Thermal Arc 161 S, Operating Manual

Page 1: ...Art A 09194_AB 50 60 Hz THERMAL ARC Inverter Arc Welder 161 S Operating Manual Revision AC Issue Date September 29 2010 Manual No 0 5073 Operating Features ...

Page 2: ...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 ThermalArcisaGlobalBrandofArcWeldingProductsforThermadyne Industries Inc We manufacture and supply to major welding industry sectors worldwide including Manufacturing Construction Mining Automotive Aerospace En...

Page 3: ...ing Street West Lebanon New Hampshire USA 03784 603 298 5711 www thermalarc com Copyright 2010 by Thermadyne Industries Inc All rights reserved Reproduction of this work in whole or in part without written permission of the publisher is prohibited The publisher does not assume and hereby disclaims any liability to any party for any loss or damage caused by any error or omission in this Manual whet...

Page 4: ...ique de Symbole 1 13 SECTION 2 INTRODUCTION 2 1 2 01 How to Use This Manual 2 1 2 02 Equipment Identification 2 1 2 03 Receipt of Equipment 2 1 2 04 Description 2 1 2 05 Transportation Methods 2 1 2 06 Duty Cycle 2 1 2 07 Specifications 2 2 SECTION 3 INSTALLATION 3 1 3 01 Environment 3 1 3 02 Location 3 1 3 03 Electrical Input Connections 3 1 3 04 Electromagnetic Compatibility 3 4 3 05 Setup for W...

Page 5: ... 4 11 Arc Welding Practice 4 5 4 12 Welding Position 4 6 4 13 Joint Preparations 4 7 4 14 Arc Welding Technique 4 8 4 15 The Welder 4 8 4 16 Striking the Arc 4 8 4 17 Arc Length 4 8 4 18 Rate of Travel 4 8 4 19 Making Welded Joints 4 9 4 20 Distortion 4 11 4 21 The Cause of Distortion 4 11 4 22 Overcoming Distortion Effects 4 12 SECTION 5 SERVICE 5 1 5 01 Maintenance and Inspection 5 1 5 02 STICK ...

Page 6: ...stick electrodes 230V to 115V adapter Quick set up DVD Operating manual Thermal Arc 161S TIG Stick System Part Number W1003603 Thermal Arc 161 S power supply in toolbox 17V TIG torch 12 5ft 3 8m with accessory kit Tweco electrode holder 13ft 4m lead Tweco ground clamp 10ft 3 1m lead 4 GP 1 8 3 2mm dia stick electrodes Victor CutSkill 2G Gas Regulator 230V to 115V adapter Quick set up DVD Operating...

Page 7: ...ut 14 Wear a safety harness to prevent falling if working above floor level 15 Keep all panels and covers securely in place WARNING ARC RAYS can burn eyes and skin NOISE can damage hearing Arc rays from the welding process produce intense heat and strong ultraviolet rays that can burn eyes and skin Noise from some processes can damage hearing 1 Wear a welding helmet fitted with a proper shade of f...

Page 8: ...d where flying sparks can strike flammable material 3 Remove all flammables within 35 ft 10 7 m of the welding arc If this is not possible tightly cover them with approved covers 4 Be alert that welding sparks and hot materials from welding can easily go through small cracks and openings to adjacent areas 5 Watch for fire and keep a fire extinguisher nearby 6 Be aware that welding on a ceiling flo...

Page 9: ...e 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 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 bef...

Page 10: ...ound 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 1 02 General Safety Information for Victor CS Regulator A Fire Prevention Welding and cutting operations use fire or combustion as a basic tool The process is very u...

Page 11: ...cylinders away from full cylinders Mark them EMPTY and close the cylinder valve 4 NEVER use compressed gas cylinders without a pressure reducing regulator attached to the cylinder valve 5 Inspect the cylinder valve for oil grease and damaged parts WARNING DO NOT use the cylinder if you find oil grease or dam aged parts Inform your gas supplier of this condition immediately 6 Momentarily open and c...

