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P-Wee® 160S INVERTER ARC WELDER Service Manual

1. IHERMAL P Wee 160S INVERTER ARC WELDEH RC a Service Manual May 5 2005 Manual No 0 4755 Version AA A WARNINGS Read and understand this entire Manual and your employer s safety practices before installing oper ating 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 160S Inverter Arc Welder Service Manual Number 0 4755 For the Following Catalog Part Number 10 3066 1605 115 230V 1 ph 50 60 Hz Published by Thermadyne Corporation 82 Benning Street West Lebanon New Hampshire USA 03784 603 298 5711 http www thermadyne com Copyright 2005 by Thermadyne Corporation All rights reserved Reproduction of this work in whole or in part without written permission of the publisher is prohibited The publisher does not assume and hereby disclaims any liability to any party for any loss or damage caused by any error or omission in this Manual whether such error results from negligence accident or any other cause Publication Date May 5 2005 Record the following information for Warranty purposes Where Purchased Purchase Date Equipment Serial CONTENTS GENERAL INFO RIVA E EE 4 1 00 Notes Cautions O e Gees 4 HERE ee EE SURdards sad 8 LOO Note TER TEEN ee 9 LOT Principal Normes de Se e ec is A TS 13 LOT Declaration Of Coniornmi
2. When you re assemble the parts conduct the above process backwards May 5 2005 Page 79 P Wee 160S 11 02 04 04 PCB5 and PCB6 Replacement Procedure 1 Remove the side covers See section 11 01 01 2 Remove the protection panel cover over the front panel Figure 51 Protection panel cover To remove the protection panel cover push both edges of the cover in slightly as indicated by left and right arrows in Figure 51 and pull up the cover frontward May 5 2005 Page 80 P Wee 160S 3 Remove the screws 4 places circled as shown in Figure 52 holding the operation panel onto the front panel Figure 52 Operation panel 4 Unplug harness connectors 3 places circled as shown in Figure 53 from CNI on PCBS and from CNS and CN9 on PCB6 Figure 53 Welding equipment front side top view May 5 2005 Page 81 P Wee 160S 5 Pull the operation panel out of the front panel frontward Figure 54 Operation panel frontward May 5 2005 Page 82 P Wee 160S 6 Disconnected and remove PCBS and PCB6 from PCB4 by pulling the two PCB s apart Figure 55 Disassembling the operation panel 7 Remove the retainer plugs 3 places circled as shown in Figure 56 securing PCBS to PCB6 Figure 56 B side view of PCB6 May 5 2005 Page 83 P Wee 160S 8 Disconnect the flat ribbon cable circled as shown in Figure 57 from PCB6 with PCB5 and PCB6 pulling open and away Figure 57 PCB6 9 Pull up
3. APPENDIX A INTERCONNECT DIAGRAM serial numbers xxxxxxA3066 and earlier E1 IGBT Gate Circuit Board WK3367 ICircuit Board WK5015 SIDE CHASSIS 5 Ground Y REAR PANEL 777 SIDE CHASSIS 4 Connect Circuit Board PCB2 WK5071 Main 1 Circuit Board WK4977 Case Ground Contactor Control 1 24VDC Contactor Control 2 GND 12VDC Supply Potentiometer Maximum Potentiometer Minimum GND Amperage Control Wiper 0 10VDC Remote Installed 12VDC Front View id 1 SIDE CHASSIS 3 l I y 2 3 4 5 6 7 8 May 5 2005 Page 120 P Wee 160S TO1 Output Terminal 4 LJ TO2 O Output Terminal SIDE CHASSIS 1 SIDE CHASSIS 2 PCB6 Circuit Board PCB5 WK4987 Control 1 l Circuit Board WK4986 _CN 4 CN 5 CN 6 CN 7 l CN 4 CN 5 CN 6 CN 7 PCB4 Panel l T Circuit Board WK4985 r 3 Lem May 5 2005 Page 121 P Wee 160S APPENDIX B INTERCONNECT DIAGRAM serial numbers xxxxxxA3066 and later E1 IGBT Gate Circuit Board WK3367 ICircuit Board WK5015 SIDE CHASSIS 5 Ground Y REAR PANEL 777 SIDE CHASSIS 4 Connect Circuit Board PCB2 WK5071 Main 1 Circuit Board WK4977 Case Ground Contactor Control 1 24VDC Contactor Control 2 GND 12VDC Supply Potentiometer Maximum Potentiometer Minimum GND Ampera
4. souder PEUT ENDOMMAGER L OUI F 11 Ne touchez pas l lectrode lorsqu en contact aem L arc de soudage produit une chaleur et des ray avec le circuit de soudage terre ons ultraviolets intenses susceptibles de br ler 12 N utilisez que des quipements en bon tat les Leid et la peau Le bruit caus par certains R parez ou remplacez aussit t les pi ces proc d s peut endommuger l ouie endommag es OO E A 1 Portez une casque de soudeur avec filtre oculaire de nuance appropri e consultez la norme ANSI Z49 indiqu e ci apres pour vous prot ger le visage et les yeux lorsque vous soudez ou que vous observez l ex cution d une 13 Dans des espaces confin s ou mouill s n utilisez pas de source de courant alternatif moins qu il soit muni d un r ducteur de ten sion Utilisez plut t une source de courant ntinu SS soudure 14 Portez un harnais de s curit si vous travaillez SE I 2 Portez des lunettes de s curit approuv es Des en hauteur I S crans lat raux sont recommand s 15 Fermez solidement tous les panneaux et les p 3 Entourez l aire de soudage de rideaux ou de capots cloisons pour prot ger les autres des coups d arc ou de l blouissement avertissez les observateurs de ne pas regarder l arc 4 Portez des v tements en mat riaux ignifuges et durables laine et cuir et des chaussures de s curit SELECTION DES NUANCES DE FILTRES OCULAIRS POUR LA
5. 02 for the replacement and installation of PCB2 and section 11 02 04 04 for PCB5 and PCB6 May 5 2005 Page 51 P Wee 160S 11 01 04 Fault Isolation Tests 11 01 04 01 Preparation The following initial conditions must be met prior to starting any of the procedures in this section 11 01 04 1 Connect the appropriate input voltage Check the data tag on the rear of the power supply for the proper input voltage Note 14 Operate at ALL input voltages as noted on the nameplate on the rear panel when testing the power supply 2 Close primary power source wall disconnect switch or circuit breaker 3 Place power supply MAIN CIRCIT SWITCH S1 on rear of unit in the ON position WARNING 12 Dangerous voltage and power levels are present inside this unit Be sure the operator is equipped with proper gloves clothing and eye and ear protection Make sure no part of the operator s body comes into contact with the workpiece or any internal components while the unit is activated 11 01 04 02 Verification of the Power Input Circuitry Refer to Note 9 on page 41 Refer to Note 11 on page 41 1 Verify the AC input voltage using an AC voltmeter Verify input voltage Phase to Phase using an AC voltmeter The capability of the voltmeter should be more than 300V AC Measure the point between lines Ul and V1 on the input switch S1 The location of points U1 and Vlon switch S1 are indicated in Figure 10 Ed Figure
6. 02 for the replacement of PCB2 4 E01 E02 Over Temperature at the primary side Cause Occurs when an over temperature condition of the primary IGBT is detected Verification Remedy a Unit may be in thermal shutdown mode e Review the rated duty cycle of the unit per section 3 04 Exceeding the duty cycle can damage the unit and void the warranty Refer also to section 3 05 for additional information b Verify the ventilating condition e Maintain a clear and unobstructed distance of more than 30cm in the front and more that 50cm in the rear of the unit for ventilation purposes e Verify and maintain clean dust free front and rear airflow paths Cleaning and removing dust from the front and rear panels once every six months in a normal working environment is recommended Extremely dusty environments will require more frequent cleanings c Verify the operation of the cooling fan FAN and replace it 1f necessary e Verify the condition of FAN Verify that there are no broken or cracked fan blades and that FAN is not producing and abnormal sounds e If broken or cracked FAN blades or abnormal sounds are emanating from FAN replace FAN e Refer to the section 11 02 10 for the replacement of FAN e Refer to section 11 01 04 04 for addition FAN tests d Verify the operation of the cooling fan and replace it 1f the condition of FAN is inactive e Follow the instruction in section 11 01 04 04 e Replace PCB5 WK 4986 and PCB6
7. 5 2005 Page 112 P Wee 160S 12 0 SEQUENCE TIMING DIAGRAMS 12 01 STICK Mode 12 01 01 STICK with VRD DISABLED Voltage Reduction Device Figure 115 shows the STICK timing waveforms with the VRD control DISABLED Place Pin2 of DSWI on PCBS WK 4986 in OFF position to turn off the VRD Arc control Output Current Iw Hot start dl e e e e e e e re rm rm rm rm rm rm rm e e e e e e e e rm rm rm ri OCV Output Voltage Arc control level about 18V Figure 116 STICK mode timing with the VRD DISABLED 12 01 02 STICK with VRD ENABLED Voltage Reduction Device Figure 116 shows the STICK timing waveforms with the VRD function ENABLED Place Pin2 at DSW1 on PCB5 WK 4986 in ON position to turn on the VRD I DET Output Current Iw TE Output Voltage e A Arc control level p about 18V Figure 115 STICK mode timing with the VRD ENABLED May 5 2005 Page 113 P Wee 160S 12 02 LIFT TIG Mode 12 02 01 LIFT TIG STD Mode Figure 117 shows the LIFT TIG STD timing waveforms May 5 2005 STD MODE Contactor Electrode Solenoid Pre flow time Output current 25A fixed Lift only Figure 117 LIFT TIG STD mode timing Page 114 P Wee 160S 13 0 PARTS LIST i A Ai LEE CN Page 115 May 5 2005 P Wee 160S 990 0 VXXXxxx Jaquinu elas uy Bunes peje eq xx 990 0 l yxxxxxx Jequunu eues uy Bunue s peppy x e690 OO8GEGvOd
8. 9 Pull LI out of the power supply as shown in Figure 92 and remove L1 Figure 92 Remove L1 When you re assemble the parts conduct the above process backwards May 5 2005 Page 101 P Wee 160S 11 02 08 02 Transformer T1 a Test Procedure 1 Inspect the Transformer T1 for signs of overheating or loose connections 2 Check for continuity across the primary windings of both transformers 3 Check for continuity across the secondary windings of both transformers 4 Check for insulation of between the primary winding and the secondary winding of both transformers b Replacement Procedure 1 Remove the side covers See section 11 01 01 2 Remove PCBI See section 11 02 04 01 Figure 93 Welding equipment internal view 3 Remove the insulating tube applied to the connection between T1 and Cl Figure 94 Insulating tube May 5 2005 Page 102 P Wee 160S 4 Remove the screw connecting T1 to C1 circled as shown in Figure 95 Figure 95 Connecting T1 to C1 5 Remove PCB2 See section 11 02 04 02 Figure 96 Welding equipment internal view 6 Remove the screws 1 place for each 2 places in total circled as shown in Figure 97 mounting T1 on D2 and D3 Figure 97 Screws mounting TI May 5 2005 Page 103 P Wee 160S 7 Remove the insulating tube applied to the connection between LI and TI Figure 98 Insulating Tube 8 Remove the screw connecting LI to T1 circled as shown in F
9. E Bee CANON reed On dd Qa Sh ae On ee D nn kaka ce diet 39 2 02 V RD Maitena paa eegene 39 lOOPOWNER SOURCE ERROR CODES ids tate ted eebe Pan nteger au 40 PLOADVANCBDOAROUBLDESHOO J BN 3 hee ettet enda ee dio 42 LOL Systeme evel Fault TSO Ati OM uuu w u a A ias 43 NEO TO Opens the Bacilos tl tas 43 11 01 02 Verification and Remedy to the indicated error codes 45 11 01 03 Verification and Remedy to Failures Without Indication Codes 49 INDIES Tan ls ON e T rc 52 EIEOT OX OLI PICDAtatlOfbeu s D u ee esa tei east astare ln vds de tcu 22 11 01 04 02 Verification of the Power Input Clrcuttry 52 KEE Power Supply voltase Les 54 11 01 04 04 Verification of the Cooling Fan FANI and Drive Circuitry S6 11 01 04 05 Verification of No load voltage NoOCN nono nono non anno nana nana nenne nennen nennen 58 110104 00 Output BOAT EST Mr ida 59 11 02 Subsystem Test and Replacement Procedures 61 RIA a A A 61 11 02 02 T stand Replacement Parts Listu u u u u uum geek es Sti obe ua eem RC ae aa 61 BOZO Servico TOOS ART REFERT 64 RE 2204 Priore renit e 65 1020401 PCBIRepl cement Proc EE um bg A none 65 11020402 PC ET 69 11020403 PCB4R placement Procedi iaa 49 I1 02 04 04 PC B5 and PCB6 Replacem
10. EXPLOSER batiment Les bouteilles contiennent des gaz protecteurs sous haute pression Des bouteilles endommag es 7 d peuvent exploser Comme les bouteilles font AVERTISSEMENT normalement partie du proc d de soudage EE LE CARBURANT PEUR CAUSER UN 1 Prot gez les bouteilles de gaz comprim contre les sources de chaleur intense les chocs et les arcs de soudage Le carburant est hautement inflammable 1 Arr tez le moteur avant de v rifier le niveau e 2 Enchainez verticalement les bouteilles un sup carburant ou de faire le plein port ou un cadre fixe pour les emp cher de tomber ou d tre renvers es 2 Nefaites pasle plein en fumant ou proche d une source d tincelles ou d une flamme nue 3 Eloignez les bouteilles de tout circuit lectrique ou de tout soudage 3 Si c est possible laissez le moteur refroidir avant de faire le plein de carburant ou d en 4 Emp chez tout contact entre une bouteille et une v rifier le niveau au d but du soudage lectrode de soudage 4 Ne faites pas le plein de carburant ras bord 5 N utilisez que des bouteilles de gaz protecteur pr voyez de l espace pour son expansion des d tendeurs des boyauxs et des raccords con us pour chaque application sp cifique ces 5 Faites attention de ne pas renverser de quipements et les pi ces connexes doivent tre carburant Nettoyez tout carburant renvers maintenus en bon tat avant de faire d marrer le
11. PROTECTION DES YEUX EN COUPAGE ET SOUDAGE selon AWS 8 2 73 Dimension d lectrode ou Epiasseur de m tal ou Intensit de courant Dimension d lectrode ou Op ration de coupage Nuance de Op ration de coupage Epiasseur de m tal ou ou soudage e filtre oculaire ou soudage Intensit de courant Brassage tendre Soudage l arc sous gaz toutes conditions 2 au chalumeau avec fil plein GMAW Brassage fort i 9 toutes conditions 3ocu4 m taux non ferreux toutes conditions au chalumeau Soudage l arc sous gazavec 1 2 2 tout t mince moins de 1 po 25 mm lectrode de tungst ne GTAW outes conditions MN Nuance de filtre oculaire Oxycoupage Soudage l hydrog ne SEN Soudage l arc avec I Soudage aux gaz os Soudage l arc Plasma PAW toutes dimensions mince moins de 1 8 po 3 mm 40u5 m e avon lectrode de carbone moyen de 184 1 po B tamm Sous mme pais plus de 1 2 po 12 mm pas 4 Soudage l arc avec lectrode enrobees moins de 5 32 po 4 mm 10 Coupage l arc Plasma PAC SMAW 5 32 1 4 po 4 6 4 mm plus de 1 4 po 6 4 mm moins de 300 amper s de 300 4 400 amper s pais plus de 400 amper s May 5 2005 Page 10 5 Portez un casque antibruit ou des bouchons d oreille approuv s lorsque le niveau de bruit est lev E gt AVERTISSEMENT LES VAPEUKS EI LE
