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Svarog ARC 160-PFC User Manual

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ARC 160-PFC Welding Machine
USER MANUAL
REVISION : 2016-03-30

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Summary of Contents for Svarog ARC 160-PFC

  • Page 1 ARC 160-PFC Welding Machine USER MANUAL REVISION : 2016-03-30...
  • Page 3 Preface This manual includes hardware description and operation introduction of ARC 160-PFC equipment. For your and other people’s safety, please read the manual carefully. Pay attention Pay attention to the words after the signs below. Sign Description The words after this sign means there is great potential danger, which may cause major accident, damage or even death, if it is not followed.

  • Page 4: Table Of Contents

    CONTENTS 1 Safety warning 2 Product 2.1 General 2.2 Technical data 3 Installation...

  • Page 5: Safety Warning

    1 Safety warning The safety notes listed in this manual is to ensure correct use of the machine and to keep you and other people from being hurt. The design and manufacture of welding machine considers safety. Please refer to the safety warning listed in the manual to avoid accidents.
  • Page 6 Please follow the rules below to avoid heavy accidents.  Never use the equipment to do other things but welding.  Follow related regulations for the construction of the input-driven power source, choice of place, usage of high-pressure gas, storage, configuration, safe-keeping of workpiece after welding and disposal of waste, etc.
  • Page 7  Do move away the combustible around when weld the dooryard, ground and wall,.  The wire connection of base metal should be as close to the welding place as possible.  Never weld those facilities with gas pipe or airtight slot. ...
  • Page 8  Read the manual of gaseous regulator carefully before using it, and pay attention to the safety notes.  Fix the gas cylinder with appropriate holder and other relative parts.  Never put the cylinder under high temperature or sunshine environment. ...
  • Page 9 welding. Electromagnetic interference needing attention:  It may need extra preventive measures when the equipment is used in particular location.  Before the installation, please estimate the potential electromagnetism problems of the environment as follows. a) Upper and lower parts of the welding equipments and other nearby power cable, control cable, signal cable and phone cable.

  • Page 10: Product

    2 Product 2.1 General The welding machine applies the most advanced inversion technology in the world. The principle of inversion is to transform the power frequency of 50Hz/60Hz into direct current and invert it into high frequency (25KHz) through high-power device IGBT, then perform voltage-drop and commutation with the output high-power D.C power supply via Pulse Width Modulation (PWM).

  • Page 11: Technical Data

    2.2 Technical data Mode Arc 160-PFC Parameters Power voltage (V) 1 phase AC95V~265V Frequency (Hz) 50/60 Rated input current (A) No-load voltage(V) Output current adjustment (A) 95-180V 20-110(MMA) 5-110(TIG) 180-265V 20-160(MMA) 5-160(TIG) Rated Output voltage (V) 20.8-26.4(MMA) 10.2-16.4(TIG) Duty cycle (%) Power factor More than 0.95...

