160 DualArc AC Stick Welder
Contents
1. FLOPUWER 160 DualArc AC Stick Welder Model FLOW160DA000 Operator s Manual and Parts List Florida Power amp Welding International LLC 1 305 698 2220 www flopower com r CONTENTS INTRODUCTION DESCRIPTION AND SPECIFICATIONS FLOPOWER LIMITED WARRANTY SAFETY PRECAUTIONS COMPONENTS ACCESSORIES ASSEMBLY AND INSTALLATION OPERATION ARC WELDING BASICS BASIC CARE TECHNICAL SPECIFICATIONS WIRING SCHEMATIC PARTS LIST TROBLESHOOTING REFERENCE PUBLICATIONS INTRODUCTION Congratulations on the purchase of your FLOP WER welder The welding machine you now own is the result of careful research aimed at providing good quality and easy to use equipment The FLOP WER 160 DualArc welder is a compact lightweight unit that delvers 160 Amps of AC alternated current welding current It is ideal for basic repairs and general purpose welding It is designed for use with 220V and 110V circuits making it a versatile and low cost choice Before attempting to use the welder please make sure to read this manual carefully Should you have any technical problems or questions regarding this unit contact us by email at sales flopower com or by telephone at 800 535 1185 from outside the USA 1 305 698 2220 DESCRIPTION AND SPECIFICATIONS Process Welding Current Range Input Rated Duty Cycle Overload Protection Included Accessories Arc welder for use wit2. from the vapors of chlorinated solvents and cleansers Remove all sources of these vapors This product when used for welding or cutting produces fumes or gases which contain chemicals known to the State of California to cause birth defects and in some cases cancer California Health amp Safety Code Sec 25249 5 et seq PN ELECTRIC SHOCK Electric shock can injure or kill Electricity used during welding can cause severe or fatal shock to the operator or others in the workplace e Never touch any parts that are electrically live or hot Wear dry welding gloves and protective clothing Insulate yourself from the work piece or other parts of the welding circuit e Never store or operate the welding machine its parts the welding surface or electrode in a humid environment or near water sources If the welder becomes wet for any reason make absolutely sure that it is completely dry before using the welder e Replace or repair all worn or damaged parts e Disconnect the power source before performing any service or repairs e Read and follow all the instructions in this Operator s Manual A FIRE AND EXPLOSION Fire and explosion can be caused by hot slag sparks or the welding arc e Be sure there are no combustible or flammable materials and gases in the work area Any material that cannot be removed must be protected e Ventilate all flammable or explosive vapors out of the weld area e Donot weld on containers th
3. out of the vents of the machine to avoid premature overheating The unit should have enough unobstructed air space around it at all times Passes Sometimes more than one pass is necessary in order to obtain a strong weld You should ensure that any slag is removed from the weld and that the metal is properly cooled after performing subsequent passes Quality of the bead The graphic below provide guidelines to evaluate the weld based on the appearance of the weld bead Note Weld bead width N should be approximately wi twice the diameter of the me ua b oe ese 38 electrode rod used Base Metal j D r JJ j 2 gt A A A 4 m Or LE a fL Normal current arc length speed us Speed too fast Current too low Speed too low Current too high Arc length too long Arc length too short BASIC CARE Always unplug the welder when it is not being used Worn parts or damaged parts cables switches plugs handle should be replaced promptly see Parts List When the welder is used outdoors it should be kept from rain or long exposure to the sun Inspect the welding cables from time to time to ensure that they are in good condition If the welder is not in use for a long time it should be kept dry and have good ventilation to free it from moisture corrosive agents etc The welder should be kept at temperatures ranging from 25 C 13 F to 55 C 13