12. WK 4987 e Refer to section 11 02 04 04 for the replacement of PCB5 and PCB6 May 5 2005 Page 46 P Wee 160S 5 E03 Primary Over Current Failure Cause Occurs when excessive current is detected flowing into the primary side of the main transformer Verification Remedy a Confirm the operation of the machine within the rated specification e Refer to the specification data sheet in Section 3 04 b Verify the secondary diode D2 and D3 e Refer to section 11 02 06 03 for the test and replacement of D2 and D3 c Verify the primary IGBT Q1 e Refer to section 11 02 06 02 for the test and replacement of Q1 d Replace the Hall CT CTI Note 12 Pay special attention to installed direction of CTI The Hall CT will not function properly if installed in the incorrect direction e Refer to section 11 02 09 for the replacement of CTI 6 E93 Memory Failure Cause Occurs when the memory fails to save the requested welding parameters Verification Remedy a Replace PCB5 WK 4986 and PCB6 WK 4987 e Refer to section 11 02 04 04 for the replacement of PCB5 and PCB6 7 E94 Thermistor Failure Cause Occurs when the thermistor for the temperature detection circuitry 1s open Verification Remedy a Verify the wiring harness and connection between CN8 on PCB6 WK 4987 and thermistors TH1 e Confirm a secure connection of the harness wired between CNS on PCB6 and TH1 and re install the harnesses with a secure c
13. adjustments not cov ered in this manual at the risk of voiding the warranty Read both this manual and the Operating Manual thor oughly A complete understanding of the capabilities and functions of the equipment will assure obtaining the per formance for which it was designed G There are extremely dangerous voltage and power levels present inside this unit Do not attempt to diagnose or repair unless you have had training in high power electronics measurement and trouble shooting 2 02 General Service Philosophy Several key points are essential to properly support the application and operation of this equipment A Application Confirm that the equipment is capable of handling the application desired Specifications supplied and described in Subsection 2 05 of this manual B Modifications No physical or electrical modifications other than se lection of standard options and accessories are to be made to this equipment May 5 2005 P Wee 160S C Customer Operator Responsibilities It is the customer operator s responsibility to main tain the equipment and peripheral accessories pro vided by Thermal Dynamics in good operating order in accordance with the procedures outlined in the Operating Manual and to protect the equipment from accidental or malicious damage D Repair Restrictions The electronics consists of printed circuit board as semblies which must be carefully handled and must be
14. cuttin 3o Oxygen Cutting Ferrous base metal Under 1 in 25 mm 3or4 Gas tungsten arc welding i 2 4 i So LE or6 TE EMEN S cu 5 Gas welding m Media OwriZin i2mm 6or8 um 2 Shieldedmetakarc Under 5 32 in 4mm 10 Heen 14 om 12 Plasmaarccutting Teran 4mm i4 ES Amp 9 May 5 2005 Page 5 5 Work in a confined space only if it is well ventilated or while wearing an air supplied respirator Shielding gases used for welding can displace air causing injury or death Be sure the breathing air is safe Do not weld in locations near degreasing cleaning or spraying operations The heat and P Wee 160S Be aware that welding on a ceiling floor bulkhead or partition can cause fire on the hidden side Donot weld on closed containers such as tanks or drums 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 rays of the arc can react with vapors to form highly toxic and irritating gases 7 Do not weld on coated metals such as galvanized lead or cadmium plated steel unless the coating is removed from the weld 10 Remove stick electrode from holder or cut off area the area is well ventilated and if welding wire at contact tip when not in use necessa
15. moteur 6 Ne placez pas le visage face l ouverture du robinet de la bouteille lors de son ouverture 7 Laissez en place le chapeau de bouteille sauf si en utilisation ou lorsque raccord pour utilisation May 5 2005 Page 12 P Wee 160S y 5 Utilisez la polarit correcte et de we AVERTISSEMENT l accumulateur e m DES PIECES EN MOUVEMENT PEUVENT CAUSER DES BLESSURES C X Des pieces en mouvement tels des ventilateurs AVERTISSEMENT des rotors et des courroies peuvent couper doigts et mains ou accrocher des v tements amples LA VAPEUR El EE LIQUIDE DE REFROIDISSEMENT BRULANT SOUS 1 Assurez vous que les portes les panneaux les capots et les protecteurs soient bien ferm s Avant d installer ou de connecter un syst me arr tez le moteur Seules des personnes qualifi es doivent d monter des protecteurs ou des capots pour faire l entretien ou le d pannage n cessaire Pour emp cher un d marrage accidentel pen dant l entretien d branchez le c ble d accumulateur la borne n gative N approchez pas les mains ou les cheveux de pi ces en mouvement elles peuvent aussi accrocher des v tements amples et des outils R installez les capots ou les protecteurs et fermez les portes apr s des travaux d entretien et avant de faire d marrer le moteur Wy D AVERTISSEMENT DES ETINCELLES PEUVENT FAIRE EXPLOSER UN ACCUMULATEUR L ELECTROLYTE D UN ACCUMU LATEUR PEUT BRULER L
16. of the electrical input voltages shown on the input data label on the unit nameplate Contact the local electric utility for information about the type of electrical service available how proper connections should be made and inspection required The line disconnect switch provides a safe and convenient means to completely remove all electrical power from the welding power supply whenever necessary to inspect or service the unit Note 1 These units are equipped with a two conductor with earth power cable that 1s connected at the 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 Refer to figure 3 and 1 Connect end of ground GREEN conductor to a suitable ground Use a grounding method that complies with all applicable electrical codes 2 Connect ends of line 1 BLACK and line 2 WHITE input conductors to a de energized line disconnect switch 3 Use Table 1 and Table 2 as a guide to select line fuses for the disconnect switch May 5 2005 Page 20 P Wee 160S Input Voltage 115 VAC 40 Amps 208 230 VAC 45 Amps Table 1 Electrical Input Connections Note 2 Fuse size 1s based on not more than 200 percent of the rated input amperage of the welding power source Based on Article 630 National Electrical Code EA AA gm A A gu A m A m Weiding Power Suppl
17. open flames Allow engine to cool before fueling If possible check and add fuel to cold engine before beginning job Do not overfill tank allow room for fuel to expand Do not spill fuel If fuel is spilled clean up before starting engine May 5 2005 P Wee 160S Ca we WARNING MOVING PARTS can cause injury Moving parts such as fans rotors and belts can cut fingers and hands and catch loose clothing 1 Keep all doors panels covers and guards closed and securely in place Stop engine before installing or connecting unit Have only qualified people remove guards or covers for maintenance and troubleshooting as necessary To prevent accidental starting during servicing disconnect negative battery cable from battery Keep hands hair loose clothing and tools away from moving parts Reinstall panels or guards and close doors when servicing is finished and before starting engine WS WARNING SPARKS can cause BATTERY GASES TO EX PLODE BATTERY ACID can burn eyes and skin Batteries contain acid and generate explosive gases Page 7 k Always wear a face shield when working on a battery Stop engine before disconnecting or connecting battery cables Do not allow tools to cause sparks when working on a battery Do not use welder to charge batteries or jump start vehicles Observe correct polarity and on batteries W
18. replaced as units No replacement of printed cir cuit solder mounted components is allowed except as noted in this manual If the Printed Circuit Board is to be returned the re placed Printed Circuit Board Assemblies must be prop erly packaged in protective material and returned in tact per normal procedures 2 03 Service Responsibilities The Service Technician should be familiar with the equip ment and its capabilities and should be prepared to rec ommend arrangements of components which will provide the most efficient layout utilizing the equipment to its best possible advantage Maintenance work should be accomplished in a timely manner If problems are encountered or the equipment does not function as specified contact Thermadyne Inc Thermal Arc Technical Service Department 82 Benning Street West Lebanon New Hampshire USA 03784 603 298 5711 http www thermadyne com tai 2 04 160S Inverter Arc Welder Description The Thermal Arc Model P Wee 1606 is a self contained single phase DC arc welding power source with Constant Current CC output characteristics This unitis equipped with a Digital Volt Amperage Meter and lift arc starter for use with Gas Tungsten Arc Welding GTAW and Shielded Metal Arc Welding SMAW processes The power source is totally enclosed in an impact resistant flame resistant and non conductive plastic case Page 16 P Wee 160S 2 05 Symbol Chart Not all of these sym
19. the power supply Frequently review the Important Safety Precautions in section 1 02 Be sure the operator is equipped with proper gloves clothing and eye and ear protection Make sure no part of the operator s body comes into contact with the work piece or any internal components while the unit is activated May 5 2005 Page 42 P Wee 160S 11 01 System Level Fault Isolation If none of the suggestions provided in Section 8 have solved the problem or corrected the faulty operation the next step is to isolate one or more of the internal subassemblies that may be defective CAUTION 7 Perform all steps in each procedure in sequence Skipping portions of procedures or performing steps out of sequence can result in damage to the unit and possible injury or worse to the operator 11 01 01 Opening the Enclosure 1 Confirm that the switch of power supply and the switch on switchboard distribution panel are all OFF CAUTION 8 The capacitors inside the power supply will slowly discharged after you turn off the switch of the power supply or the switch at the breaker box distribution panel Wait at least 5 minutes for the discharge to complete 2 Remove all screws and nuts on the side covers a n Ww Ki 3 Loosen the screws on the front panel and the rear panel by turning them approximately twice m Ke Note 7 m e AR Do NOT remove the screws completely M SA a og May 5 2005 Page 43
20. the retainer bar securing the flat cable into CN5 circled as shown in Figure 58 10 Disconnected and remove PCB5 and PCB6 from PCB4 by pulling the two PCB s apart 11 Disconnect the flat ribbon cable from CNS connector by pulling straight up the cable Figure 58 CNS on PCB6 12 When re connecting the flat cable make sure that it 1s oriented in such a manner that its wire lead side portion is positioned on the backside as shown in Figure 58 When you re assemble the parts conduct the above process backwards May 5 2005 Page 84 P Wee 160S 11 02 05 Switch S1 Replacement Procedure 1 Remove the side covers See section 11 01 01 2 Remove the screws 4 places circled as shown in Figure 59 holding the rear panel Figure 59 Rear panel 3 Remove the screws 2 places for each 4 places in total circled as shown in Figure 60 from the switch along with four lug terminals a I i d a CHE CI Figure 60 Terminals on S1 May 5 2005 Page 85 P Wee 160S 4 Remove the two mounting screws and remove the switch w L A AL AL RK SI Jn Figure 61 Screws holding the rear panel When you re assemble the parts conduct the above process backwards May 5 2005 Page 86 P Wee 160S 11 02 06 Semiconductors 11 02 06 01 Diode D1 a Test Procedure 1 Verify the characteristic of the diode DI on PCBI using a diode tester 2 Referthe Table 6 and Figure 62 for the checkpoints o
21. 0 360 V following the process in section 11 02 06 01 PCB Figure 11 The check points TB9 TB11 A 6 After the replacement of DI if the above voltage 1s still abnormal replace PCB1 WK 4980 following the process in section 11 02 04 01 May 5 2005 Page 53 P Wee 160S 11 01 04 03 Power Supply Voltage Test 1 Connect the power supply to a source of rated input voltage Check the data tag on the rear of the power supply for the proper input voltage Refer to Note 14 on page 48 2 Apply power to the unit and place the switch of the power supply to the ON position 3 On the PCB2 WK 4977 measure the voltages according to the following table The test point and the reference are obtainable on the solder side of PCB2 WK 4977 The location of points for CN4 on PCB2 WK 4977 CN4 is circled in Figure 12 are indicated in Figure 12 15 a 8 gt e a D d d A m T LIMITI Imm gt LET LEAN A LET bs De gd we H Sue e GE gt T Ce e Chek wi m KS hd wi hd k Z M S a LJ Ta 4 Aer E E S e a ds N d Figure 13 The check points 12V Figure 14 The check points 5V May 5 2005 Page 54 P Wee 160S Figure 15 The check points 12V Test Point Reference ACCEPTABLE PCB2 WK 4977 PCB2 WK 4977 VALUE PINI CN4 PIN4 CN4 12VDC PIN2 CN4 PIN4 CN4 5VDC PIN3 CN4 PIN4 CN4 12VDC 4 If any of these voltag
22. 10 The check points U1 U2 V1 and V2 2 If the input voltage is out of the operating range of the unit which is 10 103 127V AC 187 253V AC of the rated voltage 115 230V verify the available power capacity at the installed site May 5 2005 Page 52 P Wee 160S If the input voltage 1s within the operating range recheck the input voltage while welding as welding may cause the input voltage to decrease to a value below the operating range of the unit 3 Verify input voltage after the input switch S1 using an AC voltmeter The capability of the voltmeter should be more than 300VAC Using an AC voltmeter measure between the points U2 and V2 on the input switch S1 The location of points U2 and V2 on switch Slare indicated in Figure 10 4 Ifthis voltage is out of the operating range which 1s 10 103 127V AC 187 253 VAC of the rated voltage 115 230V AC replace S1 following the process in section 11 02 05 5 Verify the rectified output voltage of the input diode D1 using a DC voltmeter The capability of the voltmeter should be more than 400VDC Using a DC voltmeter measure between the points TB9 and of TB11 A on PCBI WK 4980 Points TB9 and TB11 A are obtainable on the solder side of PCBI See Figure 11 The measured voltage should be approximately 1 4 times larger than input voltage measured in 1 above Replace diode D1 if the calculated measurement is not within the corresponding range DC26
