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P-WEE® 160TS Service Manual

1. 4 Select WELD position press control knob Set minimum current counterclockwise 5 Depress the torch switch The amperage meter will indicate approximately 1 Amp 6 Slowly turn the Control Knob clockwise to the maximum of the power supply then counterclockwise back to 1 Amp as the control returns to its minimum position The amperage meter should indicate a continuous range of Amperes between the 1 Amp minimum and the 160A maximum 7 Set minimum current counterclockwise 8 Press the Welding mode selection button to select STICK welding mode The amperage meter will indicate approximately 1 Amps 6 18 160A maximum 10 Place the power supply MAIN CIRCUIT SWITCH on the rear of the unit to the OFF position 11 Remove the dead short between the OUTPUT TERMINALS NOTE This completes the output load test If the results of any step differ from those above then refer to the various test procedures in this section to isolate the problem August 12 2005 PRO LITE 160TS 6 11 Preparation for Subsystem Test and Replacement procedures The following sections provide specific procedures for verifying the operation and replacement of each subsystem within the power supply Before undertaking any of these procedures eliminate the obvious first visually inspect the suspect subsystem for physical damage overheating and loose connections Test and Replacement Parts List No Item Code Manual Section Num
2. Figure 4 12 STICK mode timing with the VRD disabled STICK with VRD ENABLED Voltage Reduction Device Figure 4 13 shows the STICK timing waveforms with the VRD function OFF If place Pin2 at DSW1 on PCB5 WK 4986 in ON position to turn on the VRD DE Output lw Output Voltage Arc control Art A 0580 Vrd y about 18V Figure 4 13 STICK mode timing with the VRD enabled 4 14 August 12 2005 PRO LITE 160TS LIFT TIG Mode LIFT TIG STD Mode Figure 4 14 shows the LIFT TIG STD timing waveforms with PULSE control ON and OFF Contactor Electrode Solenoid Pulse f ulse frequency Output Current Peak Cur Art A 05881 i Base cur Initial current EF 25A fixed Lift only Figure 4 14 LIFT TIG STD mode timing LIFT TIG SLOPE Mode Figure 4 15 shows the LIFT TIG SLOPE timing waveforms with PULSE control ON and OFF Solenoid Output current Initial cur NE Crater cur i i Art A 05882 Up slope time Down slope time Figure 4 15 LIFT TIG SLOPE mode timing August 12 2005 4 15 PRO LITE 160TS LIFT TIG REPEAT Mode Figure 4 16 shows the LIFT TIG REPEAT timing waveforms with PULSE control ON and OFF Output current Initial cur ae Crater cur D IN d NT AL C m nn E mcm mr m eem ee ee ee Den s rm is ee la zi I 1 Leti PB ra Up slope time Down slope time Figure 4 16 LIFT TIG REPEAT mode timing 4 16 August
3. Figure 6 8 The check points TB9 TB11 A 6 After the replacement of D1 if the above voltage is still abnormal replace PCB1 WK 4980 following the process in section 6 12 August 12 2005 PRO LITE 160TS 6 11 PRO LITE 160TS 6 06 Power Supply Voltage Test 1 Connect the power supply to a source of rated input voltage Check the data tag on the rear of the power supply for the proper input voltage Refer to NOTE on page 6 10 2 Apply power to the unit and place the switch of the power supply to the ON position 3 On the PCB2 WK 4977 measure the voltages according to Table 6 1 The test point and the reference are obtainable on the solder side of PCB2 WK 4977 The location of points on CN4 on PCB2 WK 4977 circle as shown in Figure 6 9 are indicated in Figures 6 9 through 6 12 Test Point Reference ACCEPTABLE PCB2 WK 4977 PCB2 WK 4977 VALUE Table 6 1 Test point voltage values 4 If any of these voltages are not present or are below a 10 tolerance replace the PCB2 WK 4977 following the process in section 6 13 Art A 05891 Figure 6 9 Check point CN4 on PCB2 6 12 August 12 2005 PRO LITE 160TS Art A 05892 Figure 6 10 Check Points 12V Art A 05894 Figure 6 11 Check Points 5V Art A 05894 Figure 6 12 Check Points 12V August 12 2005 6 13 PRO LITE 160TS 6 07 Verification of the Cooling Fan and Drive Circuitry 1 Verify the condition of th
4. Cooling fan voltage tests and replacement of the cooling fan FANT Follow the instruction in section 6 07 August 12 2005 PRO LITE 160TS 2 Gas Valve Failure No Gas flow through unit Occurs when the gas valve is defective damaged or the driving voltage is incorrect a Oo O lt O Confirm that TIG welding is selected on the welding mode Do not change welding modes while welding Only change welding modes when the unit 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 a higher setting Verify the layout the of the gas hose Confirm that the hose is securely connected into the fitting at the inlet and the outlet Confirm that the layout of the gas hose so that it is not bent or kinked Confirm there are no breaks burns or holes in the hose Confirm the layout of the TIG torch gas hose and that the hose adapters are properly connected Gas Valve SOL voltage tests and replacement Follow the instruction in section 6 08 Replace the PCB5 WK 4986 and PCB6 WK 4987 Refer to section 6 15 for the replacement and installation of PCB5 and PCB6 6 7 PRO LITE 160TS 3 No weld output 6 6 NOTE When in High Frequency TIG HF TIG mode if the High Frequency is not generated present refer to High Frequency Output Failure symptom 5
5. de l accumulateur 1 10 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 N tez pas le bouchon de radiateur tant que le moteur n est pas refroidi 2 Mettez des gants et posez un torchon sur le bouchon pour l ter Laissez la pression s chapper avant d ter compl tement le bouchon 1 05 PRINCIPALES NORMES DE SECURITE Safety in Welding and Cutting norme ANSI Z49 1 American Welding Society 550 N W LeJeune Rd Miami FL 33128 Safety and Health Standards OSHA 29 CFR 1910 Superintendent of Documents U S Government Printing Office Washington D C 20402 Recommended Safe Practices for the Preparation for Welding and Cutting of Containers That Have Held Hazardous Substances norme AWS F4 1 American Welding Society 550 N W LeJeune Rd Miami FL 33128 National Electrical Code norme 70 NFPA National Fire Protection Association Batterymarch Park Quincy MA 02269 Safe Handling of Compressed Gases in Cylinders document P 1 Compressed Gas Association 1235 Jefferson Davis Highway Suite 501 Arlington VA 22202 Code for Safety in Welding and Cutting norme CSA W117 2 Association canadienne de normalisation Standards Sales 276 Rexdale Boulevard Rexdale Ontario Canada M9W 1R3 Safe Practices for Occupation and Educational Eye an
6. oet the digital volt ohm meter to the diode test scale Using figure A 6 and A 7 check each diode in the module Each diode must be checked in both the forward bias positive to negative and reverse bias negative to positive direction 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 A 6 A properly functioning diode will conduct in the forward bias direction and will indicate between 0 3 and 0 9 volts To check the diode in the reverse bias direction reverse the meter leads refer to figure A 6 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 If any diode in the module tests as faulty replace the diode module Reconnect all cables to the proper terminals Forward Bias Diode Conducting Art A 06015 Figure A 6 Forward bias diode test August 12 2005 August 12 2005 P WEE 160TS Reverse Bias Diode Not Conducting Art A 06016 Anode Cathode Figure A 7 Reverse bias diode test A 11 IHERMAL ARC K Global Customer Service Contact Information Thermadyne USA 82 Benning Street West Lebanon NH 03784 USA Telephone 603 298 5711 800 752 7621 Fax 800 221 4401 Email sales thermalarc com Ther
7. Figure 6 31 PCB2 mounted on chassis 3 Unplug the harness connectors from CN10 and CN15 on PCB2 Art A 05914 Figure 6 32 CN15 and CN10 on PCB2 4 Unplug the harness connector from CN9 on PCB2 Art A 05915 Figure 6 33 CN9 on PCB2 August 12 2005 PRO LITE 160TS 5 Unplug the harness connector from CN2 on PCB2 Art AC a Figure 6 34 CN2 on PCB2 6 Unplug the harness connector from CN3 on PCB2 ar Aer F li E red Eus i ow J al il Art A 05917 Figure 6 35 CN3 on PCB2 7 Unplug the harness connector from CN1 on PCB2 Art A 05918 Figure 6 36 CN1 on PCB2 6 25 PRO LITE 160TS 8 Unplug the harness connector from CN12 on 11 Unplug the harness connector from CN8 on PCB2 PCB2 Art A 05922 Art A 05919 Figure 6 40 CN8 on PCB2 Figure 6 37 CN12 on PCB2 12 Unplug the harness connector from CN7 on PCB2 9 Unplug the harness connector from CN4 on PCB2 Holding the upper portion of the harness to unlock the contact between the harness connectors and CN1 4 CN6 10 CN12 and CN15 pull the harness lightly To unplug the harness connector do not pull the harness excessively Art A 05920 Figure 6 38 CN4 on PCB2 10 Unplug the harness connector from CN6 on PCB2 ARt A 05923 Figure 6 41 CN7 on PCB2 Art A 05921 Figure 6 39 CN6 on PCB2 6 26 August 12 2005 13 Disconnect a flat cable from CN5 on PCB2 14
8. Remove all flammables within 35 ft 10 7 m of the welding arc If this is not possible tightly cover them with approved covers Be alert that welding sparks and hot materials from welding can easily go through small cracks and openings to adjacent areas Watch for fire and keep a fire extinguisher nearby Beaware 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 10 Remove stick electrode from holder or cut off welding wire at contact tip when not in use August 12 2005 P WEE 160TS Ah gt WARNING FLYING SPARKS AND HOT METAL can cause injury Chipping and grinding cause flying metal As welds 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 LD 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 Protect compressed gas cylinders from excessive heat mecha
9. Test Procedure 1 Confirm there are no abnormal appearances on PCB3 2 Verify the characteristic of the IGBT Q1 using a diode tester 3 Refer the Table 6 8 and Figure 6 74 for the test points on Q1 COMPONENT TESTED Uu es ACCEPTABLE VALUE Positive lead Negative lead Figure 6 4 Q1 Test Points Replacement Procedure 1 Remove the side covers See section 6 01 2 Remove PCB1 See section 6 12 3 Replace Q1 together with PCB3 ZEE Ql wrth PCRS at Art A 05951 Figure 6 75 Location of Q1 with PCB3 August 12 2005 6 37 PRO LITE 160TS 4 Unplug a harness connector connected to PCB2 from CN1 on PCB3 circled as shown in Figure 6 16 Art A 05952 Figure 6 76 CN3 on PCB3 5 Remove the screw mounting C1 on C2E1 on Q1 circled as shown in Figure 6 77 Art A 05953 Figure 6 77 C2E1 on PCB3 6 Remove the two 2 screws securing Q1 to heatsink circled as shown in Figure 6 78 Art A 05954 Figure 6 78 Q1 mounting screws 6 38 7 Remove Q1 from the unit 8 Remove the two Q bus bar1 mounted on C1 and E2 circled as shown in Figure 6 79 and remove the IGBT D Art A 05955 Figure 6 79 Q bus bari on Q1 NOTE When replacing the IGBT apply heat sink compound Shinetsu silicon G 747 or equivalent uniformly to the base surface of the diode as shown in Figure 6 80 Art A 05956 Figure 6 80 Base surface of Q1 NOTE When you reasse
10. lt Confirm a secure connection between CN13 on PCB1 WK 4980 and CN12 on PCB2 WK 4977 Replacement of PCB2 WK 4977 PCB5 WK 4986 and PCB6 WK 4987 Refer to section 6 13 for the replacement and installation of PCB2 and section 6 15 for PCB5 and PCB6 August 12 2005 5 High Frequency Output Failure Unit does not generate High Frequency Occurs when the HE UNIT is defective or blown m 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 a C O Verify the connection between High Frequency HF Unit and Coupling Coil CC Verify the connection between the HF Unit and CC confirm that the quick disconnect terminals are inserted onto the terminals of HF Unit CC1 and CC2 correctly and completely Confirm there are no short circuits burnt or broken wires between the HF unit and the CC Refer to section 6 21 for the replacement and installation of the CC Verify the connection between High Frequency HF Unit and Current limiting Resistor R2 Verify the connection between the HF Unit and R2 confirm that the quick disconnect terminals are inserted onto the terminals of HF Unit R1 and R2 correctly and completely Confirm the
11. portez un respirateur adduction d air approuv Lisez les fiches signal tiques et les consignes du fabricant relatives aux m taux aux produits consummables aux rev tements et aux produits nettoyants Ne travaillez dans un espace confin que s il est bien ventil sinon portez un respirateur adduction d air Les gaz protecteurs de soudage peuvent d placer l oxyg ne de l air et ainsi causer des malaises ou la mort Assurez vous que l air est propre la respira tion Ne soudez pas proximit d op rations de d graissage de nettoyage ou de pulv risation La chaleur et les rayons de l arc peuvent r agir avec des vapeurs et former des gaz hautement toxiques et irri tants 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 ix ooo Wy AVERTISSEMENT LE SOUDAGE PEUT CAUSER UN INCENDIE OU UNE EXPLOSION L arc 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 brulures Le contact accidentel de l lectrode ou du fil lectrode avec un objet m tallique peut provoquer des tincelles un chauffement o
12. 12 2005 PRO LITE 160TS HF TIG Mode HF TIG STD Mode Figure 4 17 shows the HF TIG STD timing waveforms with PULSE control ON and OFF Contactor solenoid Pre flow time _ _ Bien time Hot start E Hot cur I Mte ci Pulse frequency Peak Output current cur Iw Art A 05884 Base cur Figure 4 17 HF TIG STD mode timing HF TIG SLOPE Mode Figure 4 18 shows the HF TIG SLOPE timing waveforms with PULSE control ON and OFF Contactor HF Solenoid Output current Initial eur i We Art A 05885 E les ae ET gusce m SS Se eee ee a m ee 1 1 I m ra Up slope time Down slope time Figure 4 18 HF TIG SLOPE mode timing August 12 2005 4 17 PRO LITE 160TS HF TIG REPEAT Mode Figure 4 19 shows the HF TIG REPEAT timing waveforms with PULSE control ON and OFF Contactor HF Solenoid Output current Initial cur NR BE e 0 0 0 5b Crater CUr Art A 05886 Up slope time Down slope time Figure 4 19 HF TIG REPEAT mode timing HF TIG SPOT Mode Figure 4 20 shows the HF TIG SPOT timing waveforms with PULSE control ON and OFF Contactor Solenoid O Z eee ae en TRS Pre flow time opottime RE Output current Art A 05887 Figure 4 20 HF TIG SPOT mode timing 4 18 August 12 2005 PRO LITE 160TS SECTION 5 5 02 Basic Troubleshooting SERVICE A There are extremely dangerous voltages and 5 01 Routine Main
13. 64V 2 Verify the no load voltage in High Frequency TIG HF TIG mode m CAUTION Electric shock hazard and test equipment damage The unit will generate OCV along with a High Voltage component that can cause extreme personal harm and test equipment damage PRO LITE 160TS NOTE When in HF TIG mode the unit will generate high voltage To prevent personal harm and test equipment damage remove the indicated wire from the HF Unit shown in Figure 6 17 circled as shown in Figure 20 left To prevent electric shock always wrap the removed wire with electrical tape or other suitable insulation a Confirm a secure connection between CON1 of the 8 pin connector and the TIG torch cable b Confirm a secure connection of the harness and the connections between CON1 and PCB2 WK 4977 are all correct and there are no open circuits c Contact the manufacturer if you find any broken connectors or damaged wiring harnesses d While depressing the Torch switch verify the OCV using a DC voltmeter The capability of the voltmeter should be more than 100VDC NOTE In TIG mode the OCV ceases 3 seconds after you depress the torch switch e The normal no load voltage is approximately 64V f Return PIN2 of DSW1 to the original position Art A 05899 Figure 6 17 Remove the indicated wire from the HF Unit August 12 2005 6 17 PRO LITE 160TS 6 10 Output Load Test This test verifies that the output curren
