies to the 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 word WARNING, CAUTION and NOTE may appear. Pay particular attention to the information provided under these headings.
THERMAL ARC 161 S INTRODUCTION 2.07 Specifications Power Source Part Number Mains Power Nominal Supply Voltage Number of Phases Input Voltage Range Nominal Supply Frequency W1003606 AC 115V Single Phase AC 104- 127V 50/60 Hz AC 208/230V Single Phase AC 187- 253V 50/60 Hz Effective Input Current (l1eff) for STICK (SMAW) Welding 16.4 Amps 14.7/13.2 Amps Effective Input Current (l1eff) for LIFT TIG (GTAW) Welding 13.8 Amps 9.8/8.9 Amps Maximum Input Current (l1 max) for STICK (SMAW) Welding ∆ 27.
INSTALLATION THERMAL ARC 161 s SECTION 3: INSTALLATION 3.01 Environment These units are designed for use in environments with increased hazard of electric shock. Examples of environments with increased hazard of electric shock are: A. In locations in which freedom of movement is restricted, so that the operator is forced to perform the work in a cramped (kneeling, sitting or lying) position with physical contact with conductive parts. B.
THERMAL ARC 161 S INSTALLATION 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. Lock-out/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.
INSTALLATION THERMAL ARC 161 s 208-230V, 50A, 1Ø Welding Power Supply 120 V, 20A, 1Ø The Adapters enable connection to all these power outlets 120 V, 15A, 1Ø Primary Power Cable Art# A-09862 Figure 3-1: Electrical Input Connections Input Power Each unit incorporates an INRUSH circuit. When the MAIN CIRCUIT SWITCH is turned on, the inrush circuit provides pre-charging for the input capacitors.
THERMAL ARC 161 S 3.04 Electromagnetic Compatibility WARNING Extra precautions for Electromagnetic Compatibility may be required when this Welding Power Source is used in a domestic situation. The size of the surrounding area to be considered will depend on the structure of the building and other activities that are taking place. The surrounding area may extend beyond the boundaries of the premises. C. Methods of Reducing Electromagnetic Emissions 1.
INSTALLATION 5. Earthing of the Work Piece THERMAL ARC 161 s 3.05 Setup for Welding Where the work piece is not bonded to earth for electrical safety, nor connected to earth because of its size and position, e.g. ship’s hull or building steelwork, a connection bonding the work piece to earth may reduce emissions in some, but not all instances. Care should be taken to prevent the earthing of the work piece increasing the risk of injury to users, or damage to other electrical equipment.
THERMAL ARC 161 S INSTALLATION 3.06 STICK (SMAW) Setup Set Welding Current as specified by the Electrode Manufacturer. Set Process Selection Switch to SMAW (Stick) Negative Output Terminal (Dinse™ 50) Positive Output Terminal (Dinse™ 50) 200A Art #: A-09878 Figure 3-2: Setup for STICK (SMAW) Welding STICK (SMAW) Mode Sequence of Operation CAUTION Before any welding is to begin, be sure to wear all appropriate and recommended safety equipment. 3. Connect the ground clamp to your workpiece. 4.
INSTALLATION THERMAL ARC 161 s 3.07 LIFT TIG (GTAW) Setup Set Process Selection Switch to GTAW (Lift TIG). Secure the gas cylinder in an upright position by chaining it to a stationary support to prevent falling or tipping. Set Welding Current as specified by the Electrode Manufacturer.
THERMAL ARC 161 S 2. The regulator body will be stamped “IN” or “HP” at the inlet port. Attach the inlet port to the system supply pressure connection. 9. Set the “Process Selection Switch” to LIFT TIG 10. Set the weld current control knob to the desired amperage. 3. Wrap pipe threads with Teflon tape 1 1/2 to 2 turns to effect a seal. If other sealants are used, they must be compatible with the gas that will be used in the system. 11.
INSTALLATION THERMAL ARC 161 s ! WARNING DO NOT attach or use the regulator if oil, grease, flammable substances or damage is present! Have a qualified repair technician clean the regulator or repair any damage. Art # A-09828 Figure 3-6: Open Cylinder Valve 10. On all cylinders, except acetylene, open the valve completely to seal the valve packing. On gaugeless regulators, the indicator will register the cylinder contents open. 11.