4. 1 F and at relative humidity of no more than 90 measured at 25 C when stored and not in use While being utilized the welder should be kept between 10 C and 40 C Do not allow any external objects to intrude into the welder case through its vents Make sure the unit is not dropped shaken or otherwise damaged physically M least once a year remove any accumulated dust and check the machine s external fasteners to make sure there are no loose connections If you need to open the case for an inspection of the internal components you must make sure the unit is not plugged into an electrical circuit The welder must be serviced repaired only by a qualified technician TECHNICAL SPECIFICATIONS WIRING SCHEMATIC Welding Rated Input Input Power Input Open Circuit Rated Insulation Case Overload Current Current Cable Capacitance Voltage Output Grade Protection Protection Range Voltage Grade 55 160A AC 110VAC or 160A at 10 38A or 76A at 7 7 KVA 47 50V 24 4V at 160A IP21S Automatic Fan cooled 220VAC I 113A at 20 160A output shutdown Phase 60Hz 86A at 35 122041 0 10V i up Switch PARTS LIST Exploded View Descriptions Part Numbers 1 Handle FLOW160DA001 2 Amperage current indicator FLOW160DA002 3 Heat Relay FLOW160DA003 4 Secondary Winding FLOW160DA004 5 Inset FLOW160DA005 6 Indicator amperage FLOW160DA006 1 Sliding iron core bracket FLOW160DA007 8 Rotating Amperage control FLOW160
5. DA008 9 Power indicator light green FLOW160DA009 10 Overheat indicator light yellow FLOW160DA010 11 Cable connection FLOW160DA011 12 Work cable clam FLOW160DA012 13 Welding cable holder FLOW160DA013 14 Power selector switch FLOW160DA014 15 Underpan FLOW160DA015 16 Sliding iron Core FLOW160DA016 17 Nip FLOW160DA017 18 Static iron Core FLOW160DA018 19 Primary Winding FLOW160DA019 20 Axle shaped Fan FLOW160DA020 21 Input cable support FLOW160DA021 22 Input power Cable FLOW160DA022 23 Back panel FLOW160DA023 24 Case FLOW160DA024 25 Operator s Manual not shown FLOW160DA025 26 Warnings Dekal not shown FLOW160DA026 27 Descritpive leaflet not shown FLOW160DA027 28 Face shield not shown FLOW160DA028 29 Chipping hammer not shown FLOW160DA029 TROUBLESHOOTING Problem Welder does not power up indicator light is not on Welder stops working during welding operation Unit is powered green light is on but no weld current is generated Unit is powered green light is on but no weld current is generated Arc is unstable or wavers Possible Fault No power is available at receptacle The input power cable is damaged or broken Unit has reached or exceeded its duty cycle the yellow overheat indicator light should light Work clamp has been detached from weld area There is a bad or no connection between work clamp and work piece Insufficient input current is available Incorrect Voltage has b
6. achine Read the instructions of the electrode you are using as they contain more specific guidelines The chart below provides a benchmark for welding carbon steel with an E6013 electrode Electrode diameter Metal thickness Amperage needed 1 16 inches 1 6mm 1 16 inches 1 6mm 40 55 1 16 inches 1 6mm 5 64 inches 2 0mm 50 70 1 16 inches 1 6mm 3 32 inches 2 4mm 15 95 1 8 inches 3 2mm 1 8 inches 3 2mm 100 140 1 8 inches 3 2mm 5 32 inches 4 0mm 140 180 Current Current represents the actual flow of electricity and is regulated by a rotating knob on the welder The current to be used depends on the size diameter and type of electrode used position of the weld and the thickness of the weld piece Consult specifications listed on the electrode package or generalized chart in the case of the unit Excessive current burns through light metals and the weld bead is flat and porous or the bead undercuts the work piece The bead appears high and irregular if the current is too low Starting Initiating the arc may be challenging especially to the novice welder It is recommended that users practice and familiarize themselves with the machine by welding some scrap metals before starting a job An arc can be initiated by either scratching or tapping the electrode onto the weld metals After the arc is started it is important to swiftly leave a slight gap or the electrode will weld itself onto the metal However the gap must not be