14. Art A 05964 Figure 6 88 TH1 4 Unplug harness connector circled as shown in Figure 6 89 from CN8 on PCB6 and remove the TH1 Art A 05965 Figure 6 89 Front side top view of CN8 August 12 2005 6 41 PRO LITE 160TS 6 21 Coupling Coil CC Test Procedure 1 Inspect the Coupling Coil CC for signs of overheating or loose connections 2 Check for continuity through the coupling coil by measuring between both of the terminals Replacement Procedure 1 Remove the side covers See section 6 01 2 Remove the screws 4 places circled as shown in Figure 6 91 from the front panel Art A 05967 Figure 6 91 Power supply front view of panel screws 3 Remove the screws holding the front panel and then the screws 2 places circled as shown in Figure 6 92 mounting the output terminals Art A 05968 Figure 6 92 Output terminal mounting screws 6 42 4 Unlock and remove the gas tube as shown in Figure 6 93 Art A 05969 Figure 6 93 Gas Tube 5 Disconnect the harnesses from CC1 and CC2 terminals by pulling up the harnesses lightly as shown in Figure 6 94 Art A 05970 Figure 6 94 CC1 and CC2 on HF UNIT 6 Remove the front panel from the chassis on the welding equipment Art A 05971 Figure 6 95 Front panel bottom view August 12 2005 7 Remove the insulating tube applied to the connection between CC and L1 Art A 05972 Figure 6 96 Intern
15. CONSEQUENTIAL DAMAGES SUCH AS BUT NOT LIMITED TO LOST PROFITS AND BUSINESS INTERRUPTION The remedies of the Purchaser set forth herein are exclusive and the liability of Thermal Arc with 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 negligence strict tort or under any warranty or otherwise shall not except as expressly provided herein exceed the price of the goods upon which such liability is based No employee agent or representative of Thermal Arc is authorized to change this warranty in any way or grant any other warranty PURCHASER S RIGHTS UNDER THIS WARRANTY ARE VOID IF REPLACEMENT PARTS OR ACCESSORIES ARE USED WHICH IN THERMAL ARC S SOLE JUDGEMENT MAY IMPAIR THE SAFETY OR PERFORMANCE OF ANY THERMAL ARC PRODUCT PURCHASER S RIGHTS UNDER THIS WARRANTY ARE VOID IF THE PRODUCT IS SOLD TO PURCHASER BY NON AUTHORIZED PERSONS The warranty is effective for the time stated below beginning on the date that the authorized distributor delivers the products to the Purchaser Notwithstanding the foregoing in no event shall the warranty period extend more than the time stated plus one year from the date Thermal Arc delivered the product to the authorized distributor ROWER SUPPLIES ALL OTHER CIRCUITS AND COMPONENTS INCLUDING BUT NOT LIMIT
16. HF TIG mode 8 pin remote control receptacle Used for connecting remote device A remote control device is required for use during LIFT TIG and HF TIG operation See section 4 01 page 4 2 Remote Control Socket for complete details of the remote device TIG Mode Functions Pressing this button scrolls through the output TIG function modes Standard Slope Slope w repeat opot Art A 05876 C1 Figure 4 5 160TS Front Panel Button Descriptions August 12 2005 4 9 PRO LITE 160TS 4 08 Stick Welding Setup 1 Connect electrode lead to positive terminal O c BR CO N 4 09 4 10 ae De de f 8 9 Connect work lead to negative terminal Switch machine on Set weld current Connect remote control device if required 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 Set HOT START Set WELD current Commence welding HF TIG amp Lift TIG Welding Setup Connect work lead to positive terminal Connect TIG torch to negative terminal owitch machine on Set weld current Connect remote control device remote control device is required for use during LIFT TIG and HF TIG operation See section 4 01 page 4 2 Remote Control Socket for complete details of the remote device Use the Scroll Buttons to move to the parameter to be set
17. PCB6 WK 4987 Refer to 6 15 for the replacement of PCB5 and PCB6 7 E94 Thermistor Failure Occurs when the thermistor for the temperature detection circuitry is open a Verify the wiring harness and connection between CN8 on PCB6 WK 4987 and thermistors TH1 Confirm a secure connection of the harness wired between CN8 on PCB6 and TH1 and Oo reinstall the harnesses with a secure connection Contact the manufacturer if you find any broken connectors or damaged wiring harnesses Replace thermistors TH1 Refer to section 6 20 for the replacement of THI O lt Replace PCB5 WK 4986 and PCB6 WK 4987 Refer to section 6 15 for the replacement of PCB5 and PCB6 6 5 PRO LITE 160TS 8 E99 Initial Power Receiving 6 6 Occurs when the initial AC power received signal has not reached the CPU NOTE This error occurs normally during the power OFF sequence of the unit a Verify the wiring harness and connection of CN1 on PCBS WK 4986 and CN8 on PCB2 WK 4977 Confirm a Secure connection of the harness wired between CN1 on PCB5 and CN8 on PCB2 O lt O and reinstall the harness with a secure connection Contact the manufacturer if you find any broken connectors or damaged wiring harness Verify and replace PCB2 WK 4977 Confirm a secure connection of the harness wired between CN13 on PCB1 and CN12 on PCB2 and reinstall the harness
18. PRO LITE 160TS Refer to Figure 3 1 and Input Voltage Fuse Size 1 Connect end of ground GREEN conductor to a suitable ground Use a grounding method that complies with all applicable electrical codes 2 Connectends ofline 1 BLACK and line 2 WHITE input conductors to a de energized line disconnect switch 3 Use Table 3 1 and Table 3 2 as a guide to select Fuse size is based on not more than 200 line fuses for the disconnect switch percent of the rated input amperage of the welding power source Based on Article 630 National Electrical Code Table 3 1 Electrical Input Connections Note P Ground Terminal Welding Power Supply Ground Conductor NS Line Disconnect Switch Primary Power Cable Art A 05872 Figure 3 1 Electrical Input Connections Each unit incorporates an INRUSH circuit and input voltage sensing circuit When the MAIN CIRCUIT SWITCH is turned on the inrush circuit provides a pre charging of the input capacitors SCR s in the Power Control Assembly PCA will turn on after the input capacitors have charged to full operating voltage after approximately 5 seconds Note Note the available input power Damage to the PCA could occur if 460VAC or higher is applied 3 2 August 12 2005 PRO LITE 160TS The following 115 230V Primary Current recommendations are required to obtain the maximum welding current and duty cycle from this welding equipment Current amp Duty Cy
19. Pull up the retainer bar that is securing the flat ribbon cable into CN5 circled as shown in Figure 6 42 Art A 05924 Figure 6 42 Retainer bar of CN5 on PCB2 15 Disconnect the flat ribbon cable from CN5 connector by pulling straight up on the cable Art A 05925 Figure 6 43 Removing cable from CN5 August 12 2005 PRO LITE 160TS 16 When reconnecting the flat cable make sure that it is oriented in such a manner that its lug portion is positioned on the front side When you reassemble the parts conduct this process backwards Check slide switches S1 S2 and S3 Identify locations of slide switches S1 S2 and S3 Make sure that all of S1 S2 and S3 are placed in their respective A positions i mee ps orm Sa dnkRex 4377 Art A 05926 Figure 6 44 1 S2 and 3 on PCB2 6 27 PRO LITE 160TS by arrow in Figure 6 47 Art A 05927 Figure 6 45 Power Source front view Art A 05929 Figure 6 47 Operation Panel and control knob cap 1 Remove the side covers See section 6 01 a m 4 Remove screw indicated by arrow in Figure 6 2 Remove the protection panel cover over the front 48 securing the control knob to the operation panel panel loosen the screw and remove the control To remove the protection panel cover push AOE OEE both edges of the cover in slightly as indicated by left and right arrows in Figure 6 46 and pull up the cover
20. Remove the screws securing D2 and D3 to heatsink 2 places for each 4 places in total circled as shown in figure 6 86 and remove the D2 and D3 Art A 05962 Figure 6 86 D2 and D3 Refer to NOTE on page 6 36 Art A 05963 Figure 6 87 Base surface of D2 D3 NOTE When you reassemble the parts conduct the above process backwards Additionally when install the diode apply 11 5in Ib force to the diode base screws Pay attention to the direction of the diode when installing the diode August 12 2005 PRO LITE 160TS 6 20 Thermistors TH1 NOTE When replacing the thermistors apply heat sink compound Shinetsu silicon G 747 or 1 Select the Ohms scale on the digital meter equivalent uniformly to the base surface of 2 Disconnect the connector at CN8 on PCB6 the thermistors as shown in Figure 6 90 Test Procedure 3 The resistance of a good sensor measured between pins 1 and 2 on the connector should be in the 10kW to 21 6kW range with the reading decreasing as the temperature of the power supply increases A shorted reading indicates a bad Sensor and it should be replaced Replacement Procedure 1 Remove the side covers See section 6 01 2 Remove PCB2 See section 6 13 Art A 05966 Figure 6 90 Base portion of TH1 3 Remove the screw circled as shown in Figure 6 88 securing TH1 to heatsink When you reassemble the parts conduct this process backwards 9 E
21. Voltage Failure procedure does not rectify the failure perform the following tests in the sequence below Replace any defective components found 1 Diode D2 D3 Refer to the Section 6 19 2 Coupling coil CC Refer to the Section 6 21 3 Reactor L1 Refer to the Section 6 22 4 Transformer T1 Refer to the Section 6 23 5 IGBT Q1 Refer to the Section 6 18 6 Hall CT CT1 Refer to the Section 6 24 4 Operating Panel Failure LED s do not light properly or welding setting cannot be establish Occurs when there is a connection failure among PCB4 WK 4985 PCB5 WK 4986 and PCB2 WK 4977 or PCBS and PCB2 are defective a Verify the harness connection between CN4 on PCB2 WK 4977 and CN1 on PCB5 WK 4986 Confirm a secure connection of the harness and the connections between CN4 on PCB2 and CN1 on PCB5 Contact the manufacturer if you find any broken connectors or damaged wiring harnesses b Verify the connection between PCB4 WK 4985 and PCB5 WK 4986 Confirm that all four connectors between PCB4 and PCB5 are tightly connected Confirm the condition of the pins on the connectors and the connectors themselves if bent pins or damaged connectors are found replace the suspected PCB Refer to section 6 14 for the replacement and installation of PCB4 and section 6 15 for PCB5 PCB6 WK 4987 Verify the connection between CN13 on PCB1 WK 4980 and CN12 on PCB2 WK 4977 O
22. before performing this Section Occurs when the 8 pin connector or associated circuitry is defective damaged or the TIG torch cable is defective m 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 a Verify the 8 pin connector Applies to LIFT TIG and High Frequency TIG HF TIG mode Confirm a secure between CON1 of the 8 pin connector and the remote device Confirm a secure connection of the harness and the connections between CON1 and PCB2 WK 4977 are all correct and there are no open Circuits Contact the manufacturer if you find any broken connectors or damaged wiring harnesses Confirm the proper pins outs of the 8 pin connector at the TIG Torch side Refer to section 4 01 Confirm that there is no open circuit on the 8 pin connector at TIG Torch side Verify the condition and connections of the welding cable the stick rod holders and the ground clamp Applies to all welding modes O lt Confirm 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 No OCV in section 6 08 first before continuing this section O lt If performing the No Load
23. gravement L lectrode et le circuit de soudage B sont sous tension des la mise en circuit Le 7 N utilisez que des porte lectrodes bien isol s Ne circuit d alimentation et les circuits internes jamais plonger les porte lectrodes dans l eau pour de l quipement sont aussi sous tension des les refroidir Ne jamais les laisser trainer par terre ou la mise en marche En soudage automatique sur les pi ces souder Ne touchez pas aux porte ou semi automatique avec fil ce dernier le lectrodes raccord s deux sources de courant en rouleau ou la bobine de fil le logement des m me temps Ne jamais toucher quelqu un d autre galets d entrainement et toutes les pi ces avec l lectrode ou le porte lectrode m talliques en contact avec le fil de soudage 8 N utilisez pas de c bles lectriques us s sont sous tension Un quipement a A a E endommag s mal piss s ou de section trop petite inad quatement install ou inad quatement mis la terre est dangereux 9 N enroulez pas de c bles lectriques autour de votre pr P fM COrps 1 6 August 12 2005 P WEE 160TS 10 N utilisez qu une bonne prise de masse pour la mise 1 Portez une casque de soudeur avec filtre oculaire de la terre de la pi ce souder nuance appropri e consultez la norme ANSI 749 indiqu e ci apr s pour vous prot ger le visage et les yeux lorsque vous soudez ou que vous observez l ex cution d une soud
24. meulage produisent des particules m talliques volantes En refroidissant la soudure peut projeter du clats de laitier EE 1 Portez un cran facial ou des lunettes protectrices approuv es Des crans lat raux sont recommand s 2 Portez des v tements appropri s pour prot ger la peau August 12 2005 Z 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 soudage traitez les avec soin SS al Prot gez les bouteilles de gaz comprim contre les sources de chaleur intense les chocs et les arcs de soudage AVERTISSEMENT 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 l
25. of equipment and proper welding technique Possible Cause Increase weld current 1 Excessive beard build up or poor A Welding current is too low penetration or poor fusion at and or faulty joint edges of weld preparation 2 Weld bead too wide and flat or A Welding current is too high JA Decrease weld current undercut at edges of weld or excessive burn through 3 Weld bead too small or Travel speed too fast Reduce travel speed insufficient penetration or ripples in bead are widely spaced apart 4 Weld bead too wide or excessive JA Travel speed too slow bead build up or excessive Increase travel speed penetra tion in butt joint 5 Uneven leg length in fillet joint A Wrong placement of filler rodjA Re position filler rod 6 Electrode melts when arc is A Electrode is connected to thelA Connect the electrode to Struck terminal the terminal Dirty weld pool A Electrode contaminated through contact with work piece or filler rod material A Clean the electrode by grinding off the contaminates B Gas contaminated with air B Check gas lines for cuts and loose fitting or change gas cylinder 8 Electrode melts or oxidizes when A No gas flowing to welding A Check the gas lines for an arc is struck region kinks or breaks and gas _ cylinder contents D Gas passage contains D Disconnect gas hose from impurities torch then raise gas pressure and blow ou
