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160 TS ARCMASTER® Service Manual

1. E w B e E ea bol Q CN3 CN4 ARCMASTER 160TS 1 PCB3 2nd Diode Circuit Board I WK 5609 1 Cl SIDE CHASSIS 2 HF UNIT ACI AC2 gt 12 gt 12 gt GND PCB4 Control Circuit Board WK 5449 Circuit Board PCBS Panel WK 5448 AATF Cn on Oo NS 104 Output Terminal Output Terminal ARCMASTER 160TS APPENDIX D DIODE TESTING BASICS Testing of diode modules requires a digital Volt Ohmmeter that has a diode test scale 1 Locate the diode module to be tested 2 Remove cables from mounting studs on diodes to isolate them within the module 3 Set the digital volt ohm meter to the diode Forward Bias test scale Diode Conducting 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 ee direction Figure D 1 Forward bias diode test Anode Cathode 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
2. Art A 07331 37 ARCMASTER 160TS SECTION 8 BASIC TROUBLESHOOTING WARNING There are extremely dangerous voltages and power levels present inside this product Do not attempt to open or repair unless you are an Accredited Thermal Arc Service Agent and you have had training in power measurements and troubleshooting techniques If major complex subassemblies are faulty then the Welding Power Source must be returned to an Accredited Thermal Arc Service Agent for repair The basic level of troubleshooting is 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 is too low Increase weld current and or build up or poor faulty joint preparation penetration or poor fusion at edges of weld Weld bead too wide Welding current is too high Decrease weld current and flat or undercut at edges of weld or excessive burn through Weld bead too Travel speed too fast Reduce travel speed small or insufficient penetration or ripples in bead are widely spaced apart Weld bead too wide Travel speed too slow Increase travel speed or excessive bead build up or excessive penetra tion in butt joint Table 8 1 TIG Welding Problems 38 ARCMASTER 160TS 5 Uneven leg length Wrong placement of filler rod R
3. ARCMASTER 160TS 2 04 Symbol Chart Note that only some of these symbols will appear on your model A Amperage STICK Shielded Metal Arc SMAW V Voltage Pulse Current Function Hertz frequency Spot Time GTAW SEC Seconds Remote Control Panel Remote Percent Remote Function DC Direct Current p N Arc Control SMAW AC Alternating Current SUN N Gas Post Flow Standard Function Gas Pre Flow Slope Function ix eC Voltage Reduction Device Circuit GTAW ERDE 1i Slope W Repeat Function Negative Spot Function Positive Impulse Starting High Frequency Gas Input GTAW Touch Start Lift Start TIG circuit gt Gas Output 14 ARCMASTER 160TS 2 05 Description The Thermal Arc Model 160TS is a self contained single phase DC arc welding power sources with Constant Current CC output characteristics This unit is equipped with a Digital Volt Amperage Meter gas control valve built in Sloper and Pulser lift arc starter and high frequency arc starter for use with Gas Tungsten Arc Welding GTAW Gas Tungsten Arc Welding Pulsed GTAW P Gas Tungsten Arc Welding Sloped GTAW S and Shielded Metal Arc Welding SMAW processes The power source is totally enclosed in an impact resistant flame resistant and non conductive plastic case Note Volt Ampere curves show the maximum Voltage and Ampe
4. WARNING SPARKS can cause BATTERY GASES TO EXPLODE BATTERY ACID can burn eyes and skin Batteries contain acid and generate explosive gases 1 2 Always ware 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 4 and on batteries C D ph WARNING STEAM AND PRESSURIZED HOT COOLAWT can burn face eyes and skin The coolant in the radiator can be very hot and under pressure Do not remove radiator cap when engine is hot Allow engine to cool Wear gloves and put a rag over cap area when removing cap Allow pressure to escape before completely removing Cap A WARNING This product when used for welding or cutting produces fumes or gases which contain chemicals know to the State of California to cause birth defects and in some cases cancer California Health 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 ver
5. DWG NO PARTS NAME SECTION PART NO 1 C1 Capacitor 12 03 2 10 6510 2 IRI Resistor 12 03 2 W7001448 3 odd Transformer 12 03 3 W7001501 4 HF UNIT High Frequency Unit 12 03 12 W7001399 5 FCH1 Reactor 12 03 9 W7001502 6 C C Coupling Coil 12 03 9 W7001384 75 ARCMASTER 160TS 5 6 7 8 9 10 REFERENCE NO DWG NO PARTS NAME SECTION PART NO 1 4 51 Main ON OFF Switch 12 03 14 W7001453 2 01 Primary Diode 12 03 1 W7001481 3 FAN1 Cooling Fan 12 03 11 10 5227 4 S0L1 Solenoid Valve 12 03 13 10 6645 5 TH1 Primary Thermistor 12 03 16 10 5228 6 Remote Connector 12 03 15 10 6627 7 D3 Secondary Diode 12 03 8 10 6229 8 D2 Secondary Diode 12 03 8 10 6629 9 TH2 Thermistor 12 03 17 10 5228 10 CT1 Hall Current Trans 12 03 10 10 5003 76 ARCMASTER 160TS 12 02 Service Tools 1 Tools and Parts The tools and parts to be used for maintenance are shown by icons Head A Long Nose Tee E Silicon 9 Screwdriver Pliers t C Ring Fiers Snap Band Compound Figure 12 1 Icon of tool 2 Notes of disassembly and assembly Note When removing the locking type connectors and board supporters disengage the locking mechanism first and then disconnect them Note 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 suppo
6. Interference due to high frequency The machine should NOT be used in the initiated or stabilized arc is almost invariably vicinity of blasting operations due to the traced to improper installation The following danger of premature tiring information is intended as a guide for personnel installing high frequency welding machines A WARNING Computers It is also possible that operation close to computer Installations cause computer malfunction 19 ARCMASTER 160TS 3 07 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 if the equipment is 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 is 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 minimize this type
7. Switch machine off then on to reset solenoid valve sequence Gas valve is faulty Have an Accredited Thermal Arc Service Agent repair or replace the gas valve Gas valve jammed open Have an Accredited Thermal Arc Service Agent repair or replace the gas valve POST FLOW control is set to Reduce POS7 FLOWtime 60 sec 6 The TIG electrode The Weld Process Mode Do not change Weld has been STICK HF TIG or LIFT TIG Process Mode before the contaminated due was changed before POST POST FLOW gas time had to the gas flow FLOW gas time had finished finished shutting off before the programmed POST FLOWtime has elapsed Table 8 3 continued Power Source Problems 45 ARCMASTER 160TS SECTION 9 VOLTAGE REDUCTION DEVICE VRD 9 01 VRD Specification ARC MASTER Description 160TS Notes 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 Table 9 1 VRD Specification 9 02 VRD Maintenance Routine inspection and testing power source An inspection of the power source should 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 o
8. 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 j Slowly turn the Control Knob clockwise to the maximum of the power supply then counter clockwise back to 1 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 k Place the power supply MAIN ON OFF SWITCH on the rear of the unit to the OFF position Remove the dead short between the OUTPUT TERMINALS 12 01 Maintenance List SECTION 12 MAINTENANCE ARCMASTER 160TS 2 3 4 REFERENCE NO DWG NO PARTS NAME PART NO PCB6 Q1A Printed Circuit Board WK 5460 aoc Primary IGBT 12 03 6 W7001516 2 PCBI Printed Circuit Board WK 5466 12 03 1 W7001403 3 iE Printed Circuit Board WK 5460 12 037 W7001516 4 PCB3 Printed Circuit Board WK 5609 12 03 3 17001520 5 PCB4 Printed Circuit Board WK 5449 12 03 4 W7001412 6 PCBS Printed Circuit Board WK 5448 12 03 5 W7001724 7 PCB2 Printed Circuit Board WK 5467 12 03 2 W7001405 74 ARCMASTER 160TS 3 4 REFERENCE NO
9. 0 10 1 45 10 6659 Outlet Gas gen 3 1 IPS E5A925600 with PC4 02 1 oo Qon S IP TES 2 47 10 6660 Output Terminal F gen 3 1 1PS_ TRAK BES5 70S_ 2 48 NA input Cable gen 8 1 1PS 13212 2S50WBLKW S T5P 1 49 W7001484 Clamp Input gen3 1 IPS_ SCLBI4A 1 50 W7001489 Heatsink gen 3 1 IPS E18834200 2 51 W7001490 Heatsink gen 3 1 IPS E1B83680 J1 52 W7001488 Insulated Board gen3 1 IPS E1B834100 1 2 53 10 6665 Knob gen 8 1 1PS 2621600 1 54 10 6666 3 1 1 5 3021104 1 55 W7001565 Cover Protector gen 3 1 IPS N1803640 J1 56 W7001493 Terminal Sheet gen 8 1 1PS ECA775700 OS 4 57 10 5069 5 gen 8 1 IPS E5A98700 1 1 0 0 0 1 58 7001496 Post 1 M4 M4 gen 3 1 IPS 59 W7001495 Post Output gen 3 1 IPS ECA790900 M8 MB 12 60 7001499 Bus Bar T Dt gen3 1 IPS ECA848700 1 1 1 0 0 1 61 W7001500 Bus Bar 2 T D gen3 1 IPS ECA848800 S1 62 W7001492 Bus Bar CTI gen 8 1 IPS ECA775600 0 1 63 W7001494 Bus Bar Output gen 8 1 IPS ECA788600 1 1 1 1 64 W70013 4 Clipgen3 1 IPS 74 NATURAL 4 65 W7001503 Chassis gen 3 1 IPS J4B983800 1 1 66 W7001487 Clip Spring IGBT gen 8 1
10. 20402 Recommended Safe Practices for the Preparation for Welding and Cutting of Containers That Have Held Hazardous Substances American Welding Society Standard AWSF4 1 obtainable from the American Welding Society 550 N W LeJeune Rd Miami FL 33126 National Electrical Code NFPA Standard 70 obtainable from the National Fire Protection Association Batterymarch Park Quincy MA 02269 Safe Handling of Compressed Gases in Cylinders CGA Pamphlet P 1 obtainable from the Compressed Gas Association 1235 Jefferson Davis Highway Suite 501 Arlington VA 22202 Code for Safety in Welding and Cutting CSA Standard W117 2 obtainable from the 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 787 1 obtainable from American National Standards Institute 1430 Broadway New York NY 10018 Cutting and Welding Processes NFPA Standard 51B obtainable from the National Fire Protection Association Batterymarch Park Quincy MA 02269 ARCMASTER 160TS 1 03 PRECAUTIONS DE SECURITE EN SOUNDAGE A L ARC Mans EN GARD 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 CONSE
11. 5460 and Q1A Q2C Primary IGBT a Remove the Side Panel See section 11 01 1 b Remove the four screws and two IGBT Spring Clips Remove the cables from edge holder 3 Disconnect the connector CN1 on the PCB6 Cut the lead of the Q1A Q2C Remember to install new Silicone Rubber Sheets where silicone compound Shinetsu Silicone G 747 or equivalent was spread when reinstalling the PCB6 Spread the silicone compound on IGBT 85 ARCMASTER 160TS 7 PCB7 WK 5460 and Q3A Q4C Primary IGBT a Remove the Side Panel See section 11 01 1 b Remove the four screws and two IGBT Spring Clips Remove the cables from edge holder In i TE C3 co in n C Disconnect the connector CN1 on the PCB6 Cut the lead of the Q3 Q4C Remember to install new Silicone Rubber Sheets where silicone compound Shinetsu Silicone G 747 or equivalent was spread when reinstalling the PCB7 Spread the silicone compound on IGBT 8 D2 and D3 Secondary Diode a Remove the Side Panel See section 11 01 1 b Remove PCB3 WK 5569 and T1 See section 12 03 3 c Remove six screws and then detach the D2 and D3 Do not have the wrong direction of the diodes when reinstalling Before installing a new diode apply a uniform coat of silicone compound Shinetsu Silicone G 747 or equivalent on the base Wy y J YY y yy Ul 86 ARCMASTER 160TS 9
12. HF UNIT1 and R6 on WK5609 PCB3 Its resistance can be measured across pins 1 and 3 of CN3 PCB3 WK5609 c Verify the connection between the terminals between AC1 AC2 TB1 TB2 0 Verify the connection between AC1 AC2 Verify that the quick disconnect terminals are inserted onto the terminals of HF UNIT1 correctly and completely L Verify there are no short circuits burnt or broken wires between AC1 and AC2 d Verify and replace the Gap GAP of the High Frequency Unit HF UNIT1 L1 Verify that the GAP is connected to HF UNIT correctly and completely C1 Verify there is no dust or foreign debris between the space of the GAP If there are any abnormalities observed with the GAP replace the GAP CO The gap is set to 1 0mm In the case of a gap 1 0mm or more high frequency voltage and period increases In the case of a gap 1 0mm or less high frequency voltage and period decreases Replace the High Frequency HF UNIT1 L1 Refer to section 12 03 12 f Replace PCB3 WK 5609 L1 Refer to section 12 03 3 62 ARCMASTER 160TS 11 04 Fault Isolation Tests 1 Preparation The following initial conditions must be met prior to starting any of the procedures in this section a Connect the appropriate input voltage Check the name plate on the rear of the power supply for the proper input voltage Note Operate at all input voltages as noted on the nameplate on the rear panel when testing the power sup
13. IPS E1B832400 4 67 W7001504 Chassis D1 gen 3 1 IPS JEA280400 1 68 W7001505 Chassis C1 gen 3 1 1PS JEA280000 1 1 1 1 69 W7001563 Support Board gen 3 1 IPS ECAZ74900 y 70 07001498 Cushion CT1 gen 8 1 1PS ECA793900 O 0 1 71 07001497 Cushion Dust gen 8 1 IPS ECA793800 1 0 1 0 1 72 017001485 Holder Edge gen 3 1 IPS EHMIU 3 73 10 6681 Hose Nylon gen 3 1 IPS 04258 Nylon Hose L 0 5m 74 300x4858 Operating Manual gen 3 1 IPS Operating Manual 16075 17 96 S q EU u i 7 B La v D S M 4 LAS 160TS PARTS LIST APPENDIX 2 CONNECTION WIRING GUIDE Destination Destination A PCB1 CN1 CON1 FAN1 B PCB1 CN2 5011 C PCB1 CN3 e PCB3 CN1 D PCB1 CN4 CT1 E PCB1 CN5 e TH1 F PCB1 CN6 o TH2 G PCB1 CN7 o PCB6 CN1 H PCB1 CN8 PCB7 CN1 PCB1 CN101 e 4 CN1 J PCB1 CN103 4 CN3 CN2 e HF UNIT L PCBS3 CN3 e HF UNIT 99 160TS CONNECTION WIRING GUIDE HF UNIT 100 ARCMASTER 160TS 2 Connection Wire List
14. SOL1 10 6645 Valve Solenoid gen 3 1 IPS 5505NBR1 5 DC24V 11VA 10W with Gas Inlet and PC4 02 SOLENOID VALVE W7001501 Transformer gen 3 1 IPS F3A013701 200A MTR TRANSFORMER TH2 10 5228 Thermistor gen 3 1 IPS ERTA53D203 20KQ 25 C B 3950K THERMISTOR 95 160TS PARTS LIST No DWGNo PartNo Description Additional Information QTY 30 7001458 Panel Front 3 1 1 5 EOD004501 1 0 1 31 07001459 Panel Rear gen 3 1 IPS EOD004601 1011 0 1 32 ____ 7001457 Label Side gen 8 1 IPS E0D004707 33 W7001460 Case Front Control gen 8 1 1PS E0C341900 S1 34 10 6653 jCover Protector gen 3 1 IPS E06303200 S1 35 10 6791 Cover Encoder gen 8 1 IPS EBAS14400 1 36 __ 06705 Cover PCB gen 3 1 IPS E1B550900 with Caution Label 1 37 017001566 Label Name gen 8 1 IPS N4A93260 2 38 107001512 Label Side gen 3 1 IPS N4A75100 2 39 07001508 Label 1 Warning gen 8 1 1PS N1B029500 1 40 W7001509 Label2Waming gen 8 1 1PS N1B029600 11 41 10 6732 Label Output gen 8 1 IPS N4A04000 J1 42 10 6733 Label Gas Input gen 3 1 IPS N4A040700 0 1 43 07001513 Label VRD gen3 1 IPS N4A918800 1 1 1 10 0 1 44 007001511 Labe VRD gen 8 1 IPS N4A598700 1