7. andard 51 OXYGEN FUEL GAS SYSTEMS FOR WELDING CUTTING AND ALLIED PROCESSES obtainable from the National Fire Protection Association Batterymarch Park Quincy MA 02269 NFPA Standard 70 NATIONAL ELECTRICAL CODE obtainable from the National Fire Protection Association Batterymarch Park Quincy MA 02269 NFPA Standard 51B CUTTING AND WELDING PROCESSES obtainable from the National Fire Protection Association Batterymarch Park Quincy MA 02269 CGA Pamphlet P 1 SAFE HANDLING OF COMPRESSED GASES IN CYLINDERS obtainable from the Compressed Gas Association 1235 Jefferson Davis Highway Suite 501 Arlington VA 22202 CSA Standard W117 2 CODE FOR SAFETY IN WELDING AND CUTTING obtainable from the Canadian Standards Association Standards Sales 178 Rexdale Boulevard Rexdale Ontario Canada M9W 1R3 NWSA booklet WELDING SAFETY BIBLIOGRAPHY obtainable from the National Welding Supply Association 1900 Arch Street Philadelphia PA 19103 American Welding Society Standard AWSF4 1 RECOMMENDED SAFE PRACTICES FOR THE PREPARATION FOR WELDING AND CUTTING OF CONTAINERS AND PIPING THAT HAVE HELD HAZARDOUS SUBSTANCES obtainable from the American Welding Society 550 N W LeJeune Rd Miami FL 33126 ANSI Standard 788 2 PRACTICE FOR RESPIRATORY PROTECTION obtainable from American National Standards Institute 1430 Broadway New York NY 10018
8. at may have held combustibles e Provide a fire watch when working in an area where fire hazards may exist WELDING RAYS The welding process produces very bright ultraviolet rays These arc rays can damage your eyes and burn your skin if you are not properly protected e To protect your eyes always wear a welding helmet or shield Also always wear safety glasses with side shields goggles or other protective eye wear The protective shade must be number 10 or higher for welding up to 160A e Keep helmet and safety glasses in good condition Replace lenses when cracked chipped or dirty e Wear welding gloves and suitable clothing to protect your skin from the arc rays and sparks e Protect others in the work area from the arc rays Use protective booths screens or shields PIN DUAL VOLTAGE WARNING This unit is a dual voltage machine and can be used both with 110VAC and 220VAC input power It is very important to select the correct welding voltage in the machine according to the power circuit being used Failure to do so may result in electric shock fire harm to you and damage to the machine For a list of publications and documents which can help you adopt correct operating procedures and avoid harmful actions please consult the section REFERENCE PUBLICATIONS at the end of this manual COMPONENTS ACCESSORIES Below is a list of the components of the 160 DualArc stick welder by FLOPUWER Work cable clamp to be connected to weld piec
9. e Electrode cable holder holds welding electrode Input power cable comes without plug Rotating Amperage control knob Power selector switch to choose between OFF 1 10V and 220V input Power indicator light green lights when machine is connected to electricity Overheat indicator light yellow lights when machine exceeds duty cycle Handle to be mounted Chipping hammer Face shield with shade l 2 3 4 5 6 i 8 9 l c ASSEMBLY AND INSTALLATION Carefully unpack the product and verify that all the parts and accessories identified earlier are present in the machine and do not appear to have been broken during transportation If a missing or defective part is found please contact your retailer to obtain a replacement The 160 DualArc welding machine comes without a power plug A qualified electrician must install on the machine a NEMA rated plug of at least 80A with proper grounding The welding machine should be used in a dedicated circuit with a slow blow fuse or a circuit breaker rated at 90A Extension cords are not recommended for this machine Do not run other appliances lights or tools on the same circuit as the one for the welder when using it as this may compromise your safety and negatively affect the quality of the weld Assemble the face shield provided with this unit following the instructions below i NAT E N LA Lens ra pr Lens Retainer B NN Retainer mm Stiff
10. een selected There is a bad or no connection between work clamp and work piece Insufficient input current is available Incorrect Voltage has been selected Metal is soiled greasy Correction Check fuses or breakers Have cable replaced or repaired Allow machine to cool off Reconnect the work clamp with the weld piece Properly connect work clamp and weld piece Utilize an adequate power circuit Select the voltage 110V or 220V that matches the input current being supplied Properly connect work clamp and weld piece Utilize an adequate power circuit Select the voltage 110V or 220V that matches the input current being supplied Clean the metal surface with wire brush Unit overheats prematurely It is difficult to start the arc Excessive spatter occurs Weld bead is irregular too thin too thick shows poor penetration 17 n extension cord is being used Electrode being used is too thick Electrode diameter is too large for the Amperage setting Work clamp is not properly attached to the weld metal or is attached too far from the weld area Power line is being shared by other electrical apparatuses Electrodes are humid soiled or cracked Travel speed angle or arc distance is incorrect Relocate the welder or use a thicker extension cord Use smaller diameter electrode Reduce electrode size or increase Amperage Secure the work clamp properly Use a dedicated