26. such as wire cable sleeving tubing etc and permanently 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 corresponding Parts List SPEC NUMBERS P Wee 160TS 100085 August 12 2005 P WEE 160TS f P WEE 160TS 7 03 Parts List DWG No Description Type amp Rating 1 2 August 12 2005 P WEE 160TS DWG No Description Type amp Rating August 12 2005 1 3 P WEE 160TS DWG No Description Type amp Rating 7 4 August 12 2005 August 12 2005 T1 Art A 06007 Art A 06008 P WEE 160TS 1 5 P WEE 160TS SOL Art A 06009 1 6 August 12 2005 APPENDIX 1 GENERAL INFORMATION e Note the model and specification number shown on the equipment nameplate August 12 2005 P WEE 160TS A 1 P WEE 160TS APPENDIX 2 INTERCONNECT DIAGRAM SERIAL NUMBERS XXXXXXA AND EARLIER id oa a c PCB1 Q1 Main 2 ZZ Circuit Board WK4980 pnis G1 E1 PCB3 IGBT Gate Circuit Board WK3367 IN Circuit Board IN WK5015 SIDE CHASSIS 5 Ground REAR PANEL SIDE CHASSIS 4 Connect Circuit Board PCB2 WK5071 Main 1 Circuit
27. the unit Voltage measurement PIN 1 Remed PIN 2 of CN3 on PCB2 Replace PCB2 WK 4977 Case 2 Rotating Refer to section 6 13 Replace PCB2 WK 4977 Case 3 Refer to section 6 13 Table 6 2 Possible Failure Modes for Fan1 August 12 2005 PRO LITE 160TS and Drive Circuitry chart below for possible failure modes Refer to Notes on page 6 15 1 Verify the voltage between the PIN 3 and PIN 4 of connector CN3 on PCB2 WK 4977 while you press the torch switch while in TIG Mode The capacity of the voltmeter should be more than 50VDC The location of connector CN3 of PCB2 WK 4977 is indicated in Figures 6 15 through 6 16 Refer to Note on page 6 14 Voltage Measurment Between PIN 3 PIN 4 of Remedy CN3 on PCB2 Art A 05897 Figure 6 15 The check point CN3 on PCB2 Art A 05898 Figure 6 16 Check points SOL Voltage 6 16 August 12 2005 6 09 Verification of No load voltage No OCV 1 Verify the no load voltage in Stick mode m CAUTION Electric shock hazard The unit will generate OCV immediately when STICK mode is selected a In STICK welding mode mark and then place PIN2 of DSW1 on PCB5 WK 4986 in OFF position to turn off the electric shock protector function Voltage Reduction Device VRD b Verify the no load voltage using a DC voltmeter The capability of the voltmeter should be more than 100VDC c The normal no load voltage is approximately
28. with a secure connection Refer to section 6 13 for the replacement of PCB2 Replace PCBS WK 4986 and PCB6 WK 4987 Refer to section 6 15 for the replacement of PCB5 and PCB6 August 12 2005 6 03 Verification and Remedy to Failures without Indication Codes See Notes on page 6 4 and symptom cause remedy example on the same page 1 Cooling Fan Failure Fan is not rotating Occurs when the cooling fan is defective damaged or the driving voltage is incorrect a O O lt Verify the cooling fan FANT 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 Verify that there are no wiring harnesses entangled inside the fan confirm that the harnesses do not have any brakes in the wire or damaged connectors Contact the manufacturer if you find any broken connectors or damaged wiring harnesses Replace the fan if there are any broken cracked or missing fan blades Refer to section 6 25 for replacement of FAN Verify the wiring harness between the cooling fan FAN1 and CN3 on PCB2 WK 4977 Confirm a secure connection of the harness to CN3 on PCB2 Contact the manufacturer if you find any broken connectors or damaged wiring harnesses
29. work and inserting the electrode in the electrode holder make sure the Primary power supply is switched off m 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 m CAUTION DO NOT change the Weld Mode or Weld Process Mode until after POST FLOW time has finished OS OKO Figure 4 4 160TS Setup 4 8 August 12 2005 4 07 SEQUENCE OF OPERATION 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 NOTE Scroll Buttons are used to select the parameters to be set The LED s show which function is being adjusted on the weld sequence graph Refer to Symbols Table located in the front of the manual for Symbol descriptions 3 Digital LED display Welding amperage and parameter values are displayed in this window Internal warnings such as over temperature low or high input voltage applied are signaled to the operator by a warning sound and error message on the screen PRO LITE 160TS Control knob Allows the operator to adjust the output amperage Within the entire range of the power source also used to set each parameter value Pushing the knob inward displays the actual welding voltage Process Button This button selects between STICK Lift or
30. 005 4 3 PRO LITE 160TS 4 02 Weld Parameters and Descriptions 4 4 PRE FLOW PA HOT START Art A 05874 Figure 4 3 Front Panel Description This parameter operates in TIG modes only and is used to get gas to the weld zone prior to striking the arc once the torch trigger switch has been pressed This control is used to dramatically reduce weld porosity at the start of a weld This parameter operates in all weld modes except Lift TIG mode and is used to heat up the weld zone in TIG modes or improve the start characteristics for stick electrodes 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 released 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 TIG WELD current in S7D SLOPE REPEATand SPOT modes when PULSE is off This parameter also sets the STICK weld current Table 4 2a Weld Parameter Descriptions August 12 2005 PRO LITE 160TS DOWN SLOPE This parameter operates in TIG modes only and is used to s
31. 3 INSTALLATION 3 01 Environment The P Wee 160TS is designed for use in adverse environments Examples of environments with increased adverse conditions are a In locations in which freedom of movement is restricted so that the operator is forced to perform the work in a cramped kneeling sitting or lying position with physical contact with conductive parts b 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 but 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 steam and corrosive gases In areas not subjected to abnormal vibration or shock In areas not exposed to direct sunlight or rain Place at a distance of 12 304 9mm or more from walls or similar that could restrict natural airflow for cooling WARNING Thermal Arc advises that this equipment be electrically connected by a
32. 5 01 System Level Fault Isolation cioc ceeace annee aaa dat 6 2 6 02 Verification and Remedy to the Indicated Error Codes 6 4 6 03 Verification and Remedy to Failures without Indication Codes 6 7 6 04 Preparation of Fault Isolation Tests ccce 6 10 6 05 Verification of the power input circuitry eene 6 10 6 06 Power Supply Voltage Re ca second 6 12 6 07 Verification of the Cooling Fan1 and Drive Circuitry 6 14 6 08 Verification of the Solenoid Valve and Drive Circuitry 6 16 6 09 Verification of No load voltage NO OCV ou eee 6 17 6 10 Output Load TES micii dooain aia aia dan i a inca ia aa amer aa a ace 6 18 6 11 Preparation for Subsystem Test and Replacement procedures 6 19 6 12 PCB1 Replacement Procedure 6 23 6 13 PCB2 Replacement Procedure 6 25 6 14 PCB4 Replacement Procedure 6 28 6 15 PCB5 and PCB6 Replacement Procedure eee eee 6 31 6 16 Switch S1 Replacement Procedure eeeeennne 6 34 6 17 Semiconductor Diode DT inserer 6 35 6 18 Semiconductor IGBT QT iii 6 37 6 19 Semiconductor Diode D2 D3 ie 6 39 6 20 Thermistors HI eee 6 41 6 21 COURIR eA E e E mda Rd aa i iat 6 42 6 22 Reactor seaiecite tau aa tea so it aaa ed ad eee ul Bd Bai a a a ei idee e 6 44 AO IEI si ceai oara ae orare e ad aaa Eat tari t
33. Association Standards Sales 1 8 Rexdale Boulevard Rexdale Ontario Canada MOW 1R3 Safe Practices for Occupation and Educational Eye and Face Protection ANSI Standard 287 1 from American National Standards Institute 1430 Broadway New York NY 10018 Cutting and Welding Processes NFPA Standard 51B from National Fire Protection Association Batterymarch Park Quincy MA 02269 P WEE 160TS 1 03 PRECAUTIONS DE SECURITE EN SOUDAGE A L ARC A MISE EN GARDE LE SOUDAGE A LARC EST DANGEREUX PROTEGEZ VOUS AINSI QUE LES AUTRES CONTRE LES BLESSURES GRAVES POSSIBLES OU LA MORT NE LAISSEZ PAS LES ENFANTS S APPROCHER NI LES PORTEURS DE STIMULATEUR CARDIAQUE A MOINS QU ILS N AIENT CONSULTE UN MEDECIN CONSERVEZ CES INSTRUCTIONS LISEZ LE MANUEL D OPERATION OU LES INSTRUC TIONS AVANT D INSTALLER UTILISER OU ENTRETENIR CET EQUIPEMENT Les produits et proc d s de soudage peuvent sauser des blessures graves ou la mort de m me que des dommages au reste du mat riel et la propri t si l utilisateur n adh re pas strictement toutes les r gles de s curit et ne prend pas les pr cautions n cessaires En soudage et coupage des pratiques s curitaires se sont d velopp es suite l exp rience pass e Ces 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 Certai
34. Board WK4977 Case Ground Contactor Control 1 24VDC Contactor Control 2 GND 12VDC Supply Potentiometer Maximum Potentiometer Minimum GND Amperage Control Wiper 0 10VDC Remote Installed 12VDC Front View 26 r SIDE CHASSIS 3 AI215 1415161718 Art A 06010 1 2 3 4 5 6 7 8 A 2 August 12 2005 P WEE 160TS CT1 TO1 Output o Terminal C4 CC TO2 Output AIT O Femina SIDE CHASSIS 1 B2 AC SIDE CHASSIS 2 PCB6 Circuit Board LE PCB5 WK498 7 Control 1 Circuit Board WK4986 NETL NETL ne CN4 CN5 CN6 CN7 PCB4 Panel Circuit Board WK4985 Lil Art A 06010 August 12 2005 A 3 P WEE 160TS APPENDIX 3 INTERCONNECT DIAGRAM SERIAL NUMBERS XXXXXXA103067 AND LATER _ i PCB1 Q1 Main 2 Ye Circuit Board WK4980 l G1 E1 PCB3 Sir i IGBT Gate IMI Circuit Board WK3367 17 Diod 1Circuit Board TB10 Un TB11 WK5015 SIDE CHASSIS 5 Ground D REAR PANEL SIDE CHASSIS 4 SOLENOID1 Owe PCB8 Connect Circuit Board PCB2 WK5071 Main 4 Circuit Board WK4977 Case Ground Contactor Control 1 24VDC Contactor Control 2 GND 12VDC Supply Potentiometer Maximum Potentiometer Minimum GND Amperage Control Wiper 0 10VDC Remote Installed 12VDC Front Vi
35. ED TO CONTACTORS RELAYS SOLENOIDS PUMPS 1 YEAR 1 YEAR POWER SWITCHING SEMI CONDUCTORS ENGINES ENGINES ARE NOT WARRANTED BY THERMAL ARC ALTHOUGH MOST ARE WARRANTED BY THE ENGINE MANUFACTURER SEE THE ENGINE MANUFACTURE S 1 YEAR 1 YEAR WARRANTY FOR DETAILS CONSOLES CONTROL EQUIPMENT HEAT EXCHANGES ACCESSORY EQUIPMENT NOTE Dragster 85 excluded from this policy Refer to Dragster 85 warranty in Dragster 85 Owner s Manual Warranty repairs or replacement claims under this limited warranty must be submitted to Thermal Arc by an authorized Thermal Arc repair facility within thirty 30 days of purchaser s notice of any Warranty Claim No transportation costs of any kind will be paid under this warranty Transportation charges to send products to an authorized warranty repair facility shall be the responsibility of the Purchaser All returned goods shall be at the Purchaser s risk and expense This warranty supersedes all previous Thermal Arc warranties Thermal Arc is a Registered Trademark of Thermadyne Industries Inc September 27 2004 August 12 2005 1 11 P WEE 160TS 1 12 August 12 2005 SECTION 2 INTRODUCTION 2 01 Scope of Manual This manual provides service instructions for the Thermal Arc 160TS Inverter Arc Welder Information in this edition is particularly applicable to the troubleshooting and repair of the equipment For information on operating procedures please refer to the 1601S Inverter Arc Wel
36. IHERMAL A RC 16075 P WEE INVERTER ARC WELDER Art A 05870 ervice Manual Version No AA Issue Date August 12 2005 Manual No 0 4754 Operating Features LES S ec oc o IHERMAL 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 1 800 752 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
37. The LED will show which function is being adjusted on the weld sequence graph Use the control knob to adjust each parameter Set PRE FLOW time Set HOT START current Set POST FLOW time 10 Set WELD current 11 Set POST FLOW time Slope Mode Parameters if required 12 Set INITIAL CUR current 13 Set UP SLOPE time 14 Set WELD PEAK CUR current 15 Set BASE current 16 Set DOWN SLOPE time 17 Set CRATER CUR current Pulse Mode parameters if required 18 Set PULSE WIDTH for PEAK CURRENT 19 Set PEAK CURRENT 20 Set PULSE FREQ 21 Commence welding August 12 2005 4 10 Slope Mode Sequence Description NOTE Slope function operates with a Remote ON OFF device only 1 To start Slope sequence Close remote switch contacts Once the welding arc is established the Power Source will maintain 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 current setting b In the Lift TIG mode after preflow time Lift 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 2 Open Remote Switch Current increases to weld current Once welding arc has reached weld current the power source will maintain
38. a aste a ate 3 4 3 06 High Frequency Interference 2 22 ac at ra a 3 4 TABLE OF CONTENTS SECTION 4 OPERATION ee ee ae ee de eee es ee 4 1 COR a alia al 4 1 4 02 Weld Parameters and Descriptions cece cecene eee eee eeaaae eee 4 4 4 03 Weld FaratflBlBES cosas dea aoleu aaa aa aaa o ll aia tt dati 4 5 4 04 Weld Process selection mes eee sido atitea aia beat ind ada arii dt aa tal 4 6 4 05 Power Source FAT iat en ai ti d at a 4 7 4 seis ifs erc tad RR 4 8 4 07 SEQUENCE OF OPERATION oces 4 9 4 08 Stick Welding Setup men eee eneeeeeaneeeane ana aee eee ana 4 10 4 09 HF TIG amp Lift TIG Welding Setup 4 10 4 10 Slope Mode Sequence Description nenea 4 11 4 11 Pulse Controls inner 4 12 4 12 Switching VRD On Off 4 13 4 13 SEQUENCE TIMING DIAGRAMS scenerne 4 14 SECTION 5 ddl A 9 ia 5 1 5 01 Routine MOITtelldf GO SR uta a ti ti ie e tie ol a la 5 1 9 07 Basic OS OR area at au ccce sensit tuer a ded a a pem ELLE 5 1 5 03 TIG Welding Problems OPRIRI III RR AR IERI RR IRI IE RI dtum set RR RI RTS 5 2 5 04 Stick Welding Problems e eee nns 5 4 5 05 Power Source Problems nnns 5 6 5 06 VOLTAGE REDUCTION DEVICE VRD eene 5 7 9 07 POWER SOURCE ERROR CODES a aa ur Fco at 0 0 TABLE OF CONTENTS SECTION 6 ADVANCED TROUBLESHOOTING 6 1
39. 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 outlined in the American National Standard 749 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 3 Insulate yourself from work and ground using dry insulating mats or covers 4 Disconnect input power or stop engine before installing or servicing this equipment Lock input WARNING power disconnect switch open or remove line fuses so power cannot be turned on accidentally 5 Properly install and ground this equipment according to its Owner s Manual and national state and local codes ELECTRIC SHOCK can kill Touching live electrical parts can cause fatal shocks or severe burns The electrode and work circuit is electrically live whenever the 6 Turn off all equipment when not in use Disconnect power to equipment if it will be left unattended or