23. 2269 Safe Handling of Compressed Gases in Cylinders document P 1 Compressed Gas Association 1235 Jefferson Davis Highway Suite 501 Arlington VA 22202 Code for Safety in Welding and Cutting norme CSA W117 2 Association canadienne de normalisation Standards Sales 276 Rexdale Boulevard Rexdale Ontario Canada M9W 1R3 Safe Practices for Occupation and Educational Eye and Face Protection norme ANSI Z87 1 American National Standards Institute 1430 Broadway New York NY 10018 Cutting and Welding Processes norme 51B NFPA National Fire Protection Association Batterymarch Park Quincy MA 02269 Page 13 P Wee 160S 1 02 DECLARATION OF CONFORMITY Manufacturer Thermadyne Corporation Address 82 Benning Street West Lebanon New Hampshire 03784 USA The equipment described in this manual conforms to all applicable aspects and regulations of the Low Voltage Directive European Council Directive 73 23 EEC as amended by Council Directive 93 68 EEC and to the National legislation for the enforcement of this Directive The equipment described in this manual conforms to all applicable aspects and regulations of the EMC Directive European Council Directive 89 336 EEC and to the National legislation for the enforcement of this Directive Serial numbers are unique with each individual piece of equipment and details description parts used to manufacture a unit and date of manufacture National Standard an
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25. 949 Mp s oonog IOMOd SUIPIOM SU 1 puooos ouo 10 popoooxo SI SIO03Ioedeo reuird 1e ogej oA 3ndur Ajddns reuruq 19A Q poAv dsip opoo 10113 14 USIU 00 uano ndur AIT podvydsip opoo 10110 CO puooos I oqe 10 9 08 ULY 1916915 SI SLHOI SJ99J01d HL 1osu s o1nje1oduro Y po Ae dsrp opoo 10119 104 I Page 40 uondrnosoq S1409 40442 194NOS H83MOd 00L ISN I QISSOg May 5 2005 P Wee 160S JO IUTYIBUL YOUMS puejsuoo spunos 1ozzng Soseoo JUOLINO PI9 AA JO IUTYIBUL YOUMS puejsuoo spunos 19zzng Soseoo JUOLINO PIO Sos oJout ogej oA IY UOUM J9S91 IM A eoneuromne TIA 9poo 10114 puejsuoo spunos 1ozzng S9SB99 JUSIINO p 2AA SIOSUOS o1njeJoduio oy ooe do JO J999 JUISY 99IAI9S DIV eunou P9JIP9LDIY ue savy god onuoo 201 yooyo JuoS y 99IAI9S IV euro poupouooy UL oAeH sasny 29 o qevo Aewnd y yooyo uerornoo o porjipenb e Jo JUISY 99IAI9S DIV eunou P9JIP9LDIY ue oAvH ASLI OA SUEN SU Yoo uerornoo o porjipenb e Jo JUISY 99IAI9S DIV eun ponporoy UL SAPH V peuonounjg eui SAVY SIOSUIS o1njeJoduiroj s oo1nog IOMOd SUIPI9M au JOLIS NOUdaA dyo Lown PAST MO SNOJ93UBP o UMOP SI aseyjoa A ddns Sure a sne2 o qissoqd MOIS uodo ue SI S L 10J TH dosu s o4nje1oduro Y PSALIdSIP opoo 1011 Gel SI9JQUIBJEA pram IJLIM PR3I jou uto gOd onuoo uo INOY4 HA digo Lowo po Ae dsrp opoo JOLIN Ce puooos ouo IO poonpoi SI
26. A PEAU ET LES YEUX Les accumulateurs contiennent de l lectrolyte acide et d gagent des vapeurs explosives May 5 2005 1 Portez toujours un cran facial en travaillant sur un accumu lateur Arr tez le moteur avant de connecter ou de d connecter des c bles d accumulateur N utilisez que des outils anti tincelles pour travailler sur un accumulateur N utilisez pas une source de courant de soudage pour charger un accumulateur ou survolter momentan ment un v hicule PRESSION PEUVENT BRULER LA PEAU EITES YEUX Le liquide de refroidissement d un radiateur peut tre br lant et sous pression 1 N tez pas le bouchon de radiateur tant que le moteur n est pas refroidi 2 Mettez des gants et posez un torchon sur le bouchon pour l ter 3 Laissez la pression s chapper avant d ter completement le bouchon 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 CFH 1910 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 norme AWS F4 1 American Welding Society 550 N W LeJeune Rd Miami FL 33128 National Electrical Code norme 70 NFPA National Fire Protection Association Batterymarch Park Quincy MA 0
27. ARNING STEAM AND PRESSURIZED HOT COOL ANT can burn face eyes and skin The coolant in the radiator can be very hot and under pressure eee m0 1 Do not remove radiator cap when engine is hot Allow engine to cool 2 Wear gloves and put a rag over cap area when removing cap 3 Allow pressure to escape before completely removing cap A WARNING This product when used for welding or cutting produces fumes or gases which contain chemi cals know to the State of California to cause birth defects and in some cases cancer California Health amp 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 Congress Office of Technology Assessment Biological Effects of Power Frequency Electric amp Magnetic Fields Background Paper OTA BP E 63 Washington DC U S Government Printing Office May 1989 there is now a very large volume of scientific findings based on experiments at the cellular level and from studies with animals and people which clearly establish that low frequency magnetic fields and interact with and produce changes in biological systems While most of this work is of very high quality the results are complex Current scientific understanding does not yet allow us to interpret the evidence in a single coherent framework Even mo
28. Cooling Fan Failure Fan is not rotating Cause Occurs when the cooling fan 1s defective damaged or the driving voltage 1s incorrect Verification Remedy a Verify the cooling fan FANI e Inspect the condition of the fan blades and all peripheral parts Clean the fan blades and all peripheral parts if covered with dust Cleaning and removing dust from the fan blades once every 6 months in a normal environment is recommended Extremely dusty environments will require more frequent cleanings e Verify that there are no wiring harnesses entangled inside the fan confirm that the harnesses do not have any brakes in the wire or damaged connectors e Contact the manufacture if you find any broken connectors or damaged wiring harnesses e Replace the fan if there are any broken cracked or missing fan blades e Refer to section 11 02 10 for replacement of FANI b Verify the wiring harness between the cooling fan FAN and CN3 on PCB2 WK 4977 e Confirm a secure connection of the harness to CN3 on PCB2 e Contact the manufacture if you find any broken connectors or damaged wiring harnesses c Cooling fan voltage tests and replacement of the cooling fan FANI e Follow the instruction in section 11 01 04 04 2 No weld output Cause Occurs when the 8 pin connector or associated circuitry is defective damaged or the TIG torch cable is defective Verification Remedy CAUTION 9 Read and understand this entire section before pro
29. E MANUFACTURER SEE THE ENGINE MANUFACTURE S 1 YEAR 1 YEAR WARRANTY FOR DETAILS CONSOLES CONTROL EQUIPMENT HEAT EXCHANGES ACCESSORY EQUIPMENT NOTE Dragster 85 9 excluded from this policy Refer to Dragster 85 warranty in Dragster 85 Owner s Manual Warranty repairs or replacement claims under this limited warranty must be submitted to Thermal Arc by an authorized Thermal Arc repair facility within thirty 30 days of purchaser s notice of any Warranty Claim No transportation costs of any kind will be paid under this warranty Transportation charges to send products to an authorized warranty repair facility shall be the responsibility of the Purchaser All returned goods shall be at the Purchaser s risk and expense This warranty supersedes all previous Thermal Arc warranties Thermal Arc is a Registered Trademark of Thermadyne Industries Inc September 27 2004 May 5 2005 Page 15 SECTION 2 INTRODUCTION 2 01 Scope of Manual This manual provides service instructions for the Thermal Arc 160S Inverter Arc Welder Information in this edition is particularly applicable to the troubleshoot ing and repair of the equipment For information on oper ating procedures please refer to the 1605 Inverter Arc Welder Operating Manual 430429 504 NOTE Service of this equipment is restricted to properly trained service technicians familiar with this equip ment unqualified personnel are strictly cautioned against attempting repairs or
30. ENDIE O UNE EXPLOSION AVERTISSEMENT L arc produit des tincellies et des projections Les particules volantes le m tal chaud les pro jections de soudure et l quipement surchauff peuvent causer un incendie et des br lures Le contact accidentel de l lectrode ou du fil lectrode avec un objet m tallique peut provoquer des tincelles un chauffement ou un incendie A SL LCLLUCLLULELIeLLEINETSOGO H CGOO COTUGUGGZDGA AUAAaAaABBAAoO 9 90o927A AJAJ amp BA 10 11 Page 11 Prot gez vous ainsi que les autres contre les tincelles et du m tal chaud Nesoudez pas dans un endroit o des particules volantes ou des projections peuvent atteindre des mat riaux inflammables Enlevez toutes mati res inflammables dans un rayon de 10 7 m tres autour de l arc ou couvrez les soigneusement avec des b ches approuv es M fiez vous des projections brulantes de soudage susceptibles de p n trer dans des aires adjacentes par de petites ouvertures ou fissures M fiez vous des incendies et gardez un extincteur port e de la main N oubliez pas qu une soudure r alis e sur un plafond un plancher une cloison ou une paroi peut enflammer l autre c t Ne soudez pas un r cipient ferm tel un r servoir ou un baril Connectez le c ble de soudage le plus pr s pos sible de la zone de soudage pour emp cher le courant de suivre un long parcours inconnu et pr venir ainsi les risques d lect
31. J9S UJIM Bues Diogo ux 1049 01 00L600VrN Z 00L600VEN lege1epis Ek FL ENEZ 00286S VEN Fr 00286SVEN AN A00H 1ewog ew EE SGL6vXEZ 00 866VtN 1 00 869vbN ieqequopneo QHA uo J oeren O069glVrN X edel 3GISNIQHAV 90 9 01 00 00 VvtN z opgoen Eau 690S 01 0007 6V0c3 1 1 000 t6evc3 deas 3049 01 OOZ90ZVON 9q87 uonne2 uiw 006095913 19402 99d v 9901 OObyigwaa Lil OOyblowvaaj 4JewopJepoud vOZ9 0L 00 0091 L OOZOOSYLA 49109 UOl j29 OJd 0 901 00890 VON 12q87 uu 0084 L LWar Je o onuoD JeeH 0 901 OOvSIGHv b o oosa 19A09 04u09 UUs 107901 0009000000 z X 000900000 leued epis 488901 007 622VO b 00900401 leued Ben 0889 01 0096y2V0N 008v00d003 guEg IO uonooejoJd ssauJeu M Lv89 0l OOCEELVON 6 8 OoS0C M0c 0cQ esv L3 JOjSIuJJ9U LHL 869801 ooerozyza O0tvo VCj ugeet LL vv99 0 OOse00os89z A08 d7 A08y D0SHSZS dOQ MST LS 6005 0 O0EOLISGOEO OMO ME OLTNVEOHNJ ossoa e 4699 001 OO0L0L0S0 0v pots abs 4699 00 OOLOLOSOEOr sis VH 4699 00 O0LOLOGOEO b JOiseH eA 4699 00 OOLOLOSOEOr O erSeoHd SIA ved OLOS 0 OO07 viSOCOY EA JONseH ly 9699 01 0089072 VO0f VOOLAO09 c dcisnaoo p JojsisuEJ penumguo LSI SLAVd OSL Page 117 May 5 2005 P Wee 160
32. May 5 2005 Page 95 P Wee 160S 6 Remove the screws securing D2 and D3 to heatsink 2 places for each 4 places in total circled as shown in Figure 81 and remove the D2 and D3 Figure 81 D2 and D3 Note 25 When you re assemble the parts conduct the above process backwards Additionally when installing the diode apply 8 85 m lb force to the diode base screws Note 26 Pay attention to the direction of the diode when installing the diode Figure 82 Base surface of D2 D3 Refer to Note 22 on page 86 May 5 2005 Page 96 P Wee 160S 11 02 07 Thermistors TH 1 a Test Procedure 1 Select the Ohms scale on the digital meter 2 Disconnect the connector at CN8 on PCB6 3 The resistance of a good sensor measured between pins and 2 on the connector should be in the 10kQ to 21 6kQ range with the reading decreasing as the temperature of the power supply increases A shorted reading indicates a bad sensor and it should be replaced b Replacement Procedure 1 Remove the side covers See section 11 01 01 2 Remove PCB2 See section 11 02 04 02 3 Remove the screw circled as shown in Figure 83 securing TH1 to the heatsink Figure 83 TH1 4 Unplug harness connector circled as shown in Figure 84 from CNS on PCB6 and remove the TH1 Figure 84 Welding equipment front side top view May 5 2005 Page 97 May 5 2005 P Wee 160S Figure 85 Base portion of TH1 Note 27 When replacing t
33. P Wee 160S 4 Pull the front panel slightly forward and pull the rear panel slightly backward The interlocking hooks of the side case covers can now be disengaged from the front and rear panels 5 Remove the side covers 6 Remove protection cover sheet by removing the plastic tabs Ji a n Note 8 When you re assemble the parts conduct the above process backwards May 5 2005 Page 44 P Wee 160S 11 01 02 Verification and Remedy to the indicated error codes Note 9 The capacitors inside the power supply will slowly discharged after you turn off the switch of the power supply or the switch at the breaker box distribution panel Wait at least 5 minutes for the discharge to complete and then remove the cases to continue your inspection and repair or maintenance inside the power supply As for the removal and installation of the case refer to the illustration on Page 40 Note 10 During the Verification Remedy procedures below follow the alphabetical sequence a b c and proceed with your verification and confirmation Note LI After you confirm and replace all spare parts and components confirm that there are no damaged harnesses or connectors uninstalled or loose screws 1 E85 Pre Charge Error Cause Occurs after you apply power when a failure is detected during the preliminary charging of the capacitors Verification Remedy a Verify the AC input voltage and t
34. Pamphlet P 1 from Compressed Gas Association 1235 Jefferson Davis Highway Suite 501 Arlington VA 22202 Code for Safety in Welding and Cutting CSA Standard W117 2 from Canadian Standards Association Standards Sales 178 Rexdale Boulevard Rexdale Ontario Canada M9W 1R3 Safe Practices for Occupation and Educational Eye and Face Protection ANSI Standard Z87 1 from American National Standards Institute 1430 Broadway New York NY 10018 Cutting and Welding Processes NFPA Standard 51B from National Fire Protection Association Batterymarch Park Quincy MA 02269 P Wee 160S 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 Les produits et proc d s de soudage peuvent sauser des blessures graves ou la mort de m me que des dommages au reste du mat riel et la propri t si l utilisateur n adh re pas strictement toutes les r gles de s curit et ne prend pas les pr cautions n cessaires En soudage et coupage des pratiques s curitaires se sont d velopp es suite l exp rience pass e Ces pra tiques doive
35. Philips Head Slotted Head Torque Wrench Wrench Screwdriver Screwdriver Diagonal Cutter C Ring Pliers Note 19 When removing the locking type connectors and board supporters disengage the locking mechanism first and then disconnect them Note 20 Locking type connectors and board supporters are indicated in this manual using the following symbols black star marks for locking connectors and white star marks for locking board supports May 5 2005 Page 64 P Wee 160S 11 02 04 Print Circuit Boards 11 02 04 01 PCB1Replacement Procedure 1 Remove the side covers See section 11 01 01 2 Remove the three 3 screws circled as shown in Figure 18 mounting PCB1 on chassis Figure 18 PCB1 mounted chassis 3 Remove the screws 4 places at input diode D1 3 places at primary IGBT Q1 7 places in total mounting D1 and Q1 on PCB as shown in figure 19 Figure 19 Expanded view of PCB1 May 5 2005 Page 65 P Wee 160S 4 Remove the screw mounting main transformer T1 on TB6 at PCB circled as shown in Figure 20 Figure 20 PCBI top view 5 Pull PCBI out frontward lightly Figure 21 PCBI top view2 6 Unplug a harness connector from CN13 on PCBI Figure 22 CN13 on PCBI May 5 2005 Page 66 P Wee 160S 7 Unplug harness connectors from CN14 and CN16 on PCB Figure 23 CN14 and CN16 on PCB1 Holding the upper portion of the harness to unlock the contact between the harness