THERMAL ARC 161 S 3.09 Leak Testing the System INSTALLATION 3.10 When You Finish Using the Regulator Leak test the system before putting into operation. 1. Close the cylinder valve. 1. Be sure that there is a valve in the downstream equipment to turn off the gas flow. 2. Open the valve on the downstream equipment. This drains all pressure from the system. 2. With the cylinder valve open, adjust the regulator to deliver the maximum required delivery pressure. 3.
OPERATION THERMAL ARC 161 s SECTION 4: OPERATION 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 the electrode. The welding current range values should be used as a guide only.
THERMAL ARC 161 S OPERATION Output Scale for 115V 4.02 Welding Current Control Explanation 15 Amp Outlet The mains power 15 Amp circuit breaker or fuse should not trip at this Weld Current value when STICK welding. The environmental conditions that may cause the mains power 15 Amp circuit breaker or fuse to trip are: The inside number scale identifies the available output weld current for STICK or LIFT TIG weld modes. STICK Mode: Identifies the STICK weld point for 15 Amp outlet.
OPERATION 4.03 STICK (SMAW) Electrode Polarity Stick electrodes are generally connected to the "+" Positive Output Terminal and the work lead to the "−" Negative Output Terminal but if in doubt consult the electrode manufacturers literature for further information. 4.
THERMAL ARC 161 S OPERATION 4.05 GTAW Electrode Polarity Connect the TIG torch to the "-" Negative Output Terminal and the work lead to the "+" Positive Output 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. 4.06 Guide for Selecting Filler Wire Filler Wire Diameter DC Current (Amps) 1/16" (1.6mm) 20 - 90 3/32" (2.
OPERATION THERMAL ARC 161 s 4.10 TIG Welding Parameters for Steel DC Current Base Metal Mild Steel Thickness 0.040" (1.0mm) 0.045" (1.22mm) 1/16" (1.6mm) 1/8" (3.2mm) 3/16" (4.8mm) 1/4" (6.4mm) Stainless Steel 35-45 20-30 40-50 25-35 45-55 30-45 50-60 35-50 60-70 40-60 70-90 50-70 80-100 65-85 90-115 90-110 115-135 100-125 140-165 125-150 160-175 135-160 170-200 160-180 Electrode Diameter Filler Rod Diameter Argon Gas Flow Rate 0.040" (1.0mm) 1/16" (1.
THERMAL ARC 161 S OPERATION 4.12 Welding Position The electrodes dealt with in this publication can be used in most positions, i.e. they are suitable for welding in flat, horizontal, vertical and overhead positions. Numerous applications call for welds to be made in positions intermediate between these. Some of the common types of welds are shown in Figures 4-2 through 4-9.
OPERATION THERMAL ARC 161 s 4.13 Joint Preparations In many cases, it will be possible to weld steel sections without any special preparation. For heavier sections and for repair work on castings, etc., it will be necessary to cut or grind an angle between the pieces being joined to ensure proper penetration of the weld metal and to produce sound joints. In general, surfaces being welded should be clean and free of rust, scale, dirt, grease, etc. Slag should be removed from oxy-cut surfaces.
THERMAL ARC 161 S 4.14 Arc Welding Technique A Word to Beginners For those who have not yet done any welding, the simplest way to commence is to run beads on a piece of scrap plate. Use mild steel plate about 1/4" (6.4mm) thick and a 1/8" (3.2mm) electrode. Clean any paint, loose scale or grease off the plate and set it firmly on the work bench so that welding can be carried out in the downhand position.
OPERATION THERMAL ARC 161 s 4.19 Making Welded Joints Having attained some skill in the handling of an electrode, you will be ready to go on to make up welded joints. A. Butt Welds Set up two plates with their edges parallel, as shown in Figure 4-12, allowing 1/16" (1.6mm) to 3/32" (2.4mm) gap between them and tack weld at both ends. This is to prevent contraction stresses from the cooling weld metal pulling the plates out of alignment. Plates thicker than 1/4" (6.
THERMAL ARC 161 S Art # A-07700_AB OPERATION Art # A-07701 6 3 5 1 2 4 Figure 4-16: Multi-runs in HV fillet weld C. Vertical Welds 1. Vertical Up Figure 4-17: Single run vertical fillet weld Tack weld a three feet length of angle iron to your work bench in an upright position. Use a 1/8" (3.2mm) E7014 electrode and set the current at 120 amps. Make yourself comfortable on a seat in front of the job and strike the arc in the corner of the fillet.