40. al TABLE OF CONTENTS SECTION 1 SAFETY INSTRUCTIONS AND WARNINGS 1 1 LOLA eC OL A022 0 Senne tame stati in atei ainu e a ee 1 1 1 02 PRINCIPAL SAP PES ANDRE cai setate tere uda scada ali rea cate 1 5 1 03 PRECAUTIONS DE SECURITE EN SOUDAGE A LARC 1 6 1 04 Dangers relatifs au soudage l arc 1 6 1 05 PRINCIPALES NORMES DE SECURITE 22 5 1 10 LOGEMENT m 1 11 SECTION 2 INTRODUCTION taram cutate nat aa Dutu apelata Cala arata teens a iata i Bi 2 1 2 01 Scope of Manual ee el oi iasa 2 1 2 02 General Service Philosophy 2 aia azur a i data 2 1 2 03 5 rvice a ets DONS IDE aa ate tata ata 2 1 POE VOOM GIA NR ee a a ta aa o d 2 2 2 05 160TS Inverter Arc Welder Description eeeeenee 2 3 2 06 Functional Block Diagrams oase ao atit aia i at ea at o it 2 3 PA 6 7 DOCINCIHOTIS RR RR RR RR PRR RR DOR RE RE IE IRI RR NR IRI ain 2 4 2 08 Transporting MethodS seic erei ratata la nai a ute 2 5 209 DUN AO LE 2 5 SECTION 3 INSTALLATION ese ceasca e cra te Buta it a natia tt Brie ra ai lt lvl la 3 1 3 0 EVO EI Se oaia adela maestra ie 3 1 SRI LOCION PREIEI ERIE NE PER RE ICR PRAI RENE PRR POR IEN ICR SR PIE PNI 3 1 3 03 Electrical Input Connections scx cece ea 3 1 3 04 Electrical Input Requirements 2282 aseara at dmat a 3 1 aoo COUL ucis cicerac ata masaje tii aaa de iasa n
41. al front view 8 Remove the insulating tube and then the screw connecting CC to L1 circled as shown in Figure 6 97 and remove the CC Art A 05973 Figure 6 97 Coupling Coil CC When you reassemble the parts conduct this process backwards August 12 2005 PRO LITE 160TS 6 43 PRO LITE 160TS 6 22 Reactor L1 Test Procedure 1 Inspect the Reactor L1 for signs of overheating or loose connections 2 Check for continuity through the Reactor by measuring between both of the terminals 4 Remove the screw connecting L1 to T1 circled as Shown in Figure 6 99 Replacement Procedure 1 Remove the side covers See section 6 01 2 Remove PCB2 See section 6 13 3 Remove the insulating tube applied to the F connection between L1 and T1 Figure 6 99 Screw connecting L1 to T1 5 Remove the screws 4 places circled as shown in Figure 6 100 from the front panel Art A 05967 Figure 6 100 Power supply front view of 4 screws 6 Remove the screws holding the front panel and then the bolts 2 places circled as shown in Figure 6 101 mounting the output terminals E Art A 05974 Figure 6 98 Insulating tube KENNA a EY till ba ALU Art A 05968 Figure 6 101 Output terminal mounting screws 6 44 August 12 2005 PRO LITE 160TS 7 Unlock and remove the gas tube as shown in 10 Remove the screw connecting L1 to CC circled Figure 6 102
42. anel cover over the front panel o remove the protection panel cover push both edges of the cover in slightly as indicated by left and right arrows in Figure 6 6 56 and pull up the cover frontward Art A 05928 Figure 6 56 Protection Panel Cover August 12 2005 PRO LITE 160TS 3 Remove the screws 4 places circled as shown in Figure 6 57 holding the operation panel onto the front panel Art A 05937 Figure 6 57 Operation Panel 4 Unplug harness connectors 3 places circled as shown in Figure 6 58 from CN1 on PCB5 and from CN8 and CN9 on PCB6 Art A 05932 Figure 6 58 Front side top view 6 31 PRO LITE 160TS 5 Pull the operation panel out of the front panel frontward Art A 05988 Figure 6 59 Operation panel removed from front panel 6 32 6 Disconnected and remove PCB5 and PCB6 from PCB4 by pulling the two PCB s apart Te a Art A 05934 Figure 6 60 Disassembling the operation panel 7 Remove the retainer plugs 3 places circled as shown in Figure 6 61 securing PCB5 to PCB6 M Art A 05938 Figure 6 61 B side view of PCB6 August 12 2005 8 Disconnect the flat ribbon cable circled as shown in Figure 6 62 from PCB6 with PCBS and PCB6 pulling open and away as shown in Figure 6 62 Art A 05939 Figure 6 62 Flat Ribbon Cable on PCB6 9 Pull up the retainer bar securing the flat ribbon cable into CN5 circled as shown in Fi
43. as shown in Figure 6 105 PU MR AGIT ps Y Art A 05973 Figure 6 102 Gas Tube Figure 6 105 L1 and CC 8 Remove the front panel from the chassis on the 11 Remove the screws 2 places circled as shown welding equipment in Figure 6 106 mounting L1 on chassis p i m 5j s mi NI i Art A 05971 ate m Figure 6 103 Front panel bottom view Figure 6 106 L1 9 Remove the insulating tube applied to the 12 Pull L1 out of the welding equipment as shown connection between L1 and CC in Figure 6 107 and remove the L1 H si P d Art A 05972 Art A 05977 Figure 6 104 Internal front view Figure 6 107 Remove L1 When you reassemble the parts conduct this process backwards August 12 2005 6 45 PRO LITE 160TS 6 23 Transformer T1 Test Procedure 1 Inspect the Transformer T1 for signs of overheating or loose connections 2 Check for continuity across the primary windings of both transformers 3 Check for continuity across the secondary windings of both transformers 4 Check for insulation between the primary winding and the secondary winding of both transformers Replacement Procedure 1 Remove the side covers See section 6 01 2 Remove PCB1 See section 6 12 Art A 05978 Figure 6 108 Internal view PCB1 side 3 Remove the insulating tube applied to the connection between T1 and C1 Art A 05979 Figure 6 109 Insulat
44. at the FAN is not producing any abnormal sounds If broken or cracked FAN1 blades or abnormal sounds are emanating from FAN1 replace FAN1 Refer to section 6 25 for the replacement of FAN Refer to section 6 07 for addition FAN1 tests Verify the operation of the cooling fan and replace it if the condition of FAN1 is inactive Follow the instruction in section 6 07 Replace PCBS WK 4986 and PCB6 WK 4987 Refer to section 6 15 for the replacement of PCB5 and PCB6 5 E03 Primary Over Current Failure Occurs when excessive current is detected flowing into the primary side of the main transformer a Confirm the operation of the machine within the rated specification Refer to the specification data sheet in Section 2 b Verify the secondary diode D2 and D3 C Refer to section 6 19 for the test and replacement of D2 and D3 Verify the H F unit HF UNIT Refer to section 6 26 for the replacement of HF UNITI August 12 2005 d e PRO LITE 160TS Verify the primary IGBT Q1 Refer to section 6 18 for the test and replacement of Q1 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 Refer to section 6 24 for the replacement of CT1 6 E93 Memory Failure Occurs when the memory fails to save the requested welding parameters a Replace PCB5 WK 4986 and
45. ator cap when engine is hot Allow engine to cool 2 Wear gloves and put a rag over cap area when removing cap 3 Allow pressure to escape before completely removing cap August 12 2005 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 very large volume of Scientific findings based on experiments at the cellular level and from studies with animals and people which clearly establish that low frequency magnetic fields and interact with and produce changes in biological systems While most of this work is of very high quality the results are complex Current scientific understanding does not yet allow us to interpret the evidence in a single coherent framework Even 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 mi
46. ber Print Circuit Board WK 4986 with PCB6 with Flat Cable Art A 05900 Figure 6 18 Location of PCB1 PCB2 PCB4 PCB5 August 12 2005 6 19 PRO LITE 160TS No item Code Description Manual Section Number Art A 05901 Figure 6 19 Location of T1 HF UNIT CC L1 6 20 August 12 2005 August 12 2005 PRO LITE 160TS No liem Description Manual Section Number Art A 05902 Figure 6 20 Location of above parts 6 21 PRO LITE 160TS Service Tools Art A 05903 Nut Driver Open End Philips Head Slotted Head Long Nose Diagonal Lr Piers Torque Wrench Box Wrench screwdriver Screwdriver Pliers Cutter 9 Figure 6 21 Service tools needed Nut driver and open end box wrench sizes Art A 05904 55mm mm 8mm 10mm 12mm Figure 6 22 Nut driver and open end wrench sizes 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 supports August 12 2005 6 12 PCB1 Replacement Procedure 1 Remove the side covers See section 6 01 2 Remove the three 3 screws circled as shown in Figure 6 23 mounting PCB1 on chassis Figure 6 23 PCB1 mounted chassis 3 Re
47. cle Primary Supply Lead Size Minimum Primary Current Factory Fitted Circuit Size Vin Amps TIG STICK P Wee 160TS 12 3 AWG minimum Table 3 2 115 230V Primary Current Circuit sizes to achieve maximum current August 12 2005 3 3 PRO LITE 160TS 3 05 High Frequency Introduction The importance of correct installation of high frequency welding equipment cannot be overemphasized Interference due to high frequency initiated or stabilized arc is almost invariably traced to improper installation The following information is intended as a guide for personnel installing high frequency welding machines A WARNING EXPLOSIVES The high frequency section of this machine has an output similar to a radio transmitter The machine should NOT be used in the vicinity of blasting operations due to the danger of premature firing A WARNING COMPUTERS It is also possible that operation close to computer installations may cause computer malfunction 3 4 3 06 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 Suppl
48. contactor device Pulse Operation in TIG Modes Table 4 5 Weld Process selection verses Weld Mode 4 6 August 12 2005 PRO LITE 160TS 4 05 Power Source Features Feature Description Digital Meter C Displays weld current for 20 seconds after weld has been completed Voltage Reduction Device VRD Control Knob Self Diagnosis Using Error A An error code is displayed on the Dig ta Mefterwhen a problem Codes occurs with Mains supply voltage or internal component problems Refer to service section 5 Table 4 6 Power Source Features August 12 2005 4 7 PRO LITE 160TS 4 06 General Set Up Conventional operating procedures apply when using the Welding Power Source i e connect work lead directly to Work piece and electrode lead is used to hold electrode Wide safety margins provided by the coil design ensure that the Welding Power Source will withstand short term overload without adverse effects The welding current range values should be used as a guide only 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 Art A 05875 WARNING Before connecting the work clamp to the
49. controls mounting screws Art A 0560 Figure 4 9 VRD ON OFF step b c Access the VRD control see Figure 4 10 Gently pry back the front panel controls to access the VRD on off switch m 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 August 12 2005 PRO LITE 160TS Art A 05606 Figure 4 10 VRD ON OFF step c d Turning the VRD ON OFF see Figure 4 11 To turn VRD ON rotate the trim potentiometer on the display PCB fully clockwise When VRD is turned ON check that it operates as per VRD Specifications in Table 5 4 page 5 7 To turn VRD OFF rotate the trim potentiometer on the display PCB fully counter clockwise A WARNING The VRD ON OFF trim potentiometer MUST ONLY be positioned fully clockwise OR fully counter clockwise as the VAD function will be unknown for every other position Art A 05607 Figure 4 11 VRD ON OFF step d 4 13 PRO LITE 160TS 4 13 SEQUENCE TIMING DIAGRAMS STICK Mode STICK with VRD DISABLED Voltage Reduction Device Figure 4 12 shows the STICK timing waveforms with the VRD control DISABLED Placing Pin2 of DSW1 on PCB5 WK 4986 in the OFF position to turn off the VRD Arc Control Output Current ollm OCV Output Voltage Arc control level about 18V Art A 05879
50. d Face Protection norme ANSI Z87 1 American National Standards Institute 1430 Broadway New York NY 10018 Cutting and Welding Processes norme 51B NFPA National Fire Protection Association Batterymarch Park Quincy MA 02269 August 12 2005 P WEE 160TS 1 06 LIMITED WARRANTY LIMITED WARRANTY Thermal Arc Inc A Thermadyne Company hereafter Thermal Arc warrants to customers of itsauthorized distributors hereafter Purchaser that its products will be free of defects in workmanship or material Should anyfailure to conform to this warranty appear within the time period applicable to the Thermal Arc products as stated below Thermal Arc shall upon notification thereof and substantiation that the product has been stored installed operated and maintained in accordance with Thermal Arc s specifications instructions recommendations and recognized standard industry practice and not subject to misuse repair neglect alteration or accident correct such defects by suitable repair or replacement at Thermal Arc s sole option of any components or parts of the product determined by Thermal Arc to be defective THERMAL ARC MAKES NO OTHER WARRANTY EXPRESS OR IMPLIED THIS WARRANTY IS EXCLUSIVE AND IN LIEU OF ALL OTHERS INCLUDING BUT NOT LIMITED TO ANY WARRANTY OF MERCHANTABILITY OR FITNESS FOR ANY PARTICULAR PURPOSE LIMITATION OF LIABILITY THERMAL ARC SHALL NOT UNDER ANY CIRCUMSTANCES BE LIABLE FOR SPECIAL INDIRECT OR
51. der Operating Manual 430429 505 NOTE Service of this equipment is restricted to properly trained service technicians familiar with this equipment unqualified personnel are Strictly cautioned against attempting repairs or adjustments not covered in this manual at the risk of voiding the warranty Read both this manual and the Operating Manual thoroughly A complete understanding of the capabilities and functions of the equipment will assure obtaining the performance for which it was designed A WARNING There are extremely dangerous voltage and power levels present inside this unit Do not attempt to diagnose or repair unless you have had training in high power electronics measurement and troubleshooting 2 02 General Service Philosophy several key points are essential to properly support the application and operation of this equipment A Application Confirm that the equipment is capable of handling the application desired Specifications supplied and described in Subsection 2 08 of this manual B Modifications No physical or electrical modifications other than Selection of standard options and accessories are to be made to this equipment August 12 2005 PRO LITE 160TS C Customer Operator Responsibilities It is the customer operator s responsibility to maintain the equipment and peripheral accessories provided by Thermal Dynamics in good operating order in accordance with the procedures outlined in t
52. e 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 and PIN 2 of CN3 on PCB2 WK 4977 The location of connector CN3 of PCB2 WK 4977 is indicated in Figures 6 13 and Pin1 and Pin2 in 6 14 NOTE When you measure the above voltage do not remove the connector Conduct the measurement while the connector plug and receptacle are still connected F i i 1 d TE d a 2 rua E ES T Am B i ia 1 Fh i E Eg P mh S MN H ra p m 1 M r s hl Li wl p d j T Li LL a y E ca a z J a nr E gi m ai E a z s i E RN a as LES JI LJ al i mb D ee im LU Ww es a i EN d z M m Art A 05895 Figure 6 13 Connector CN3 on PCB2 Art A 05896 Figure 6 14 Check Points on CN3 for Fant 6 14 August 12 2005 PRO LITE 160TS 2 Using the measurement taken in step 1 follow Table 6 2 below for possible failure modes NOTE This welding unit has a feature that will slow the rotational speed of the cooling fan during low output current and while in standby Under these conditions the voltages in the above table will be inaccurate therefore when verifying the voltage do so during the failure condition NOTE When verifying the voltage confirm that the AC input voltage remain within the operating range of