15. Thermistors TH1 TH2 Re install the harness with a secure connection 0 Contact the manufacturer if you find any broken connectors or damaged wiring harness b Replace thermistors TH1 TH2 O Refer to sections 12 16 and 12 17 c Replace PCB5 WK 5448 L Refer to section 12 03 5 5 E99 Initial Power Receiving Cause Occurs when the initial AC power received signal has not reached the CPU This error occurs normally during the power OFF sequence of the unit Verification Remedy a Verify the connection between terminal of Primary diode D1 and PCB1 WK 5466 L Verify that there is no omission of a loosening connected wire between the PCB1 and D1 L1 Contact the manufacturer if you find any broken connectors or damaged wire b Verify that there is no omission of a loosening screws and connected harness with PCB1 WK 5466 O Re install the harness with a secure connection L1 Contact the manufacturer if you find any broken connectors or damaged wiring harness 0 Replace PCB1 Refer to section 12 03 1 Replace PCB4 WK 5449 and PCB5 WK 5448 L Refer to section 12 03 4 12 03 5 for the replacement of PCB4 and PCB5 58 ARCMASTER 160TS 11 03 Verification and Remedy to Failures without Indication Codes Refer to Note on Section 11 02 1 Cooling Fan FAN1 Failure Fan is not rotating 2 Gas Valve Failure No Gas flow through unit Cause Cause Occurs
16. descriptions Figure 6 1 160TS Front Panel 1 Pulse function Pressing this button enables the TIG current pulse functions 2 Scroll Buttons used to select the parameter to be set The LED s show which function is being adjusted on the weld sequence graph 3 Digital LED display Welding amperage and parameter values are displayed in this window Internal warnings such as over temperature primary input current too high applied are signaled to the operator by a warning sound and error message on the screen 4 Control knob allows the operator to adjust the output amperage within the entire range of the power source also used in set each parameter value Pushing the knob inward displays the actual welding voltage 5 Process Button This button selects between STICK Lift or HF TIG mode 6 8 pin remote control receptacle for connecting remote device 7 TIG Mode Functions Pressing this button scrolls through the output TIG function modes Standard Slope Slope w repeat Spot 8 Save Load Button by using the Save amp Load buttons the operator can easily save up to 5 welding parameter program 32 ARCMASTER 160TS 6 01 Stick Welding L Connect work lead to negative terminal C Connect electrode lead to positive terminal Switch machine C Set weld current O Connect remote control device if required Use the Scroll Buttons to move to the parameter that needs to be set The LED will show which funct
17. if the condition of FAN1 is inactive Follow the instruction in section 12 03 11 L Refer to section 11 05 3 for addition tests 0 Refer to section 12 03 11 for the replacement of FAN1 d Replace PCB4 WK 5449 and PCB5 WK 5448 L Refer to section 12 03 4 replacement of PCB4 and PCB5 12 03 5 for the 57 2 E02 Over Temperature at the secondary side Cause Occurs when an over temperature condition of the secondary IGBT and diode are detected Verification Remedy a Unit may be in thermal shutdown mode L Review the rated duty cycle of the unit per section 3 08 Exceeding the duty cycle can damage the unit and void the warranty b Verify the ventilating condition O Maintain a clear and unobstructed distance of more than 12 in in the front and more that 20 in in the rear of the unit for ventilation purposes 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 FAN1 and replace it if necessary C1 Verify the condition of FAN1 Verify that there are no broken or cracked fan blades and that FAN1 is not producing any abnormal sounds L1 If broken or cracked FAN1 blades or abnormal sounds are emanating from FAN1 replace FAN1 L V
18. inside this activated 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 unauthorizedrepairs 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 Thefaulty subassembly should then be returned toThermal Arc through established procedures 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 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 52 ARCMASTER 160TS 1 Opening the Enclosure a Verify that the switch on the power supply and the switch on the switchboard distribution panel are all OFF E A T 48 O e Figure 11 1 Switch OFF CAUTION 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
19. is established the Power Source will maintain the initial current setting as long as the remote switch contacts are closed a In the HF TIG mode after Preflow time High Frequency is present at the torch When the torch is positioned close to the work the welding current will transfer to the work and establish the arc at the initial 2 Open Remote Switch current increases to weld current Once welding arc has reached weld current the power source will maintain weld current as long as the remote switch contacts are open Close Remote Switch Welding current decreases to final current setting Once final welding current is reached the power source will maintain final current setting as long as the remote switch contacts are closed current setting 4 Open Remote Switch Welding arc stops and b In the Lift TIG mode after Preflow time Lift post flow begins Start current is present at the torch When the electrode is touched to the work and lifted off the welding arc is established at the initial current setting 6 04 Slope Mode with repeat sequence The repeat function is operated during the down slope cycle of the Slope Sequence and is active through the down slope period only During the down slope period by opening the Remote Switch contacts the current will increase back to weld current Within the Down Slope period the repeat function can be operated as many times as desired To continue the slope cycle and
20. is sold to purchaser by unauthorized 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 Warranty repairs or replacement claims under this limited warranty must be submitted to Thermal Arc via an authorized Thermal Arc repair facility within thirty 30 days of purchaser s discovery of any defect Thermal Arc shall pay no transportation costs of any kind 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 dated April 1 2006 supersedes all previous Thermal Arc warranties Thermal Arc is a Registered Trademark of Thermal Arc Inc WARRANTY SCHEDULE This information applies to Thermal Arc products that were purchased in the USA and Canada April 2006 ENGINE DRIVEN WELDERS WARRANTY PERIOD LABOR Scout Raider Explorer Original Main Power Stators and Inductors 3 years Original Main Power Rectifiers Control P C Boards 3 years All other original circuits and components including but not limited to relays switches contactors solenoids fans power switch semi conductor
21. least 5 minutes for the discharge to complete b Remove all screws and nuts on the Side Panel aq 4 Figure 11 2 Remove screws 58 ARCMASTER 160TS c Loosen the screws on the Front Panel and the Rear Panel by turning them approximately two turns CCW Figure 11 3 Loosen screws Note DO NOT remove the screws completely d 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 Panel and Rear Panel Figure 11 4 Loosen Front Panel and Rear Panel 54 ARCMASTER 160TS e Remove the Side Panel Figure 11 5 Remove Side Panel f Remove PCB Cover sheet by removing the four clips Figure 11 6 Remove PCB Cover Note When you re assemble the parts conduct the above process backwards 55 ARCMASTER 160TS 11 02 Verification and Remedy to the Indicated Error Codes Note 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 section 11 01 1 Note During the Veritication Remedy procedures below follow the alphabetical sequence a D c an
22. manual including the chapter on safety instructions and warnings Throughout this manual the words WARNING CAUTION and NOTE may appear Pay particular attention to the information provided under these headings These special annotations are easily recognized as follows A WARNING A WARNING gives information regarding possible personal injury CAUTION A CAUTION refers to possible equipment damage NOTE A NOTE offers helpful information concerning certain operating procedures Additional copies of this manual may be purchased by contacting Thermal Arc at the address and phone number in your area listed in the inside back cover of this manual Include the Service Manual number and equipment identification numbers Electronic copies of this manual can also be downloaded at no charge in Acrobat PDF format by going to the Thermal Arc web site listed below and clicking on the Literature Library link http www thermalarc com ARCMASTER 160TS 2 02 Equipment Identification The unit s identification number specification or part number model and serial number usually appear on a nameplate attached to the control panel In some cases the nameplate may be attached to the rear panel Equipment which does not have a control panel such as gun and cable assemblies is identified only by the specification or part number printed on the shipping container Record these numbers on the bottom of page i for future reference
23. merchantability fitness for any particular purpose or other warranty of quality whether express implied or statutory Limitation of liability Thermal Arc shall not under any circumstances be liable for special indirect incidental or consequential damages including 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 respect 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 tort including negligence or strict liability or under any warranty or otherwise shall not 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 and Thermal Arc shall not be bound by any such attempt Correction of non conformities in the manner and time provided herein constitutes fulfillment of thermal s obligations to purchaser with respect to the product This warranty is void and seller bears no liability hereunder if purchaser used replacement parts or accessories which in Thermal Arc s sole judgment impaired the safety or performance of any Thermal Arc product Purchaser s rights under this warranty are void if the product
24. once the arc has extinguished This control is used to dramatically reduce oxidation of the tungsten electrode The SAVE LOAD buttons are used to save and retrieve a total number of 5 programs into the 16075 memory Table 4 3 Weld Parameter Descriptions for ARC MASTER 160TS 27 ARCMASTER 160TS Figure 4 4 ARC MASTER 160TS Front Panel with Parameter Description Parameter Description This parameter operates in STICK weld mode and is 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 A Weld Current Amperage sets the STICK and TIG WELD current D ARC CONTROL This parameter provides a suitable short circuit current in STICK welding to improve electrode sticking and arc stability L LIFT TIG mode of operation A remote control device may be used for use during LIFT TIG operation See section 4 01 section 2 Remote Control Socket for complete details of the remote device m STICK Mode of operation at Table 4 4 Weld Parameter Descriptions for ARC MASTER 160TS 28 ARCMASTER 160TS 4 04 Weld Parameters for ARC MASTER 160TS Weld Mode Weld Parameter Parameter Range Factory Setting Incremental Unit PRE FLOW 0 0 to 1 0 sec 0 sec HOT START 0 to 70A 20A INITIAL CUR 1 to 160A 30A UP SLOPE 0 to 15 sec 1 sec PEA
25. supply voltage Welding current reduces when welding No gas flow when the torch trigger switch is depressed A The Primary supply voltage has not been switched ON B The Welding Power Source switch is switched OFF Loose connections internally Defective control circuit Loose welding cable connections Incorrect welding cable size Improper input connections Poor electrode condition Wrong welding polarity Gas hose is cut Gas passage contains impurities Gas regulator turned off Torch trigger switch lead is disconnected or switch cable is faulty Table 8 3 Power Source Problems 44 A Switch ON the Primary supply voltage Switch ON the Welding Power Source Have an Accredited Thermal Arc Service Agent repair the connection Have an Accredited Thermal Arc Service Agent repair the connection Tighten all welding cable connections Use proper size and type of cable Refer to Section 2 05 Electrical Input Requirements D Replace electrode Verify output torch connections Replace gas hose Disconnect gas hose from the rear of Power Source then raise gas pressure and blow out impurities Turn gas regulator on Reconnect lead or repair faulty switch cable ARCMASTER 160TS Description Possible Cause 5 Gas flow won t shut Weld Mode 57D SLOPE A Strike an arc to complete the REPEAT or SPOT was weld cycle changed before POS7 FLOW OR gas time had finished
26. 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 adjacent areas Watch for fire and keep a fire extinguisher nearby Be aware that welding on a ceiling floor bulkhead or partition can cause fire on the hidden side Do not 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 Do not use welder to thaw frozen pipes Remove stick electrode from holder or cut off welding wire at contact tip when not in use mechanical shocks and arcs Install and secure cylinders in an upright position by chaining them to a stationary support or equipment cylinder rack to prevent falling or tipping Keep cylinders away from any welding or other electrical circuits Never allow a welding electrode to touch any cylinder 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 S
27. too high Lack of inter run fusion 7 Lack of side fusion scale Lack of Root Fusion dirt small electrode amperage too low Figure 8 2 Example of lack of fusion 42 ARCMASTER 160TS 5 Non metallic parti cles are trapped in the weld metal slag inclusion Non metallic particles may be trapped in undercut from previous run Joint preparation too restricted Irregular deposits allow slag to be trapped Lack of penetration with slag trapped beneath weld bead Rust or mill scale is preventing full fusion Wrong electrode for position in which welding is done 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 is done otherwise proper control of slag is difficult Table 8 2 continued STICK Welding Problems Not cleaned or incorrect electrode Slag trapped in undercut SS I Slag trapped in root Figure 8 3 Examples of slag inclusion 43 8 03 Power Source Problems ARCMASTER 160TS 1 The welding arc cannot be established Maximum output welding current can not be achieved with nominal Mains
28. unattended or out ELECTRIC SHOCK can kill 7 Use fully insulated electrode holders Never dip holder Touching live electrical parts can cause fatal shocks or in water to cool it or lay it down on the ground or the severe burns The electrode and work circuit is work surface Do not touch holders connected to two electrically live whenever the output is on The input welding machines at the same time or touch other power circuit and machine internal circuits are also people with the holder or electrode live when power is on In semiautomatic or automatic wire welding the wire wire reel drive roll housing 8 Do not use worn damaged undersize or poorly and all metal parts touching the welding wire are spliced cables electrically live Incorrectly installed or improperly grounded equipment is a hazard 9 Do not wrap cables around your body 1 Do not touch live electrical parts 10 Ground the workpiece to a good electrical earth round 2 Wear dry hole free insulating gloves and body ae protection 11 Do not touch electrode while in contact with the work round circuit 3 Insulate yourself from work and ground using dry 9 insulating mats or covers 12 Use only well maintained equipment Repair or replace damaged parts at once 4 Disconnect input power or stop engine before MR installing or servicing this equipment Lock input 13 power disconnect switch open or remove line fuses so power cannot be turned on