Page 12: ...Arc Welding GMAW Increase Decrease Circuit Breaker AC Auxiliary Power Remote Duty Cycle Percentage Amperage Voltage Hertz cycles sec Frequency Negative Positive Direct Current DC Protective Earth Ground Line Line Connection Auxiliary Power Receptacle Rating Auxiliary Power Art A 04130 115V 15A t t1 t2 X IPM MPM t V Fuse Wire Feed Function Wire Feed Towards Workpiece With Output Voltage Off Preflow...

Page 13: ...alets d entrainement et toutes les pièces métalliques en contact avec le fil de soudage sont sous tension Un équipement inadéquatement installé ou inadéquatement mis à la terre est dangereux 1 Ne touchez pas à des pièces sous tension 2 Portez des gants et des vêtements isolants secs et non troués 3 Isolez vous de la pièce à souder et de la mise à la terre au moyen de tapis isolants ou autres 4 Déc...

Page 14: ... de nettoy age ou de pulvérisation La chaleur et les rayons de l arc peuvent réagir avec des vapeurs et former des gaz hautement toxiques et irritants 7 Ne soudez des tôles galvanisées ou plaquées au plomb ou au cadmium que si les zones à souder ont été grattées à fond que si l espace est bien ventilé si nécessaire portez un respirateur à adduction d air Car ces revêtements et tout métal qui conti...

Page 15: ...alliques volantes En refroidissant la soudure peut projeter du éclats de laitier 1 Portez un écran facial ou des lunettes protectrices approu vées Des écrans latéraux sont recommandés 2 Portez des vêtements appropriés pour protéger la peau AVERTISSEMENT LES BOUTEILLES ENDOMMAGEES PEUVENT EX PLOSER Les bouteilles contiennent des gaz protecteurs sous haute pression Des bouteilles endommagées peuvent...

Page 16: ...e déconnecter des câbles d accumulateur 3 N utilisez que des outils anti étincelles pour travailler sur un ac cumulateur 4 N utilisez pas une source de courant de soudage pour charger un accumulateur ou survolter momentanément un véhicule 5 Utilisez la polarité correcte et de l accumulateur AVERTISSEMENT LA VAPEUR ET LE LIQUIDE DE REFROIDISSEMENT BRULANT SOUS PRESSION PEUVENT BRULER LA PEAU ET LES...

Page 17: ...vironnement non dédié au soudage ou découpage portez toujours une protection des yeux appropriées ou un masque facial AVERTISSEMENT Mettez en pratique les procédures de sécurité et de mode opératoire suivantes à chaque fois que vous utilisez cet appareil de régulation de pression Si vous déviez de ces procédures cela peut entraîner incendie explosion dégâts matériels et ou blessures corporelles po...

Page 18: ...g 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...

Page 19: ...age Intensité de Courant Tension Hertz cycles sec Fréquence Négatif Positif Courant Continue DC Terre de Protection Ligne Connexion de la Ligne Source Auxiliaire Classement de Prise Source Auxiliaire Art A 07639 115V 15A t t1 t2 X IPM MPM t Fusible Déroulement du Fil Alimentation du Fil Vers la Pièce de Fabrication Hors Tension Durée de Pré Dèbit Durée de Post Dèbit Duréc du Pulse Soudure Par Poin...

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Page 21: ...n in your area listed in the inside back cover of this manual Include all equipment identification numbers as described above along with a full description of the parts in error 2 04 Description This compact inverter welding machine has infinitely adjustable welding current from 10 to 160 amps It uses standard general purpose STICK SMAW 3 32 2 5mm electrodes for light gauge work generally less tha...

Page 22: ...ut Terminal Type Heavy Duty DinseTM 50 Classification Protection Class IP23S Standards EN 60974 1 EN50199 Cooling Method Fan Cooled Dimensions and Weight Welding Power Source Mass 17 4 lb 7 9 kg Welding Power Source Dimensions Height x Width x Depth H 9 0 x W 5 3 x D 15 5 H230mm x W135mm x D393mm The recommended time delay fuse or circuit breaker size is 30 amp An individual branch circuit capable...

Page 23: ...ing to the following guidelines In areas free from moisture and dust Ambient temperature between 32 F 0 C to 104 F 40 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 300mm or more from walls or similar that could restrict natural air flow for cooling WARNING Thermal Ar...