53. e harnesses from HF UNIT resistor R2 terminals R1 and R2 terminals circled as shown in Figure 6 135 Art A 06000 Figure 6 135 R1 and R2 on HF UNIT August 12 2005 PRO LITE 160TS 4 Disconnect the harnesses from the terminals on the Welding Power Source side ACT and AC2 terminals circled as shown in Figure 6 136 i F4 2 Je A Ce Jg i E es am EE ai ai Art A 06001 Figure 6 136 AC1 and AC2 on HF UNIT 5 Remove the screws circled as shown in Figure 6 137 mounting HEUNIT on chassis Art A 06002 Figure 6 137 HF UNIT mounting screws 6 51 PRO LITE 160TS 6 Remove HF UNIT from the chassis on the welding equipment and Pull up and remove GAP mounted on HF UNIT as shown in Figure 6 138 Art A 06003 Figure 6 138 HF UNIT and GAP When you reassemble the parts conduct this process backwards 6 52 August 12 2005 6 27 Current limiting Resistor for HF UNIT R2 Test Procedure 1 Inspect the Resistor R2 for signs of overheating or loose connections 2 With an Ohmmeter set the R 1 scale measure between both of the terminals as about 150W Replacement Procedure 1 Remove the side covers See section 6 01 2 Unplug the harnesses from HF UNIT resistor R2 terminals R1 and R2 terminals circled as shown in Figure 6 139 gt a Art A 06004 Figure 6 139 Expanded bottom view 3 Remo
54. e ra aa 6 46 6 24 Hall Current Transformer HCT CIN ne aie ai a aaa s 6 49 6 25 FANI Replacemeril PTOCEMUE m 2 edita aaa tai nad 6 50 6 26 HF UNIT Replacement Procedure uuu nenea eee 6 51 6 27 Current limiting Resistor for HF UNIT R2 eee 6 53 6 28 Gas Valve SOL Replacement Procedure naien 6 54 SECTION 7 PARIS EIST c ES 7 1 7 01 Equipment Identification 1 1 A02 Aow T0 Use HIS PAS aa sat saca ii a setat d 1 1 7 03 Parts List eee oana 1 2 TABLE OF CONTENTS APPENDIX 1 GENERAL INFORMATION APPENDIX 2 INTERCONNECT DIAGRAM SERIAL NUMBERS XXXXXXA AND EARLIER A 2 APPENDIX 3 INTERCONNECT DIAGRAM SERIAL NUMBERS XXXXXXA103067 AND LATER A 4 APPENDIX 4 HARDWARE TES A 6 APPENDIX 5 AUTOMATION A 8 APPENDIX 6 DIODE TESTING BASICS A 10 P WEE 160TS SECTION 1 SAFETY INSTRUCTIONS AND WARNINGS WARNING PROTECT YOURSELF AND OTHERS FROM POSSIBLE SERIOUS INJURY OR DEATH KEEP CHILDREN AWAY PACEMAKER WEARERS KEEP AWAY UNTIL CONSULTING YOUR DOCTOR DO NOT LOSE THESE INSTRUCTIONS READ OPERATING INSTRUCTION MANUAL BEFORE INSTALLING OPERATING OR SERVICING THIS EQUIPMENT 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
55. ean trapped in the weld metal trapped in undercut from Slag out and cover with a run slag inclusion previous run from a smaller diameter electrode B Joint preparation too B Allow for adequate penetration restricted and room for cleaning out the Slag Sufficient current to give adequate penetration Use Suitable tools to remove all slag from corners F Wrong electrode for position F Use electrodes designed for in which welding is done position in which welding is done otherwise proper control of Slag is difficult Table 5 2c Stick Welding Problems Art A 05612 T A Figure 5 3 Examples of slag inclusion August 12 2005 5 5 PRO LITE 160TS 5 05 Power Source Problems J Description Possible Gauss Remedy 1 The welding arc cannot be established 2 Maximum output welding curernt can not be achieved with nominal Mains supply voltage 3 Welding current reduces when welding 4 No gas flow when the torch trigger switch is depressed B Gas passage contains impurities B Disconnect gas hose from the rear of Power Source then raise gas pressure and blow out impurities D Torch trigger switch lead is D Reconnect lead or repair faulty disconnected or switch cable switch cable is faulty A Weld Mode STD SLOPE JA Strike an arc to complete the weld REPEATor SPOT was cycle OR Must switch machine changed before POST off then on to reset solenoid FLOW gas time had valve
56. ed below and clicking on the Literature Library link http www thermalarc com 2 1 PRO LITE 160TS 2 04 Symbol Chart Note that only some of these symbols will appear on your model Wire Feed Towards Workpiece With Output Voltage Off Three Phase Static Frequency Converter Welding Gun Transformer Rectifier 2 Continuous Weld Circuit Breaker x Duty Cycle Mode PR AC Auxiliary Power O Percentage Spot Weld Mode O A Shielded Metal 2 Preflow Time DIS Arc Welding SMAW t1 Gas Metal Arc Gas Tungsten Arc f 2 Step Trigger Z Hertz cycles sec Welding GTAW __ Operation Press to initiate wirefeed and Air Carbon Arc welding release to stop f PEBHBONEN Cutting CAC A J P 4 Step Trigger fe 0 Sons D d nop Operation Press and hold for preflow release Positi Constant Voltage to start arc Press to stop arc and MEME Or Constant Potential hold for preflow V Direct Current DC High Temperature At Burnback Time Protective Earth L Disturbance In Ground ault Indication Ground System Spot Time Line Connection Touch Start GTAW Meters Per Minute Auxiliary Power Receptacle Rating Auxiliary Power Art A 04130 2 2 August 12 2005 PRO LITE 160TS 2 05 160TS Inverter Arc Welder 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 Digi
57. emove the T1 Art A 05989 Du Figure 6 119 Rear panel removed Art A 05992 Figure 6 122 Removing T1 14 Remove the screws 2 places circled as shown in Figure 6 120 mounting C1 on chassis When you reassemble the parts conduct this process backwards Art A 05990 Figure 6 120 C1 chassis mounting screws 15 Remove the screw connecting T1 to TB6 of PCB1 circled as shown in Figure 6 121 Art A 05991 Figure 6 121 Screw connecting T1 to TB6 6 48 August 12 2005 PRO LITE 160TS CT1 CN7 on PCB2 circled as shown in Figure 6 124 Test Procedure 1 Remove the locking connector CN7 attached to PCB2 2 With an Ohmmeter set the R 10 scale measure between the pins on the CN7 plug as follows Pin 4 and Pin 1 about 3 to 5 MW Pin 4 and Pin 2 about 10 kW Replacement Procedure Art A 05994 Figure 6 124 Harness connector on CT1 1 Remove the side covers See section 6 01 2 Remove PCB2 See section 6 13 3 Remove the screw circled as shown in Figure 6 9 Remove the screw circled as Shown in Figure 123 connecting L1 to the diode bus bar on D2 125 mounting CT1 on the diode bus bar on D2 and D3 and D3 and remove the CT1 Art A 05995 Figure 6 125 Diode bus bar and screw mounting CT1 NOTE When you reassemble the parts conduct this process backwards When installing CT1 be sure to orient it as shown in Figure 6 126 Art A 05993 Figure 6 123 Screw connec
58. es 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 w AVERTISSEMENT LES MOTEURS PEUVENT ETRE DANGEREUX LES GAZ D ECHAPPEMENT DES MOTEURS PEUVENT ETRE MORTELS Les moteurs produisent des gaz d chappement nocifs August 12 2005 P WEE 160TS 1 Utilisez l quipement l ext rieur dans des aires ouvertes et bien ventil es 2 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 du b timent Pi y 7 AVERTISSEMENT LE CARBURANT 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 Nefaites 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 Nefaites pas le plein de carburant ras bord pr voyez de l espace pour son expansion Faites attention de ne pas renverser de carburant Nettoyez tout carburant renvers avant de faire d marrer le moteur we AVERTISSEMENT DES PIECES EN MOUVEMENT PEUVENT CAUSER DES BLESSURES Des pieces en mouvement tels des ventilateurs des rotors et d
59. es courroies peuvent couper doigts et mains ou accrocher des v tements amples Assurez vous que les portes les panneaux les capots et les protecteurs soient bien ferm s Avant d installer ou de connecter un syst me arr tez le moteur Seules des personnes qualifi es doivent d monter des protecteurs ou des capots pour faire l entretien ou le d pannage n cessaire P WEE 160TS 4 Pour emp cher un d marrage accidentel pendant l entretien debranchez 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 des 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 Wy D AVERTISSEMENT EZ DES ETINCELLES PEUVENT FAIRE EXPLOSER UN ACCUMULATEUR LELECTROLYTE 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 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
60. et 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 CRATER CUR 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 POST FLOW This parameter operates in TIG modes only and is used to adjust the post gas L flow time once the arc has extinguished This control is used to dramatically Sf reduce oxidation of the tungsten electrode Table 4 2b Weld Parameter Descriptions Continued 4 03 Weld Parameters Weld Mode Mode Weld Parameter Factory Incremental HF LIFT Parameter Range Setting i STICK TIG TIG Table 4 3 Weld Parameters August 12 2005 4 5 PRO LITE 160TS PULSE FREQ Range Incremental Unit Table 4 4 Pulse Frequency Range and Incremental Units 4 04 Weld Process selection Weld Mode Weld Process LIFT Selection STICK HF TIG TIG YES Pulse ON OFF JUL Description 2T operatoin in TIG Modes using remote devices to control contactor and current AT Operation in TIG Modes with crater fill using remote devices to control contactor and current 4T operation in TIG Modes with repeat operation and crater fill using a remote contactor device 21 operation spot welding in HF TIG a remote
61. ew el 1 r i SIDE CHASSIS 3 I 1 I 1 CHERE 1 2 3 1415161718 Art A 06011 1 2 3 4 5 6 7 8 A 4 August 12 2005 P WEE 160TS AC1 f zm PCB9 Diode Snubber Circuit Board WK5336 D2 TO1 Output Terminal Le PCB10 Output Filter Circuit Board WK5358 2 e ail a SIDE CHASSIS 4 e A eich CE TOZ Output A PE HF UNIT 1 EAJ SIDE CHASSIS 1 ACA AC ACS EB SIDE CHASSIS 2 PCB6 Circuit Board PCB5 WK498 7 Control 1 Circuit Board WK4986 EN 4 CN 5 CN 6 CN 7 CN 4 CN 5 CN 6 CN 7 l PCB4 Panel l Circuit Board WK4985 LIL LL Art A 06011 mis rs nn e August 12 2005 A 5 P WEE 160TS A 6 APPENDIX 4 HARDWARE Description L A B CodeNo Order No Art A 06012 August 12 2005 August 12 2005 THIS PAGE INTENTIONALLY LEFT BLANK P WEE 160TS A 7 P WEE 160TS APPENDIX 5 AUTOMATION SLIDE SWITCH SETTING FOR OK TO MOVE Models 160S TS Three slide switches S1 S2 and 3 are provided on PC Board WK 4977 for automation purposes This PCB is the units right side main PCB This PCB can be accessed by removing the side covers by loosening 4 screws on each the front and rear panel then removing the 4 side panel screws as well as the 2 handle screws Carefully pull the front and rear panels outward to release and remove the side cover Lift up the
62. finished 5 Gas flow wont shut off 6 The TIG electrode has been contaminated due to the gas flow shutting off before the programmed POST FLOWtime has elapsed A The Weld Process Mode A Do not change Weld Process STICK HF TIG or LIFT TIG Mode before the POS7 FLOW gas was changed before POST time had finished FLOWgas time had finished Table 5 3 Power Source Problems 5 6 August 12 2005 PRO LITE 160TS 5 06 VOLTAGE REDUCTION DEVICE VRD VRD Specification Wee G0TS Notes Table 5 4 VRD Specifications VRD Maintenance Routine inspection and testing power source An inspection of the power source an insulation resistance test and an earth resistance test 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 of the equipment shall keep 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 IEC 60974 1 Requirements Table 5 5 VRD Tests If this equipment is used in a location or environments with a high risk of electrocution then the above tests should be carried out prior to installation at th
63. frontward Art A 05930 Figure 6 48 Control Knob Screw 5 Remove the screws 4 places circled as shown in Figure 6 49 holding the operation panel onto DES the front panel Figure 6 46 Protection panel cover Art A 05931 Figure 6 49 Operation panel with control knob removed 6 28 August 12 2005 PRO LITE 160TS 6 Unplug harness connectors 3 places circled as 8 Disconnect and remove PCB5 and PCB6 from shown in Figure 6 50 from CN1 on PCB5 and PCB4 by pulling the two PCB s apart from CN8 and CN9 on PCB6 Art A 059 05932 Figure 6 50 Front side top view 7 Pull the operation panel out of the front panel frontward Figure 6 52 Disassembling the operation panel 9 Remove the screws 4 places circled as shown in Figure 6 53 mounting PCB4 on the operation panel sheet id Art A 05933 Figure 6 51 Operation Panel removed from front panel Figure 6 53 B side view of PCB4 Art A 05935 August 12 2005 6 29 PRO LITE 160TS 10 Remove PCB4 and dust cover for control knob Art A 05936 Ki F Pt 1 L Ts zar al rer at 1 T EAS ic F Figure 6 54 Removing PCB4 When you reassemble the parts conduct this process backwards 6 30 August 12 2005 6 15 PCB5 and PCB6 Replacement Procedure Art A 05927 Figure 6 55 Power Source Front view 1 Remove the side covers See section 6 01 2 Remove the protection p
64. gure 6 63 10 Disconnected and remove PCB5 and PCB6 from PCB4 by pulling the two PCB s apart 11 Disconnect the flat ribbon cable from CN5 connector by pulling straight up the cable 12 When reconnecting the flat ribbon cable make sure that it is oriented in such a manner that its wire lead side portion is positioned on the backside as shown in Figure 6 63 hv Art A 05940 Figure 6 63 CN5 on PCB6 When you reassemble the parts conduct this process backwards August 12 2005 PRO LITE 160TS 6 33 PRO LITE 160TS the switch 1 Remove the side covers See section 6 01 WW 2 Remove the screws 4 places circled as shown in Figure 6 64 holding the rear panel Art A 05943 Figure 6 66 Mounting Screws Art A 05941 Figure 6 64 Rear panel When you reassemble the parts conduct this process backwards 3 Remove the screws 2 places for each 4 places in total circled as shown in Figure 6 65 from the switch along with four lug terminals Art A 05942 Figure 6 65 Terminals on 1 6 34 August 12 2005 PRO LITE 160TS 6 17 Semiconductor Diode D1 Test Procedure 1 Verify the characteristic of the diode D1 on PCB1 using a diode tester 2 Refer the Table 6 7 and Figure 6 67 for the test points on D1 COMPONENT TESTED S ACCEPTABLE VALUE Positive lead Negative lead Table 6 7 D1 Test points PCB1 Art A 05890 Figure 6 67 PCB1 v
65. he Operating Manual and to protect the equipment from accidental or malicious damage D Repair Restrictions The electronics consists of printed circuit board assemblies which must be carefully handled and must be replaced as units No replacement of printed circuit solder mounted components is allowed except as noted in this manual If the Printed Circuit Board is to be returned the replaced Printed Circuit Board Assemblies must be properly packaged in protective material and returned intact per normal procedures 2 03 Service Responsibilities The Service Technician should be familiar with the equipment and its capabilities and should be prepared to recommend arrangements of components which will provide the most efficient layout utilizing the equipment to its best possible advantage Maintenance work should be accomplished in a timely manner If problems are encountered or the equipment does not function as specified contact Thermadyne Inc Thermal Arc Technical Service Department 02 Benning Street West Lebanon New Hampshire USA 03784 603 298 5711 http www thermadyne com Additional copies of this manual may be purchased by contacting Thermal Arc at the address and phone number given in the next section Include the Owner s 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 list