29. when the cooling fan FAN1 is defective damaged or the driving voltage is incorrect Verification Remedy a Verify the cooling fan FANT L 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 L Verify that there are no wiring harnesses entangled inside the fan Verify that the harnesses do not have any breaks in the wire or damaged connectors O Replace wiring harnesses if you find any broken connectors or damaged wiring harnesses L Replace the fan if there are any broken cracked or missing fan blades Refer to section 12 03 11 b Verify the wiring harness between the cooling fan FAN1 and CN2 on PCB1 WK 5466 L Verify a secure connection of the harness to CN2 on PCB1 c Verify the drive circuitry of the cooling fan FAN1 on 1 L Verify the drive circuitry of the cooling fan FAN1 on O Refer to section 11 05 3 L Replace PCB1 if necessary Refer to section 12 03 1 59 Occurs when the gas valve SOL1 is defective damaged or the driving voltage is incorrect Verification Remedy a Verify that TIG welding is selected on the welding mode Do not change welding modes while welding Only change welding modes when the u
30. 25 150mm 4005 Toutes conditions 12 me Soudage l arc avec plus de 6 po 150mm 5006 lectrode de carbone CAW Toutes conditions 12 Soudage auxgaz Soudage l arc Plasma PAW Toutes conditions 12 mince moins de 1 8 po 3mm 4005 Gougeage M lectrode de carbone moyen de 18 5 ou6 mince 3 12mm pais plus de 1 2 po 12mm 6 ou 8 pais 12 Soudage l arc avec lectrode enrobes monis de 5 32 po 4mm 10 Coupage l arc Plasma PAC 14 SMAW 5 32 1 4 po 4 6 4mm 12 mince monis de 300 amper s 9 plus de 1 4 po 6 4mm 14 moyen de 300 400 amper s 12 pais plus de 300 amper s 14 1 Eloignez la tete des fum es pour viter de les respirer 2 l int rieur assurez vous que l aire de soudage est bien ventil e ou que les fumees et les vapeurs sont aspir es l arc 3 Sila ventilation est inadequate portez un respirateur adduction d air approuv ARCMASTER 160TS 4 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 a 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 a la respiration Ne soudez pas proximit d op rations de d g
31. 51 Jalan Industri 3 5A Rawang Integrated Industrial Park JIn Batu Arang 48000 Rawang Selangor Darul Ehsan West Malaysia Telephone 603 6092 2988 Fax 603 6092 1085 Cigweld Australia T1 Gower Street Preston Victoria Australia 3072 Telephone 61 3 9474 7400 Fax 61 3 9474 7510 Thermadyne Italy OCIM S r L Via Benaco 3 20098 S Giuliano Milan Italy Tel 39 02 98 80320 Fax 39 02 98 281773 Thermadyne International 2070 Wyecroft Road Oakville Ontario Canada L6L5V6 Telephone 905 827 9777 Fax 905 827 9797 World Headquarters THERMAL Thermadyne Holdings Corporation IHERMAL RC Suite 300 16052 Swingley Ridge Road By THERMADYNE DK St Louis 63017 Telephone 636 728 3000 Fascimile 636 728 3010 Email sales thermalarc com www thermalarc com
32. 6 CN1 2 IGBT Gate signal G 101 ARCMASTER 160TS Connection Wire List continued ele le else 5 5 2 5 5 5 Device No SIGNAL NAME CN3 1 CN1 1 GND CN3 3 CN1 3 Short Detect signal CN3 5 CN1 5 12VDC CN3 6 CN1 6 HF signal CN2 1 HF UNIT AC2 HF Input Voltage CN3 3 HF UNIT AC1 HF Input Voltage CN1 2 CON1 2 Contactor Control 12V CN1 3 CON1 3 Contactor Control GND CN1 4 CON1 4 Panel Remote signal CN1 5 CON1 5 Potentiometer Max CN1 6 CON1 6 Potentiometer Min GND CN1 7 CON1 7 Potentiometer Wiper CN1 8 CON1 8 Panel Remote signal 102 APPENDIX C CONNECTION DIAGRAM ARCMASTER 160TS PCB6 IGBT Gate Circuit Board WK 5460 CN6 PCBI Control Source Circuit Board WK 5466 Front View je f i i 26115161718 Case Ground 2 Contactor Control 1 24VDC 3 Contactor Control 2 GND 4 12VDC Supply 5 Potentiometer Maximum 6 Potentiometer Minimum GND 7 Amperage Control Wiper0 10VDC 8 Remote Installed 12VDC 103 Main Circuit Board WK 5467 QIA 7 ta X QIB 1 A X 01 TR 02 mo c D e Cr mes TA o N S co gt m JN AS E c CCH DP o gt PCB7 IGBT Gate cool Circuit Board I WK 5460 r Q hh
33. 61 TLUS Fault IsOlation TESIS 2 aan e eter teen ene e E E Ete ete te eei 62 11 05 Verification of the Power Input Circuitry 63 1 Verification of the AC input voltage using an AC voltmeter sess 63 2 Verification of the Power Supply Voltage sssessseseeeeneneennn trennen nter ener 65 3 Verification of the Cooling Fan FAN1 Drive Circuitry 67 4 Verification of the Gas Valve SOL1 Drive Circuitry 68 5 Verification of the primary Diode D1 ss 69 6 Verification of the secondary Diode D2 03 70 7 Verification of the primary IGBT Q1A Q4C eee 71 8 Verification of No load Voltage OCV ss 72 9 Output Eoad T65t cote AEE AAAA UE UE 73 SECTION 12 aks e RUE Re 74 12 01 Maintenance List re RR ee hoes te ee ae deri ee Pede ni mets 74 12 02 Service TOOlS tr erre ip tert e satu PER de e ENTE RUE 77 120a Replacement Procedure niet tete te e EL ERU PUER een aces 78 1 PCB1 WK 5466 and Primary Diode D1 tnter ennt entren 78 2 PCB2 WK 5467 Capacitor C1 and Resistor
34. 8 2 ae S2 S Device No SIGNAL NAME CN103 1 CN3 1 GND CN103 2 CN3 2 Output Current Signal CN103 3 CN3 3 Output Voltage signal CN103 4 CN3 4 Torch Switch signal CN103 5 CN3 5 Panel Remote signal CN103 6 CN3 6 GND CN103 7 CN3 7 Potentiometer Max CN103 8 CN3 8 01 Potentiometer Wiper CN103 9 CN3 9 D1 G GND CN103 10 CN3 10 FAN FAN signal CN103 11 CN3 11 FAN GND CN103 12 CN3 12 SOL1 P Primary Current signal CN103 14 CN3 14 SOL1 N GND CN103 15 CN3 15 Pre start complete CN103 16 CN3 16 115V 230V detect signal CN103 17 CN3 17 Error signal CN103 19 CN3 19 Thermal Sensor CN103 20 CN3 20 Thermal Sensor CN103 21 CN3 21 Thermal Sensor2 CN103 22 CN3 22 Thermal Sensor2 CN103 24 CN3 24 HF signal CN103 25 CN3 25 Gas signal CN103 26 CN3 26 Short Detect signal CN101 1 CN1 1 12VDC CN101 2 CN1 2 5VDC CN101 3 CN1 3 12VDC CN101 4 CN1 4 GND CN101 5 CN1 5 IGBT Gate signal E CN101 6 CN1 6 IGBT Gate signal G CN101 7 CN1 7 GND CN4 1 HCT1 1 12VDC CN4 2 HCT1 2 12VDC CN4 3 HCT1 3 Current signal CN4 4 HCT1 4 GND CN5 1 Thermal Sensor CN5 2 Thermal Sensor CN6 1 Thermal Sensor2 CN6 3 Thermal Sensor2 CN2 1 FAN FAN CN2 2 FAN FAN CN2 3 SOL1 SOL1 P CN2 4 SOL1 SOL1 N CN7 1 CN1 1 IGBT Gate signal E CN7 2 CN1 2 IGBT Gate signal G CN7 5 CN1 5 IGBT Gate signal E CN7 6 CN1 6 IGBT Gate signal G CN8 1 CN1 5 IGBT Gate signal E CN8 2 CN1 6 IGBT Gate signal G CN8 5 CN1 1 IGBT Gate signal E CN8
35. C C Coupling Coil and FCH1 Reactor a Remove the Side Panel See section 11 01 1 b Remove the Gas Tube Remove the two bolts two toothed washers and the terminal d Remove the screw and then remove the cable Remove the two terminals from HF UNIT Remove the terminal from PCB3 87 ARCMASTER 160TS e Remove the C C and FCH1 10 CT1 Hole Current Trans a Remove the Side Panel See section 11 01 1 b Remove the bolts the spring and the washer Remove the three screws and then remove the Output Bus Bar c Remove the CT1 Disconnect the connector 88 ARCMASTER 160TS 11 FAN1 Cooling Fan a Remove the Side Panel See section 11 01 1 b Remove the Gas Tube Remove the two terminals and Cut the three snap bands 89 ARCMASTER 160TS e Remove the FAN1 Do not place the fan in the wrong direction when reinstalling 12 HF UNIT1 High Frequency Unit a Remove the Side Panel See section 11 01 1 b Remove the high frequency gap Remove the four terminals c Remove the two screws and the two washers Detach the HF UNIT1 13 SOL1 Solenoid GAS Valve a Remove the Side Panel See section 11 01 1 b Remove the Gas Tube and two terminals 90 ARCMASTER 160TS c Remove the C ring and then detach the SOL1 When reinstalling make sure that the C ring seats in the sol
36. IHERMAL ARC TS ARCMASTER INVERTER ARC WELDER E Service Manual Revision AB Issue Date June 16 2006 Manual No 0 4881B Operating Features x Exp pepe oc ec THERMAL A RC WE APPRECIATE YOUR BUSINESS Congratulations on your new Thermal Arc product We are proud to have you as our customer and will strive to provide you with the best service and reliability in the industry This product is backed by our extensive warranty and world wide service network To locate your nearest distributor or service agency call 800 752 7621 or visit us on the web at www thermalarc com This Operating Manual has been designed to instruct you on the correct use and operation of your Thermal Arc product Your satisfaction with this product and its safe operation is our ultimate concern Therefore please take the time to read the entire manual especially the Safety Precautions They will help you to avoid potential hazards that may exist when working with this product YOU ARE IN GOOD COMPANY The Brand of Choice for Contractors and Fabricators Worldwide Thermal Arc is a Global Brand of Arc Welding Products for Thermadyne Industries Inc We manufacture and supply to major welding industry sectors worldwide including Manufacturing Construction Mining Automotive Aerospace Engineering Rural and DIY Hobbyist We distinguish ourselves from our competition through market leading dependable products that have st
37. K CUR 1 to 160A 120A WELD CUR 1 to 160A 230V 1 to 85A 115V 80A 80A SPOT TIME 0 5 to 5 0 sec 2 sec PULSE WIDTH 15 to 80 50 PULSE FREQ 0 5 to 500Hz 100 0Hz See Table 4 6 DOWN SLOPE 0 to 25 sec 3 Sec 0 1 sec CRATER CUR 1 to 160A 30A 1A POST FLOW 0 0 to 60 sec 10 sec 0 1 sec Table 4 5 Weld Parameters for ARC MASTER 160TS Incremental Unit 0 1Hz 1Hz 5Hz PULSE FREQ Range 0 5 to 20Hz 20 to 100Hz 100 to 500Hz Table 4 6 PULSE FREQ Range and Incremental Units 29 ARCMASTER 160TS 4 05 Power Source Features Feature Description New Digital Control e Almost all welding parameters are adjustable Touch Panel Switches e Touch switches eliminate mechanical damage Front Control Cover e Protects front panel controls 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 Save Load Function e A total number of 5 programs can be saved into the 160TS memory SAVE the Current Weld Parameters into Memory e Press the SAVE button e Select a memory location by rotating the control knob 1 to 5 is displayed on the meter e After selecting the desired
38. Ne touchez pas des pi ces sous tension Portez des gants et des v tements isolants secs et non trou s Isolez vous de la pi ce souder et de la mise la terre au moyen de tapis isolants ou autres D connectez la prise d alimentation de l quipement ou arr tez le moteur avant de l installer ou d en faire corps N utilisez qu une bonne prise de masse pour la mise la terre de la pi ce souder Ne touchez pas l lectrode lorsqu en contact avec le circuit de soudage terre N utilisez que des quipements en bon tat R parez ou remplacez aussit t les pi ces endommag es Dans des espaces confin s ou mouilles n utilisez pas de source de courant alternatif moins qu il soit muni d un r ducteur de tension Utilisez plut t une source de courant continu 14 Portez un harnais de s curit si vous travaillez en hauteur 15 Fermez solidement tous les panneaux et les capots 9 __ X AVERTISSEMENT LE RAYONNEMENT DE L ARC PEUT BR LER LES YEUX ET LA PEAU LE BRUIT PEUT ENDOMMAGER L OUIEL Larc de soudage produit une chaleur et des rayons ultraviolets intenses susceptibles de br ler les yeux et la peau Le bruit caus par ARCMASTER 160TS yeux lorsque vous soudez ou que vous observez l ex cution d une soudure Portez des lunettes de s curit approuv es Des crans lat raux sont recommand s Entourez l aire de soudage de rideaux ou de cloisons pour pro
39. PMENT WARRANTY PERIOD Dragster 85 Original Main Power Magnetics Original Main Power Rectifiers Control P C Boards All other original circuits and components including but not limited to relays switches contactors solenoids fans power switch semi conductors 160S 300S 400S Original Main Power Magnetics Original Main Power Rectifiers Control P C Boards All other original circuits and components including but not limited to relays switches contactors solenoids fans power switch semi conductors GENERAL ARC EQUIPMENT LABOR Water Recirculators 1 year Plasma Welding Torches 180 days 180 days Gas Regulators Supplied with power sources 180 days Nil MIG and TIG Torches Supplied with power sources Nil Replacement repair parts Nil MIG TIG and Plasma welding torch consumable items i Nil IHERMAL ARC GLOBAL CUSTOMER SERVICE CONTACT INFORMATION Thermadyne USA 2800 Airport Road Denton Tx 76207 USA Telephone 940 566 2000 800 426 1888 Fax 800 535 0557 Email sales thermalarc com Thermadyne Canada 2070 Wyecroft Road Oakville Ontario Canada L6L5V6 Telephone 905 827 1111 Fax 905 827 3648 Thermadyne Europe Europe Building Chorley North Industrial Park Chorley Lancashire England PR6 7Bx Telephone 44 1257 261755 Fax 44 1257 224800 Thermadyne China RM 102A 685 Ding Xi Rd Chang Ning District Shanghai PR 200052 Telephone 86 21 69171135 Fax 86 21 69171139 Thermadyne Asia Sdn Bhd Lot 1
40. R1 trennen 81 3 PCB3 WK 5609 and T1 Transformer 82 A PCB4 WK5449 tt et edet cd M 83 52PCB5 WICb448 ic tenth he late eate 84 6 PCB6 WK 5460 and Q1A Q2C Primary IGBT 85 7 PCB7 WK 5460 and Q3A Q4C Primary IGBT sssseeseseeeeeen ener enne nnne 86 8 D2 and D3 Secondary Diode iii 86 9 Coupling Coil and FCH1 Reactor 160TS only 87 107 CT1 Hole Current Trans i rhet ert trece t tete ey e tnter ea 88 EAM s rer E pterea Bree dette p E E ORE ERN E ER REDE 89 12 HF UNIT1 High Frequency Unit 160TS only 90 13 SOL1 Solenoid GAS Valve 160TS only 90 91 15 CONTE Remote Recepten Ru RR ER RE n teed nies 92 16 CHI Primary PU OUT 93 T7 TH Secondary Thermmistor SE 93 APPENDIX A PARTSLIST tnnt bem booa a pne Ab Resto 95 APPENDIX B CONNECTION WIRING GUIDES rennen 100 TsConnectiondaulde aire et emat e ne t Rma piae t rA eR T e E RE ee 100 2 Connection Wire Listean oriei RE RE SER UR ERREUR NEG ERI EIU TR 101 APPENDIX C CONNECTION DIAGRAM 103 APPENDIX D DIODE TESTING BASICS E E SELA EE ETRA 105 ARCMASTER 160TS SECTION 1 SAFETY INSTRUCTIONS AND WARNINGS une PROTECT YOURSELF AND OTHER
41. RVEZ 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 meme 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 pratiques doivent 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 249 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 connaitre avant d utiliser cet quipement sont pr sent s la fin de ces instructions de s curit SEULES DES PERSONNES QUALIFIEES DOIVENT FAIRE DES TRAVAUX D INSTALLATION DE REPARTION D ENTRETIEN ET D ESSAI l entretien Bloquez le commutateur en circuit ouvert ou enlevez les fusibles de l alimentation afin d viter une mise en marche accidentelle 5 Veuillez installer cet quipement e