11. en depleted to about an inch from the electrode holder the remaining stub must be discarded and the electrode replaced with a new one If the welding machine exceeds its duty cycle that is it is being used for more than one minute in a ten minute interval at the maximum Amperage setting an overheat relay will automatically shut down the machine You can resume welding once the machine has cooled down adequately ARC WELDING BASICS Arc welding is a process in which metals are joined together using heat developed by a welder Current passes through the metals via the work clamp and the electrode and the electrode holder thus forming intense heat which results in a weld The incandescent space between the weld area and the burning electrode is commonly referred to as the arc This unit is an AC alternating current welder which means that current travels in both directions of the welding circuit in quick alternations 50 or 60 times per second for 50Hz and 60Hz frequencies Electrode selection The diameter thickness of the welding electrode should be approximately the same as the thickness of the metal being welded However specific electrodes have different properties suited to the welding job to be done such as type of metal weld position type of flux coating of the electrode etc The thicker the metal and the electrode the higher the amperage setting needed to weld this can be seen on the chart on the top portion of the welding m
12. ener E p Fasten the handle of the unit with a screw and screw driver as illustrated below OPERATION You must identify whether your input power circuit is 110V or 220V 10 This will determine whether you will choose to weld in the 110V or 220V mode Selecting the wrong welding voltage will result in damage to the welding machine If you are not certain of the voltage provided by the circuit do not operate the welder and seek assistant from a qualified electrician All metals that are welded must be properly cleaned of any rust moisture grease plastic or other non metal external agents before welding Starting with the power selector switch in the OFF 0 symbol position perform the following a Select the Voltage setting according to the input current being used b Select the welding Amperage desired for the weld job c Plug the input power plug to the power outlet being used d Secure the welding electrode in the electrode holder fix it on the non coated end e Connect the ground clamp on the metal being welded near the weld area f Cover your face with the assembled face shield g Begin welding by tapping or scratching the weld area with the electrode The electrode will feed into the arc and create a molten metal pool that will solidify slowly Slag the material formed on and around the welded joint will have to be hammered on and brushed away for a neat weld to be achieved Once the electrode has be
13. h 55 160Amp AC 110VAC or 220VAC I Phase 160Amp at 10 Automatic shutdown Face shield 47 7 lbs 21 5 kgs coated electrodes Shielded 50Hz or 60Hz 113Amp at 20 Chipping hammer Metal Arc Welding SMAW 86Amp at 35 FLOPOWER LIMITED WARRANTY FLOPOWER warrants to its original retail purchaser that this unit is is free of defects in material and workmanship at the time it is shipped by FLOPOWER Within one year after the date of purchase FLOPOWER will repair or replace any warranted parts or components that fail due to defects in material or workmanship determined at FLOPOWER s discretion through an inspection conducted by the technical staff of FLOPOWER or its authorized resellers or repair service providers The reseller where the unit was purchased must he notified within 30 days of such defect or failure and transport costs will be borne by the reseller The limited warranty shall not apply to e Units that have been disassembled or otherwise tampered by non authorized personnel e Equipment that has been improperly installed for example not grounded improperly operated for example through the selection of the incorrect Voltage level or mishandled for example dented e Equipment which has not had resonable and necessary maintenance and care or that has been exposed to water rain excessive moisture or excessive heat e Signsof natural wear and tear SAFETY PRECAUTIONS PIN HEALTH HAZARDS Welding produces intense electr