66. iew of checkpoints Replacement Procedure 1 Remove the side covers See section 6 01 2 Remove PCB1 See section 6 12 3 Replace D1 together with PCB7 E DlwihPCE D Art A 05944 Figure 6 68 Location of PCB with D1 August 12 2005 6 35 PRO LITE 160TS 4 Remove the screw circled as shown in Figure 6 69 securing PCB7 to heatsink Art A 05945 Figure 6 69 Expanded view of PCB7 5 Pull out D1 together with PCB7 frontward Art A 05946 Figure 6 70 PCB7 and D1 6 Unplug a harness connector from CN1 on PCB7 Holding the upper portion of the harness to unlock the contact between the harness connector and CN1 pull the harness lightly To unplug the harness connector from CN1 do not pull the harness excessively At A 05947 Figure 6 71 CN1 on PCB7 6 36 7 Remove the screw mounting the U phase input cable lug on TB1 at PCB7 and remove the D1 Art A 05948 Figure 6 72 TB1 on PCB NOTE When you reassemble the parts conduct this process backwards Additionally when installing the diode apply 11 5 in Ib force to tighten the diode base screws and the terminal SCrews NOTE When replacing the diode apply heat sink compound Shinetsu silicon G 747 or equivalent uniformly to the base surface of the diode as shown in Figure 6 73 Art A 05949 Figure 6 73 Base surface of D1 August 12 2005 PRO LITE 160TS 6 18 Semiconductor IGBT Q1
67. ilable is determined to be sufficient replace PCB2 Refer to section 6 13 for the replacement of PCB2 3 E12 Low Input Voltage Failure Occurs when the input voltage is less than approximately 150VAC 1 1 41 of the maximum value of the sinusoidal wave a Verify input voltage Follow the instruction in section 6 05 b Replace PCB2 WK 4977 If the voltage and current available is determined to be sufficient replace PCB2 Refer to section 6 13 for the replacement of PCB2 4 E01 Over Temperature at the primary side Occurs when an over temperature condition of the primary IGBT is detected a Unit may be in thermal shutdown mode Review the rated duty cycle of the unit per section 3 04 Exceeding the duty cycle can damage the unit and void the warranty August 12 2005 b O c CD Verify the ventilation condition Maintain a clear and unobstructed distance of more than 30cm in the front and more that 50cm in the rear of the unit for ventilation purposes 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 cleaning Verify the operation of the cooling fan FAN and replace it if necessary Verify the condition of FAN1 Verify that there are no broken or cracked fan blades and th
68. ing tube between T1 and C1 6 46 4 Remove the screw connecting T1 to C1 circled as shown in Figure 6 110 ARt A 05980 Figure 6 110 Screw connecting T1 to C1 5 Remove PCB2 See section 6 13 ui Art A 05981 Figure 6 111 Internal view PCB2 side 6 Remove the screws 1 place for each 2 places in total circled as shown in Figure 112 mounting T1 on D2 and D3 Art A 05982 Figure 6 112 Mounting screw T1 August 12 2005 PRO LITE 160TS 7 Remove the insulating tube applied to the 10 Unlock and remove the gas tube as shown in connection between L1 and T1 Figure 6 116 ARt A 05983 Figure 6 113 Insulating tube between L1 and T1 Figure 6 116 Rear gas tube 8 Remove the screw connecting L1 to T1 circled 11 Disconnect the harnesses from SOL terminals as shown in Figure 114 circled as shown in Figure 6 117 L a Art A 05984 Art A 05987 Figure 6 114 L1 to T1 connecting screw Figure 6 117 SOL terminals 9 Remove the screw connecting C1 to E1C2 of Q1 12 Remove the screws 4 places circled as shown circled as shown in Figure 115 in figure 6 118 securing chassis to the rear panel Art A 05988 Figure 6 115 C1 Figure 6 118 Rear panel screws n Art A 05985 August 12 2005 6 47 PRO LITE 160TS 13 Remove the rear panel from the welding 16 Remove the screws 4 places circled as shown equipment in Figure 6 122 mounting T1 on chassis and r
69. ir supplied 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 is well ventilated or while wearing an air supplied respirator Shielding gases used for welding can displace air causing injury or death Be sure the breathing air is safe Electrode Size Filter a a a MINI POT POT POT oO c gt 2 gt 2 2 2 TD D August 12 2005 9 Do not weld in locations near degreasing cleaning or Spraying operations The heat and rays of the arc can react with vapors to form highly toxic and irritating gases Do not weld on coated metals such as galvanized lead or cadmium plated steel unless the coating is removed from the weld area the area is well ventilated and if necessary while wearing an air supplied respirator The coatings and any metals containing these elements can give off toxic fumes if welded AR TN M i WARNING WELDING can cause fire or explosion Sparks and spatter fly off from the welding arc The flying sparks and hot metal weld spatter hot workpiece and hot equipment can cause fires and burns Accidental contact of electrode or welding wire to metal objects can cause sparks overheating or fire Protect yourself and others from flying sparks and hot metal Do not weld where flying sparks can strike flammable material
70. is location August 12 2005 5 PRO LITE 160TS 5 07 POWER SOURCE ERROR CODES Description E01 error code displayed Temperature sensor TH1 protects IGBTS is greater than 90 C for about 1 second A E03 error code displayed Primary input current too high B E11 error code displayed Over Primary supply input voltage at primary capacitors is exceeded for one second E12 error code displayed Under mains supply input voltage primary capacitors is reduced for one second E85 error code displayed Pre charge abnormality E93 error code displayed A Memory chip EEPROM on control PCB can not read write weld parameters E94 error code displayed A Temperature sensor TH1 for IGBTs or sensor TH2 for secondary diodes are open circuit E99 error code displayed A Mains supply input voltage has been turned off but control circuit has power from the primary capacitors 5 8 Possible Cause A The Welding Power Source s duty cycle has been exceeded Primary current is too high because welding arc is too long Mains supply voltage is more than 10 below nominal voltage greater than the nominal voltage plus 10 Mains supply voltage is down to dangerously low level the Welding Power Source primary capacitors are not charging correctly Memory chip EEPROM error The Welding Power Source s temperature sensors have malfunctioned Mai
71. l tank allow room for fuel to expand 5 Do not spill fuel If fuel is spilled clean up before starting engine we WARNING MOVING PARTS can cause injury Moving parts such as fans rotors and belts can cut fingers and hands and catch loose clothing 1 Keep all doors panels covers and guards closed and securely in place 2 Stop engine before installing or connecting unit 3 Have only qualified people remove guards or covers for maintenance and troubleshooting as necessary 4 To prevent accidental starting during servicing disconnect negative battery cable from battery 5 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 wy WARNING SS SPARKS can cause BATTERY GASES TO EXPLODE BATTERY ACID can burn eyes and Skin Batteries contain acid and generate explosive gases 1 Always wear a face shield when working on a battery 2 Stop engine before disconnecting or connecting battery cables 3 Do not allow tools to cause sparks when working on a battery 4 Do not use welder to charge batteries or jump start vehicles 9 Observe correct polarity and on batteries cA m C WARNING STEAM AND PRESSURIZED HOT COOLANT can burn face eyes and Skin The coolant in the radiator can be very hot and under pressure 1 Do not remove radi
72. madyne Victor Brasil Avenida Brasil 13629 Cordovil Rio de Janeiro Brazil 21012 351 Telephone 55 21 2485 8998 Fax 55 21 2 485 8735 Thermadyne Chile Piloto Lazo 90 Cerrillos Santiago Chile 7278 654 Telephone 56 2 557 2465 Fax 56 2 557 5349 Thermadyne Europe Europe Building Chorley North Industrial Park Chorley Lancashire England PR6 7Bx Telephone 44 1257 261755 Fax 44 1257 224800 Thermadyne Asia Pacific Pte Ltd 5 Shenton Way 37 02 38 02 UIC Building singapore 068808 Telephone 65 6832 8066 Fax 65 6763 5812 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 151 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 71 Gower Street Preston Victoria Australia 3072 Telephone 61 3 9474 7400 Fax 61 3 9474 7510 Corporate Headquarters 82 Benning Street IHERMAL IRC West Lebanon NH 03784 USA By THERMADYNE SK Telephone 603 298 5711 i 800 752 7621 Fascimile 800 221 4401 Email sales thermalarc com www thermalarc com
73. mble the parts conduct this process backwards Additionally when install the IGBT apply 27 44 in Ib force to the IGBT base screws and 2 6N m to the terminal SCrews August 12 2005 PRO LITE 160TS 6 19 Semiconductor Diode D2 D3 Test Procedure 1 Verify the characteristic of the diode D2 and D3 using a diode tester 2 Refer the Table 6 9 and Figure 6 81 for the test points on D2 D3 COMPONENT TESTED ie ACCEPTABLE VALUE Positive lead Negative lead Diode1 of D2 D3 Anode Cathode 0 2 to 0 3V Cathode Anode Open circuit Anode Cathode 0 2 to 0 3V URL Cathode Anode Open circuit Table 6 9 D2 and D3 test points RE Figure 6 81 D2 D3 test points Replacement Procedure 3 Remove the screws 1 place for each 2 places in wm total circled as shown in Figure 6 83 mounting 1 Remove the side covers See section 6 01 T1 on D and D3 2 Remove PCB2 See section 6 13 12 3 Art A 05959 Art 4 A 05958 Figure 6 83 T1 mounting screws Figure 6 82 Location of D2 and D3 August 12 2005 6 39 PRO LITE 160TS 6 40 4 Remove the screws mounting bus bars on and connecting snubber resistors to D2 and D3 4 places for each 8 places in total circled as shown in Figure 6 84 Art A 05960 Figure 6 84 Screws mounting D2 and D3 5 Remove the mounting screws and then bus bars circled as shown in Figure 6 85 from D2 and D3 o Art A 05961 Figure 6 85 Bud bars on D2 and D3 6
74. move the screws 4 places at input diode D1 3 places at primary IGBT Q1 7 places in total mounting D1 and Q1 on PCB1 as shown in Figure 6 24 RENTE Figure 6 24 Expanded view of PCB1 4 Remove the screw mounting main transformer T1 on TB6 at PCB1 circled as shown in Figure 6 25 August 12 2005 PRO LITE 160TS Art A 05907 Figure 6 25 PCB1 top view 5 Pull PCB1 out frontward lightly Art A 05908 Figure 6 26 PCB1 top view pushed out 6 Unplug aharness connector from CN13 on PCB1 Art A 05909 Figure 6 27 CN13 on PCB1 6 23 PRO LITE 160TS 7 Unplug harness connectors from CN14 and CN16 on PCB1 Holding the upper portion of the harness to unlock the contact between the harness connector and CN13 CN14 and CN16 pull the harness lightly To unplug the harness connector do not pull the harness excessively i Art A 05910 Figure 6 28 CN14 and CN16 on PCB1 8 Remove the screw mounting S1 with screwdriver etc aS shown in Figure 6 29 E Art 4 A 05911 Figure 6 29 Power Supply with PCB1 pulled out T Er Figure 6 30 TB1 on PCB1 Art A 05912 6 24 When you reassemble the parts conduct this process backwards August 12 2005 6 13 PCB2 Replacement Procedure 1 Remove the side covers See section 6 01 2 Remove the four 4 screws circled as Shown in Figure 6 31 mounting PCB2 on chassis Art A 05913
75. n 2 Increase penetration 3 Travel speed control 4 Better consistent quality 5 Distortion on lighter or thinner materials Pulse current provides a system in which the welding current continuously changes between two levels 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 stays 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 moved the foot rheostat up and down the faster the frequency Pulse Width DES Pulse Frequency Peak Current Figure 4 7 Pulse Control Sequence Base Background Current Art A 05878 August 12 2005 4 12 Switching VRD On Off Switch the machine Off a Remove the controls clear cover see Figure 4 8 Lift up the cover so it rests on the top of the unit Place a small flat bladed screw driver between the cover hinge on the front panel Gently lift the cover hinge out of the front cover mounting hole Remove the controls clear cover Art A 05604 Figure 4 8 VRD ON OFF step a b Remove the controls mounting screws see Figure 4 9 Remove the four
76. n 6 26 for the replacement and installation of HF Unit 6 9 PRO LITE 160TS 6 04 Preparation of Fault Isolation Tests 6 05 The following initial conditions must be met prior to Verification of the power input circuitry starting any of the procedures in this section Refer to Notes on page 6 4 1 Connect the appropriate input voltage Check the 1 data tag 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 supply 2 Close primary power source wall disconnect switch or circuit breaker 3 Place the power supply MAIN CIRCUIT SWITCH S1 on rear of 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 2 the operators body comes into contact with the work piece or any internal components while the unit is activated N CD I 6 10 Verify the AC input voltage using an AC voltmeter Verify input voltage Phase to Phase using an AC voltmeter The capability of the voltmeter should be more than 300VAC Measure the point between lines U1 and V1 on the input switch 1 The location of points U1 and V1 on switch S1 are indicated in Figure 6 7 Art A 05889 Figure 6 7 Check points U1 U2 V1 V2 If the input
77. n 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 Table 4 1 8 Socket Pin Descriptions 3 Positive Terminal Welding current flows from the Power Source via heavy duty Dinse type terminal It is essential however that the male plug is inserted and turned securely to achieve a sound electrical connection 4 Negative Terminal Welding current flows from the Power Source via heavy duty Dinse type terminal It is essential however that the male plug is inserted and turned securely to achieve a sound electrical connection CAUTION Loose welding terminal connections can cause overheating and result in the male plug being fused in the bayonet terminal 4 2 August 12 2005 PRO LITE 160TS 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 WARNING When the welder is connected to the Primary supply voltage the internal electrical compo nents maybe 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 Art A 05873 Figure 4 1 P Wee 160TS Power Supply August 12 2
78. n on off switch on machine has been turned off Mains supply input voltage has been turned off Due to malfunction insidelA Please refer to Advanced Remedy A Let Power Source cool down Weld current ceases then keep within its duty cycle A Reduce length of welding arc Weld current ceases B A qualified electrician checks for low Mains voltage or refers to advanced troubleshooting A Primary supply voltage is JA A qualified electrician checks the Primary voltage or refers to the following chapter A Aqualified electrician checks the Mains voltage checks the primary cable amp fuses or refers to advanced troubleshooting Troubleshooting Please refer to Advanced Troubleshooting Please refer to Advanced Troubleshooting Turn on off switch on B Please refer to Advanced Troubleshooting Table 5 6 Power Source Error Codes Remarks Buzzer sounds constantly E01 resets when TH1 decreases to Buzzer sounds constantly Switch machine off then on to reset E03 error Weld current ceases Buzzer sounds constantly Error code E11 automatically will reset when the voltage reduces Weld current ceases Buzzer sounds constantly Error code E12 automatically will reset when the voltage reduces No weld current is available Buzzer sounds constantly owitch machine off then on to reset E85 error Weld current ceases Buzzer sounds constantl