Page 24: ...OW conductor to a suitable ground Use a grounding method that complies with all applicable electrical codes 2 Connect ends of line 1 BLACK and line 2 WHITE input conductors to a de energized line disconnect switch 3 Use Table 3 1 as a guide to select line fuses for the disconnect switch Input Voltage Circuit Breaker or Fuse Size 115V 30A 208 230V 50A Table 3 1 Fuse Guide CAUTION The time delay fus...

Page 25: ...r the input capacitors have charged to operating voltage after approximately 5 seconds NOTE Damage to the PCA could occur if 253 VAC or higher is applied to the Primary Power Cable Model Primary Supply Lead Size Factory Fitted Minimum Primary Current Circuit Size Vin Amps Current Duty Cycle LIFT TIG GTAW STICK SMAW Thermal Arc 161 S 12 AWG 3 3mm 115V 27 3A 100A 35 115V 20A 110A 50 208 230V 25A 160...

Page 26: ... additional protection measures The size of the surrounding area to be considered will depend on the structure of the building and other activities that are taking place The surrounding area may extend beyond the boundaries of the premises C Methods of Reducing Electromagnetic Emissions 1 Mains Supply Welding equipment should be connected to the mains supply according to the manufacturer s recomme...

Page 27: ...eening the entire welding installation may be considered for special applications 3 05 Setup for Welding NOTE 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 design ensure that the Welding Power Source will withstand short term overload without a...

Page 28: ...rminal and the electrode holder cable to the positive output terminal NOTE This set up is known as DC Electrode Positive or reverse polarity Please consult with the stick electrode manufacturer for specific polarity recommendations 3 Connect the ground clamp to your workpiece 4 Plug the power cable into the appropriate outlet and turn the switch to the ON position The power L E D light should illu...

Page 29: ... the TIG torch cable to the negative output terminal NOTE This set up is known as Straight Polarity or DC Electrode Negative This is commonly used for DC TIG welding on most materials such as steel and stainless steel 3 Using a secured Argon cylinder slowly crack open then close the cylinder valve while standing off to the side of the valve This will remove any debris that may be around the valve ...

Page 30: ... to their intended system 1 Note the maximum inlet pressure stamped on the regulator DO NOT attach the regulator to a system that has a higher pressure than the maximum rated pressure stamped on the regulator 2 The regulator body will be stamped IN or HP at the inlet port Attach the inlet port to the system supply pressure connection 3 Wrap pipe threads with Teflon tape 1 1 2 to 2 turns to effect ...

Page 31: ...own stream equipment from high pressures WARNING DO NOT tamper with the relief valve or remove it from the regulator WARNING Stand to the side of the cylinder opposite the regulator when opening the cylinder valve Keep the cylinder valve between you and the regulator For your safety NEVER STAND IN FRONT OF OR BEHIND A REGULATOR WHEN OPENING THE CYLINDER VALVE 9 Slowly and carefully open the cylind...

Page 32: ... service or repair take it to a qualified repair technician 5 Once leak testing has been performed and there are no leaks in the system slowly open the cylinder valve and proceed WARNING If a leak has been detected anywhere in the system dis continue use and have the system repaired DO NOT use leaking equipment Do not attempt to repair a leaking system while the system is under pressure 3 10 When ...

Page 33: ...es between LIFT TIG and STICK Welding modes B Power On Indicator The Power ON Indicator illuminates when the ON OFF switch is in the ON position and the nominal mains volt age is present C Warning Indicator The welding power source is protected by a self resetting thermostat and over primary current protection devices Welding can not take place if the Warning Indicator lights up continuously or is...

Page 34: ...arts in circuit breaker c Using an extension cable d Low line mains power voltage Output Scale for 115V The inside number scale identifies the available output weld current for STICK or LIFT TIG weld modes STICK Mode Identifies the STICK weld point for 15 Amp outlet Identifies the STICK weld point for 20 Amp outlet Exceeding these points will cause nui sance tripping of the circuit breaker or fuse...