42. Reduce welding current metal Porosity Surface impurities such as Clean joint before welding oil grease paint etc Crack occurring in Rigidity of joint Redesign to relieve weld joint weld metal soon of severe stresses or use after solidification crack resistance electrodes commences Insufficient throat thickness Travel slightly slower to allow greater build up in throat Cooling rate is too high Preheat plate and cool slowly A gap is left by Welding current is too low Increase welding current failure of the weld Electrode too large for joint Use smaller diameter metal to fill the electrode root of the weld Insufficient gap Allow wider gap Incorrect sequence Use correct build up sequence Incorrect sequence Insufficient gap Figure 8 1 Example of insufficient gap or incorrect sequence 41 ARCMASTER 160TS 4 Portions of the weld A Small electrodes used on Use larger electrodes and pre run do not fuse to heavy cold plate heat the plate the surface ofthe B Welding current is too low Increase welding current metal or edge of the joint C Wrong electrode angle Adjust angle so the welding arc is directed more into the base metal D Travel speed of electrode is Reduce travel speed of too high electrode E Scale or dirt on joint surface Clean surface before welding Table 8 2 continued STICK Welding Problems Lack of fusion caused by dirt electrode angle incorrect rate of travel
43. S 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 property 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 Some of these practices apply to equipment CONNECTED TO POWER LINES other practices apply to engine driven equipment Anyone not having extensive training in welding and cutting practices should not attempt to weld Safe practices are outline in the American National Standard 249 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 1 01 Arc Welding Hazards 5 Properly install and ground this equipment according to its Owner s Manual and national state and local codes 6 Turn off all equipment when not in use Disconnect WARNING power to equipment if it will be left
44. accidentally In confined spaces or damp locations do not use a welder with AC output unless it is equipped with a voltage reducer Use equipment with DC output ARCMASTER 160TS 14 Wear a safety harness to prevent falling if working above fool level 15 Keep all panels and covers securely in place An 4s WARNING ARC RAYS can burn eyes and skin NOISE can damage hearing Arc rays from the welding process produce intense heat and strong ultraviolet rays that can eyes and skin Norse from some processes can damage hearing 9 OP WARNING FUMES AND GASES can be hazardous your health Welding produces fumes and gases Breathing these fumes and gases can be hazardous to your health 1 Keep your head out of the fumes Do not breath the fumes 2 lfinside ventilate the area and or use exhaust at the arc to remove welding fumes and gases If ventilation is poor use an approved air supplied 1 Wear a welding helmet fitted with a proper shade of filter see ANSI 749 1 listed in Safety Standards to protect your face and eyes when welding or watching recommended Wear approved safety glasses Side shields 3 Use protective screens or barriers to protect others from flash and flare warn others not to watch the arc respirator Read the Material Safety Data Sheets MSDSs and the manufacturer s instruction for metals consumables coatings and cleaners Work in a confined space only if it i
45. afety Standards ARCMASTER 160TS WARNING Engines can be dangerous 9 WARNING ENGINE EXHAUST GASES can kill Engines produce harmful exhaust gases 1 2 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 Hs t WARNING ENGINE FUEL can cause fire or explosion Engine fuse is highly flammable Stop engine before checking or adding fuel Do not add fuel while smoking or if unit is near any sparks or 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 stating engine 2 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 6 Reinstall panels or guards and close doors when servicing is finished and before starting engine
46. and 0 9 volts 6 To check the diode in the reverse bias Rev s Blas direction reverse the meter leads refer to Diode Not Conducting 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 Cathode If any diode in the module tests as faulty Figure D 2 Reverse bias diode tes replace the diode module Anode 8 Reconnect all cables to the proper terminals 105 LIMITED WARRANTY This information applies to Thermal Arc products that were purchased in the USA and Canada April 2006 LIMITED WARRANTY Thermal Arc Inc A Thermadyne Company Thermal Arc warrants to customers of authorized distributors Purchaser that its products will be free of defects in workmanship or material Should any failure to conform to this warranty appear within the warranty period 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 damage 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 This warranty is exclusive and in lieu of any warranty of
47. ce the unit Note This unit is equipped with a 250 VAC NEMA 6 50P plug molded on the two conductor with earth power cable that is connected at the welding power source for single phase electrical input power For direct wiring installation have a qualified person install according to all applicable codes and instructions for single and three 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 1 and 1 Connect end of ground GREEN conductor to a suitable ground Use a grounding method that complies with all applicable electrical codes Connect ends of line 1 BLACK and line 2 WHITE input conductors to a de energized line disconnect switch Use Table 1 and Table 2 as a guide to select line fuses for the disconnect switch Input Voltage Fuse Size 115V 75 Amps 230V 75 Amps Table 3 1 Electrical Input Connections Weiding Power Supply Ground Terminal Figure 3 1 m Note Fuse size is based on not more than 200 percent of the rated input amperage of the welding power source Based on Article 630 National Electrical Code 2 18 E 20 Ground Conductor Electrical Input Connections ARCMASTER 160TS 3 05 Input Power Each unit incorporates an INRUSH circuit and input voltage sensing circuit Whe
48. d ON check that it operates as per VRD Specifications on page 9 01 1 To turn VRD OFF rotate the trim potentiometer VR1 on the display PCB fully counter clockwise WARNING The VRD ON OFF trim potentiometer MUST ONLY be positioned fully clockwise OR fully counter clockwise as the VRD function will be unknown for every other position 49 1 E01 error code displayed Temperature sensor TH1 protects IGBTs is greater than 80 C for about 1 second E02 error code displayed Temperature sensor TH2 protects secondary diodes is greater than 80 C for about 1 second E03 error code displayed Primary Transformer current too high SECTION 10 POWER SOURCE ERROR CODE A The Welding Power Source s duty cycle has been exceeded B Fan ceases to operate Air flow is restricted by vents being blocked The Welding Power Source s duty cycle has been exceeded Fan ceases to operate Air flow is restricted by vents being blocked Primary Transformer current is too high because welding arc is too long Mains supply voltage is more than 1096 below nominal voltage A Let Power Source cool down then keep within its duty cycle Have an Accredited Thermal Arc Service Agent investigate Unblock vents then let Power Source cool down Let Power Source cool down then keep within its duty cycle Have an Accredited Thermal Arc Service Agent investigate Unblock vents then l
49. d proceed with your verification and confirmation Note After you Verify and replace all spare parts and components Verity that there are no damaged harnesses or connectors uninstalled or loose screws 56 ARCMASTER 160TS 1 E01 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 L Review the rated duty cycle of the unit per Exceeding the duty cycle can damage the unit and void the warranty Refer section 3 08 also to section 1 06 for additional information b Verify the ventilating condition L1 Maintain a clear and unobstructed distance of more than 12 in in the front and more that 20 in in the rear of the unit for ventilation purposes L 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 FAN1 and replace it if necessary Verify the condition of FAN1 Verify that there are no broken or cracked fan blades and that FAN1 is not producing abnormal sounds L1 If broken or cracked FAN1 blades or abnormal sounds are emanating from FAN1 replace FAN1 L Verify the operation of the cooling fan and replace it
50. e below Replace any defective components found 1 Secondary diode D2 D3 O Verification Refer to section 11 05 6 L Replacement Refer to section 12 03 8 2 Coupling coil C C and Reactor FCH1 L Replacement Refer to section 12 03 9 L Replacement FCH1 Refer to section 12 03 9 3 Transformer T1 L Replacement T1 Refer to section 12 03 3 4 Primary IGBT Q1A Q4C O Verification Refer to section 11 05 7 L Replacement Refer to section 12 03 6 12 03 7 5 Hall CT1 L Replacement CT1 Refer to section 12 03 10 ARCMASTER 160TS 4 Operating Panel Failure LED s do not light properly or welding setting cannot be established Cause Occurs when there is a connection failure among PCB1 WK 5466 PCB5 WK 5448 PCB6 WK 5449 and PCB1 or PCB5 or PCB6 are defective Verification Remedy a Verify the harness connection between CN101 on PCB1 WK 5466 and CN1 on PCB4 WK 5449 L Verify a secure connection of the harness and the connections between CN101 on PCB1 and CN1 on PCB5 L1 Contact the manufacturer if you find any broken connectors or damaged wiring harnesses b Verify the connection between PCB5 WK 5448 and PCB4 WK 5449 L Verify that there are no loose screws or harness connections between the PCB4 and PCB5 1 Replace PCB4 and 5 if necessary Refer to section 12 03 5 12 03 6 5 High Frequency Output Failure Unit does not generate High Frequ
51. e position filler rod in fillet joint 6 Electrode melts A Electrode is connected to the Connect the electrode to the when arc is struck terminal terminal B WAVE BALANCE is greater B Reduced WAVE BALANCE to than 50 below 50 or increase the electrode size 7 Dirty weld pool A Electrode contaminated Clean the electrode by through contact with work grinding off the contaminates piece or filler rod material Gas contaminated with air Check gas lines for cuts and loose fitting or change gas cylinder 8 Electrode melts or A No gas flowing to welding Check the gas lines for kinks oxidizes when an region or breaks and gas cylinder arc is struck contents Torch is clogged with dust B Clean torch Gas hose is cut C Replace gas hose Gas passage contains D Disconnect gas hose from impurities torch then raise gas pressure and blow out impurities Gas regulator turned off Turn on Torch valve is turned off F Turn on The electrode is too small for G Increase electrode diameter the welding current or reduce the welding current WAVE BALANCE is set above Reduced WAVE BALANCE to 50 below 50 or increase the electrode size 9 Poor weld finish Inadequate shielding gas Increase gas flow or check gas line for gas flow problems 10 Arc flutters during A Tungsten electrode is too Select the right size electrode TIG welding large for the welding current Refer to Basic TIG Welding guide Abse
52. ence ACCEPTABLE PCB1 PCB1 VALUE Pin 1 on CN2 Pin 2 on CN2 24VDC Table 11 2 Checkpoints CN2 on PCB1 C If any of these voltages are not present or are below a 10 tolerance replace the PCB1 WK 5466 Refer to section 12 03 1 66 ARCMASTER 160TS 3 Verification of the Cooling Fan FAN1 Drive Circuitry CAUTION Before performing any portion of the procedure below make certain the unit is placed in the Initial set up condition as described in section 77 04 1 Preparation a Verify the condition of the cooling fan FAN1 using a DC voltmeter The capability of the voltmeter should be more than 50VDC Using a DC voltmeter measure between PIN 1 Positive and PIN 2 Negative of CN11 on PCB1 WK 5466 The location of connector CN2 of PCB3 is indicated in Figure 11 12 When you measure the above voltage do not remove the connector Conduct the measurement while the connector plug and receptacle are still connected Rss Figure 11 12 Verification of the FAN1 b Using the measurement taken above follow the chart below for possible failure modes Voltage measurement m DC 18 25V drive circuit is normal Replace PCB1 Case 2 2 Below DC 18V Refer to section 12 021 Replace PCB1 Refer to section 12 03 1 aes aede FROM DETON Perform Verification of the Power Supply Voltage Refer to section 11 05 2 Replace the FAN1 Refer to section 12 03 11 Table 11 3 Ve
53. ency Cause Occurs when the High Frequency unit HF UNIT1 is defective or blown Verification Remedy Caution Read and understand this entire section before proceeding Extreme personal harm and test equipment damage will occur if the procedures are not performed accurately The unit will generate a High Voltage component that can cause extreme personal harm and test equipment damage Capacitors installed inside the Welding Power Source are electrically charged for a while after the Mains ON OFF switch or distribution panel switch has been turned off Before inspecting the inside of the Welding Power Source leave it for about 5 min after switching off power for discharging the capacitors and then remove the top and side panels a Verify the connection between High Frequency Unit HF UNIT1 and Coupling Coil C C L Verify the connection between the HF UNIT1 and C C Verify that the quick disconnect terminals are inserted onto the terminals of HF UNIT1 TB5 TB6 correctly and completely L Verify there are no short circuits burnt or broken wires at C C 0 Replace C C Refer to section 12 03 9 b Verify the connection between High Frequency Unit HF UNIT1 and the current limiting resistor R6 on WK5609 PCB3 L Verify that the quick disconnect terminals are inserted onto the terminals of HF UNIT1 TB3 TB4 correctly and completely L Verify there are no short circuits burnt or broken wires between the
54. end the slope sequence close the remote switch contacts and allow the weld current to reach the final current setting Once the final current setting is reached opening the Remote Switch again will turn off the welding arc and post flow begins 34 ARCMASTER 160TS 6 05 Pulse Controls Pulse Width Peak Current Base Background Current The Pulse controls are used primarily to control heat input Pulse offers a number of advantages as follows 1 Control puddle size and fluidity especially out of position 2 Increase penetration 3 Travel speed control 4 Better consistent quality 5 Decreased distortion on lighter or thinner materials Pulse current provides a system in which the welding current continuously changes between two levels During the periods of Peak current heating and fusion takes place and during the background base current periods cooling and solidification take place Pulse Width is the time in one cycle the Current remains at the peak current setting Pulse Frequency measured in Hertz is the number of cycles per second the current travels between peak and background current settings It is as if the foot rheostat were moved up and down to increase and decrease the welding current on a regular basis The faster you move the foot rheostat up and down the faster the frequency 35 ARCMASTER 160TS SECTION 7 ROUTINE MAINTENANCE The only routine maintenance required for the power s