79. nel screws and nuts 3 Loosen the screws on the front panel and the rear panel by turning them approximately twice NOTE Do NOT remove the screws completely Art A 05614 Figure 6 3 Loosen front and rear panel screws August 12 2005 4 Pull the front panel slightly forward and pull the rear panel slightly backward The interlocking hooks of the side case covers can now be disengaged from the front and rear panels Art A 05615 Figure 6 4 Disengage front and rear interlocking hooks 5 Remove the side covers Art A 05616 Figure 6 5 Remove side panels August 12 2005 PRO LITE 160TS 6 Remove protection cover sheet by removing the plastic tabs Sh amp gt f m bu e prs i a hh Nr 4 a b p Art A 05617 Figure 6 6 Remove cover sheet NOTE When you reassemble the parts conduct this entire process backwards 6 3 PRO LITE 160TS 6 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 6 01 NOTE During the Verification Remedy procedures bel
80. nes pratiques concernent les quipements raccord s aux lignes d alimentation alors que d autres s adressent aux groupes lectrog nes La norme Z49 1 de l American National Standard intitul e SAFETY IN WELDING AND CUTTING pr sente les pra tiques 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 Me touchez pas des pi ces sous tension DES TRAVAUX D INSTALLATION DE REPARATION 2 Portez des gants et des v tements isolants secs et D ENTRETIEN ET D ESSAI non trou s 1 04 Dangers relatifs au soudage l arc 3 Isolez vous de la pi ce souder et de la mise la terre au moyen de tapis isolants ou autres 4 D connectez la prise d alimentation de l quipement ou arr tez le moteur avant de l installer ou d en faire l entretien Bloquez le commutateur en circuit ouvert ou enlevez les fusibles de l alimentation afin d viter une mise en marche accidentelle AVERTISSEMENT 5 Veuillez installer cet quipement et le mettre la terre selon le manuel d utilisation et les codes nationaux provinciaux et locaux applicables L ELECTROCUTION PEUT ETRE MORTELLE 6 Arr tez tout quipement apr s usage Coupez l alimentation de l quipement s il est hors d usage Une d charge lectrique peut tuer ou br ler ou inutilis
81. nical 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 in Safety Standards P WEE 160TS A WARNING Engines can be dangerous 9 w WARNING ENGINE EXHAUST GASES can kill Engines produce harmful exhaust gases 1 Use equipment outside in open well ventilated areas 2 If used in a closed area vent engine exhaust outside and away from any building air intakes y y 7 WARNING ENGINE FUEL can cause fire or explosion Engine fuel is highly flammable 1 Stop engine before checking or adding fuel 2 Do not add fuel while smoking or if unit is near any sparks or open flames 3 Allow engine to cool before fueling If possible check and add fuel to cold engine before beginning job 4 Do not overfil
82. nimize or avoid potential risks 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 normally recommended for pacemaker wearers Consult your doctor for complete information August 12 2005 P WEE 160TS 1 02 PRINCIPAL SAFETY STANDARDS Safety in Welding and Cutting ANSI Standard Z49 1 from American Welding Society 550 N W LeJeune Rd Miami FL 33126 Safety and Health Standards OSHA 29 CFR 1910 from Superintendent of Documents U S Government Printing Office Washington D C 20402 Recommended Safe Practices for the Preparation for Welding and Cutting of Containers That Have Held Hazardous Substances American Welding Society Standard AWS F4 1 from American Welding Society 550 N W LeJeune Rd Miami FL 33126 National Electrical Code NFPA Standard 70 from National Fire Protection Association Batterymarch Park Quincy MA 02269 Safe Handling of Compressed Gases in Cylinders CGA Pamphlet P 1 from Compressed Gas Association 1235 Jefferson Davis Highway Suite 501 Arlington VA 22202 Code for Safety in Welding and Cutting CSA Standard W117 2 from Canadian Standards
83. out nM of service output is on The input power circuit and machine internal circuits are also live when 7 Use fully insulated electrode holders Never dip holder power is on In semiautomatic or automatic in water to cool it or lay it down on the ground or the wire welding the wire wire reel drive roll work surface Do not touch holders connected to two housing and all metal parts touching the welding machines at the same time or touch other welding wire are electrically live Incorrectly people with the holder or electrode installed or improperly groun ipment ge 2707 PORN RUN OR ane 8 Do not use worn damaged undersized or poorly is a hazard 1 Do not touch live electrical parts 9 Do not wrap cables around your body 2 Wear dry hole free insulating gloves and body 10 Ground the workpiece to a good electrical earth protection ground August 12 2005 1 1 P WEE 160TS 11 Do not touch electrode while in contact with the work ground circuit 12 Use only well maintained equipment Repair or replace damaged parts at once 13 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 14 Wear a safety harness to prevent falling if working above floor level 15 Keep all panels and covers securely in place di En x ARC RAYS can burn eyes and skin NOISE can damage hearing WARNING Arc rays from the welding proces
84. ow follow the alphabetical sequence a b c and proceed with your verification and confirmation NOTE After you confirm and replace all spare parts and components confirm that there are no damaged harnesses or connectors uninstalled or loose screws The symptoms causes and solutions to the error codes indicated will be in the following format 1 Symptom Cause a Remedy the first remedy being the most common and the first to be checked 1 E85 Pre Charge Error Occurs after you apply power when a failure is detected during the preliminary charging of the capacitors a Verify the AC input voltage and the Capacitor Bus Voltage on PCB1 WK 4980 Follow the instruction in section 6 05 b Verify the input diode D1 Refer to section 6 17 for the test and replacement of D1 c Verify the IGBT Q1 Refer to section 6 18 for the test and replacement of Q1 6 4 d Replace PCB1 WK 4980 and PCB2 WK 4977 If the tests in the above sections a b c are within expected results and the unit is still defective replace PCB1 and PCB2 Refer to section 6 12 for the replacement of PCB1 and section 6 13 for PCB2 2 E11 High Input Voltage Failure Occurs when the input voltage is more than approximately 275VAC 1 1 41 of the maximum value of the sinusoidal wave a Verify input voltage Follow the instruction in section 6 05 b Replace PCB2 WK 4977 If the voltage and current ava
85. proc d s peut endommager l ouie SELECTION DES NUANCES DE FILTRES OCULAIRS POUR LA PROTECTION DES YEUX EN COUPAGE ET SOUDAGE selon AWS a 8 2 73 Dimension d lectrode ou P Dimension d lectrode ou E Op ration de coupage Nuance de Op ration de coupage Epiasseur de m tal ou Epiasseur de m tal ou ou soudage filtre oculaire ou soudage Intensit de courant Intensit de courant Brassage tendre Soudage l arc sous gaz g toutes conditions 2 19 g au chalumeau avec fil plein GMAW Brassage fort E g toutes conditions 3 O 4 m taux non ferreux toutes conditions au chalumeau Soudage l arc sous gaz avec v 1 po 2 2 tout t Nuance de filtre oculaire Soudage l hydrog ne 2 Soudage l arc avec NENNEN mince moins de 1 8 po 3 mm 4 ou 5 ee dioi ded lectrode de carbone monjea po Bamm Bou mime plus de 1 2 po 12 mm MM pou Soudage l arc avec lectrode enrobees moins de 5 32 po 4 mm 10 Coupage l arc Plasma PAC SMAW 2 528 pom i2 mince moins de 300 amperes plus de 1 4 po 6 4 mm de 300 400 amperes pais plus de 400 amper s August 12 2005 1 7 P WEE 160TS 1 2 Eloignez la t te des fum es pour viter de les respirer l int rieur assurez vous que l aire de soudage est bien ventil e ou que les fum es et les vapeurs sont aspir es l arc Si la ventilation est inadequate
86. protective PCB cover sheet from the bottom and the slide switches will be accessible through a slot in the PCB Board See figure on next page for details All units are shipped from the factory with the slide switches set in position A This is for normal semi automatic operation utilizing a remote device such as a foot control The 8 pin remote operates as described earlier in this manual Placing all slide switches in position B would be primarily used for automation with an arc establish relay remote amperage and contactor An arc establish signal is located from pins 4 and 8 when in this mode Placing slide switches S1 and S2 in B position and slide switch S3 in A position would have the configuration of an arc establish signal and remote contactor but the unit s front panel would control the amperage I ZZ A COM B WK 4977 B I I COM A CM QM POSITION De le J I 9 4 Remot Short 4 to 8 Panel Open A A CN6 CONT 9 Q gt Load 24V 50ma Art A 06013 OK TO MOVE RELAY A 8 August 12 2005 August 12 2005 sanhex WK 6977 i Art A 06014 Figure A 4 Slide switch location P WEE 160TS P WEE 160TS APPENDIX 6 DIODE TESTING BASICS Testing of diode modules requires a digital Volt Ohmmeter that has a diode test scale 1 Remove cables from mounting studs on diodes to isolate them within the module I co N A 10 Locate the diode module to be tested
87. qualified electrician August 12 2005 PRO LITE 160TS 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 3 04 Electrical Input Requirements 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 inspection required The line disconnect switch provides a safe and convenient means to completely remove all electrical power from the welding power supply whenever necessary to inspect or service the unit Note These units are equipped with a two conductor with earth power cable that is connected at the welding power source end for single phase electrical input power Do not connect an input WHITE or BLACK conductor to the ground terminal Do not connect the ground GREEN conductor to an input line terminal 3 1
88. r to Basic TIG Welding Guide Table 5 1b TIG Welding Problems Continued August 12 2005 5 3 PRO LITE 160TS 5 04 Stick Welding Problems Description Possible Cause Remedy 1 Gas pockets or voids in weld metal Porosity 2 Crack occurring in weld A Redesign to relieve weld joint of metal soon after Severe stresses or use crack Solidification commences resistance electrodes weld metal to fill the root of the weld 1 rat u b a Art A 05610 Figure 5 1 Example of insufficient gap or incorrect sequence 4 Portions of the weld run do A Small electrodes used on A Use larger electrodes and pre heat not fuse to the surface of heavy cold plate the plate the metal or edge of the B Welding current is too low B Increase welding current joint C Wrong electrode angle C Adjust angle so the welding arc is directed more into the base metal D Travel speed of electrode is ID Reduce travel speed of electrode too high E Scale or dirt on joint E Clean surface before welding surface Table 5 2b Stick Welding Problems 5 4 August 12 2005 PRO LITE 160TS Lir GT Fries Care Bey diri riertrome ugue rapa ht em dri Ezra hen Art A 05611 m LL CES CE Tiger un dg ri SE it or RRD LCR E ZI TL BEC ITENE TETE Cor Ro Figure 5 2 Example of lack of fusion J Description Possible Cause Remey 5 Non metallic particles are A Non metallic particles may be A If bad undercut is present cl
89. re are no short circuits burnt or broken wires between the HF unit and R2 Verify the connection between the terminals between AC1 AC2 Verify the connection between AC1 and AC2 Confirm that the quick disconnect terminals are inserted onto the terminals of HF Unit correctly and completely Confirm there are no short circuit in the harness between AC1 and AC2 August 12 2005 d PRO LITE 160TS Verify and replace the Gap GAP of the High Frequency HF Unit Confirm that the GAP is connected to H F Unit correctly and completely Confirm 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 CD h o The GAP is factory set for an optimal setting for most welding applications It is recommended that the GAP setting not be changed The GAP is factory set at 0 8mm If the GAP is increased larger than 0 8mm the HF voltage increases and the frequency tends to decrease If the GAP is increased too much HF will no longer be generated If the GAP is decreased smaller than 0 8mm the HF voltage decreases and the frequency tends to increase Verify and replace the Current limiting Resistor R2 of the High Frequency HF Unit If R2 is defective blown burnt cracked etc replace R2 Refer to section 6 27 for the replacement and installation of R2 Replace the High Frequency HF Unit Refer to sectio
90. rough established procedures A WARNING Disconnect primary power at the source before disassembling the power supply Frequently review the Important Safety Precautions page iii Be sure the operator is equipped with proper gloves clothing and eye and ear protection Make sure no part of the operators body comes into contact with the work piece or any internal components while the unit is activated August 12 2005 PRO LITE 160TS 6 1 PRO LITE 160TS 6 01 System Level Fault Isolation If none of the suggestions provided in Section 5 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 Opening the Enclosure 1 Confirm that the switch of power supply and the switch on the switchboard distribution panel are all 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 least 5 minutes for the discharge to complete Art A 05888 Figure 6 1 Confirm Power Switch is Off 6 2 2 Remove all screws and nuts on the side covers Figure 6 2 Remove side pa
91. s produce intense heat and strong ultraviolet rays that can burn eyes and skin Noise from some processes can damage hearing 1 Wear a welding helmet fitted with a proper shade of filter see ANSI Z49 1 listed in Safety Standards to protect your face and eyes when welding or watching 2 Wear approved safety glasses Side shields recommended 3 Use protective screens or barriers to protect others from flash and glare warn others not to watch the arc Torch soldering O Oxygen Cutting Eye protection filter shade selector for welding or cutting goggles or helmet from AWS A6 2 73 2 Gas metatare Torch brazng S074 Non ferrous base metal Ferrous base metal r OI Al taswelding Gamonarcweling co Shielded metal arc 89821 van 12 Plasmaare cutting rer ain eamm a LighiUnder 300 Am 2 lt 00 to 400 Am Over 400 Amp Wear protective clothing made from durable flame resistant material wool and leather and foot protection Use approved ear plugs or ear muffs if noise level is high 9 WARNING FUMES AND GASES can be hazardous to your health Welding produces fumes and gases Breathing these fumes and gases can be hazardous to your health Keep your head out of the fumes Do not breath the fumes If inside ventilate the area and or use exhaust at the arc to remove welding fumes and gases If ventilation is poor use an approved a