Page 35: ...s the high rate of heat con ductivity of copper making pre heating of heavy sections necessary to give proper fusion of weld and base metal Types of Electrodes Arc Welding electrodes are classified into a number of groups depending on their applications There are a great number of electrodes used for specialized industrial purposes which are not of particular interest for everyday general work The...

Page 36: ...165 4 07 Tungsten Electrode Current Ranges Electrode Diameter DC Current 040 1 0mm 25 85 1 16 1 6mm 50 160 3 32 2 4mm 135 235 4 08 Shielding Gas Selection Alloy Shielding Gas Carbon Steel Welding Argon Stainless Steel Welding Argon Nickel Alloy Welding Argon Copper Welding Argon Titanium Welding Argon 4 09 Tungsten Electrode Types Electrode Type Ground Finish Welding Application Features Color Cod...

Page 37: ... 70 40 60 1 16 1 6mm 1 16 1 6mm 15 CFH 7 LPM Butt Corner 70 90 50 70 Lap Filler 1 8 3 2mm 80 100 65 85 1 16 1 16mm 3 32 2 4mm 15CFH 7 LPM Butt Corner 90 115 90 110 Lap Filler 3 16 4 8mm 115 135 100 125 3 32 2 4mm 1 8 3 2mm 21CFH 10 LPM Butt Corner 140 165 125 150 Lap Filler 1 4 6 4mm 160 175 135 160 1 8 3 2mm 5 32 4 0mm 21CFH 10 LPM Butt Corner 170 200 160 180 Lap Filler 4 11 Arc Welding Practice ...

Page 38: ...in this publication can be used in most positions i e they are suitable for welding in flat horizontal vertical and overhead positions Numerous applications call for welds to be made in positions intermediate between these Some of the common types of welds are shown in Figures 4 2 through 4 9 Art A 07687 Figure 4 3 Flat position down hand butt weld Art A 07688 Figure 4 4 Flat position gravity fill...

Page 39: ...es being welded should be clean and free of rust scale dirt grease etc Slag should be removed from oxy cut surfaces Typical joint designs are shown in Figure 4 10 Gap varies from 1 16 1 6mm to 3 16 4 8mm depending on plate thickness Joint Open Square Butt 1 16 1 6mm max 1 16 1 6mm Single Vee Butt Joint Not less than 70 Double Vee Butt Joint 1 16 1 6mm Lap Joint Tee Joints Fillet both sides of the ...

Page 40: ...sticking to the work piece This is caused by making too heavy a contact with the work and failing to withdraw the electrode quickly enough A low amperage will accentuate it This freezing on of the tip may be overcome by scratching the electrode along the plate surface in the same way as a match is struck As soon as the arc is established maintain a 1 16 1 6mm to 1 8 3 2mm gap between the burning e...

Page 41: ...event slag being trapped by the second run Subsequent runs are then deposited using either a weave technique or single beads laid down in the sequence shown in Figure 4 13 The width of weave should not be more than three times the core wire diameter of the electrode When the joint is completely filled the back is either machined ground or gouged out to remove slag which may be trapped in the root ...

Page 42: ...ry to cover the first run and obtain good fusion at the edges At the completion of each side motion pause for a moment to allow weld metal to build up at the edges otherwise undercut will form and too much metal will accumulate in the centre of the weld Figure 4 17 illustrates multi run technique and Figure 4 18 shows the effects of pausing at the edge of weave and of weaving too rapidly Art A 077...

Page 43: ...ture and attempts to expand in all directions It is able to do his freely at right angles to the surface of the plate i e through the weld but when it attempts to expand across the weld or along the weld it meets considerable resistance and to fulfill the desire for con tinued expansion it has to deform plastically that is the metal adjacent to the weld is at a high temperature and hence rather so...

Page 44: ...d of overcoming distortion although an unsuitable sequence may exaggerate it Simultaneous welding of both sides of a joint by two welders is often successful in eliminating distortion C Restraint of Parts Forcible restraint of the components being welded is often used to prevent distortion Jigs positions and tack welds are methods employed with this in view D Presetting It is possible in some case...

Page 45: ...161 s Manual 0 5073 4 13 Operation Art A 07710 Figure 4 26 Welding sequence Art A 07711 Figure 4 27 Step back sequence Art A 07712 Figure 4 28 Chain intermittent welding Art A 07713 Figure 4 29 Staggered intermittent welding ...