55. endies et gardez un extincteur port e de la main 10 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 possible de la zone de soudage pour emp cher le courant de suivre un long parcours inconnu et pr venir ainsi les risques d lectrocution 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 An gt 2 AVERTISSEMENT LES ETINCELLES ET LES PROJECTIONS BRULANTES PEUVENT CAUSER DES BLESSURES Le piquage et le meulage produisent des particules m talliques volantes En refro dissant la soudure peut projeter du clats de laitier Portez un cran facial ou des lunettes protectrices approuv es Des crans lat raux sont recommand s Portez des v tements appropri s pour prot ger la peau SJ e AVERTISSEMENT LES BOUTEILLES ENDOMMAGEES PEUVENT EXPLOSER Les bouteilles contiennent des gaz protecteurs sous haute pression Des bouteilles endommag es peuvent exploser Comme les bouteilles font normalement partie du proc d de
56. enoid valve groove 14 S1 Switch a Remove the Side Panel See section 11 01 1 b Remove the four screws and the four cables 91 ARCMASTER 160TS 15 CON1 Remote Receptacle a Remove the Side Panel See section 11 01 1 b Remove the screw and then three ground cables Cut the two snap bands 92 ARCMASTER 160TS 16 TH1 Primary Thermistor a Remove the Side Panel See section 11 01 1 b Remove the snap band Disconnect the connector CN5 on the PCB1 Remove the screw and then detach the TH1 Before installing a new Thermistor apply a uniform coat of silicone compound Shinetsu Silicone G 747 or equivalent on the base 17 TH2 Secondary Thermistor a Remove the Side Panel See section 11 01 1 b Remove PCB3 unit See section 12 03 3 Cut the three snap bands Disconnect the connector CN6 on the PCB1 Remove the screw and then detach the TH1 Before installing a new Thermistor apply a uniform coat of silicone compound Shinetsu Silicone G 747 or equivalent on the base ozs 1 SESS 93 ARCMASTER 160TS APPENDIX A PARTS LIST 1 Equipment Identification All identification numbers as described in the Introduction chapter must be furnished when ordering parts or making inquiries This information is usually found on the nameplate attached to the equipment Be sure to include any dash numbers f
57. erify the operation of the cooling fan and replace it if the condition of FAN1 is inactive Follow the instruction in section 12 03 11 L Refer to section 11 05 3 for additional FAN1 tests 1 Refer to section 12 03 11 for the replacement of d Replace PCB4 WK 5449 5 WK 5448 L Refer to section 12 03 4 12 03 5 for the replacement of PCB4 and PCB5 3 E03 Primary Over Current Failure Cause Occurs when excessive current is detected flowing into the primary side of the main transformer Verification Remedy a Verify the operation of the machine within the rated specification L Refer to the specification data sheet in Section 3 09 b Verify the secondary diode D2 and D3 1 Refer to section 11 05 6 for the test of D2 and D3 L Refer to section 12 03 8 for the replacement of D2 and D3 Verify the H F unit HF UNIT1 only L Refer to section 12 03 12 for the replacement of HF UNIT 1 d Replace the Hall CT CT1 Note Pay special attention to installed direction of CT1 The Hall CT will not function properly if installed in the incorrect direction 1 Refer to section 12 03 10 for the replacement of CTI 4 E94 Thermistor malfunction Cause Thermistors for detecting temperature of internal components have malfunctioned ARCMASTER 160TS Verification Remedy a Verify a secure connection of the harness wired between CN5 6 on PCB1 WK 5466 and
58. et Power Source cool down Reduce length of welding arc Have an Accredited Thermal Arc Service Agent or a qualified electrician check for low Mains voltage Table 10 3 Power Source Error Codes 50 ARCMASTER 160TS Weld current ceases Buzzer sounds constantly Fan operates at max speed E01 resets when TH1 decreases to 70 C for about 30 seconds Weld current ceases Buzzer sounds constantly Fan operates at max speed E02 resets when TH2 decreases to 70 C for about 30 seconds Weld current ceases Buzzer sounds constantly Switch machine off then on to reset E03 error ARCMASTER 160TS 4 E94 error code The Welding Power Have an Accredited Weld current ceases displayed Source s Thermal Arc Service Buzzer sounds Temperature sensor temperature sensors Agent check or constantly TH1 for IGBTs or have malfunctioned replace the Switch machine off sensor TH2 for temperature sensors secondary diodes are open circuit E99 error code Main on off switch Turn on off switch Weld current ceases displayed on machine has been on Buzzer sounds Mains supply input turned off Have an Accredited constantly voltage has been Th Arc Servi Mains supply input ermal Arc oervice turned off but pply input Agent ora control circuit has dia 6s is electrician check the power from the bod Mains voltage and primary capacitors fuses i Must switch machine off then on to reset E99 erro
59. ety and Health Standards OSHA 29CFR 1910 SAFETY AND HEALTH STANDARDS obtainable from Superintendent of Documents U S Government Printing Office Washington D C 20402 Recommended Safe Practices for the Preparation for Welding and Cutting of Containers That Have Held Hazardous Substances American Welding Society Standard AWSF4 1 obtainable from the American Welding Society 550 N W LeJeune Rd Miami FL 33126 National Electrical Code NFPA Standard 70 obtainable from the National Fire Protection Association Batterymarch Park Quincy MA 02269 Safe Handling of Compressed Gases in Cylinders CGA Pamphlet P 1 obtainable from the Compressed Gas Association 1235 Jefferson Davis Highway Suite 501 Arlington VA 22202 Code for Safety in Welding and Cutting CSA Standard W117 2 obtainable from the 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 obtainable from American National Standards Institute 1430 Broadway New York NY 10018 Cutting and Welding Processes NFPA Standard 51B obtainable from the National Fire Protection Association Batterymarch Park Quincy MA 02269 SECTION 2 INTRODUCTION 2 01 How To Use This Manual This Service Manual applies to just specification or part numbers listed on page i To ensure safe operation read the entire
60. f the equipment shall keeo a suitable record of the periodic tests Note 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 tests should also be conducted by an accredited Thermal Arc service agent Description IEC 60974 1 Requirements VRD Open Circuit Voltage Less than 20V at Vin 230V VRD Turn ON Resistance Less than 200 ohms VRD Turn OFF Time Less than 0 3 seconds Table 9 2 Periodic Tests If this equipment is used in a location or an environment with a high risk of electrocution then the above tests should be carried out prior to entering this location The VRD test is shown below 1 In STICK welding mode mark and then turn potentiometer VR1 on PCB4 WK 5449 fully clockwise and turn on the electric shock protector function Voltage Reduction Device VRD 46 ARCMASTER 160TS 2 Verify the no load voltage OCV using a DC voltmeter The capability of the voltmeter should be more than 100VDC 3 The normal no load voltage is approximately 18V 4 In STICK welding mode mark and then turn potentiometer VR1 on PCB4 WK 5449 fully clockwise and turn off the VRD 5 Contactor function is put into the state of ON by pushing the Function button Refer to section 6 WARNING Electric
61. fore moving the welding power source WARNING FALLING EQUIPMENT can cause serious personal injury and equipment damage O Lift unit with handle on top of case O Use handcart or similar device of adequate capacity O f using a fork lift vehicle place and secure unit on a proper skid before transporting 16 SECTION 3 INSTALLATION 3 01 Environment The ARC MASTER 160TS is designed for use in adverse environments Examples of environments with increased adverse conditions are In locations in which freedom of movement is restricted so that the operator is forced to perform the work in a cramped kneeling sitting or lying position with physical contact with conductive parts b In locations which are fully or partially limited by conductive elements and in which there is a high risk of unavoidable or accidental contact by the operator or c In wet or damp hot locations where humidity or perspiration considerably reduces the skin resistance of the human body and the insulation 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 In areas free from moisture and dust Ambient temperature between 0 degrees C to 40 degrees C In areas free from oil stea
62. hase Date Equipment Serial CONTENTS SECTION 1 SAFETY INSTRUCTIONS AND WARNINGS entente 3 1 01 Arc Welding Hazards ri te e Aetna ote het rcd te a 3 1 02 PRINCIPAL SAFETY STANDARDS 4 rcr tn ttti trie m orte reete 7 1 03 PRECAUTIONS DE SECURITE EN SOUNDAGE A LARG un 8 1 04 Dangers relatifs au soudage l arc entente ss 8 1 05 PRINCIPAL SAFETY STANDARDS rente p iie el e e e ied 12 SECTION 2 INTRODUCTION ie 13 2 01 How To Use ThIs Manilal i5 5 nia E p a n e prie iE a e ri e e s 13 2 02 Equipment IdentifiCatlon eec tee tete erre be a b ec re Lote e Pres 13 2 04 Symbol Gllakt sur en ate dave e WIR REOR RE 14 2 05 Description ehe aep ete pet 15 2 06 Functiorial Block Dl grams c eer eee Reeder 16 207 Fransporting Methods ui ERR t ete re ee a e te i em E 16 SEGTION SS INSTALLATION trt tm a te the t e t de 17 3 0 T EnVIROTWTIG TTE 2 trie eh et mand re e tht eerte et Ci ret eerte eir tede od 17 SAEPE 17 3 03 Electrical Input Connections sin 17 3 04 Electrical Input Requirement ss 18 3 05InpUtiPOWOE s esset iet ee tant tnit mate tet tte ord 19 3 06 High Frequency Introduction ss 19 3 07 High Frequency Interference ss 20 3 09 Duty CyCl8 eese tee ei IBI b eB ED 20 3 09 S peCIfICatlOl
63. ications 46 9 02 VRD Malnternari6e aea enm bea RT RUNS 46 9 03 Switching VRD On Off issus 49 SECTION 10 POWER SOURCE ERROR CODE sise 50 CONTENTS SECTION 11 ADVANCED TROUBLE SHOOTING esses ener nennen eesse 52 11 01 System Level Fault Isolation sess en nnn tenent trt 52 Ty Opening thie Enclos Ee usce Lir r a oriente ten in eee 53 11 02 Verification and Remedy to the Indicated Error Codes sse 56 1 E01 Over Temperature at the primary side 57 2 E02 Over Temperature at the secondary side 57 3 E03 Primary Over Current Failure siens 58 4 E94 Thermistor malfunction sien 58 5 E99 Initial PowerRecelvilig ue tede re esr irte eee aab ava ee ie OH 58 11 03 Verification and Remedy to Failures without Indication Codes sse 59 1 Cooling Fan FAN1 Failure Fan is not rotating nnns 59 2 Gas Valve Failure No Gas flow through unit 59 3 NO Weld OUtput rto etre to eR ROUES FR RA URB EENEDD 60 4 Operating Panel Failure LED s do not light properly or welding setting cannot be established 61 5 High Frequency Output Failure Unit does not generate High
64. ion is being adjusted on the weld sequence graph Use the control knob to adjust each parameter Set HOT START Set WELD current Commence welding 6 02 HF TIG amp Lift TIG Welding C Connect work lead to positive terminal L Connect TIG torch to negative terminal O Switch machine O Set WELD current Connect remote control device A remote control device is required for use during LIFT TIG and HF TIG operation See section 4 1 section 2 Remote Control Sockel 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 is being adjusted on the weld sequence graph Use the control knob to adjust each parameter O Set PRE FLOWtime Set HOT START current Set POST FLOWtime O Set WELD current O Set POST FLOWtime Slope Mode Parameters if required Set 7 4 CUR current O Set UP SLOPEtime 0 Set WELD PEAK CUR current Set BASE current CO Set DOWN SLOPEtime Set CRATER CUR current Pulse Mode parameters if required C Set PULSE WIDTH for PEAK CURRENT 0 Set PEAK CURRENT Set PULSE FREQ Commence welding 38 ARCMASTER 160TS Switch Open 6 03 Slope Mode Sequence Switch Switch Switch Closed Open Closed Up Weld Current Down Tidal oes Current iu Final Current Postflow Figure 6 3 Slope Mode Sequence To start the Slope sequence close the remote switch contacts Once the welding arc
65. is connected OV Table 4 1 Socket Pin Functions ARCMASTER 160TS 3 Positive Terminal Welding current flows from the Power Source via heavy duty Dinse type terminal Size 25mm Dinse It is essential however that the male plug is inserted and turned securely to achieve a sound electrical connection A Negative Terminal Welding current flows from the Power Source via heavy duty Dinse type terminal Size 25mm Dinse Itis essential however that the male plug is inserted and turned securely to achieve a sound electrical connection CAUTION Loose welding terminal connections can cause overheating and result in the male plug being fused in the bayonet terminal 5 Gas Outlet The Gas Outlet is a 5 8 18 UNF female gas fitting 6 ON OFF Switch This switch connects the Primary supply voltage to the inverter when in the ON position This enables the Power Supply A WARNING When the welder is connected to the Primary Supply voltage the internal electrical components may be at 240V potential with respect to earth 7 Input Cable The input cable connects the Primary supply voltage to the equipment 8 Gas Inlet The Gas Inlet is a 5 8 18 UNF female gas fitting 24 ARCMASTER 160TS 4 02 Weld Process selection for 160TS Weld Mode Weld Process Selection Description 2T operation in TIG Modes using remote devices to control contactor amp current AT operation in TIG Modes with crater fill
66. ition as described insection 77 04 1 Preparation a Check whether there are any abnormalities on the appearance of PCB6 and PCB7 b Verify the characteristic of the primary IGBT Q1A Q4C using a diode tester Refer to Table 11 7 and Figure 11 16 for the checkpoints on PCB6 and PCB7 COMPONENT TERMINALS ACCEPTABLE TESTED E lead VALUE Collector Emitter of Q1A Open Q2C with PCB6 0 2 to 0 5V Collector Emitter of Q3A o Open Q4C with PCB7 GE 0 2 to O 5V Table 11 7 wails checkpoints for 1 04 LJ il 2 p Figure 11 16 Tester checkpoints for Q1A Q4C 71 ARCMASTER 160TS 8 Verification of No load Voltage OCV 1 When in HF TIG mode the unit will generate high voltage To prevent CAUTION personal harm and test equipment damage mark and then remove the indicated wire from the HF UNIT1 shown in Figure 11 17 To prevent electric shock always wrap the removed wire with electrical tape or other suitable insulation Before performing any portion of the procedure below make certain the unit is placed in the initial set up condition as described in section 11 04 1 Preparation a Verify the no load voltage in STICK mode 1 In STICK welding mode mark and then turn potentiometer VR1 on PCB4 WK 5449 fully counter clockwise to turn off the electric shock protector function Voltage Reduction Device VRD Refer to section 9 02 Figure 11 17 Removal and insta
67. lS 255 nae aan pma as 21 SEGTION 4 OPERATOR CONTROLS i 4 ee tee retten tre rites ra ta teta eth ie Sah des 23 4 01 ARC MASTER 160TS Controls tnter 23 4 02 Weld Process selection for 160TS uns 25 4 03 Weld Parameter Descriptions for ARC MASTER 16075 essent 26 4 04 Weld Parameters for ARC MASTER 1607S 00 ccc cccscsesecescscsessescscsesscseseseseesessssescsesasseeesecsesessesesesecseseeseees 29 4 05 Power Source Features isa ere ott rte cited a ente eet merde d 30 SECTION 5 SET UP FOR SMAW STICK AND TIG enne 31 SECTION 6 SEQUENCE OF OPERATION inner 32 601 SLICK Weldirig a em tom E meon e AUS 33 6 02 HF TIG amp Lift TIG Welding sis 33 6 03 Slope M de Sequences eate tede en ohm t radit 34 6 04 Slope Mode with repeat sequence nn 34 6 05 Pulse Controls is sn e tribe ete RR HIIS ERU 35 SEGTION 7 ROUTINE MAINTENANGE 4 tt th eee n et metr rete i aed 36 SECTION 8 BASIC TROUBLESHOOTING eene tenente tenens 38 8 01 TlG Welding Problems ient tre eee eR Re RERO ND RE ERAT RENE A EEE 38 8 02 Stick Weldirig Problams cni serment ne a tr E pete ERI Ced 41 8 09 Power Source Problems iret eer ra b itte rv eed b etn tbi e 44 SECTION 9 VOLTAGE REDUCTION DEVICE VRD s 46 9 01 VRD Specif