92. t amperage controls are functioning properly clamp type amperage meter or equivalent meter capable of reading approximately 180A 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 at the beginning of this section 1 Connect the POSITIVE and NEGATIVE A WARNING At this time some voltage is applied to the Stick electrode holder Never touch the current conducting portion of it Extra care shall be taken to prevent electric shock Further to prevent the risk of striking the arc inadvertently care shall be taken to keep the work piece to be welded away from the said electrode holder 9 Slowly turn the Control Knob clockwise to the maximum of the power supply OUTPUT TERMINALS to a piece of metal separated by approximately three feet one meter 2 Connect the clamp on amperage meter or equivalent to the output loop between the counterclockwise back to 1 Amp as the control returns to its minimum position The amperage meter should indicate a continuous range of Amperes between the 1 Amp minimum and the POSITIVE and NEGATIVE OUTPUT TERMINALS 3 Place the power supply PRIMARY POWER SWITCH on the rear of the unit to the ON position A WARNING This welding mode produces high frequency and high voltage Extra care shall be taken to prevent electric shock
93. t impurities G The electrode is too small for G Increase electrode diameter the welding current Or reduce the welding current A Increase gas flow or check A Inadequate shielding gas gas line for gas flow problems Table 5 1a TIG Welding Problems 5 2 August 12 2005 PRO LITE 160TS 10 Arc flutters during TIG welding A Tungsten electrode is too Select the right size large for the welding current electrode Refer to Basic TIG Welding guide B Absence of oxides in the B Refer Basic TIG Welding weld pool Guide for ways to reduce arc flutter 11 Welding arc can not be A Work clamp is not connected A Connect the work clamp to established to the work piece or the the work piece or connect work torch leads are not the work torch leads to the connected to the right right welding terminals welding terminals C Gas flow incorrectly set C Select the right flow rate cylinder empty or the torch change cylinders or turn valve is off torch valve on 12 Arc start is not smooth A Tungsten electrode is too A Select the right size large for the welding current electrode Refer to Basic TIG Welding Guide B The wrong electrode is being B Select the right electrode used for the welding job type Refer to Basic TIG Welding Guide C Gas flow rate is too high C Select the correct rate for the welding job Refer to Basic TIG Welding Guide D Incorrect shielding gas is D Select the right shielding being used gas Refe
94. tal 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 nonconductive plastic case 2 06 Functional Block Diagrams Input Pat np Mea input Capacitor GBT r Hall Current Circuil Diode nverter Todes Transformer Power Switch DC Power Thermal EA GT Fier Iter Primary Thermal To each control circuit Sensor t MSVDC 18VDC Circuit 24V DC 5VDC Torch Contra Fan Control Connection Gas Control CONT Circuit Solenoid Current Reference Adjustment Adjustments amp Circuit Mode select Switches Panel Circur Board Art A 05870 Figure 2 1 160TS Function Block Diagram August 12 2005 2 3 PRO LITE 160TS 2 07 Specifications MODEL TGOTS NENNEN DC STICRIIET TIGARETE Table 2 1 Specifications for 160TS 2 4 August 12 2005 PRO LITE 160TS 2 08 Transporting Methods 2 09 Duty Cycle These units are equipped with a handle for carrying The duty cycle of a welding power source is the percentage purposes of a ten 10 minute period that it can be operated at a given output without causing overheating and damage
95. tenance The only routine maintenance required for the power power levels present inside this product Do supply is a thorough cleaning and inspection with the not attempt to open or repair unless you are frequency depending on the usage and the operating an Accredited Thermal Arc Service Agent and environment you have had training in power measurements and troubleshooting techniques E WARNING If major complex subassemblies are faulty then the Welding Power Source must be returned to an Accredited Disconnect primary power at the source before Thermal Arc Service Agent for repair opening the enclosure Wait at least two The basic level of troubleshooting is that which can be minutes before opening the enclosure to allow performed without special equipment or knowledge the primary capacitors to discharge To clean the unit open the enclosure please refer to the section Opening the Enclosure and use a vacuum cleaner to remove any accumulated dirt and dust The unit should also be wiped clean if necessary with solvents 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 August 12 2005 J PRO LITE 160TS 5 03 TIG Welding Problems Weld quality is dependent on the selection of the correct consumables maintenance
96. that have stood 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 WARNINGS Read and understand this entire Manual and your employer s safety practices before installing operating or servicing the equipment While the information contained in this Manual represents the Manufacturer s best judgement the Manufacturer assumes no liability for its use P Wee 160T Inverter Arc Welding Power Supply Instruction Manual Number 0 4754 for spec Number 103067 Published by Thermal Dynamics Corporation 82 Benning Street West Lebanon New Hampshire USA 03784 603 298 5711 www thermalarc com Copyright 2001 by Thermal Dynamics Corporation All rights reserved Reproduction of this work in whole or in part without written permission of the pub lisher 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 August 12 2005 Record the following information for Warranty purposes Where Purchased Purchase Date Equipment Seri
97. ting L1 to diode bus bar Art A 05996 Figure 6 126 Orientation of CT1 August 12 2005 6 49 PRO LITE 160TS 6 25 FAN1 Replacement Procedure 1 Remove the side covers See section 6 01 2 Unlock and remove the gas tube as shown in Figure 6 127 Figure 6 127 Removing gas tube in rear 3 Disconnect the harnesses from SOL terminals circled as shown in Figure 6 128 Figure 6 128 SOL terminals Art A 05987 4 Remove the screws 4 places circled as shown in Figure 6 129 securing chassis to the rear panel Art A 05988 Figure 6 129 Rear panel screws 6 50 5 Remove the rear panel from the welding equipment Art A 05989 Figure 6 130 Removing rear panel 6 Unplug the harness connector from CN3 on PCB2 and remove the FANI Art A 05917 Figure 6 131 CN3 on PCB2 NOTE When you reassemble the parts conduct the above process backwards When installing FANT be sure to orient it as shown in Figure 6 132 E Art A 05997 Figure 6 132 FAN1 orientation August 12 2005 6 26 HF UNIT Replacement Procedure 1 Remove the side covers See section 6 01 Turn power source onto side Art A 05998 Figure 6 133 Welding equipment bottom view 2 Disconnect the harnesses from HF coupling coil CC terminals CC1 and CC2 terminals circled as shown in Figure 6 134 Art A 05999 Figure 6 134 CC1 and CC2 on HF UNIT 3 Disconnect th
98. to the unit If the welding amperes decrease the duty cycle WARNING increases If the welding amperes are increased beyond the rated output the duty cycle will decrease A WARNING Exceeding the duty cycle ratings will cause the thermal overload protection circuit to become ELECTRIC SHOCK can kill DO NOT TOUCH live electrical parts Disconnect input power conductors from de energized supply line before moving the welding power source A WARNING energized and shut down the output until the unit has cooled to normal operating temperature FALLING EQUIPMENT can cause serious personal injury and equipment damage mmm CAUTION Lift unit with handle on top of case Continually exceeding the duty cycle ratings Use handcart or similar device of adequate capacity can cause damage to the welding power If using a fork lift vehicle place and secure unit on a proper source and will void the manufactures skid before transporting 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 August 12 2005 2 5 PRO LITE 160TS 2 6 August 12 2005 SECTION
99. u un incendie 1 9 Protegez 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 incendies et gardez un extincteur port e de la main N oubliez pas qu une soudure r alis e sur un plafond un plancher une cloison ou une paroi peut enflammer l autre c t Ne soudez pas un r cipient ferm tel un r servoir ou un baril Connectez le c ble de soudage le plus pr s 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 10 Otez l lectrode du porte lectrode ou coupez le fil au tube contact lorsqu inutilis apr s le soudage 11 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 ah gt B AVERTISSEMENT _ LES ETINCELLES ET LES PROJECTIONS BRULANTES PEUVENT CAUSER DES BLESSURES Le piquage et le
100. ure 11 Ne touchez pas l lectrode lorsqu en contact avec le circuit de soudage terre 12 N utilisez que des quipements en bon tat R parez 2 iz da Portez des lunettes de s curit approuv es Des crans ou remplacez aussit t les pi ces endommag es lat raux sont recommand s 13 Dans des espaces confin s ou mouill s n utilisez pas a de source de courant alternatif moins qu il soit muni d un r ducteur de tension Utilisez plut t une source de courant continu Entourez l aire de soudage de rideaux ou de cloisons pour prot ger les autres des coups d arc ou de l blouissement avertissez les observateurs de ne pas regarder l arc 14 Portez un harnais de s curit si vous travaillez en hau A teur Portez des v tements en mat riaux ignifuges et durables laine et cuir et des chaussures de s curit 15 Fermez solidement tous les panneaux et les capots E Portez un casque antibruit ou des bouchons d oreille ah approuv s lorsque le niveau de bruit est lev 9 QP AVERTISSEMENT 2 AVERTISSEMENT iF LE RAYONNEMENT DE L ARC PEUT BRULER LES YEUX ET LA PEAU LE BRUIT PEUT LES VAPEURS ET LES FUMEES SONT ENDOMMAGER L OUIE DANGEREUSES POUR LA SANTE Larc de soudage produit une chaleur et des Le soudage d gage des vapeurs et des fum es rayons ultraviolets intenses susceptibles de dangereuses respirer br ler les yeux et la peau Le bruit caus par certains
101. ve the screw circled as shown in Figure 6 140 mounting R2 on chassis and remove R2 Art A 06005 Figure 6 140 R2 mounting screw When you reassemble the parts conduct the above process backwards August 12 2005 PRO LITE 160TS 6 53 PRO LITE 160TS 6 28 Gas Valve SOL Replacement Procedure 1 Remove the side covers See section 6 01 2 Unlock and remove the gas tube as shown in Figure 6 141 lg Art A 05986 Figure 6 141 Gas tube rear 3 Disconnect the harnesses from SOL terminals circled as shown in Figure 6 142 6 54 4 Remove the C ring of the gas valve at the rear frame using C ring pliers and remove the SOL Art A 06006 Figure 6 143 Gas valve When you reassemble the parts conduct this process backwards August 12 2005 SECTION 7 PARTS LIST 7 01 Equipment Identification Allidentification 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 following the Specification or Assembly numbers 7 02 How To Use This Parts List The Parts List is a combination of an illustration and a corresponding list of parts which contains a breakdown of the equipment into assemblies subassemblies and detail parts All parts of the equipment are listed except for commercially available hardware bulk items
102. voltage is out of the operating range of the unit which is 10 103 127VAC 187 253 VAC of the rated voltage 115 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 input voltage to decrease to a value below the operating range of the unit Verify input voltage after the input switch S1 using an AC voltmeter The capability of the voltmeter should be more than 300VAC Using an AC voltmeter measure between the points U2 and V2 on the input switch S1 The location of points U2 and V2 on switch 1 are indicated in Figure 6 7 If this voltage is out of the operating range which is 10 103 12 VAC 187 253 VAC of the rated voltage 115 230VAC replace 1 following the process in section 6 16 August 12 2005 5 Verify the rectified output voltage of the input diode D1 using a DC voltmeter The capability of the voltmeter should be more than 400VDC Using a DC voltmeter measure between the points TB9 and of TB11 A on PCB1 WK 4980 Points TB9 and TB11 A are obtainable on the solder side of PCB1 See Figure 6 8 The measured voltage should be approximately 1 4 times larger than input voltage measured in 1 Replace diode D1 if the calculated measurement is not within the corresponding range DC260 360 V following the process in section 6 17 PCB1 Art A 05890
103. weld current as long as the remote switch contacts are open Switch Closed Initial Current switch Open Weld Current Up Slope Preflow PRO LITE 160TS 3 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 4 Open Remote Switch Welding arc stops and post flow begins 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 operated as many times as desired To continue slope cycle and end slope sequence close remote switch contacts and allow weld current to reach final current setting Once final current setting is reached opening the Remote Switch again will turn off the welding arc and post flow begins Switch Closed Down Slope Switch Open Final Current Postflow Art A 05877 Figure 4 6 Slope Mode Description August 12 2005 PRO LITE 160TS 4 11 Pulse Controls 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 positio
104. y Switch machine off Weld current ceases Buzzer sounds constantly Switch machine off Weld current ceases Buzzer sounds constantly Must switch machine off then on to reset E99 error August 12 2005 SECTION 6 ADVANCED TROUBLESHOOTING If you are here all of the troubleshooting suggestions in oection 5 Basic Troubleshooting have either failed to resolve the faulty operation or have indicated that one or more of the subsystems within the power supply are defective This section provides the information needed to take live measurements on the various subsystems within the power supply and replace those subsystems that prove faulty m CAUTION Troubleshooting and repairing this unit is a process which should be undertaken only by those familiar with high voltage high power electronic equipment WARNING There are extremely dangerous voltage and power levels present inside this unit Do not attempt to diagnose or repair unless you have training in power electronics measurement and troubleshooting techniques Under no circumstances are field repairs to be attempted on printed circuit boards or other subassemblies of this unit Evidence of unauthorized repairs will void the factory warranty If a subassembly is found to be defective by executing any of the procedures in this Service Manual the subassembly should be replaced with a new one The faulty subassembly should then be returned to Thermal Arc th
105. y 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 of interference Looping and Suspending of leads should be avoided where possible Reradiation from Unearthed Metallic Objects A major factor contributing to interference is reradiation from unearthed metallic objects close to the welding leads Effective grounding of such objects will prevent reradiation in most cases August 12 2005 SECTION 4 OPERATION 4 01 Controls See Figure 4 1 1 Control Knob PRO LITE 160TS This control sets the selected weld parameter rotating it clockwise increases the parameter and is indicated on the digital meter Pushing the knob inward displays the actual welding voltage 320mm 130mm Fi li i ll gl D VE TES QE ei FE TE 1 93 a gt I SA S I H i L DL Lt Li A Art A 05873 MI Figure 4 1 P Wee 160TS Power Source August 12 2005 4 1 PRO LITE 160TS 2 Remote Control Socket The 8 pi

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P-WEE® 160TS Service Manual