OPERATION THERMAL ARC 161 s 4.20 Distortion 3. Overhead Welds Apart from the rather awkward position necessary, overhead welding is not much more difficult that downhand welding. Set up a specimen for overhead welding by first tacking a length of angle iron at right angles to another piece of angle iron or a length of waste pipe. Then tack this to the work bench or hold in a vice so that the specimen is positioned in the overhead position as shown in the sketch.
THERMAL ARC 161 S The metal in the weld area is stretched (plastic deformation), the job may be pulled out of shape by the powerful contraction stresses (distortion), or the weld may crack, in any case, there will remain “locked-up” stresses in the job. Figures 4-20 and 4- 21 illustrate how distortion is created. Upsetting Weld Art # A-07705_AB Expansion with compression Hot Hot Cool Figure 4-21: Parent metal expansion Art # A-07706_AB Weld Permanent Upset Contraction with tension OPERATION D.
OPERATION THERMAL ARC 161 s 3 2 1 Art # A-07710_AB Block Sequence. The spaces between the welds are filled in when the welds are cool.
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SERVICE THERMAL ARC 161 s SECTION 5: SERVICE 5.01 Maintenance and Inspection 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. To clean the unit, open 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.
THERMAL ARC 161 S SERVICE 5.02 STICK (SMAW) Welding Problems Description 1. Gas pockets or voids in weld metal A. (Porosity). B. Possible Cause Electrodes are damp. Remedy A. Dry electrodes before use. Welding current is too high. B. Reduce welding current. Surface impurities such as oil, C. Clean joint before welding grease, paint, etc. A. Redesign to relieve weld joint of severe 2. Crack occurring in weld metal soon A. Rigidity of joint.
SERVICE THERMAL ARC 161 s 5.03 TIG Welding Problems Weld quality is dependent on the selection of the correct consumables, maintenance of equipment and proper welding technique. Description 1. Excessive bead build-up or poor penetration or poor fusion at edges of weld. 2. Weld bead too wide and flat or undercut at edges of weld or excessive burn through. 3. Weld bead too small or insufficient penetration or ripples in bead are widely spaced apart. 4.
THERMAL ARC 161 S SERVICE TIG Welding Problems (Continued) Description 12. Arc start is not smooth. Possible Cause Remedy A. Tungsten electrode is too large for the welding current. B. The wrong electrode is being used for the welding job. C. Gas flow rate is too high. A. Refer to section Tungsten Electrode Current Ranges for the correct size. B. Refer to section Tungsten Electrode Types for the correct electrode type. C. Select the correct flow rate for the welding job. D.
REPLACEMENT PARTS THERMAL ARC 161 S SECTION 6: replacement PARTS 6.01 Replacement Parts Item No Description Part No.
THERMAL ARC 161 S REPLACEMENT PARTS 1 2 20 3 19 4 22 5 6 18 7 17 10 11 8 12 9 13 14 Art # A-09896_AB 16 21 Replacement Parts 6-2 15 Manual 0-5199
APPENDIX THERMAL ARC 161 s APPENDIX 1: OPTIONS AND ACCESSORIES Description 17V style TIG Torch with 12.5ft lead, gas valve, 50mm dinse connection and accessory kit with 1/16", 3/32", 1/8" thoriated tungstens; 1/16", 3/32", 1/8" collets; 1/16", 3/32", 1/8" collet bodies; No.
PUT 230VAC/115VAC 50/60Hz SHEETMETAL COVER 60W4Ω ACOUT BLACK DC DC + 2 8 3 FAN 2 J8-2 J8-1 GND -24V IFB J6 J3 CONNECTOR LAYOUT DIAGRAM OT J7 WVIN MBIN IMOUT J3-8 FJ J8 J2-8 FJ J3-7 Over Current Signal GND J3-6 J2-7 J7-3 J2-6 VRD OFF 1 J3-5 GND Over Current Signal +15V J2-5 OT J3-4 IGBT Driver B J7-2 J1 JC J2-4 ON J3-3 IGBT Driver A Control PCB2 IMOUT J3-2 J2-3 ON BLACK IN J3-1 J2-2 J7-1 JC RED G G J2-1 +15V 115VAC STICK --1.
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LIMITED WARRANTY This information applies to Thermal Arc products that were purchased in the USA and Canada. August 2011 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. August 2011 SAFETY EQUIPMENT Auto-Darkening Welding Helmet (Electronic Lens) Harness Assembly WARRANTY PERIOD 2 year 1 Month ENGINE DRIVEN WELDERS WARRANTY PERIOD Scout, Raider, Explorer Original Main Power Stators and Inductors .....................................................................................................
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