68. leased after it has been depressed This parameter operates in TIG modes only and is used to set the time for the weld current to ramp up after the torch trigger switch has been pressed then released from INITIAL CUR to PEAK or BASE current This parameter sets the PEAK weld current when in PULSE mode This parameter sets the TIG WELD current in 72 SLOPE REPEAT and SPOT modes when PULSE is off This parameter also sets the STICK weld current This parameter sets the Background current when in Pulse TIG mode This parameter sets the duration of the SPOT 7 MEin HF TIG mode only This parameter sets the percentage on time of the PULSE FREQUENCY for PEAK weld current when the PU S is on This parameter sets the PULSE FREQUENCY when the PULSE is on 26 ARCMASTER 160TS Parameter DOWN SLOPE CRATER CUR POST FLOW p 12 SAUVEGARDER CHARGER Description This parameter operates in TIG modes only and is used to set the time for the weld current to ramp down after the torch trigger switch has been pressed to CRATER CUR This control is used to eliminate the crater that can form at the completion of a weld This parameter operates in SLOPE or REPEAT AT TIG modes only and is used to set the finish current for TIG The CRATER Current remains on until the torch trigger switch is released after it has been depressed This parameter operates in TIG modes only and is used to adjust the post gas flow time
69. llation from the A HF UNIT1 WARNING To disable the operation of the HF unit Flectric shock hazard The unit will generate OCV immediately when 2 Press the Welding mode selection Process mode is put into the state of button to select HF TIG welding mode ON pushing Process button enabling STICK mode 3 While depressing the Torch switch verify the OCV using a DC voltmeter The capability of the voltmeter should 2 Verify the no load voltage using a DC lc more than 100VDC The check point voltmeter The capability of the with a tester is the voltage between voltmeter should be more than 100VDC output terminal and In TIG mode the OCV ceases 3 seconds after you depress 3 The normal no load voltage is ihe torch Switch approximately 65V 4 The normal no load voltage is b Verify the no load voltage OCV in High approximately 65V Frequency TIG mode 5 Return the setting variable resister VR1 A to the original position Return to the WARNING position recorded by a 1 clause This welding mode produces high L1 Fully clockwise VRD ON frequency and high voltage Extra care Fully counter clockwise VRD OFF Shall be taken fo prevent electric shock 6 Return connection with HF UNIT1 to the original position 72 ARCMASTER 160TS 9 Output Load Test This test verifies that the output current amperage controls are functioning properly A clamp type amperage meter or equivalent mete
70. m and corrosive gases In areas not subjected to abnormal vibration or shock In areas not exposed to direct sunlight or rain ARCMASTER 160TS Place at a distance of 12 304 79mm or more from walls or similar boundaries that could restrict natural airflow for cooling WARNING Thermal Arc advises that this equipment be electrically connected by a qualified electrician 3 03 Electrical Input Connections WARNING ELECTRIC SHOCK can kill SIGNIFICANT DC VOLTAGE is present after removal of input power DO NOT TOUCH live electrical parts SHUT DOWN welding power source disconnect input power employing lockout tagging procedures Lockout tagging procedures consist of padlocking line disconnect switch in open position removing fuses from fuse box or shutting off and red tagging circuit breaker or other disconnecting device ARCMASTER 160TS 3 04 Electrical Input Requirement Operate the welding power source from a single phase 50 60 Hz AC power supply The input voltage must match one 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 any 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 servi
71. memory location ie 1 to 5 press the right scroll button and the machine will give a beep to verify the weld parameters from the control panel are saved LOAD retrieve a Program to Control Panel e Press the LOAD button e Select a memory location by rotating the control knob 1 to 5 is displayed on the meter e After selecting the desired memory location ie 1 to 5 press the right scroll button and the machine will give a beep to verify the weld parameters from the weld parameters are loaded Voltage Reduction Device Reduces the OCV when the power supply is not in use Eliminates the VRD 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 counter clockwise decreases the parameter e A selected weld parameter value can be adjusted at any time even while welding e Pushing the knob in displays actual arc voltage Self Diagnosis Using Error An error code is displayed on the Digital Meterwhen a problem Codes occurs with Primary supply voltage or internal component problems Refer to troubleshooting guide Table 4 7 Power Source Features 30 ARCMASTER 160TS SECTION 5 SET UP FOR SMAW STICK AND GTAW TIG Conventi
72. n 12 03 6 12 03 7 d Remove the screw and the cable 81 ARCMASTER 160TS f Remove the screw and Remove the Capacitor C1 and Resistor R1 from the PCB2 Remove the two edge holders and the PCB2 Insulation Sheet from PCB2 3 PCB3 WK 5609 and T1 Transformer a Remove the Side Panel See section 11 01 1 b Remove the CT1 See section 12 03 10 Cut the snap band and Remove the cables Disconnect the three connectors CN1 3 on the PCB3 Remove the three screws and the three cables Remove the terminal d Remove the 11 screws and PCB3 unit Take note of the shape of the screw when you replace PCB3 82 ARCMASTER 160TS e Remove the two tap of T1 with the soldering iron from the PCB3 Remove the T D Bus Barl and the T D Bus Bar2 Open the tap of T1 and Remove the four screws Remove the T1 from the PCB3 4 PCB4 WK 5449 a Remove the Side Panel See section 11 01 1 b Remove the Protection Cover 83 ARCMASTER 160TS d Disconnect the two connectors CN1 3 on the PCB4 Remove the four screws Pull out the Operation panel and bring it down 5 PCB5 WK 5448 a Remove the Side Panel See section 11 01 1 b Remove the PCB4 See section 12 03 4 c Remove the three latches of Front Control Cover and then remove the PCB5 84 ARCMASTER 160TS When reinstalling the PCB5 engage two latches of Front Control Cover first 6 PCB6 WK
73. n coated metals such as galvanized lead or cadmium plated steel unless the coating is removed from the weld area the area is well ventilated and if necessary while wearing an air supplied respirator The coatings and any metals containing these elements can give off toxic fumes if welded YN c N Hab WARNING WELDING can cause fire or explosion Sparks and spatter fly off from the welding arc The flying sparks and hot metalweld 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 ARCMASTER 160TS An a WARNING FLYING SPARKS AND HOT METAL can cause injury V Chipping and grinding cause flying metal As weld cool they can throw off slag 1 Wear approved face shield or safety goggles Side shields recommended 2 Wear proper body protection to protect skin 2 7 PT WARNING CYLINDERS can explode if damaged Shielding gas cylinders contain gas under high pressure If damaged a cylinder can explode Since gas cylinders are normally part of the welding process be sure to treat them carefully 1 Protect compressed gas cylinders from excessive heat 10 Protect yourself and others from flying sparks and hot metal Do not weld where flying sparks can strike flammable material Remove all flammables within 35 ft 10 7m of the welding arc If this is not possible
74. n the MAIN CIRCUIT SWITCH is turned on the inrush circuit provides a pre charging of the input capacitors At this point the Bus Voltages are checked and the welder is enabled after the input capacitors have charged to full operating voltage approximately 5 seconds Note Note the available input power Damage to the welder could occur if 460VAC or higher is applied The following 208 230V Primary Current recommendations are required to obtain the maximum welding current and duty cycle from this welding equipment Primary Supply Minimum Primary Current amp Duty Cycle Lead Size Current Circuit Size Factory Fitted Vin Amps STICK 115 23 85 Q 100 12 3 AWG 230 25 minimum 115 40 85 100 208 44 ee louer 230 39 pe Table 3 2 208 230V Primary Current Circuit sizes to achieve maximum current HEX ED 208 28 160 Q 35 RS The ARC MASTER 160TS is designed for use with a generator as an input power source Contact an accredited Thermal Arc service agent for the proper sizing and set up recommendations of a generator power source system As a general rule depending on the type of generator used the generator capacity should be twice the maximum rating of the welder 3 06 High Frequency Introduction T WARNING Explosives The importance of correct installation of high The high frequency section of this machine frequency welding equipment cannot be over has an output similar to a radio transmitter emphasized
75. nce of oxides in the weld Refer Basic TIG Welding pool Guide for ways to reduce arc flutter Table 8 1 continued TIG Welding Problems 39 ARCMASTER 160TS 11 Welding arc can A Work clamp is not connected A Connect the work clamp to not be established 12 Arc start is not smooth to the work piece or the work torch leads are not connected to the right welding terminals Torch lead is disconnected Gas flow incorrectly set cylinder empty or the torch valve is off Tungsten electrode is too 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 the work piece or connect the work torch leads to the right welding terminals Connect it to the terminal Select the right flow rate change cylinders or turn torch valve on Select the right size electrode 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 Table 8 1 continued TIG Welding Problems 40 ARCMASTER 160TS 8 02 Stick Welding Problems 1 Gas pockets or A Electrodes are damp Dry electrodes before use voids in weld Welding current is too high
76. nit is idle torch switch OFF Verify the setting of Pre flow and Post flow on the front panel If the Pre flow or Post flow time is set to 0 seconds change them to higher setting b Verify the layout of the gas hose 0 Verify that the hose is securely connected into the fitting at the inlet and the outlet Verify the layout of the gas hose so that it is not bent or kinked Verify there are no breaks burns or holes in the hose L Verify the layout of the TIG torch gas hose and that the hose adapters are properly connected c Verify the wiring harness and connection of gas valve SOL1 and CN2 on PCB1 WK 5466 L Verify a secure connection of the harness to CN2 on PCB1 d Verify the drive circuitry of the gas valve SOL1 L1 Verify the drive circuitry of the gas valve SOL1 Refer to section 11 05 4 L Replace PCB1 when abnormal Refer to section 12 03 1 e Replace PCB4 WK 5449 and PCB5 WK 5448 L Refer to section 12 03 4 12 03 5 for the replacement of PCB4 and PCB5 3 No Weld Output When in High Frequency TIG HF TIG mode if the High Frequency is not generated present refer to High Frequency Output Failure in section 11 03 5 Cause Occurs when the remote connector CON1 or associated circuitry is defective damaged or the TIG torch cable is defective Verification Remedy Caution Read and understand this entire section before proceeding Extreme personal harm and tes
77. of interference Looping and suspending of leads should be avoided where possible Re radiation from Unearthed Metallic Objects A major factor contributing to interference is re radiation from unearthed metallic objects close to the welding leads Effective grounding of such objects will prevent re radiation in most cases N gt 3 08 Duty Cycle The duty cycle of a welding power source is the percentage of a ten 10 minute period that it can be operated at a given output without causing overheating and damage to the unit If the welding amperes decrease the duty cycle increases If the welding amperes are increased beyond the rated output the duty cycle will decrease 7 ooo Exceeding the duty cycle ratings will cause the thermal overload protection circuit to become energized and shut down the outout until the unit has cooled to normal operating temperature CAUTION Continually exceeding the duty cycle ratings can cause damage to the welding power source and will void the manufactures warranty NOTE 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 3 09 Specifications ARCMASTER 160TS Parameter 160TS Rated Ou
78. ollowing the Part or Assembly numbers 2 How To Use This Parts List The Parts List is a combination of an illustration and a corresponding list of parts which contains a break down of the equipment into assemblies subassemblies and detail parts All parts of the equipment are listed except for commercially available hardware bulk items such as wire cable sleeving tubing etc and per manently attached items which are soldered riveted or welded to other parts The part descriptions may be indented to show part relationships To determine the part number description quantity or application of an item simply locate the item in question from the illustration and refer to that item number in the correspond ing Parts List PART NUMBER 10 3067 ARC MASTER 160TS No DWG No PartNo Description Additional Information 1 1 10 6510 Capacitor gen 3 1 IPS SS351206PP1 DC350V 20uF CAPACITOR 2 7001384 Coil Coupling gen 3 1 IPS F3A040600 200A COUPING 100 206433 1 8P with Wiring Assembly REMOTE m CONNECTOR TRANSFORMER s 02 fiers Diode gem DBx00UGD SECONDARY DIODE T 8 FAN 10 5227 Fan gen 8 1 IPS Di2T24PSTOT COOLING FAN 17 9 _ FCHT _ W7001502 Inductor gen 3 1 IPS F3A285001 1601200A FCH REACTOR 1 11 10 6633 HF Gap gen 3 1 IP UOAGOTI00 1 W7001453 Switch gen 3 1 IPS DCP 52SR50C 480V 2P 480V MAIN ON OFF SWITCH
79. onal operating procedures apply when using the Welding Power Source i e connect work lead directly to work piece and electrode lead is used to hold electrode Wide safety margins provided by the coil design ensure that the Welding Power Source will withstand short term overload without adverse effects The welding current range values should be used as a guide only Current delivered to the arc is 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 Figure 6 1 160TS Set up 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 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 CAUTION DO NOT change the Weld Mode or Weld Process Mode until after POST FLOW time has finished 31 ARCMASTER 160TS SECTION 6 SEQUENCE OF OPERATION Note Scroll Buttons are used to select the parameters to be set The LED s show which function is being adjusted on the weld sequence graph Refer to the Symbols Table located in the front of the manual for Symbol