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37. S PUMEES SONT DANGEREUSES POUR LA SANTE Le soudage d gage des vapeurs et des fum es dangereuses a respirer May 5 2005 Eloignez la t te des fum es pour viter de les respirer A l int rieur assurez vous que l aire de soudage est bien ventil e ou que les fum es et les vapeurs sont aspir es l arc Si la ventilation est inadequate portez un respirateur adduction d air approuv Lisez les fiches signal tiques et les consignes du fabricant relatives aux m taux aux produits consummables aux rev tements et aux produits nettoyants Ne travaillez dans un espace confin que s il est bien ventil sinon portez un respirateur adduction d air Les gaz protecteurs de soudage peuvent d placer l oxyg ne de l air et ainsi causer des malaises ou la mort Assurez vous que l air est propre la respiration Ne soudez pas proximit d op rations de d graissage de nettoyage ou de pulv risation La chaleur et les rayons de l arc peuvent r agir avec des vapeurs et former des gaz hautement toxiques et irritants Ne soudez des t les galvanis es ou plaqu es au plomb ou au cadmium que si les zones souder ont t gratt es fond que si l espace est bien ventil si n cessaire portez un respirateur adduction d air Car ces rev tements et tout m tal qui contient ces l ments peuvent d gager des fum es toxiques au moment du soudage P Wee 160S is LE SOUDAGE PEUT CAUSER UN INC
38. This 1s for normal semi automatic operation utilizing a remote device such as a foot control The 8 pin remote operates as described earlier in this manual Placing all slide switches in position B would be primarily used for automation with an arc establish relay remote amperage and contactor An arc establish signal 1s located from pins 4 and 8 when in this mode Placing slide switches S1 and S2 in B position and slide switch S3 in A position would have the configuration of an arc establish signal and remote contactor but the unit s front panel would control the amperage e ND UT WK 4977 OK TO MOVE RELAY I I POSITION MAS pus e Use OK TO MOVE signal Max Load 24V 50ma OK TO MOVE RELAY May 5 2005 Page 124 P Wee 160S Fi OUEN s pg ER Q ete BE CII JE eT ba Maa Ll n u Hiel GAB E 4 TP keep TE mi E B U a SanRex WK 4977 CH Figure 18 Slide Switch Location May 5 2005 Page 125 P Wee 160S PAGE LEFT INTENTIONALLY BLANK May 5 2005 Page 126 P Wee 160S APPENDIX D HARDWARE Descipin L A B CodeNo Order No _ Le AUNAR May 5 2005 Page 127 P Wee 160S APPENDIX E DIODE TESTING BASICS Testing of diode modules requires a digital Volt Ohmmeter that has a diode test scale Locate the diode module to be tested 2 Remove cables from mounting studs on diodes to 1solate them within the module a Set the digital
39. V ieoi db ti 14 LOL cia eo nee ee ne ee Eons cen rae Oe Se ee uL d ceu ce ie 15 20 INTRODUCTION AND DESCRIPTION a dd 16 J O T E E ET EE 16 2402 General Service POMO ii 16 2 05 Service RESPONSES a 16 2 OA ee 16 2 05 75 vERDOLC BOE sies O pM a DM M LM CSV A LM E EIU EL EE L7 2 06 Functional Block DAS ANSE deir ora MR a E A DO 18 2 07 Dransporttne Eeer 18 SO INSIDAELA LION RECOMENDALIONS id o Reno i i east ausis ecu ete neon i tru e EE 19 SNL Environim nt awu umn 2 esr T 19 302 EE 19 3 03 Electrical input Connect ati 20 3 0301 Electrical Mput IR Equis ment ii 20 TOSO PO ic d M 27 3 03 09 ErehBreguenc S TOt OIC MOM so eodeni coca ae inedit es Up D iris 23 3 05 OA HAF regency TETEN CE ER 23 SA re E EIU a T E uuu A NETE E RN c 24 O aa r eid cd r A 25 ZOOPBRATOIRCONLBOLDBS a dto tears oia 26 A 0T PEN Ce TOO ES Cons iO lala 26 4 02 Weld Parameter Descriptions for P Wee Io 28 4 03 Weld Parameters for the P We TOUS crac ri iii 29 ADA PONS OUNCE POTUTO Curl dia 29 5 0 SET UP FOR SMAW STICK AND GTAW TIG a 30 6 0 SEQUENCE OF OPERA MONS date tete pcs 31 GOLS CR MN El RR yaaa mm 32 6 02 DC LIET TIG Eer 32 ELSE RRE EC RR DE LE DEE 33 SO BASIC TROUBLE SHO OW IN Ei A A A A ia 34 SOT PROA EE EE 34 8 02 SUCK ET TE el 36 rel eene e 38 9 0 VOLTAGE REDUCHION DEVICE VRD Lt dd odos 39 BC HIR
40. alling the IGBT apply 27 5 in Ib force to the IGBT base screws and 23 in lb force to the terminal screws Figure 75 Base surface of Q1 Note 24 When replacing the IGBT apply heat sink compound Shinetsu silicon G 747 or equivalent uniformly to the base surface of the diode May 5 2005 Page 93 P Wee 160S 11 02 06 03 Diode D2 D3 a Test Procedure 1 Verify the characteristic of the diode D2 and D3 using a diode tester 2 Refer the Table 8 and Figure 76 for the checkpoints on D2 D3 COMPONENT AA ACCEPTABLE Positive Negative lead lead TESTED VALUE Anode Cathode 0 2 to 0 3V Anode Cathode 0 2 to 0 3V Table 8 D2 and D3 tester checkpoints Anode P OH OF Anode O Cathode I ance Ms Figure 76 D2 D3 tester checkpoints b Replacement Procedure 1 Remove the side covers See section 11 01 01 2 Remove PCB2 See section 11 02 04 02 Figure 77 Welding equipment internal view May 5 2005 Page 94 P Wee 160S 3 Remove the screws 1 place for each 2 places in total circled as shown in Figure 78 mounting T1 on D2 and D3 Figure 78 Screws mounting TI 4 Remove the screws mounting bus bars on and connecting snubber resistors to D2 and D3 4 places for each 8 places in total circled as shown in Figure 79 Figure 79 Screws mounting D2 and D3 5 Remove the mounting screws and then bus bars circled as shown in Figure 80 from D2 and D3 Figure 80 Bud bars on D2 and D3
41. at are recommended for cleaning electrical apparatus CAUTION 4 Do not blow air into the power supply during cleaning Blowing air into the unit can cause metal particles to interfere with sensitive electrical components and cause damage to the unit May 5 2005 Page 33 P Wee 160S 8 0 BASIC TROUBLESHOOTING A WARNING 9 There are extremely dangerous voltages and power levels present inside this product Do not attempt to open or repair unless you are an Accredited Thermal Arc Service Agent and you have had training in power measurements and troubleshooting techniques If major complex subassemblies are faulty then the Welding Power Source must be returned to an Accredited Thermal Arc Service Agent for repair The basic level of troubleshooting 1s that which can be performed without special equipment or knowledge 8 01 TIG Welding Problems Weld quality is dependent on the selection of the correct consumables maintenance of equipment and proper welding technique 1 Excessive bead Welding current 1s too low Increase weld current and or build up or poor faulty joint preparation penetration or poor fusion at edges of weld 2 Weld bead too Welding current 1s too high Decrease weld current wide and flat or undercut at edges of weld or excessive burn through 3 Weld bead too Travel speed too fast Reduce travel speed small or insufficient penetration or ripples in bead are widely spaced apart 4 Weld bead too Travel spe
42. avement L lectrode et le circuit de soudage sont sous tension d s la mise en circuit Le cir cuit d alimentation et les circuits internes de codes nationaux provinciaux et locaux applicables l quipement sont aussi sous tension d s la mise 6 Arr tez tout quipement apr s usage Coupez en marche En soudage automatique ou semi l alimentation de l quipement s il est hors automatique avec fil ce dernier le rouleau ou la d usage ou inutilis bobine de fil le logement des galets _ DE d entrainement et toutes les pi ces m talliques 7 N utilisez que des porte lectrodes bien isol s en contact avec le fil de soudage sont sous ten jamais plonger les porte lectrodes dans sion Un quipement inad quatement install ou l eau pour les refroidir Ne s les laisser mad quatement mis a la terre est dangereux Hamer Pal tere HL SHE les presen souder Ne touchez pas aux porte lectrodes raccord s deux sources de courant en m me temps Ne jamais toucher quelqu un d autre avec l lectrode ou le porte lectrode May 5 2005 Page 9 P Wee 160S 8 N utilisez pas de c bles lectriques us s Am endommag s mal piss s ou de section trop pe tite D AVERTISSEMENT 9 N enroulez pas de c bles lectriques autour de e votre corps u LE RAYONNEMENT DE L ARC PEUT 10 N utilisez qu une bonne prise de masse pour la BR LER LES YEUX ET LA PEAU LE BRUIT mise la terre de la pi ce
43. ay 5 2005 Page 25 P Wee 160S 4 0 OPERATOR CONTROLS 4 01 P Wee 160S Controls Figure 3 P Wee 1608 Power Source 1 Control Knob This control sets the selected weld parameter rotating 1t clockwise increases the parameter and 1s indicated on the digital meter Pushing the knob inward displays the actual welding voltage 2 Remote Control Socket The 8 pin Remote Control Socket is used to connect remote current control devices to the welding Power Source To make connections align keyway insert plug and rotate threaded collar fully clockwise Gnd L IJ L 1 213 415 61718 0 5k Ohms Front view of 8 Socket Receptacle May 5 2005 Page 26 P Wee 160S Socket Pin Earth Ground 2 Torch Switch Input 24V to energize weld current connect pins 2 amp 3 to turn on welding current 3 Torch Switch Input 0V to energize weld current connect pins 2 amp 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 Zero ohm minimum connection to 5k ohm remote control potentiometer Wiper arm connection to 5k ohm remote control potentiometer Connect pin 4 to pin 8 to instruct machine that a remote current control device is connected OV 3 Positive Terminal 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 achi
44. bols will appear on this unit Single Phase Wire Feed Function Wire Feed Towards 3 INI Three Phase Workpiece With Output Voltage Off Three Phase Static Frequency Converter Welding Gun Transformer Rectifier Continuous Weld Duty Cycle Mode Panel Local Spot Time Shielded Metal Gas Metal Arc Gas Tungsten Arc a 2 Step Trigger Welding GTAW Operation Press to initiate wirefeed and Air Carbon Arc welding release to stop Cutting CAC A 4 Step Trigger Constant Current jc IL n Operation Press and hold for preflow release Constant Voltage to start arc Press to stop arc and Or Constant Potential hold for preflow High Temperature Burnback Time Fault Indication Line Connection Meters Per Minute Auxiliary Power Receptacle Rating Auxiliary Power May 5 2005 Page 17 Art A 04130 2 06 Functional Block Diagrams P Wee 160S Figure 2 illustrates the functional block diagram of the 160S power supply Input p Main Input Capacitor IGBT Main Output Hall Current Circuit Diode Inverter Transformers Diodes LT ower i T1 ransformer SAA Thermal ER CT4 Detector Primary Voltage Sensor Output Inductor E Thermal Stick Model Lift Tig Mode To each control circuit Sensor Drive VRD Output Short 12VDC 18VDC Circuit Circuit Sensing Sensing 24VDC 5VDC Circuit Circuit _ Trouble Primary J ensing Current Circuit Sensor Torch Control ez Fan Control Co
45. ceeding Extreme personal harm and test equipment damage will occur if the procedures are not performed accurately May 5 2005 Page 49 P Wee 160S a Verify the 8 pin connector Applies to LIFT TIG mode e Confirm a secure connection between CONI of the 8 pin connector and the remote device e Confirm a secure connection of the harness and the connections between CONI and PCB2 WK 4977 are all correct and there are no open circuits e Contact the manufacture if you find any broken connectors or damaged wiring harnesses e Confirm the proper pins outs of the 8 pin connector on the remote device Refer to section 4 01 e Confirm that there is no open circuit on the 8 pin connector at TIG Torch side b Verify the condition and connections of the welding cable the stick rod holders and the ground clamp Applies to all welding modes e Confirm a secure connection of the welding cable stick rod holders ground clamp and dinse connectors and there are no open circuits c Verify the no load voltage OCV Applies to STICK mode e Refer to the section Verification of No load voltage No OCV y in the section 11 01 04 05 first before continuing this section e If performing the No Load Voltage Failure procedure does not rectify the failure perform the following tests in the sequence below Replace any defective components found 1 Diode D2 D3 Refer to the Section 11 02 06 03 2 Reactor L1 Refer to the Sectio
46. connector and CN13 CN14 and CN16 pull the harness lightly To unplug the harness connector do not pull the harness excessively 8 Remove the screw mounting S1 with screwdriver etc as shown in Figure 25 Figure 24 Welding equipment with PCBI pulled out May 5 2005 Page 67 P Wee 160S Figure 25 TB1 on PCB1 When you re assemble the parts conduct the above process backwards May 5 2005 Page 68 P Wee 160S 11 02 04 02 PCB2 Replacement Procedure 1 Remove the side covers See section 11 01 01 2 Remove the four 4 screws circled as shown in Figure 26 mounting PCB2 on chassis Figure 26 PCB2 mounted on chassis 3 Unplug the harness connectors from CN10 and CN15 on PCB2 Figure 27 CN15 and CN10 on PCB2 4 Unplug the harness connector from CN9 on PCB2 KR CM kel MI Figure 28 CN9 on PCB2 May 5 2005 Page 69 P Wee 160S 5 Unplug the harness connector from CN2 on PCB2 Figure 29 CN2 on PCB2 6 Unplug the harness connector from CN3 on PCB2 Figure 30 CN3 on PCB2 7 Unplug the harness connector from CNI on PCB2 Figure 31 CN1 on PCB2 May 5 2005 Page 70 P Wee 160S 8 Unplug the harness connector from CN12 on PCB2 Figure 32 CN12 on PCB2 9 Unplug the harness connector from CN4 on PCB2 Figure 33 CN4 on PCB2 10 Unplug the harness connector from CN6 on PCB2 Figure 34 CN6 on PCB2 May 5 2005 Page 71 P Wee 160S 11 Unplug the harness conne
47. ctor from CN8 on PCB2 Figure 35 CNS on PCB2 12 Unplug the harness connector from CN7 on PCB2 Figure 36 CN7 on PCB2 Holding the upper portion of the harness to unlock the contact between the harness connectors and CN1 4 CN6 10 CN12 and CN15 pull the harness lightly To unplug the harness connector do not pull the harness excessively May 5 2005 Page 72 P Wee 160S 13 Disconnect a flat cable from CN5 on PCB2 14 Pull up the retainer bar securing the flat ribbon cable into CNS circled as shown in Figure 37 Figure 37 Retainer bar of CN5 on PCB2 15 Disconnect the flat cable from CNS connector by pulling straight up the cable Figure 38 CN5 on PCB2 May 5 2005 Page 73 P Wee 160S 16 When re connecting the flat cable make sure that it 1s oriented in such a manner that its lug portion is positioned on the front side When you re assemble the parts conduct the above process backwards check slide switches S1 S2 and S3 Fi i C26 R87 RES UN ERE EM R34 c251 E mie ez CRETE BRS A ERGO Figure 39 S1 S2 and S3 on PCB2 Identify locations of slide switches S1 S2 and S3 Make sure that switches S1 S2 and S3 are placed into their respective A positions May 5 2005 Page 74 P Wee 160S 11 02 04 03 PCB4 Replacement Procedure 1 Remove the side covers See section 11 01 01 2 Remove the protection panel cover over the front panel Fig