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Page 47: ...y 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 SECTION 5 SERVICE Warning Disconnect input power before maintaining Each Use Visual check of regulator and pressure Visual check of torc...

Page 48: ... current B Use smaller diameter electrode C Allow wider gap D Use correct build up sequence 4 Portions of the weld run do not fuse to the surface of the metal or edge of the joint A Small electrodes used on heavy cold plate B Welding current is too low C Wrong electrode angle D Travel speed of electrode is too high E Scale or dirt on joint surface A Use larger electrodes and preheat the plate B In...

Page 49: ... grinding contaminates off B Check gas lines for cuts and loose fitting or change gas cylinder 8 Poor weld finish Inadequate shielding gas Increase gas flow or check gas line for problems 9 Arc flutters during TIG welding Tungsten electrode is too large for the welding current Select the right size electrode Refer to section Tungsten Electrode Current Ranges 10 We l d i n g a rc c a n n o t b e es...

Page 50: ... The Primary supply voltage has not been switched ON B The Welding Power Source switch is switched OFF C Loose connections internally A Switch ON the Primary supply voltage B Switch ON the Welding Power Source C Have an Accredited Thermal Arc Service Provider repair the connection 2 The welding arc cannot be established when the Warning Indicator lights up continuously The machines duty cycle has ...

Page 51: ...sistor 6 ohm 60W W7003055 PCB Control 161S W7003057 Insulation Sheet 161S W7003060 PCB Power 161S W7003061 PCB Front Control 95S 161S W7003047 Panel Front 161S W7003022 Label Front Controls 161S W7003062 Knob control Red 21 ODx6 ID W7003063 Boot Rubber Mode Switch W7003064 Terminal Output 50mm Dinse W7003020 Thermistor 161S W7003016 Panel Base 161S W7003073 Inductor 161S W7003018 Handle 95S 161 20...

Page 52: ...UNF connection 0781 4169 Power Adapter 230V 50A Socket Nema 6 50R to 115V 15A Plug Nema 5 15P W4014000 USA Graphics Auto Darkening welding helment spare cover lens and operating manual W4011700 Canadian Graphics Auto Darkening welding helmet spare cover lens and operating manual W4011800 Claret Color Auto Darkening welding helmet spare cover lens and operating manual W4011900 Black Graphics Auto D...

Page 53: ...APPENDIX THERMAL ARC 161 s Manual 0 5073 A 3 Appendix APPENDIX 3 SYSTEM SCHEMATIC 9 6 B B 3 7 32 5 3 21752 3 URQW RQWURO 3 1 9 7 7 27 0287 1 0 2 2 0 2 2 2 QGXFWRU 3RVLWLYH 1HJDWLYH Art A 09196 ...

Page 54: ...ng out of contract tort including negligence or strict liability or under any warranty or otherwise shall not exceed the price of the goods upon which such liability is based No employee agent or representative of Thermal Arc is authorized to change this warranty in any way or grant any other warranty and Thermal Arc shall not be bound by any such attempt Correction of non conformities in the mann...

Page 55: ...ears All other original circuits and components including but not limited to relays switches contactors solenoids fans electric motors 1 year 1 year PLASMA WELDING EQUIPMENT WARRANTY PERIOD LABOR Ultima 150 Original Main Power Magnetics 5 years 3 years Original Main Power Rectifiers Control P C Boards power switch semi conductors 3 years 3 years Welding Console Weld Controller Weld Timer 3 years 3...

Page 56: ...54 727 8376 Oakville Ontario Canada Canada Customer Care Ph 1 905 827 4515 Fax 1 800 588 1714 tollfree Chorley United Kingdom Customer Care Ph 44 1257 261755 Fax 44 1257 224800 Milan Italy Customer Care Ph 39 0236546801 Fax 39 0236546840 Cikarang Indonesia Customer Care Ph 6221 8990 6095 Fax 6221 8990 6096 Rawang Malaysia Customer Care Ph 603 6092 2988 Fax 603 6092 1085 Melbourne Australia Austral...