80. onents installation location and conditions and local power grid supply conditions 21 ARCMASTER 160TS SECTION 4 OPERATOR CONTROLS 4 01 ARC MASTER 160TS Controls Figure 4 1 ARC MASTER 160TS Power Source Control Knob This control sets the selected weld parameter rotating it clockwise increases the parameter that is indicated on the digital meter Pushing the knob inward displays the actual welding voltage 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 EH Front view 8 Socket Receptacle Figure 4 2 8 Socket Receptacle 23 Socket Pin Earth Ground Torch Switch Input 24V to connect pins 2 amp 3 to turn on welding current Torch Switch Input OV to energize weld current connect pins 2 amp 3 to turn on welding current Connect pin 4 to pin 8 to instruct machine that a remote current control device is connected 12V DC supply 5k ohm maximum connection to 5k ohm remote control potentiometer 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
81. ood the test of time We pride ourselves on technical innovation competitive prices excellent delivery Superior customer service and technical support together with excellence in sales and marketing expertise Above all we are committed to develop technologically advanced products to achieve a safer working environment within the welding industry A WARNINGS Head and understand this entire Manual and your employer s safety practices before installing operating or servicing the equipment While the information contained in this Manual represents the Manufacturer s best judgment the Manufacturer assumes no liability for its use Service Manual Number 0 4881B for ArcMaster 160 TS Inverter Welding Power Supply Part No 10 3067 Published by Thermadyne Industries Inc 82 Benning Street West Lebanon New Hampshire USA 03784 603 298 5711 www thermalarc com Copyright 2006 2007 2008 by Thermadyne Industries Inc 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 June 16 2006 Revision AB Date June 5 2008 Record the following information for Warranty purposes Where Purchased Purc
82. ply b Remove the Side Panel Refer to the section 11 01 1 Close primary power source wall disconnect switch or circuit breaker d Place power supply MAIN CIRCUIT SWITCH 51 on rear of the unit in the ON position A WARNING 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 work piece or any internal components while the unit is activated ARCMASTER 160TS 11 05 Verification of the Power Input Circuitry CAUTION Before performing any portion of the procedure below make certain the unit is placed in the Initial set up condition as described in section 17 04 71 Preparation 1 Verification of the AC input voltage using an AC voltmeter a Verify input voltage Phase to Phase using an AC voltmeter The capability of the voltmeter should be more than 600VAC Measure the point between lines U1 and V1 on the input switch S1 The location of points U1 and V1 on switch S1 are indicated in Figure 11 7 Figure 11 7 Check points U1 U2 V1 and V2 b If the input voltage is out of the operating range of the unit which is 10 187 253VAC of the rated voltage 208 230V verify the available power capacity at the installed site If the input voltage is within the operating range recheck the input voltage while welding as welding may cause the inpu
83. r Table 10 3 continued Power Source Error Codes 51 ARCMASTER 160TS SECTION 11 ADVANCED TROUBLE SHOOTING If you are here all of the troubleshooting subassemblies of this unit Evidence of suggestions in Section 8 Basic Troubleshooting unauthorized repairs will void the factory have either failed to resolve the faulty operation warranty If a subassembly is found to be or have indicated that one or more of the defective by executing any of the procedures in subsystems within the power supply are this Service Manual the subassembly should be defective This section provides the information replaced with a new one The faulty subassembly needed to take live measurements on the various should then be returned to Thermal Arc through subsystems within the power supply and established procedures replace those subsystems that prove faulty CAUTION A WARNING Troubleshooting and repairing this Disconnect primary power at the unit is a process which should be source before disassembling the power undertaken only by those familar supply Frequently review the with high voltage high power Principle Safety Standards in electronic equipment section 1 02 Be sure the operator is equipped with proper gloves clothing and eye and ear protection Make sure A WARNING no part of the operator s body comes ee S into contact with the work piece or any There are extremely dangerous voltage internal components while the unit is and power levels present
84. r capable of reading approximately 160A full scale will be needed for this test CAUTION Before performing any portion of the procedure below make certain the unit is placed in the initial set up condition as described in section 11 04 7 Preparation a Connect the POSITIVE and NEGATIVE OUTPUT TERMINALS to a piece of metal separated by approximately three feet one meter b Connect the clamp on amperage meter or equivalent to the output loop between the POSITIVE and NEGATIVE OUTPUT TERMINALS c Place the power supply MAIN ON OFF SWITCH 51 on the rear of the unit to the ON position d Select HF TIG mode and DC mode WARNING This welding mode produces high frequency and high voltage Extra care Shall be taken to prevent electric shock e Select WELD position press control knob Set minimum current counterclockwise f Depress the torch switch The amperage meter will indicate approximately 5 Amps 73 g Slowly turn the Control Knob clockwise to the maximum of the power supply then counter clockwise back to 1 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 h Set minimum current counter clockwise i Press the Welding mode selection button to select STICK welding mode The amperage meter will indicate approximately 5 Amps WARNING At this time
85. rage output capabilities of the welding power source Curves of other settings will fall between the curves shown 10 25 200 5 160 LIFT TIG Process HF TIG Process 5 160 STICK Process Figure 2 1 Model 160TS Volt Ampere curve 15 ARCMASTER 160TS 2 06 Functional Block Diagrams Figure 2 2 illustrates the functional block diagram of the 160TS power supply Input Wain input reme IGBT Main Output Hal curent Power Circuit Diode Inverter Transfomers Diodes Transformer Switch Filter Themal T1 HCT1 Detector Output Coupling Inductor Coil Le Lift Tig Mode Output Short Sensing Circuit To each control circuit 42VDC 18VDC 24VDC 5VDC Thermal Drive HF Unit Stick Mode Sensor Circuit Control VRD Circuit Circuit Sensing Circuit Trouble Primary High Sensing Circuit Frequency Circuit Sensor Unit Sequence gt X lt jw Control lt gt Fan Control connection Circuit Fan CON1 a Current Reference Adjustment Adjustment amp Circuit Mode select Switch Panel Circuit Boad Figure 2 2 160TS Model Functional Block Diagram 2 07 Transporting Methods These units are equipped with a handle for carrying purposes WARNING ELECTRIC SHOCK can kill O DO NOT TOUCH live electrical parts O Disconnect input power conductors from de energized supply line be
86. raissage 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 KS 2 N s k oN AVERTISSEMENT LE SOUDAGE PEUT CAUSER UN INCENDIE OU UNE EXPLOSION Larc produit des tincellies et des projections Les particules volantes le m tal chaud les projections 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 Prot gez vous ainsi que les autres contre les tincelles et du m tal chaud Ne soudez 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 inc
87. range of the unit The AC input does not drop below 180VAC 5 Verification of the primary Diode D1 CAUTION Before performing any portion of the procedure below make certain the unit is placed in the Initial set up condition as described in section 11 4 1 Preparation a Verify the characteristic of the primary diode D1 using a diode tester b Refer to Table 11 5 and Figure 11 14 for the checkpoints on D1 COMPONENT TERMINALS ACCEPTABLE TESTED Negative lead VALUE 1 3 5 0 3 to 0 5V 1 2 3 Open Table 11 5 ns checkpoints for D1 Figure 11 14 Tester checkpoints in the D1 interconnection diagrams 69 ARCMASTER 160TS 6 Verification of the secondary Diode D2 D3 CAUTION Before performing any portion of the procedure below make certain the unit is placed in the Initial set up condition as described in section 11 04 1 Preparation a Verify the characteristic of the secondary diode D2 and D3 using a diode tester b Refer to Table 11 6 and Figure 11 15 for the checkpoints on D2 and D3 COMPONENT TERMINALS ACCEPTABLE TESTED Negative lead VALUE Anode Cathode 0 2 to 0 3V f Anode Cathode 0 2 to 0 3V Table 11 6 Tester checkpoints for D2 and D3 Figure 11 15 Tester checkpoints for D2 and D3 70 ARCMASTER 160TS 7 Verification of the primary IGBT Q1A Q4C CAUTION Before performing any portion of the procedure below make certain the unit is placed in the Initial set up cond
88. rification of the FAN1 67 ARCMASTER 160TS At the time of a low output and standby fan rotation becomes slow Therefore exact voltage measuring becomes impossible When verifying the voltage Verify that the AC input voltage remain within the operating range of the unit The AC input does not drop below 180VAC 4 Verification of the Gas Valve SOL1 Drive Circuitry CAUTION Before performing any portion of the procedure below make certain the unit is placed in the initial set up condition as described in section 17 04 71 Preparation a Verify the voltage between the PIN3 Positive and PIN4 Negative of connector CN2 on PCB1 WK 5466 while you press the torch switch while in TIG Mode The capacity of the voltmeter should be more than 50VDC The location of connector CN2 of PCB1 WK 5466 is indicated in Figure 11 13 When you measure the above voltage do not remove the connector Conduct the measurement while the connector plug and receptacle are still connected Figure 11 13 Verification of the SOL1 b Using the measurement taken above follow the chart below for possible failure modes Voltage measurement EE PIN1 PIN2 of CN2 on PCB1 Remedy Replace PCB1 DOWD Y Refer to the page 12 5 Replace SOL1 id dod Refer to the page 12 20 Table 11 4 Verification of the SOL1 68 ARCMASTER 160TS c When verifying the voltage Verify that the AC input voltage remain within the operating
89. rts Figure 12 2 Locking type connectors and board supporters Note During your maintenance or repair please cut any tie wraps necessary However after your maintenance or repair please re assemble and tie wrap all components and wiring in the same manner as before the maintenance or repair 77 ARCMASTER 160TS CAUTION Please note that you remove each connector grasp and pull out by the connector part only Do not pull the harness cable part 12 03 Replacement Procedure 1 PCB1 WK 5466 and Primary Diode D1 a Remove the Side Panel See section 11 01 1 b Remove the screw and three cables Cut the snap band 78 ARCMASTER 160TS e Remove the Gas Tube Remove the two bolts two toothed washers and the terminal es ARCMASTER 160TS Continued on next page h Remove the four screws and the Rear Panel i Remove the four screws and the two cables Disconnect the eight connectors CN1 8 on the PCB1 80 ARCMASTER 160TS k Remove the Primary Diode D1 with the soldering iron from the PCB1 Before installing a new diode apply a uniform coat of silicone compound Shinetsu Silicone G 747 or equivalent on the base SE pus 2 WS 2 2 WK 5467 Capacitor C1 and Resistor R1 a Remove the Side Panel See section 11 01 1 b Remove the PCB1 and D1 See section 12 03 1 c Remove the PCB6 and PCB7 See sectio
90. s 1 year Engines and associated components are NOT warranted by Thermal Arc although most are warranted by the engine manufacturer GMAW FCAW MIG WELDING EQUIPMENT Fabricator 131 181 190 210 251 281 Fabstar 4030 PowerMaster 350 350P 500 500P Excelarc 6045 Wire Feeders Ultrafeed Portafeed Original Main Power Transformer and Inductor Original Main Power Rectifiers Control P C Boards power switch semi conductors All other original circuits and components including but not limited to relays switches contactors solenoids fans electric motors GTAW TIG amp MULTI PROCESS INVERTER WELDING EQUIPMENT LABOR 160TS 300TS 400TS 185AC DC 200AC DC 300AC DC 400GTSW 400MST 300MST 400MSTP Original Main Power Magnetics 3 years Original Main Power Rectifiers Control P C Boards power switch semi conductors 3 years All other original circuits and components including but not limited to relays switches contactors solenoids fans electric motors 1 year PLASMA WELDING EQUIPMENT WARRANTY PERIOD LABOR Ultima 150 Original Main Power Magnetics 5 years 3 years Original Main Power Rectifiers Control P C Boards power switch semi conductors 3 years 3 years Welding Console Weld Controller Weld Timer 3 years All other original circuits and components including but not limited to relays switches contactors solenoids fans electric motors Coolant Recirculator 1 year 1 year SMAW Stick WELDING EQUI
91. s outils 6 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 AVERTISSEMENT DES ETINCELLES PEUVENT FAIRE EXPLOSER UN ACCUMULATEUR L ELECTROLYTE D UN ACCUMU LATEUR PEUT BRULER LA PEAU ET LES YEUX Les accumulateurs contiennent de l lectrolyte acide et d gagent des vapeurs explosives 1 Portez toujours un cran facial en travaillant sur un accumu lateur 2 Arr tez le moteur avant de connecter ou de d connecter des c bles d accumulateur 3 N utilisez que des outils anti tincelles pour travailler sur un accumulateur ARCMASTER 160TS 4 N utilisez pas une source de courant de soudage pour charger un accumulateur ou survolter momentan ment un v hicule 5 Utilisez la polarit correcte et de l accumulateur eS SN AVERTISSEMENT LA VAPEUR ET LE LIQUIDE DE REFROIDISSEMENT BRULANT SOUS PRESSION PEUVENT BRULER LA PEAU ET LES YEUX Le liquide de refroidissement d un radiateur peut tre br lant et sous pression 1 W 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 compl tement le bouchon s chapper avant d ter 12 1 05 PRINCIPAL SAFETY STANDARDS Safety in Welding and Cutting ANSI Standard 249 1 from the American Welding Society 550 N W LeJeune Rd Miami FL 33126 Saf
92. s 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 4 Wear protective clothing made from durable flame resistant material wool and lather and foot protection 5 Use approved ear plugs or ear muffs if noise level is high Eye protection filter shade selector for welding or cutting goggles or helmet from AWS A6 2 73 Welding or cutting Electrode Size Filter Welding or cutting Electrode Size Filter Torch soldering 2 Gas metal arc Torch brazing 3 or4 Non ferrous base metal All 11 Oxygen Cutting Ferrous base metal All 12 Light Under 1 in 25mm 3 or 4 Gas tungsten arc welding All 12 Medium 1to6in 25 150mm 40 5 TIG All 12 Heavy Over 6 in 150mm 5or6 Atomic hydrogen welding All 12 Gas welding Carbon arc welding All 12 Light Under 1 8 in 3mm 40r 5 Plasma arc welding Medium 1 8to 1 2 in 3 12mm 5or6 Carbon arc air gouging Heavy Over 1 2 in 12mm 6 or 8 Light 12 Shielded metal arc Under 5 32 in 4mm 10 Heavy 14 5 32 to 1 4 in 12 Plasma arc cutting Over 1 4 in 6 4mm 14 Light Under 300 Amp 9 Medium 300 to 400 Amp 12 Heavy Over 400 Amp 14 Do not weld in locations near degreasing cleaning or spraying operations The heat and rays of the arc can react with vapors to from highly toxic and irritating gases Do not weld o