48. d Technical Specifications The product is designed and manufactured to a number of standards and technical requirements Among them are e CSA Canadian Standards Association standard C22 2 number 60 for Arc welding equipment e UL Underwriters Laboratory rating 94VO flammability testing for all printed circuit boards used e CENELEC EN50199 EMC Product Standard for Arc Welding Equipment e SO IEC 60974 1 BS 638 PT10 EN 60 974 1 EN50192 EN50078 applicable to plasma cutting equipment and associated accessories e Forenvironments with increased hazard of electrical shock Power Supplies bearing the S mark conform to EN50192 when used in conjunction with hand torches with exposed cutting tips if equipped with properly installed standoff guides e Extensive product design verification is conducted at the manufacturing facility as part of the routine design and manufacturing process This is to ensure the product is safe when used according to instructions in this manual and related industry standards and performs as specified Rigorous testing is incorporated into the manufacturing process to ensure the manufactured product meets or exceeds all design specifications Thermadyne has been manufacturing products for more than 30 years and will continue to achieve excellence in our area of manufacture Manufacturers responsible representative Steve Ward Operations Director Thermadyne Europe Europa Building Chorley N Indus
49. e control device 1s required for use during LIFT TIG operation See section 3 01 section 2 Remote Control Socket for complete details of the remote device STICK Mode of operation Table 3 Weld Parameter Descriptions May 5 2005 Page 28 P Wee 160S 4 03 Weld Parameters for the P Wee 160S Weld Mode Weld Parameter Factory Incremental LIFT TIG Parameter Range Setting Unit STICK Y Y WELD CUR 5 to 85A 115V e LA 5 to 160A 230V SOA IA Yes es Yes No ARC CONTROL 0to100 10 1 Ye No 4 04 Power Source Features e Touch switches eliminate mechanical damage Digital Meter e Displays selected weld parameter value e Displays weld current when welding e Displays weld current for 20 seconds after weld has been completed e A selected weld parameter value can be adjusted at any time even while welding ON OFF switch e Primary voltage Supply ON OFF switch located on rear panel Voltage Reduction Device VRD Reduces the OCV when the power supply is not in use Eliminates the need for add on voltage reducers and has no effect on arc starting e VRD fully complies to IEC 60974 1 e When Stick mode is selected the green VRD light is ON when not welding and red when welding e When in TIG modes VRD is off Control Knob e For the selected weld parameter rotating the knob clockwise increases the parameter e Rotating the knob counterclockwise decreases the parameter e A selected weld parameter val
50. e this type of interference Looping and suspending of leads should be avoided where possible Re radiation from Unearthed Metallic Objects A major factor contributing to interference 1s re radiation from unearthed metallic objects close to the welding leads Effective grounding of such objects will prevent re radiation in most cases May 5 2005 Page 23 P Wee 160S 3 04 Specifications MODEL Duty Cycle 160A 16 4V 35 230VAC 130A 15 2V 60 230VAC 100A 14V 100 230VAC 85A 13 4V 100 115VAC 160A 26 4V 35 230VAC 130A 25 2V 60 230VAC 100A 24V 100 230VAC SOA 23 4V 100 LISVAC Output Current 1 160 230V 1 85 115V Range STICK 1 160 230V 1 85 115V Open Circuit Voltage 64V Dimensions Width 5 12 130mm Height 10 24 260mm Length 12 60 320mm 18 95 Ib 8 6 kg Output Rated Load Rated Input Voltage single Phase 115VAC single phase 230VAC Output Amperes 85A 160A Output Volts 23 4V 26 4V Duty Cycle 100 35 KVA 4 4 8 7 KW 2 4 Output No Load KVA KW Input Volts Single Phase Amperage Draw Rated Load 115V 29 230V 34 Thermal Arc continuously strives to produce the best product possible and therefore reserves the right to change improve or revise the specifications or design of this or any product without prior notice Such updates or changes do not entitle the buyer of equipment previously sold or shipped to the corresponding chan
51. ear a safety harness to prevent falling if level is high working above floor level 15 Keep all panels and covers securely in place 9 SC M WARNING Bi FUMES AND GASES can be hazardous to your 2 WARNING health Welding produces fumes and gases Breathing ARC RAYS can burn eyes and skin NOISE can these fumes and gases can be hazardous to your damage hearing health Arc rays from the welding process produce in tense heat and strong ultraviolet rays that can 1 Keep your head out of the fumes Do not breath burn eyes and skin Noise from some processes the fumes can damage hearing 2 If inside ventilate the area and or use exhaust ee at the arc to remove welding fumes and gases 1 Wear a welding helmet fitted with a proper shade of filter see ANSI Z49 1 listed in Safety 3 If ventilation is poor use an approved Standards to protect your face and eyes when air supplied respirator EE a p 4 Read the Material Safety Data Sheets MSDSs 2 Wear approved safety glasses Side shields and the manufacturer s instruction for metals recommended consumables coatings and cleaners 3 Use protective screens or barriers to protect others from flash and glare warn others not to watch the arc Eye protection filter shade selector for welding or cutting goggles or helmet from AWS A6 2 73 g Electrode Size Welding or cutting Electrode Size Torch soldering 2 Gesmetar ight ight Welding or
52. ection 11 02 04 02 3 Remove the screw circled as shown in Figure 106 connecting L1 to the diode bus bar on D2 and D3 Figure 107 CT1 top view May 5 2005 Page 108 P Wee 160S 4 Unplug the harness connector from CT1 from CN7 on PCB2 circled as shown in Figure 108 Figure 108 CTI1 top view 5 Remove the screw circled as shown in Figure 109 mounting CTI on the diode bus bar on D2 and D3 and remove the CTI Figure 109 Diode bus bar and screw mounting CT1 May 5 2005 Page 109 May 5 2005 P Wee 160S Note 28 When you re assemble the parts conduct the above process backwards When installing CT1 be sure it is orientated properly as shown in Figure 110 26092 NSLGPAODZNI 2H Figure 110 Direction of CTI Page 110 P Wee 160S 11 02 10 FAN1 Replacement Procedure 1 Remove the side covers See section 11 01 01 2 Remove the screws 4 places circled as shown in Figure 111 securing chassis to the rear panel Figure 111 Welding equipment rear side 3 Remove the rear panel from the welding equipment Figure 112 Welding equipment with the rear panel removed May 5 2005 Page 111 P Wee 160S 4 Unplug the harness connector from CN3 on PCB2 and remove the FANI Figure 113 CN3 on PCB2 Note 29 When you re assemble the parts conduct the above process backwards When installing FAN be sure it is orientated properly as shown in Figure 114 Figure 114 FAN May
53. ed too slow Increase travel speed wide or excessive bead build up or excessive penetra tion in butt joint 5 Uneven leg length Wrong placement of filler rod Re position filler rod in fillet joint 6 Electrode melts A Electrode is connected to the A Connect the electrode to the when arc is struck terminal terminal May 5 2005 Page 34 P Wee 160S 7 Dirty weld pool A Electrode contaminated A Clean the electrode by through contact with work grinding off the contaminates piece or filler rod material B Gas contaminated with air B Check gas lines for cuts and loose fitting or change gas cylinder 8 Electrode melts or A No gas flowing to welding A Check the gas lines for kinks oxidizes when an region or breaks and gas cylinder arc 1s struck contents Torch is clogged with dust Clean torch Gas hose is cut Replace gas hose Gas passage contains Disconnect gas hose from impurities torch then raise gas pressure and blow out impurities Gas regulator turned off Turn on Torch valve 1s turned off Turn on The electrode is too small for G Increase electrode diameter the welding current or reduce the welding current 9 Poor weld finish Inadequate shielding gas Increase gas flow or check gas line for gas flow problems 10 Arc flutters during Tungsten electrode is too Select the right size electrode TIG welding large for the welding current Refer to Basic TIG Welding guide Absence of oxid
54. ent Procedure ia 80 t0205 SWitch ST Replacement Procedure artis 85 As PP baton mn en 87 LEO SOCOTI DIR o 87 RBE T E cR TER EHE 91 MIA AE Sd D D D nn sd 94 1 07 07 WT Raten CC RO TES 97 eet 99 ES AR Or EE 99 02 06 02 Transtormer Tdci A o alado 102 11 02 09 Ha Current Transtormer ACT E odd iie ote i i Sa obe ip bd ie iens 108 11 02 OP ANT Replacement PROGGGHIO doe rot e ttd t etd ere dpud ias Ud 111 122 0 SEQUENCE TIMING Eeer 113 12 0 TAS EIC IS e Ecri ode 113 12 01 01 STICK with VRD DISABLED Voltage Reduction Device 113 12 01 02 STICK with VRD ENABLED Voltage Reduction Device 113 PANA AA AP mus E tees eheu E C asua dede 114 12 02 0T T IESE TIGE SID E 114 E AR A TET 115 APPENDIX A INTERCONNECT DIAGRAM e 120 serial numbers xxxxxxA3066 and earlier APPENDIX B INTERCONNECT DIAGRAM iiit ttis do uei S a OL ee 122 serial numbers xxxxxxA3066 and later APPENDIX C AUTOMATION accio 124 APPENDIX D HARDWARE SSSR eene 127 APPENDIX E DIODE TESTING BASICS A ee Ee 128 P Wee 160S SECTION 1 ARC WELDING SAFETY INSTRUCTIONS AND WARNINGS WARNING PROTECT YOURSELF AND OTHERS FROM POSSIBLE SERIOUS INJURY OR DEATH KEEP CHILDREN AWAY PACEMAKER WEARERS KEEP AWAY UNTIL CONSULTING YOUR DOCTOR DO NOT LOSE THESE INSTRUCTIONS READ OPERATING INSTRUCTION MANUAL BEFORE INSTALLING OPERATING OR SERVICING THIS EQUIPMENT Welding products and welding processes can cause serious injury or death or damage to other equipment or pro
55. epair the connection Maximum output Defective control circuit Have an Accredited Thermal welding current can Arc Service Agent inspect not be achieved then repair the welder with nominal Mains supply voltage Welding current Poor work lead connection to Ensure that the work lead has reduces when the work piece a positive electrical welding connection to the work piece May 5 2005 Page 38 P Wee 160S 9 0 VOLTAGE REDUCTION DEVICE VRD 9 01 VRD Specification VRD Open Circuit Voltage 15 3 to 19 8V Open circuit voltage between welding terminals VRD Resistance 148 to 193 ohms The required resistance between welding terminals to turn ON the welding power VRD Turn OFF Time 0 2 to 0 3 seconds The time taken to turn OFF the welding power once the welding current has stopped 9 02 VRD Maintenance Routine inspection and testing power source An inspection of the power source an insulation resistance test and an earth resistance test shall be carried out a For transportable equipment at least once every 3 months and b For fixed equipment at least once every 12 months The owners of the equipment shall keep a suitable record of the periodic tests Note 5 A transportable power source is any equipment that is not permanently connected and fixed in the position in which it is operated In addition to the above tests and specifically in relation to the VRD fitted to this machine the following periodic t
56. eposits allow slag to be trapped Lack of penetration with slag trapped beneath weld bead Rust or mill scale 1s preventing full fusion Wrong electrode for position in which welding 1s done Not cleaned or incorrect electrode Slag trapped in undercut P Wee 160S Use larger electrodes and pre heat the plate Increase welding current Adjust angle so the welding arc 1s directed more into the base metal Reduce travel speed of electrode Clean surface before welding Figure 8 Example of lack of fusion If bad undercut is present clean slag out and cover with a run from a smaller diameter electrode Allow for adequate penetration and room for cleaning out the slag If very bad chip or grind out irregularities Use smaller electrode with sufficient current to give adequate penetration Use suitable tools to remove all slag from corners Clean joint before welding Use electrodes designed for position in which welding 1s done otherwise proper control of slag 1s difficult Figure 9 Examples of slag inclusion May 5 2005 Page 37 P Wee 160S 8 03 Power Source Problems 1 The welding arc A The Primary supply voltage A Switch ON the Primary supply cannot be has not been switched ON voltage established B The Welding Power Source B Switch ON the Welding switch 1s switched OFF Power Source C Loose connections internally C Have an Accredited Thermal Arc Service Agent r
57. es are not present or are below a 10 tolerance replace PCB2 WK 4977 following the process in section 11 02 04 02 May 5 2005 Page 55 P Wee 160S 11 01 04 04 Verification of the Cooling Fan FAN1 and Drive Circuitry 1 Verify the condition of the cooling fan FAN using a DC voltmeter The capability of the voltmeter should be more than 50VDC Using a DC voltmeter measure between PIN 1 4 and PIN 2 of CN3 on PCB2 WK 4977 The location of connector CN3 of PCB2 WK 4977 1s indicated in Figure 16 17 Note 15 When you measure the above voltage do not remove the connector Conduct the measurement while the connector plug and receptacle are still connected Figure 17 The check points FAN voltage May 5 2005 Page 56 P Wee 160S 2 Using the measurement taken above follow the chart below for possible failure modes Fan Voltage measurement S PIN 1 PIN 2 of CN3 on PCB2 Replace PCB2 WK 4977 Case2 Rotating Below DC 18V Refer to section 11 02 04 02 Replace PCB2 WK 4977 Refer to section 11 02 04 02 Case3 Inactive Below DC 18V y Conduct the Verification of the power input circuitry 1n section 11 01 02 03 Replace the FAN Case 4 Inactive DC 18 25V Refer to section 11 02 04 10 Note 16 This welding unit has a feature that will slow the rotational speed of the cooling fan during low output current and while in standby Under these conditions the voltages in the above table w
58. es in the Refer Basic TIG Welding weld pool Guide for ways to reduce arc flutter 11 Welding arc can A Work clamp is not connected Connect the work clamp to not be established to the work piece or the the work piece or connect the work torch leads are not work torch leads to the right connected to the right welding terminals welding terminals Torch lead is disconnected Connect it to the terminal Gas flow incorrectly set Select the right flow rate cylinder empty or the torch change cylinders or turn torch valve is off valve on May 5 2005 Page 35 P Wee 160S 12 Arc start is not A Tungsten electrode 1s too A Select the right size electrode smooth 8 02 Stick Welding Problems Gas pockets or A voids in weld metal Porosity Crack occurring in weld metal soon after solidification commences A gap is left by failure of the weld metal to fill the root of the weld Insufficient gap May 5 2005 Incorrect sequence large for the welding current The wrong electrode is being used for the welding job Gas flow rate is too high Incorrect shielding gas is being used Poor work clamp connection to work piece Electrodes are damp Welding current 1s too high surface impurities such as oil grease paint etc Rigidity of joint Insufficient throat thickness Cooling rate 1s too high Welding current 1s too low Electrode too large for Joint Insufficient gap Incorrect