14. ic and magnetic emissions that may interfere with the proper functioning of cardiac pacemakers hearing aids or other electronic health equipment If you use such devices you should consult your medical health professional and the manufacturer of the health device before using the welder A GASES AND FUMES Gases and fumes produced during welding can be dangerous and hazardous to your health e Do not breathe welding fumes directly or allow others near you to do so Work in an area that is properly ventilated e Use an air supplied respirator if ventilation is not adequate to remove all fumes and gases e The kinds of fumes and gases from the welding operation depend on the kind of metal being used coatings on the metal and the different processes You must be very careful when welding any metals which may contain one or more of the following Antimony Chromium Mercury Beryllium Arsenic Cobalt Nickel Lead Barium Copper Selenium Silver Cadmium Manganese Vanadium e Always read the Material Safety Data Sheets MSDS that should be supplied with the material you are welding These MSDS s will give you the information regarding the type and amount of fumes and gases that may be dangerous to your health For information on how to test for fumes and gases in your workplace refer to the section on REFERENCE PUBLICATIONS at the end of this manual Use smoke extraction equipment if necessary Phosgene a toxic gas is generated
15. power line for the welder Use pristine dry and undamaged electrodes Ensure proper travel speed position of electrode and proper arc distance from the weld piece REFERENCE PUBLICATIONS Refer to the following standards or their latest revisions for more information on safety during welding operations c I 2 13 14 OSHA SAFETY AND HEALTH STANDARDS 29CFR 1910 obtainable from the Superintendent of Documents U S Government Printing Office Washington D C 20402 ANSI Standard 749 1 SAFETY IN WELDING AND CUTTING obtainable from the American Welding Society 550 N W LeJeune Rd Miami FL 33126 NIOSH SAFETY AND HEALTH IN ARC WELDING AND GAS WELDING AND CUTTING obtainable from the Superintendent of Documents U S Government Printing Office Washington D C 20402 ANSI Standard 787 1 SAFE PRACTICES FOR OCCUPATION AND EDUCATIONAL EYE AND FACE PROTECTION obtainable from American National Standards Institute 1430 Broadway New York NY 10018 ANSI Standard 741 1 STANDARD FOR MEN S SAFETY TOE FOOTWEAR obtainable from the American National Standards Institute 1430 Broadway New York NY 10018 ANSI Standard 749 2 FIRE PREVENTION IN THE USE OF CUTTING AND WELDING PROCESSES obtainable from American National Standards Institute 1430 Broadway New York NY 10018 AWS Standard A6 0 WELDING AND CUTTING CONTAINERS WHICH HAVE HELD COMBUSTIBLES obtainable from American Welding Society 550 N W LeJeune Rd Miami FL 33126 NFPA St
16. too large otherwise the arc will die down See drawing next page Same as electrode diameter Same as electrode diameter d Weld Angle To ensure a proper weld a correct weld angle must be maintained during the welding process The electrode must form a 70 to 80 angle with the surface being welded Work Angle Travel Angle Arc Length Arc length is the distance from the work piece to the tip of the electrode and it is constantly being adjusted as the electrode is used up during welding A proper arc length is essential to generate the heat needed for welding Too long an arc results excessive spatter poor penetration and a flat weld bead Too short an arc does not create enough heat to melt the metals and the electrode has a tendency to stick penetration is poor and uneven beads with irregular ripples result A proper arc should be no longer than the diameter of the rod The sound of a proper arc is a steady crisp sizzle Arc speed Because the electrode is melted continuously into the weld it is important to continue feeding the electrode accordingly However this must be done at the right speed When the travel speed is too fast the resulting bead is narrow and penetration is poor When the speed is too slow the bead is high and wide and the metal tends to overheat Overheat protection The unit will automatically shut down once the duty cycle is reached Ensure proper air flow in
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