93. shock hazard The unit will generate OCV Open Circuit Voltage immediately when contactor function is put into the state of ON by pushing the Function button and enabling STICK mode 7 Verify the no load voltage OCV using a DC voltmeter The capability of the voltmeter should be more than 100VDC 8 The normal no load voltage is approximately 65V 9 03 Switching VRD On Off Switch the machine Off A Remove the clear plastic cover from the control panel see Figure 9 1 C Lift up the cover so it rests on the top of the unit O Place a small flat bladed screw driver between the cover hinge on the front panel C Gently lift the cover hinge out of the front cover mounting hole O Remove the control s clear plastic cover Figure 9 1 VRD ON OFF Step A 47 ARCMASTER 160TS B Remove four mounting screws from the control panel see Figure 9 2 Figure 9 2 VRD ON OFF Step B C C Access the VRD control by gently prying back the front panel controls to reveal the VRD on off potentiometer see Figure 9 3 CAUTION Do not pull back the front panel with excessive force as this will unplug control PCB Plugging the control PCB back into the front panel controls can only be achieved by removing the side covers Figure 9 3 VRD ON OFF Step D ARCMASTER 160TS D Turning the VRD ON OFF see Figure 9 3 1 To turn VRD ON rotate the trim potentiometer VR1 on the display PCB fully clockwise When VRD is turne
94. soudage traitez les avec soin Prot gez les bouteilles de gaz comprim contre les sources de chaleur intense les chocs et les arcs de soudage Enchainez verticalement les bouteilles un support ou un cadre fixe pour les emp cher de tomber ou d tre renvers es Eloignez les bouteilles de tout circuit lectrique ou de tout soudage Emp chez tout contact entre une bouteille et une lectrode de soudage N utilisez que des bouteilles de gaz protecteur des d tendeurs des boyauxs et des raccords concus pour chaque application sp cifique ces quipements et les pi ces connexes doivent tre maintenus en bon tat Ne placez pas le visage face l ouverture du robinet de la bouteille lors de son ouverture Laissez en place le chapeau de bouteille sauf si en utilisation ou lorsque raccord pour utilisation Lisez et respectez les consignes relatives aux bouteilles de gaz comprim et aux quipements connexes ainsi que la publication P 1 de la CGA identifi e dans la liste de documents ci dessous SJ 7 PT AVERTISSEMENT LES MOTEURS PEUVENT ETRE DANGEREUX LES GAZ D ECHAPPEMENTDES MOTEURS PEUVENT ETRE MORTELS Les moteurs produisent des gaz d chappement nocifs 1 Utilisez l quipement l ext rieur dans des aires ouvertes et bien ventil es Si vous utilisez ces quipements dans un endroit confin les fum es d chappement doivent tre envoy es l ext rieur loin des prises d air d
95. t le mettre la terre selon le manuel d utilisation et les codes nationaux provinciaux et locaux applicables 1 04 Dangers relatifs au soudage l arc T 6 Arr tez tout quipement apr s usage Coupez l alimentation de l quipement s il est hors d usage ou AVERTISSEMENT inutilis L ELECTROCUTION PEUT ETRE MORTELLE 7 Une d charge lectrique peut tuer ou br ler gravement 1 lectrode et le circuit de soudage sont sous tension d s la mise en circuit Le circuit d alimentation et les circuits internes de l quipement sont aussi sous tension d s la mise en marche En soudage automatique ou semi automatique avec fil ce dernier le 8 rouleau ou la bobine de fil le logement des galets d entrainement et toutes les pi ces m talliques en contact avec le fil de soudage 9 N utilisez que des porte lectrodes bien isol s Ne jamais plonger les porte lectrodes dans l eau pour les refroidir Ne jamais les laisser trainer par terre ou sur les pi ces souder Ne touchez pas aux porteelectrodes raccordes deux sources de courant en m me temps Ne jamais toucher quelqu un d autre avec l lectrode ou le porte lectrode N utilisez pas de cables lectriques us s endommag s mal piss s ou de section trop petite N enroulez pas de cables lectriques autour de votre sont sous tension Un quipement inad quatement install ou inad quatement mis la terre est dangereux
96. t ger les autres des coups d arc ou de l blouissement avertissez les observateurs de ne pas regarder l arc Portez des v tements en mat riaux ignifuges et durables laine et cuir et des chaussures de s curit Portez un casque antibruit ou des bouchons d oreille approuv s lorsque le niveau de bruit est lev 9 certains proc d s peut endommager louie 1 Portez une casque de soudeur avec filtre oculaire de nuance appropriee consultez la norme ANSI 749 indiquee ci apr s pour vous prot ger le visage et les e s AVERTISSEMENT LES VAPEURS ET LES FUMEES SONT DANGEREUSES POUR LA SANTE Le soudage d gage des vapeurs et des fum es dangereuses respirer SELECTION DES NUANCES DE FILTRES OCULAIRS POUR LA PROTECTION DES YEUX EN COUPAGE ET SOUDAGE selon AWS 6 2 73 Op ration de Dim ension d lectrode ou Nuance M Dim ension d lectrode ou Nuance Epiasseur de m tal ou de filter Op ration de coupage ou soudage Epiasseur de m tal ou de filter coupage ou soudage 5 e ntensit de courant oculaire Intensit de courant oculaire Brassage tender au Tolites conditions 2 Soudage l arc sous gaz avec fil chalumeau plein GMAW Brassage fort au Toutes conditions 3ou4 m taux non ferreux Toutes conditions 11 chalumeau Oxycoupage m taux ferreux Toutes conditions 12 mince moins de 1 po 25mm 3 ou 4 Ma a Toutes conditions 12 moyen de 1 6 po
97. t equipment damage will occur if the procedures are not performed accurately a Verify the remote connector CON1 Applies to LIFT TIG and High Frequency TIG HF TIG mode L Verify a secure connection between the remote connector CON1 and the TIG torch cable Verify a secure connection of the harness and the connections between the remote connector CON1 and CN1 on PCB1 WK 5466 are all correct and there are no open circuits L1 Contact the manufacture if you find any broken connectors or damaged wiring harnesses L Verify the proper pins outs of the remote connector at the TIG Torch side Refer to section 4 01 2 L Verify that there is no open circuit on the remote connector at TIG Torch side In equipment for remote control use Verify the pin specification of a connector Refer to section 4 01 2 b Verify the condition and connections of the welding cable the stick rod holders and the ground clamp Applies to all welding modes 60 ARCMASTER 160TS L Verify a secure connection of the welding cable stick rod holders ground clamp and dinse connectors and there are no open circuits Verify the no load voltage OCV Applies to STICK High Frequency TIG HF TIG mode Refer to the section Verification of No load voltage OCV in section 11 05 8 If performing the No Load Voltage Failure procedure does not rectify the failure perform the following tests in the sequenc
98. t voltage to decrease to a value below the operating range of the unit c Verify input voltage after the input switch 51 using an AC voltmeter The capability of the voltmeter should be more than 600VAC O 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 51 are indicated in Figure 11 7 d If this voltage is out of the operating range which is 10 187 253VAC of the rated voltage 208 230 replace S1 following the process in section 12 3 14 e Verify the rectified output voltage of the primary diode D1 using a DC voltmeter The capability of the voltmeter should be more than 400VDC Using a DC voltmeter measure between the points and on D1 Points and are on PCB1 WK 5466 See Figure 11 8 The measured voltage should be approximately 1 4 times larger than input voltage 63 ARCMASTER 160TS measured in 1 above Replace diode D1 if the calculated measurement is not within the corresponding range 260 360VDC following the process in section 12 03 1 Figure 11 8 The check points and f Verify bus voltage the voltage of the electrolytic capacitor after rectification using a DC voltmeter The capability of the voltmeter should be more than 500VDC Using a DC voltmeter measure between the points TB1 P and TB3 N on PCB1 WK 5466 See Figure 11 9 Points TB1 P and TB2 N can be fo
99. tput 115VAC 230VAC Amperes 85 160 Volts 23 27 Duty Cycle 100 35 Duty Cycle TIG 160A 17V 35 230VAC 130A 15V 60 230VAC 100A 14V Q 100 230VAC 85A 13V 100 115VAC STICK 160A 27V Q 35 230VAC 130A 25V 60 230VAC 100A 24V 100 230VAC 85A 23V 100 115VAC Output Current TIG 1 160 230V 1 85 115V Range STICK 1 160 230 1 85 115V Open Circuit Voltage 65V Dimensions Width 5 12 130mm Height 10 24 260mm Length 12 60 320mm Weight 17 63 Ib 8 0 kg Output Rated Load 115V 230V Output Amperes 85A 160A Output Volts 23V 27N Duty Cycle 10096 35 KVA 44 8 7 KW 24 5 2 Output No Load KVA 0 5 KW 0 3 Input Volts Single Phase Amperage Draw Q Rated Load No Load Amps 208V 44 2 2 230V 39 1 6 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 changes 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 comp
100. u batiment 77 4 AVERTISSEMENT LE CARBURAMT PEUR CAUSER UN INCENDIE OU UNE EXPLOSION Le carburant est hautement inflammable Arr tez le moteur avant de v rifier le niveau e carburant ou de faire le plein Ne faites pas le plein en fumant ou proche d une source d tincelles ou d une flamme nue Si c est possible laissez le moteur refroidir avant de faire le plein de carburant ou d en v rifier le niveau au d but du soudage Ne faites pas le plein de carburant ras bord pr voyez de l espace pour son expansion 11 ARCMASTER 160TS 5 Faites attention de ne pas renverser de carburant Nettoyez tout carburant renvers avant de faire d marrer le moteur WE essen DES PIECES EN MOUVEMENT PEUVENT CAUSER DES BLESSURES Des pi ces en mouvement tels des ventilateurs des rotors et des courroies peuvent couper doigts et mains ou accrocher des v tements amples 1 Assurez vous que les portes les panneaux les capots et les protecteurs soient bien ferm s 2 Avant d installer ou de connecter un syst me arr tez le moteur 3 Seules des personnes qualifi es doivent d monter des protecteurs ou des capots pour faire l entretien ou le d pannage n cessaire 4 Pour emp cher un d marrage accidentel pendant l entretien d branchez le cable d accumulateur la borne n gative 5 N approchez pas les mains ou les cheveux de pi ces en mouvement elles peuvent aussi accrocher des v tements amples et de
101. und on the parts side of PCB2 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 260 360VDC following the process in section 12 03 1 TB1 Figure 11 9 The check points TB1 P and TB3 N g After the replacement of D1 if the above voltage is still abnormal replace PCB1 WK 5466 64 ARCMASTER 160TS 2 Verification of the Power Supply Voltage CAUTION Before performing any portion of the procedure below make certain the unit is placed in the Initial set up condition as described in section 17 04 7 Preparation a Verify Power Supply voltage using an DC voltmeter The capability of the voltmeter should be more than 50VDC Operate at all input voltages as noted on the nameplate on the rear panel when testing the power supply b On the PCB5 WK 5448 and PCB4 WK 5449 measure the voltages according to the following table The check points and the reference are obtainable on the solder side of PCB4 WK 5449 The locations of points are indicated in Figure 11 10 PCB4 WK 5449 Figure 11 10 Checkpoints on PCB6 Check Point Reference ACCEPTABLE PCB6 PCB6 VALUE TP1 TPO 5VDC TP2 TPO 12VDC TP3 TPO 12VDC Table 11 1 Checkpoints TPO TP3 on PCB6 65 ARCMASTER 160TS Figure 11 11 Checkpoints CN2 on PCB1 Check Point Refer
102. upply is a thorough cleaning and inspection with the frequency depending on the usage and the operating environment WARNING Disconnect primary power at the source before opening the enclosure Wait at least two minutes before opening the enclosure to allow the primary capacitors to discharge To clean the unit open the enclosure please refer to Section 11 01 1 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 that are recommended for cleaning electrical apparatus CAUTION 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 36 ARCMASTER 160TS Maintain more often if used under severe conditions Warning Disconnect input power before maintaining Each Use regulator and pressure Consumable parts Visual check of lt Visual check of torch fh Weekly 9 amp Visually inspect the torch i body and consumables Visually inspect the cables and leads Replace as needed 3 Months Replace all Clean broken parts exterior of power supply 6 Months Bring the unit to an authorized Thermal Arc Service Center to remove any accumulated dirt and dust from the interior This may need to be done more frequently under exceptionally dirty conditions
103. using a remote contactor device to control sequence AT operation in TIG Modes with repeat operation and crater fill using a remote contactor device 2T operation spot welding in HF TIG using a remote contactor device Pulse operation in TIG Modes PULSE ON OFF Table 4 2 Weld Process selection verses Weld Mode for 160TS 25 ARCMASTER 160TS 4 03 Weld Parameter Descriptions for ARC MASTER 160TS Figure 4 3 ARC MASTER 160TS Front Panel with Parameter Description Parameter 5 PRE FLOW HOT START INITIAL CUR UP SLOPE PEAK CUR WELD BASE Background Current SPOT TIME PULSE WIDTH PULSE FREQ Description This parameter operates in TIG modes only and is used to provide gas to the weld zone prior to striking the arc once the torch trigger switch has been pressed This control is used to dramatically reduce weld porosity at the start of a weld This parameter operates in all weld modes except Lift TIG mode and is used to heat up the weld zone in TIG modes or improve the start characteristics for stick electrodes e g low hydrogen electrodes It sets the peak start current on top of the BASE WELD current e g HOT START current 130 amps when BASE WELD 100 amps amp HOT START 30 amps This parameter operates in SLOPE or REPEAT AT TIG modes only and is used to set the start current for TIG The Start Current remains on until the torch trigger switch is re
104. y large volume of scientific findings based on experiment 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 more 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 risk 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 The above procedures are among those also normaly recommended for pacemaker wearers Consult your doctor for complete Information ARCMASTER 160TS 1 02 PRINCIPAL SAFETY STANDARDS Safety in Welding and Cutting ANSI Standard 749 1 from the American Welding Society 550 N W LeJeune Rd Miami FL 33126 Safety and Health Standards OSHA 29CFR 1910 SAFETY AND HEALTH STANDARDS obtainable from Superintendent of Documents U S Government Printing Office Washington D C

160 TS ARCMASTER® Service Manual

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160 TS ARCMASTER&reg; Service Manual

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160 TS ARCMASTER® Service Manual