59. espect to any contract or anything done in connection therewith such as the performance or breach thereof or from the manufacture sale delivery resale or use of any goods covered by or furnished by Thermal Arc whether arising out of contract negligence strict tort or under any warranty or otherwise 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 any other warranty PURCHASER S RIGHTS UNDER THIS WARRANTY ARE VOIDIF REPLACEMENT PARTS OR ACCESSORIES ARE USED WHICH IN THERMAL ARC S SOLE JUDGEMENT MAY IMPAIR THE SAFETY OR PERFORMANCE OF ANY THERMAL ARC PRODUCT PURCHASER S RIGHTS UNDER THIS WARRANTY ARE VOID IF THE PRODUCT IS SOLD TO PURCHASER BY NON AUTHORIZED PERSONS The warranty is effective for the time stated below beginning on the date that the authorized distributor delivers the products to the Purchaser Notwithstanding the foregoing in no event shall the warranty period extend more than the time stated plus one year from the date Thermal Arc delivered the product to the authorized distributor ROWER SUPPLIES ALL OTHER CIRCUITS AND COMPONENTS INCLUDING BUT NOT LIMITED TO CONTACTORS RELAYS SOLENOIDS PUMPS 1 YEAR 1 YEAR POWER SWITCHING SEMI CONDUCTORS ENGINES ENGINES ARE NOT WARRANTED BY THERMAL ARC ALTHOUGH MOST ARE WARRANTED BY THE ENGIN
60. ests should also be conducted by an accredited Thermal Arc service agent VRD Open Circuit Voltage Less than 20V at Vin 115V or 230V VRD Turn ON Resistance Less than 200 ohms VRD Turn OFF Time Less than 0 3 seconds If this equipment is used in a location or environment with a high risk of electrocution then the above tests should be carried out prior to entering this location May 5 2005 Page 39 P Wee 160S Soonpoi oSe3 oA 201 UOUM J9S91 JIM A eoneuromne I A 9poo IOUA puejsuoo spunos 1ozzng Sos oo JUSIINO p 2AA IOJIO COW 19891 0j UO uou JJO IUTYIBUI YOUMS Kpiuejsuoo spunos 1ozzng S9SB99 JUSIINO p 2AA Spuooos 0 nOq 10 O 0 01 soseo1oop IHL USUM SPSA 104 Kpuejsuoo spunos Jazzng Sose2o juaumo p 2AA ogej oA AUNG ou JII uerornoo o porjipenb e Jo JUISY 99IAI9S DIV eunou poiporooy UE oAeH ogej O0A SUIE MOT 10J 5 29qo uerornoo o porjipenb e Jo JUISY 99IAI9S DIV eun P9JIP9LDIY ue savy Ore SUIPIOM Jo YI3U9 SINPIY UMOp 009 39 MOS 19M0d 19 uou SJU9A oo qu 9JP31IS9AUI juoS y 99IAI9S OLY BULIOY L P9JP9199V ue savy 01049 Aynp sy UIUJIM doo uou umop 009 991N0S Imod PT V 0401 Sh d oSey oA BUTUIOU ou uey 1916915 SI a3e3J0A AJddns Am 93B 0A eururou MO 9Q 950 uey o1oui SI oge3 oA A ddns suey Suo 00 SI 918 SUIP OM osntooq USIU 00 SI JU9IINO reugriq P9Y90 q SUI9Q SJU9A Aq PIPSO SI MOTIF ITY ayeJodo 0 SISBII UBH popoooxo uooq sey 9
61. eve a sound electrical connection 5k ohm maximum connection to 5k ohm remote control potentiometer 4 Negative Terminal 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 CAUTION 2 Loose welding terminal connections can cause overheating and result in the male plug being fused in the bayonet terminal 5 ON OFF Switch This switch connects the Primary supply voltage to the inverter when in the ON position This enables the Power Supply los G 6 When the welder is connected to the Primary supply voltage the internal electrical components maybe at 230V potential with respect to earth 6 Input Cable The input cable connects the Primary supply voltage to the equipment May 5 2005 Page 27 P Wee 160S 4 02 Weld Parameter Description for the 160S Figure 4 P Wee 160 Front Panel with Parameter Description Parameter Description This parameter operates in STICK weld mode and 1s used to improve the HOT START start characteristics for stick electrodes e g low hydrogen electrodes It sets the peak start current on top of the WELD current Weld Current Amperage sets the STICK and TIG WELD current ARC CONTROL This parameter provides a suitable short circuit current in STICK welding to improve electrode sticking and arc stability LIFT TIG mode of operation A remot
62. ge Control Wiper 0 10VDC Remote Installed 12VDC Front View id 1 SIDE CHASSIS 3 l I y 2 3 4 5 6 7 8 May 5 2005 Page 122 P Wee 160S f a PCB9 Diode Snubber Circuit Board WK5336 Output Terminal TB3 O PONT VUE PCB10 Output Filter Circuit Board A WK5358 SIDE CHASSIS 4 Output Terminal R2 HF UNIT 1 SIDE CHASSIS 1 AC2 SIDE CHASSIS 2 PCB6 Circuit Board PCB5 WK498 7 Control 1 l Circuit Board WK4986 CN 4 CN 5 CN 6 CN 7 I l CN 4 CN 5 CN 6 CN 7 PCB4 Panel I I UT Circuit Board WK4985 I pru z DORE ss 6 l TERRE l Elo IX EG I May 5 2005 Page 123 P Wee 160S APPENDIX C AUTOMATION SLIDE SWITCH SETTING FOR OK TO MOVE Models 160S TS Three slide switches SI 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 covers by loosening 4 screws on each the front and rear panel then removing the 4 side panel screws as well as the 2 handle screws Carefully pull the front and rear panels outward to release and remove the side cover Lift up the protective PCB cover sheet from the bottom and the slide switches will be 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
63. ges updates improvements or replacement of such items The values specified in the table above are optimal values your values may differ Individual equipment may differ from the above specifications due to in part but not exclusively to any one or more of the following variations or changes in manufactured components installation location and conditions and local power grid supply conditions May 5 2005 Page 24 P Wee 160S 3 05 Duty Cycle The duty cycle of a welding power source 1s the percentage of a ten 10 minute period that 1t 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 A WARNING 5 Exceeding the duty cycle ratings will cause the thermal overload protection circuit to become energized and shut down the output until the unit has cooled to normal operating temperature CAUTION I Continually exceeding the duty cycle ratings can cause damage to the welding power source and will void the manufactures warranty NOTE 4 Due to variations that can occur in manufactured products claimed performance voltages ratings all capacities measurements dimensions and weights quoted are approximate only Achievable capacities and ratings in use and operation will depend upon correct installation use applications maintenance and service M
64. he Capacitor Bus Voltage on PCBI WK 4980 e Follow the instruction in section 11 01 04 02 b Verify the input diode D1 e Refer to the section 11 02 06 01 for the test and replacement of D1 c Verify the IGBT OI e Refer to section 11 02 06 02 for the test and replacement of Q1 d Replace PCB1 WK 4980 and PCB2 WK 4977 e Ifthe tests in the above sections a b c are within expected results and the unit is still defective replace PCB1 and PCB2 e Refer to section 11 02 04 01 for the replacement of PCB and section 11 02 04 02 for the replacement of PCB2 2 E11 High Input Voltage Failure Cause Occurs when the input voltage is more than approximately 275VAC 1 1 41 of the maximum value of the sinusoidal wave Verification Remedy e Verify input voltage e Follow the instruction in section 11 01 04 02 May 5 2005 Page 45 P Wee 160S f Replace PCB2 WK 4977 e Ifthe voltage and current available is determined to be sufficient replace PCB2 e Refer to section 11 02 04 02 for the replacement of PCB2 3 E12 Low Input Voltage Failure Cause Occurs when the input voltage is less than approximately 150VAC 1 1 41 of the maximum value of the sinusoidal wave Verification Remedy a Verify input voltage e Follow the instruction in section 11 01 04 02 b Replace PCB2 WK 4977 e Ifthe voltage and current available is determined to be sufficient replace PCB2 e Refer to section 11 02 04
65. he thermistors apply heat sink compound Shinetsu silicon G 747 or equivalent uniformly to the base surface of the thermistors When you re assemble the parts conduct the above process backwards Page 98 P Wee 160S 11 02 08 Coil 11 02 08 01 Reactor L1 a Test Procedure 1 Inspect the Reactor Ll for signs of overheating or loose connections 2 Check for continuity through the Reactor by measuring between both of the terminals b Replacement Procedure 1 Remove the side covers See section 11 01 01 2 Remove PCB2 See section 11 02 04 02 3 Remove the insulating tube applied to the connection between LI and TI Figure 86 Insulating tube May 5 2005 Page 99 P Wee 160S 4 Remove the screw connecting LI to T1 circled as shown in Figure 87 Figure 87 Welding equipment internal 5 Remove the screws 4 places circled as shown in Figure 88 from the front panel Figure 88 Welding equipment front view 6 Remove the screws holding the front panel and then the screws 2 places circled as shown in Figure 89 mounting the output terminals gems Y w d ality Figure 89 Welding equipment lower front view May 5 2005 Page 100 P Wee 160S 7 Remove the front panel from the chassis on the welding equipment Figure 90 Removing Front panel 8 Remove the insulating tube applied Remove the screws 2 places circled as shown in Figure 91 mounting L1 on chassis Figure91 L1
66. igure 99 Figure 99 Welding equipment internal 9 Remove the screw connecting CI to EIC2 of QI circled as shown in Figure 100 Figure 100 C1 May 5 2005 Page 104 P Wee 160S 10 Remove the screws 4 places circled as shown in Figure 101 securing chassis to the rear panel Figure 101 Welding equipment rear side 11 Remove the rear panel from the power supply Figure 102 Welding equipment with the rear panel removed 12 Remove the screws 2 places circled as shown in Figure 103 mounting C1 on chassis Figure 103 Welding equipment internal rear view May 5 2005 Page 105 P Wee 160S 13 Remove the screw connecting T1 to TB6 of PCBI circled as shown in Figure 104 Figure 104 Expanded rear view welding equipment 14 Remove the screws 4 places circled as shown in Figure 105 mounting T1 onto the chassis and remove the T1 Figure 105 T1 top view When you re assemble the parts conduct the above process backwards May 5 2005 Page 106 P Wee 160S PAGE LEFT INTENTIONALLY BLANK May 5 2005 Page 107 P Wee 160S 11 02 09 Hall Current Transformer HCT CT1 a Test Procedure 1 Remove the locking connector CN7 attached to PCB2 2 With an Ohmmeter set the Rx10 scale measure between the pins on the CN7 plug as follows Pin 4 and Pin 1 about 3 to 5 MQ Pin 4 and Pin 2 about 10 kQ b Replacement Procedure 1 Remove the side covers See section 11 01 01 2 Remove PCB2 See s
67. ill be inaccurate therefore when verifying the voltage do so during the failure condition Note 17 When verifying the voltage confirm that the AC input voltage remain within the operating range of the unit May 5 2005 Page 57 P Wee 160S 11 01 04 05 Verification of No load voltage No OCV a Verify the no load voltage in Stick mode May 5 2005 1 2 3 4 CAUTION 10 Electric shock hazard The unit will generate OCV immediately when STICK mode is selected In STICK welding mode mark and then place PIN2 of DSW1 on PCB3 WK 4986 in the OFF position to turn off the electric shock protector function Voltage Reduction Device VRD Verify the no load voltage using a DC voltmeter The capability of the voltmeter should be more than 100VDC The normal no load voltage 1s approximately 62V Return Pin2 of DSWI to factory position Page 58 P Wee 160S 11 01 04 06 Output Load Test This test verifies that the output current amperage controls are functioning properly A clamp type amperage meter or equivalent meter capable of reading approximately 180A full scale will be needed for this test CAUTION 11 Before performing any portion of the procedure below make certain the unit is placed in the initial set up condition as described at the beginning of this section 1 Connect the POSITIVE and NEGATIVE OUTPUT TERMINALS to a piece of metal separated by approximately three feet one mete
68. n 11 02 08 01 3 Transformer T1 Refer to the Section 11 02 08 02 4 IGBT QI Refer to the Section 11 02 06 02 5 Hall CT CTI Refer to the Section 11 02 09 4 Operating Panel Failure LED s do not light properly or welding setting cannot be establish Cause Occurs when there is a connection failure among PCB4 WK 4985 PCB5 WK 4986 and PCB2 WK 4977 or PCB5 and PCB2 are defective Verification Remedy a Verify the harness connection between CN4 on PCB2 WK 4977 and CNI on PCB5 WK 4986 e Confirm a secure connection of the harness and the connections between CNA on PCB2 and CNI on PCBS e Contact the manufacture if you find any broken connectors or damaged wiring harnesses b Verify the connection between PCB4 WK 4985 and PCB5 WK 4986 e Confirm that all four connectors between PCB4 and PCBS are tightly connected e Confirm the condition of the pins on the connectors and the connectors themselves if bent pins or damaged connectors are found replace the suspected PCB e Refer to section 11 02 04 03 for the replacement and installation of PCB4 and section 11 02 04 04 for PCB5 PCB6 WK 4987 c Verify the connection between CN13 on PCBI WK 4980 and CN12 on PCB2 WK 4977 e Confirm a secure connection between CN13 on PCB1 WK 4980 and CN12 on PCB2 WK 4977 May 5 2005 Page 50 P Wee 160S d Replacement of PCB2 WK 4977 PCB5 WK 4986 and PCB6 WK 4987 e Refer to section 11 02 04
69. n DI COMPONENT TERMINALS ACCEPTABLE TESTED Positive Negative VALUE lead lead TB9 TB10 0 3 to 0 5V TB10 TB11 0 3 to 0 5V Table 6 DI tester checkpoints PCB1 Figure 62 Expanded view of PCB1 May 5 2005 Page 87 P Wee 160S b Replacement Procedure 1 Remove the side covers See section 11 01 01 2 Remove PCBI See section 11 02 04 01 3 Replace D1 together with PCB7 Figure 63 Welding equipment internal view 4 Remove the screw circled as shown in Figure 64 securing PCB7 to the heatsink Figure 64 Expanded view of PCB7 5 Pull out DI together with PCB7 frontward Figure 65 PCB7 and D1 May 5 2005 Page 88 P Wee 160S 6 Unplug the harness connector from CN1 on PCB7 Figure 66 CN1 on PCB7 Holding the upper portion of the harness to unlock the contact between the harness connector and CN1 pull the harness lightly To unplug the harness connector from CN do not pull the harness excessively 7 Remove the screw mounting the U phase input cable lug on TB1 at PCB7 and remove the D1 Figure 67 TB1 on PCB7 Note 21 When you re assemble the parts conduct the above process backwards Additionally when installing the diode apply 23 in lb to tighten the diode base screws and the terminal screws May 5 2005 Page 89 May 5 2005 P Wee 160S Figure 68 Base surface of D1 Note 22 When replacing the diode apply heat sink compound Shinetsu silico