  • Page 12: Installation

    Both ways can be used together for better security. Arc 160-PFC Installation Procedures：  Correct Installation of LIFT TIG a) Connect the shielded-gas source correctly. The gas supplying route shall include gas cylinder, argon decompression flow meter and gas pipe.
  • Page 13 (See technical parameter table). Do not connect to the inappropriate voltage and make sure that the difference of power supply is within permitted range. Installation drawing of Arc 160-PFC (LIFT TIG)。 Installation drawing of Arc 160-PFC (STICK)。...
  • Page 14 4 Operation 4.1 Front panel layout 1 －STICK/LIFT TIG switch key 2 －Multifunctional data display 3 －Multifunctional data adjusting knob(coarse adjustment by pressing the knob and turning it: big regulating rate and high speed; fine adjustment only by turning the knob: small regulating rate and low speed) 4.2 Operation Instruction ...
  • Page 15  Operation instruction under STICK mode. When welding stops, Press the【STICK/LIFT TIG switch key】，the STICK indicator lights up，and it turns into STICK mode. under STICK mode ,Adjusting the 【Multifunctional data adjusting knob 】can change the welding current during welding process, and displayed in 【multifunctional data display】. 【multifunctional data display】shows the preset current“080 ”, its unit is ampere(A).
  • Page 16 Chart3: The preset current under LIFT TIG mode 5 seconds later after setting the welding parameters, the 【multifunctional data display 】 would flashes for one time, which means the data has been saved. Moreover, the panel would display these data when restart the machine next time if the parameters keep unchanged.
  • Page 17 Malfunction display of overheating protection The panel displays as Chart 5 when overheating, and the 【multifunctional data display】 flashes continuously, the machine can not work normally. Only when the temperature of the welding machine falls below 60 , the overheating malfunction would disappear, and the machine work ℃...
  • Page 18 4.3 Welding environment and safety  Environment a) The machine works in environment where air conditions are dry with a dampness level of max 90%. b) Ambient temperature should be between -10 to 40 degrees centigrade. c) Avoid welding in sunshine or raining. Avoid water entering the machine d) Avoid welding in dust area or the environment with corrosive gas.
  • Page 19 exceeding allowable range limits, it can damage the components of machine. The operator should understand this situation and take preventive measures. d) There is a grounding cable behind welding machine with a mark. Before operation, welding crust must be grounded reliably with cable, in order to prevent static electricity, and accidents for electricity leaking.
  • Page 20 5 Daily maintenance and checking  Daily maintenance Remove dust regularly with dry compressed air. If the welding machine is used in surroundings with heavy smoke and polluted air, it is necessary to remove dust at least one time one month. The pressure of compressed air shall fall to required level to prevent damage to small components in the machine.
  • Page 21  Daily checking WELDING POWER SUPPLY Position Check points Remarks Control  Switch condition of operation, transfer and panel installation  Test the power indicator Cooling  Check if there is wind and the sound normal If abnormal noise and no or not wind, please check the inner...
  • Page 22 CABLE Position Checking keys Remarks Torch  If torch cable over bended  Cause poor wire sending cable  If the metal connecting point of  Unstable arc if cable over mobile plug loosen bended Output  Wearing-out of the cable insulated For life security and stable welding, cable material...
  • Page 23 6 Trouble shooting and fault finding Notes: The following operations must be performed by qualified electricians with valid certifications. Before maintenance, you are suggested to contact local distributor to verify qualification. Malfunctions and solutions of Arc 160-PFC. Malfunctions Solution The meter show ...
  • Page 24 Even the machine comes up with abnormal phenomenon such as welding unable, arc unstable or bad welding effect, it is still early to judge that there is malfunction on the machine. The above-mentioned abnormal phenomenon may be caused by some reasons. For example: tight parts loosen, forgetting to switch on, wrong set up, cable broken and gas rubber pipe cracked, etc.
  • Page 25 Abnormal Items Area and Item to be Inspected and Maintained Wire Feeding Wire feeding wheel does not match with 〇 〇 〇 〇 〇 Device the diameter of wire in texturing tube Crackle on wire feeding wheel, groove blocked up or defect Too tight or loose of the handle Wire powder accumulated on the inlet of SUS pipe...
  • Page 26 Appendix I Operation parameter recommendation  Generally, welding current is adequate to welding electrode according with as following: electrode φ2.5 φ3.2 φ4.0 φ5.0 specification welding current 70-100A 110-140A 170-220A 230-280A  Welding variables when use TIG. TIG welding specifications of stainless steel as follows: Thickness Tungsten Wire...
  • Page 27 Appendix II Circuit diagram...
  • Page 28 Appendix III Spare parts list TER code I0098AA main board I0099AA display board I0100AA encoder I0101AA thermistor I0102AA rectifier I0103AA diode I0104AA single IGBT I0105AA mosfet E0010AA power switch I0106AA relay I0107AA I0108AA fast socket...