70. n G 747 or equivalent uniformly to the base surface of the diode Page 90 P Wee 160S 11 02 06 02 IGBT Q1 a Test Procedure 1 Confirm there are no abnormal appearance on PCB3 2 Verify the characteristic of the IGBT Q1 using a diode tester 3 Referthe Table 7 and Figure 69 for the checkpoints on QI COMPONENT TERMINALS ACCEPTABLE TESTED Positive Negative VALUE lead lead with PCB3 C2EI CI 0 2 to 0 5V with PCB3 E2 C2EI 0 2 to 0 5V Table 7 Q1 tester checkpoints Figure 69 Q1 tester checkpoints b Replacement Procedure 1 Remove the side covers See section 11 01 01 2 Remove PCBI See section 11 02 04 01 3 Replace QI together with PCB3 Figure 70 Welding equipment internal view May 5 2005 Page 91 P Wee 160S 4 Unplug a harness connector connected to PCB2 from CNI on PCB3 circled as shown in Figure 71 Figure 71 CN3 on PCB3 5 Remove the screw mounting Cl on C2El on QI circled as shown in Figure 72 Figure 72 C2E1 on PCB3 6 Remove the two 2 screws securing Q1 to the heatsink circled as shown in Figure 73 Figure 73 Mounting screws of Q1 7 Remove Ql from the unit May 5 2005 Page 92 P Wee 160S 8 Remove the two Q bus bar mounted on terminals C1 and E2 circled as shown in Figure 74 and remove from the IGBT Figure 74 Q bus bart on Q1 Note 23 When you re assemble the parts conduct the above process backwards Additionally when inst
71. nt tre apprises par tude ou entrainement avant d utiliser l equipement Toute personne n ayant pas suivi un entrainement intensif en soudage et coupage ne devrait pas tenter de souder Certaines pratiques concernent les quipements raccord s aux lignes d alimentation alors que d autres s adressent aux groupes lectrog nes La norme 749 1 de l American National Standard intitul e SAFETY IN WELDING AND CUTTING pr sente les pratiques s curitaires suivre Ce document ainsi que d autres guides que vous devriez conna tre avant d utiliser cet quipement sont pr sent s la fin de ces instructions de s curit pa SEULES DES PERSONNES QUALIFIEES DOIVENT FAIRE DES TRAVAUX D INSTALLATION DE REPA RATION D ENTRETIEN ET D ESSAL Ne touchez pas des pi ces sous tension dd Portez des gants et des v tements isolants secs et non trou s 3 Isolez vous de la piece souder et de la mise la terre au moyen de tapis isolants ou autres 4 AVERTISSEMENT ETRE D connectez la prise d alimentation de l quipement ou arr tez le moteur avant de l installer ou d en faire l entretien Bloquez le commutateur en circuit ouvert ou enlevez les fusibles de l alimentation afin d viter une mise en marche accidentelle L ELECLROCUTION MORI ELLE PEUT 5 Veuillez installer cet quipement et le mettre Une d charge lectrique peut tuer ou br ler la terre selon le manuel d utilisation et les gr
72. nt areas Watch for fire and keep a fire extinguisher nearby Protect compressed gas cylinders from excessive heat mechanical shocks and arcs Install and secure cylinders in an upright position by chaining them to a stationary sup port or equipment cylinder rack to prevent falling or tipping 3 Keep cylinders away from any welding or other electrical circuits 4 Never allow a welding electrode to touch any cylinder May 5 2005 Page 6 Use only correct shielding gas cylinders regulators hoses and fittings designed for the specific application maintain them and associated parts in good condition Turn face away from valve outlet when opening cylinder valve Keep protective cap in place over valve except when cylinder is in use or connected for use Read and follow instructions on compressed gas cylinders associated equipment and CGA publication P 1 listed in Safety Standards WARNING Engines can be dangerous f WARNING ENGINE EXHAUST GASES can kill Engines produce harmful exhaust gases 1 Use equipment outside in open well ventilated areas If used in a closed area vent engine exhaust outside and away from any building air intakes f y WARNING ENGINE FUEL can cause fire or explosion Engine fuel is highly flammable Stop engine before checking or adding fuel Donotadd fuel while smoking or if unitis near any sparks or
73. ntrol Connection CON1 Current Adjustment Circuit Reference Adjustments amp Mode select Switches Panel Circuit Board Figure 1 Model 160 Functional Block Diagram 2 07 Transporting Methods These units are equipped with a handle for carrying purposes WARNING 1 ELECTRIC SHOCK can kill DO NOT TOUCH live electrical parts power conductors from de energized supply line before moving the welding power source Disconnect input A 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 May 5 2005 Page 18 P Wee 160S 3 0 INSTALLATION RECOMMENDATIONS 3 01 Environment The P Wee 160 is designed for use in adverse environments Examples of environments with increased adverse conditions are a In locations in which freedom of movement 1s restricted so that the operator 1s forced to perform the work in a cramped kneeling sitting or lying position with physical contact with conductive parts b In locations which are fully or partially limited by conductive elements and in which there 1s a high risk of unavoidable or accidental contact by the operator or c In wet or damp hot locations where humidity or perspiration considerably reduces the skin resistance of the human body and the insulati
74. on properties of accessories Environments with adverse conditions do not include places where electrically conductive parts are in the near vicinity of the operator which can cause increased hazard have been insulated 3 02 Location Be sure to locate the welder according to the following guidelines e In areas free from moisture and dust e Ambient temperature between 0 degrees C to 40 degrees C e n areas free from oil steam and e In areas not subjected to abnormal corrosive gases vibration or shock e Jn areas not exposed to direct sunlight or e Place at a distance of 12 304 79mm or rain more from walls or similar that could restrict natural airflow for cooling WARNING 3 Thermal Arc advises that this equipment be electrically connected by a qualified electrician May 5 2005 Page 19 P Wee 160S 3 03 Electrical Input Connections A WARNING 4 ELECTRIC SHOCK can kill SIGNIFICANT DC VOLTAGE is present after removal of input power DO NOT TOUCH live electrical parts SHUT DOWN welding power source disconnect input power employing lockout tagging procedures Lockout tagging procedures consist of padlocking line disconnect switch 1n open position removing fuses from fuse box or shutting off and red tagging circuit breaker or other disconnecting device 3 03 01 Electrical Input Requirements Operate the welding power source from a single phase 50 60 Hz AC power supply The input voltage must match one
75. onnection e Contact the manufacturer if you find any broken connectors or damaged wiring harnesses b Replace thermistors TH1 e Refer to section 11 02 07 for the replacement of TH1 c Replace PCB5 WK 4986 and PCB6 WK 4987 e Refer to section 11 02 04 04 for the replacement of PCB5 and PCB6 May 5 2005 Page 47 May 5 2005 P Wee 160S 8 E99 Initial Power Receiving Cause Occurs when the initial AC power received signal has not reached the CPU Note 13 This error occurs normally during the power OFF sequence of the unit Verification Remedy a Verify the wiring harness and connection of CN1 on PCB5 WK 4986 and CNS on PCB2 WK 4977 e Confirm a secure connection of the harness wired between CNI on PCBS and CNS on PCB2 and re install the harness with a secure connection e Contact the manufacturer if you find any broken connectors or damaged wiring harness b Verify and replace PCB2 WK 4977 e Confirm a secure connection of the harness wired between CN13 on PCB1 and CNI2 on PCB2 and re install the harness with a secure connection e Refer to section 11 02 04 02 for the replacement of PCB2 c Replace PCB5 WK 4986 and PCB6 WK 4987 e Refer to section 11 02 04 04 for the replacement of PCB5 and PCB6 Page 48 P Wee 160S 11 01 03 Verification and Remedy to Failures Without Indication Codes Refer to Note 9 on Page 41 Refer to Note 10 on Page 41 Refer to Note 11 on Page 41 1
76. ons to move to the parameter to be set The LED will show which function 1s being adjusted on the weld sequence graph Use the control knob to adjust each parameter e Set HOT START e Set WELD current e Set Arc Control Commence welding 6 02 DC LIFT TIG Welding e Connect work lead to positive terminal e Connect TIG torch to negative terminal e Switch machine on e Set weld current e Connect remote control device A remote control device is required for use during LIFT TIG operation See section 4 01 section 2 Remote Control Socket for complete details of the remote device Use the Scroll Buttons to move to the parameter to be set The LED will show which function 1s being adjusted on the weld sequence graph Use the control knob to adjust each parameter e Set WELD current Commence welding May 5 2005 Page 32 P Wee 160S 7 0 ROUTINE MAINTENANCE The only routine maintenance required for the power supply 1s 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 two minutes before opening the enclosure to allow the primary capacitors to discharge To clean the unit open the enclosure please refer to the section Opening the Enclosure and use a vacuum cleaner to remove any accumulated dirt and dust The unit should also be wiped clean if necessary with solvents th
77. or stabilized arc 1s almost invariably traced to improper installation The following information is intended as a guide for personnel installing high frequency welding machines Warning Explosives The high frequency section of this machine has an output similar to a radio transmitter The machine should NOT be used in the vicinity of blasting operations due to the danger of premature firing Computers It 1s also possible that operation close to computer installations may cause computer malfunction 3 03 04 High Frequency Interference Interference may be transmitted by a high frequency initiated or stabilized arc welding machine in the following ways Direct Radiation Radiation from the machine can occur if the case is metal and is not properly grounded It can occur through apertures such as open access panels The shielding of the high frequency unit in the Power Source will prevent direct radiation 1f the equipment 1s properly grounded Transmission via the Supply Lead Without adequate shielding and filtering high frequency energy may be fed to the wiring within the installation mains by direct coupling The energy is then transmitted by both radiation and conduction Adequate shielding and filtering 1s provided in the Power Source Radiation from Welding Leads Radiated interference from welding leads although pronounced in the vicinity of the leads diminishes rapidly with distance Keeping leads as short as possible will minimiz
78. perty if the operator does not strictly observe all safety rules and take precautionary actions Safe practices have developed from past experience in the use of welding and cutting These practices must be learned through study and training before using this equipment Anyone not having extensive training in welding and cutting practices should not attempt to weld Certain of the practices apply to equipment connected to power lines other practices apply to engine driven equipment Safe practices are outlined in the American National Standard Z49 1 entitled SAFETY IN WELDING AND CUTTING This publication and other guides to what you should learn before operating this equipment are listed at the end of these safety precautions HAVE ALL INSTALLATION OPERATION MAINTENANCE AND REPAIR WORK PERFORMED ONLY BY QUALIFIED PEOPLE p WARNING ELECTRIC SHOCK can kill Touching live electrical parts can cause fatal shocks or severe burns The electrode and work circuit is electrically live whenever the output is on The input power circuit and machine internal circuits are also live when power is on In semiautomatic or automatic wire welding the wire wire reel drive roll housing and all metal parts touching the welding wire are electrically live Incorrectly installed or improperly grounded equipment is a hazard E 1 Do not touch live electrical parts 2 Wear dry hole free insulating gloves and body protection 3 In
79. r 2 Connect the clamp on amperage meter or equivalent to the output loop between the POSITIVE and NEGATIVE OUTPUT TERMINALS 3 Place the power supply PRIMARY POWER SWITCH on the rear of the unit to the ON position WARNING 13 This welding mode produces high frequency and high voltage Extra care shall be taken to prevent electric shock 4 Select WELD position press control knob Set minimum current counterclockwise 5 Depress the torch switch The amperage meter will indicate approximately 5 Amps 6 Slowly turn the Control Knob clockwise to the maximum of the power supply then counterclockwise back to 5 Amps as the control returns to its minimum position The amperage meter should indicate a continuous range of Amperes between the 5 Amps minimum and the 160A maximum 7 Set minimum current counterclockwise 8 Press the Welding mode selection button to select STICK welding mode The amperage meter will indicate approximately 5 Amps May 5 2005 Page 59 May 5 2005 P Wee 160S A WARNING 14 At this time some voltage is applied to the stick electrode holder Never touch the current conducting portion of it Extra care shall be taken to prevent electric shock Further to prevent the risk of striking the arc inadvertently care shall be taken to keep the work piece to be welded away from the said electrode holder 9 Slowly turn the Control Knob clockwise to the maximum of the power supply then counte
80. rclockwise back to 5 Amps as the control returns to its minimum position The amperage meter should indicate a continuous range of Amperes between the 5 Amps minimum and the 160A maximum 10 Place the power supply MAIN CIRCUIT SWITCH on the rear of the unit to the OFF position 11 Remove the dead short between the OUTPUT TERMINALS Note 18 This completes the output load test If the results of any step differ from those above then refer to the various test procedures in this section to 1solate the problem Page 60 P Wee 160S 11 02 Subsystem Test and Replacement Procedures 11 02 01 Preparation This section provides specific procedures for verifying the operation and replacement of each subsystem within the power supply Before undertaking any of these procedures eliminate the obvious first visually inspect the suspect subsystem for physical damage overheating and loose connections 11 02 02 Test and Replacement Parts List Print Circuit Board PCBI WK 4980 11 02 04 01 Print Circuit Board PCB4 WK 4985 11 02 04 03 Print Circuit Board WK 4986 3 PCBS with PCB6 11 02 04 04 with Flat Cable Print Circuit Board PCB2 WK 4977 11 02 04 02 May 5 2005 Page 61 P Wee 160S May 5 2005 Page 62 P Wee 160S Cooling Fan 11 02 10 Diode with PCB7 11 02 06 01 11 02 07 IGBT Hall Current Transformer 11 02 09 May 5 2005 Page 63 P Wee 160S 11 02 03 Service Tools Nut Driver Open End Box
81. re frustrating it does not yet allow us to draw definite conclusions about questions of possible risk or to offer clear science based advice on strategies to minimize or avoid potential risks May 5 2005 Page 8 P Wee 160S To reduce magnetic fields in the workplace use the following procedures 1 Keep cables close together by twisting or taping them 2 Arrange cables to one side and away from the operator 3 Do not coil or drape cable around the body 4 Keep welding power source and cables as far away from body as practical ABOUT PACEMAKERS p The above procedures are among those also nor mally recommended for pacemaker wearers Consult your doctor for complete information 1 01 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 5 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 1 from American Welding Society 550 N W LeJeune Rd Miami FL 33126 National Electrical Code NFPA Standard 70 from Na tional Fire Protection Association Batterymarch Park Quincy MA 02269 Safe Handling of Compressed Gases in Cylinders CGA
82. rocution et d incendie Ne d gelez pas les tuyaux avec un source de courant Otez l lectrode du porte lectrode ou coupez le fil au tube contact lorsqu inutilis apr s le soudage Portez des v tements protecteurs non huileux tels des gants en cuir une chemise paisse un pantalon revers des bottines de s curit et un casque P Wee 160S 4h 8 Lisez et respectez les consignes relatives aux AVERTISSEMENT bouteilles de gaz comprim et aux quipements a connexes ainsi que la publication P 1 de la CGA identifi e dans la liste de documents ci LES EIINCELLES ET LES PROJECTIONS dessous BRULANTES PEUVENT CAUSER DES BLESSURES Le piquage et le meulage produisent des o particules m talliques volantes En refroidissant n AVERTISSEMENT la soudure peut projeter du clats de laitier 1 Portez un cran facial ou des lunettes LES MOTEURS PEUVENT ETRE protectrices approuv es Des crans lat raux DANGEREUX LES GAZ D ECHAPPEMENT DES 2 Portez des v tements appropri s pour prot ger MOTEURS PEUVENT ETRE MORTELS la peau m M M Les moteurs produisent des gaz d chappement nocifs ad LE N 1 Utilisez l quipement l ext rieur dans des y aires ouvertes et bien ventil es 8 AVERTISSEMENT 2 Si vous utilisez ces quipements dans un endroit confin les fum es d chappement doivent tre LES BOUTEILLES ENDOMMAGEES envoy es l ext rieur loin des prises d air du PEUVENT
83. ry while wearing an air supplied la WARNING respirator The coatings and any metals containing these elements can give off toxic mmm FLYING SPARKS AND HOT METAL can SIS cause injury fumes if welded d a WARNING WELDING can cause fire or explosion 9 Do not use welder to thaw frozen pipes W Chipping and grinding cause flying metal As welds cool they can throw off slag 1 Wear approved face shield or safety goggles Sparks and spatter fly off from the welding arc p P fiy off Side shields recommended The flying sparks and hot metal weld spatter hot workpiece and hot equipment can cause fires and burns Accidental contact of electrode or welding wire to metal objects can cause sparks overheating or fire EM 2 Wear proper body protection to protect skin BS ZA e WARNING CYLINDERS can explode 1f damaged 1 Protect yourself and others from flying sparks and hot metal 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 A 2 Do not weld where flying sparks can strike flammable material 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 Be alert that welding sparks and hot materials from welding can easily go through small cracks and openings to adjace
84. s1o3roedeo Areurtid 98tJ 0A 3ndur Ajddns suru opun po Ae dsrp opoo 109 Z uondrnosoq Page 41 May 5 2005 P Wee 160S 11 0 ADVANCED TROUBLESHOOTING If you are here all of the troubleshooting suggestions in Section 8 Basic Troubleshooting have either failed to resolve the faulty operation or have indicated that one or more of the subsystems within the power supply are defective This section provides the information needed to take live measurements on the various subsystems within the power supply and replace those subsystems that prove faulty CAUTION 6 Troubleshooting and repairing this unit is a process which should be undertaken only by those familiar with high voltage high power electronic equipment A WARNING 10 There are extremely dangerous voltage and power levels present inside this unit Do not attempt to diagnose or repair unless you have training in power electronics measurement and troubleshooting techniques Under no circumstances are field repairs to be attempted on printed circuit boards or other subassemblies of this unit Evidence of unauthorized repairs will void the factory warranty If a subassembly Is found to be defective by executing any of the procedures in this Service Manual the subassembly should be replaced with a new one The faulty subassembly should then be returned to Thermal Arc through established procedures A WARNING 11 Disconnect primary power at the source before disassembling
85. sequence sequence Page 36 Refer to Basic TIG Welding Guide select the right electrode type Refer to Basic TIG Welding Guide Select the correct rate for the welding job Refer to Basic TIG Welding Guide select the right shielding gas Refer to Basic TIG Welding Guide Improve connection to work piece A Dry electrodes before use B Reduce welding current C Clean joint before welding Redesign to relieve weld joint Of severe stresses or use crack resistance electrodes Travel slightly slower to allow greater build up in throat Preheat plate and cool slowly Increase welding current Use smaller diameter electrode Allow wider gap Use correct build up sequence Figure 7 Example of insufficient gap or incorrect A Small electrodes used on heavy cold plate Portions of the weld run do not fuse to the surface of the metal or edge of the joint B Welding current is too low C Wrong electrode angle D Travel speed of electrode 1s too high E Scale or dirt on Joint surface Lack of fusion caused by dirt electrode angle incorrect rate of travel too high Lack of inter run fusion Lack of side fusion scale dirt small electrode amperage too low Lack of Root Fusion 5 Non metallic parti A Non metallic particles may cles are trapped in be trapped in undercut from the weld metal previous run slag inclusion Joint preparation too restricted Irregular d
86. sulate yourself from work and ground using dry insulating mats or covers May 5 2005 Page 4 p Disconnect input power or stop engine before installing or servicing this equipment Lock input power disconnect switch open or remove line fuses so power cannot be turned on accidentally Properly install and ground this equipment according to its Owner s Manual and national state and local codes Turn off all equipment when not in use Disconnect power to equipment if it will be left unattended or out of service Use fully insulated electrode holders Never dip holder in water to cool it or lay it down on the ground or the work surface Do not touch holders connected to two welding machines at the same time or touch other people with the holder or electrode Do not use worn damaged undersized or poorly spliced cables Do not wrap cables around your body Ground the workpiece to a good electrical earth ground Do not touch electrode while in contact with the work ground circuit Useonly well maintained equipment Repair or replace damaged parts at once P Wee 160S 13 In confined spaces or damp locations do not 4 Wear protective clothing made from durable use a welder with AC output unless it is flame resistant material wool and leather and equipped with a voltage reducer Use foot protection twith DC output j ur he Le m dd 5 Use approved ear plugs or ear muffs if noise 14 W
87. trial Park Chorley Lancashire England PR6 7BX May 5 2005 Page 14 P Wee 160S 1 03 LIMITED WARRANTY LIMITED WARRANTY Thermal ArcG Inc A Thermadyne Company hereafter Thermal Arc warrants to customers of itsauthorized distributors hereafter Purchaser that its products will be free of defects in workmanship or material Should anyfailure to conform to this warranty appear within the time period applicable to the Thermal Arc products as stated below Thermal Arc shall upon notification thereof and substantiation that the product has been stored installed operated and maintained in accordance with Thermal Arc s specifications instructions recommendations and recognized standard industry practice and not subject to misuse repair neglect alteration or accident correct such defects by suitable repair or replacement at Thermal Arc s sole option of any components or parts of the product determined by Thermal Arc to be defective THERMAL ARC MAKES NO OTHER WARRANTY EXPRESS OR IMPLIED THIS WARRANTY IS EXCLUSIVE AND IN LIEU OF ALL OTHERS INCLUDING BUT NOT LIMITED TO ANY WARRANTY OF MERCHANTABILITY OR FITNESS FOR ANY PARTICULAR PURPOSE LIMITATION OF LIABILITY THERMAL ARC SHALL NOT UNDER ANY CIRCUMSTANCES BE LIABLE FOR SPECIAL INDIRECT OR CONSEQUENTIAL DAMAGES SUCH AS BUT NOT LIMITED TO LOST PROFITS AND BUSINESS INTERRUPTION The remedies of the Purchaser set forth herein are exclusive and the liability of Thermal Arc with r
88. ue can be adjusted at any time even while welding e Pushing the knob in displays actual arc voltage Self Diagnosis Using Error Codes e An error code 1s displayed on the Digital Meter when a problem occurs with Primary supply voltage or internal component problems Refer to troubleshooting guide May 5 2005 Page 29 P Wee 160S 5 0 SET UP FOR SMAW STICK AND GTAW TIG Conventional operating procedures apply when using the Welding Power Source 1 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 Current delivered to the arc 1s dependent on the welding arc voltage and as welding arc voltage varies between different classes of electrodes welding current at any one setting would vary according to the type of electrode in use The operator should use the welding current range values as a guide then finally adjust the current setting to suit the application A WARNING 7 Before connecting the work clamp to the work and inserting the electrode in the electrode holder make sure the Primary power supply is switched off CAUTION 3 Remove any packaging material prior to use Do not block the air vents at the front or rear or sides of the Welding Power Source Figure 5 1608 Set up Ma
89. ure 41 Protection panel cover To remove the protection panel cover push both edges of the cover in slightly as indicated by left and right arrows in Figure 41 and pull the cover frontward May 5 2005 Page 75 P Wee 160S 3 Remove the cap on the control knob indicated by arrow in Figure 45 Figure 42 Operation panel 4 Remove screw indicated by arrow in Figure 43 securing the control knob to the operation panel loosen the screw and remove the control knob from operation panel k a Figure 43 Control knob 5 Remove the screws 4 places circled as shown in Figure 44 holding the operation panel onto the front panel Figure 44 Operation panel with the control knob removed May 5 2005 Page 76 P Wee 160S 6 Unplug harness connectors 3 places circled as shown in Figure 45 from CNI on PCBS and from CNS and CN9 on PCB6 Figure 45 Welding equipment front side top view 7 Pull the operation panel forward out of the front frame Figure 46 Operation panel frontward May 5 2005 Page 77 P Wee 160S 8 Disconnected and remove PCB5 and PCB6 from PCB4 by pulling the two PCB s apart Figure 47 Disassembling the operation panel 9 Remove the screws 4 places circled as shown in Figure 48 mounting PCB4 on the operation panel sheet Figure 48 B side view of PCB4 May 5 2005 Page 78 P Wee 160S 10 Remove the dust cover from the control knob Figure 49 Remove the PCB4
90. volt ohm meter to the diode test scale 4 Using figure 1 and 2 check each diode in the module Each diode must be checked in both the forward bias positive to negative and reverse bias negative to positive direction 5 To check the diode in the forward bias direction connect the volt ohm meter positive lead to the anode positive of the diode and the negative lead to the cathode negative of the diode refer to figure 1 A properly functioning diode will conduct in the forward bias direction and will indicate between 0 3 and 0 9 volts 6 To check the diode in the reverse bias direction reverse the meter leads refer to figure 1 A properly functioning diode will block current flow in the reverse bias direction and depending on the meter function will indicate an open or OL 7 If any diode In the module tests as faulty replace the diode module 8 Reconnect all cables to the proper terminals Forward Bias Diode Conducting Anode Cathode Figure 1 Forward bias diode test May 5 2005 Page 128 May 5 2005 P Wee 160S Reverse Bias Diode Not Conducting Cathode Anode Figure 2 Reverse bias diode test Page 129
91. y Ge K Ground Conductor Ground Terminal UY T Line Disconnect Switch m SS MES Y Z T 7 Line Fuse May 5 2005 Primary Power Cable Figure 2 Electrical Input Connections Page 21 P Wee 160S 3 03 02 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 3 Note the available input power Damage to the PCA could occur if 460V AC or higher is applied The following 115 230V Primary Current recommendations are required to obtain the maximum welding current and duty cycle from this welding equipment Primary Supply Minimum Primary Lead Size Current Circuit Size Current amp Duty Cycle Factory Fitted Vin Amps STICK 115 22 85A a 10094 EN MEN 160A 35 P Wee 1608 12 3 AWG 230 23 minimum 115 38 85A 100 208 42 mos gt PO Table 2 115 230V Primary Current Circuit sizes to achieve maximum current May 5 2005 Page 22 P Wee 160S 3 03 03 High Frequency Introduction The importance of correct installation of high frequency welding equipment cannot be over emphasized Interference due to high frequency initiated
92. y 5 2005 Page 30 P Wee 160S 6 0 SEQUENCE OF OPERATION O NOTE Scroll Buttons are used to select the parameters to be set The LED s show which function 1s being adjusted on the weld sequence graph Refer to Symbols Table located in the front of the manual for Symbol descriptions Figure 6 1608 Front Panel 1 Scroll Buttons used to select the parameters to be set The LED s show which function is being 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 the operator 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 the power source also used to set each parameter value Pushing the knob inward displays the actual welding voltage 4 Process Button This button selects between STICK or Lift TIG mode 5 8 pin remote control receptacle for connecting remote devices A remote control device 1s required for use during LIFT TIG operation See section 4 01 section 2 Remote Control Socket for complete details of the remote device May 5 2005 Page 31 P Wee 160S 6 01 Stick Welding e Connect work lead to negative terminal e Connect electrode lead to positive terminal e Switch machine on e Connect remote control device 1f required Use the Scroll Butt

P-Wee® 160S INVERTER ARC WELDER Service Manual

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P-Wee&reg; 160S INVERTER ARC WELDER Service Manual

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P-Wee® 160S INVERTER ARC WELDER Service Manual