Related Manuals for Thermal Arc 161 S
Summary of Contents for Thermal Arc 161 S
- Page 1 161 S THERMAL ARC ® InvERTER ARC WELdER Art# A-10380 Operating Manual Revision: AB Issue Date: February 6, 2012 Manual No.: 0-5199 Operating Features: 3163339...
- Page 2 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.
- Page 3 Operating Manual Number 0-5199 for: Thermal Arc 161 S Power Source Arc Welder Part No. W1003606 Thermal Arc 161 S System with Stick Kit & Case Part No. W1003608 Thermal Arc 161 S System with Stick/TIG Kit & Case Part No. W1003609 Published by: Thermadyne Industries Inc.
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Page 4: Table Of Contents
TABLE OF CONTENTS SECTION 1: SAFETY INSTRUCTIONS AND WARNINGS ............1-1 1.01 Arc Welding Hazards ..................1-1 1.02 General Safety Information for Victor CS Regulator .......... 1-4 1.03 Principal Safety Standards ................1-6 1.04 Symbol Chart ....................1-7 1.05 Declaration Of Conformity ................1-8 SECTION 2: INTRODUCTION .................. - Page 5 TABLE OF CONTENTS SECTION 4: OPERATION ................... 4-1 4.01 Front Panel ..................... 4-1 4.02 Welding Current Control Explanation .............. 4-2 4.03 STICK (SMAW) Electrode Polarity..............4-3 4.04 Effects of Stick Welding Various Materials ............4-3 4.05 GTAW Electrode Polarity ................. 4-4 4.06 Guide for Selecting Filler Wire ................
- Page 6 Thermal Arc 161S Stick System Part Number W1003608 • Thermal Arc 161S power supply in toolbox • Tweco electrode holder, 13ft (4m) lead • Tweco ground clamp, 10ft (3.1m) lead • 4 GP 1/8" (3.2mm) dia stick electrodes • 230V to 115V adapter • Product family overview DVD • Operating manual Art# A-10378 Thermal Arc 161S TIG/Stick System Part Number W1003609 • 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 •...
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Page 7: Safety Instructions And Warnings
SAFETY INSTRUCTIONS THERMAL ARC 161 S 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. -
Page 8: Safety Instructions
THERMAL ARC 161 S SAFETY INSTRUCTIONS 7. 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. - Page 9 SAFETY INSTRUCTIONS THERMAL ARC 161 S 6. Be aware that welding on a ceiling, floor, bulkhead, or partition can cause fire on the hidden side. 7. Do not weld on closed containers such as tanks or drums. WARNING 8. Connect work cable to the work as close to the welding area as Engines can be dangerous.
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Page 10: General Safety Information For Victor Cs Regulator
THERMAL ARC 161 S SAFETY INSTRUCTIONS 1. Keep cables close together by twisting or taping them. 2. Arrange cables to one side and away from the operator. WARNING 3. Do not coil or drape cable around the body. SPARKS can cause BATTERY GASES TO EXPLODE;... -
Page 11: Personal Protection
SAFETY INSTRUCTIONS THERMAL ARC 161 S Ventilation WARNING WARNING Cylinders are highly pressurized. Handle with care. Serious accidents can result from improper handling Ade quately ventilate welding, heating, and cutting work or mis use of compressed gas cylinders DO NOT drop... -
Page 12: Principal Safety Standards
THERMAL ARC 161 S SAFETY INSTRUCTIONS 1.03 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. -
Page 13: Symbol Chart
SAFETY INSTRUCTIONS THERMAL ARC 161 S 1.04 Symbol Chart Note that only some of these symbols will appear on your model. Single Phase Wire Feed Function Wire Feed Towards Workpiece With Three Phase Output Voltage Off. Three Phase Static Frequency Converter-... -
Page 14: Declaration Of Conformity
THERMAL ARC 161 S SAFETY INSTRUCTIONS 1.05 Declaration Of Conformity Manufacturer: Thermadyne Corporation Address: 82 Benning Street West Lebanon, New Hampshire 03784 The equipment described in this manual has been designed to all applicable aspects and regulations of the ‘Low Voltage Directive’ (2006/95 EC) and to the National legislation for the enforcement of this Directive. -
Page 15: Introduction
INTRODUCTION THERMAL ARC 161 S SECTION 2: INTRODUCTION 2.01 How to Use This Manual 2.03 Receipt of Equipment When you receive the equipment, check it against the This Manual usually applies to the part numbers listed on invoice to make sure it is complete and inspect the page i. -
Page 16: Specifications
(Based on Article 630, National Electrical Code) Thermal Arc continuously strives to produce the best product possible and therefore reserves the right to change, improve or revise the specifications or design of this or any product without prior notice. Such updates or changes do not entitle the buyer of equipment previously sold or shipped to the corresponding changes, updates, improvements or replacement of such items. -
Page 17: Installation
• 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 Arc advises that this equipment be electrically connected by a qualified electrician. Manual 0-5199 Installation... -
Page 18: Electrical Input Connections
THERMAL ARC 161 S INSTALLATION 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. Lock-out/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. - Page 19 INSTALLATION THERMAL ARC 161 S 208-230V, 50A, 1Ø Welding Power Supply 20A, 1Ø The Adapters enable connection to all these power outlets 15A, 1Ø Primary Power Cable Art# A-09862 Figure 3-1: Electrical Input Connections Input Power Each unit incorporates an INRUSH circuit. When the MAIN CIRCUIT SWITCH is turned on, the inrush circuit provides pre-charging for the input capacitors.
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Page 20: Electromagnetic Compatibility
THERMAL ARC 161 S INSTALLATION 3.04 Electromagnetic Compatibility 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. -
Page 21: Setup For Welding
INSTALLATION THERMAL ARC 161 S 5. Earthing of the Work Piece 3.05 Setup for Welding Where the work piece is not bonded to earth for NOTE electrical safety, nor connected to earth because of its Conventional operating procedures apply size and position, e.g. ship’s hull or building steelwork, when using the Welding Power Source, i.e. -
Page 22: Stick (Smaw) Setup
THERMAL ARC 161 S INSTALLATION 3.06 STICK (SMAW) Setup Set Welding Current as specified by the Set Process Selection Electrode Manufacturer. Switch to SMAW (Stick) Negative Output Positive Output Terminal Terminal (Dinse™ 50) (Dinse™ 50) Art #: A-09878 Figure 3-2: Setup for STICK (SMAW) Welding STICK (SMAW) Mode Sequence of Operation 3. -
Page 23: Lift Tig (Gtaw) Setup
INSTALLATION THERMAL ARC 161 S 3.07 LIFT TIG (GTAW) Setup Set Process Selection Switch to GTAW (Lift TIG). Set Welding Current as specified by the Electrode Manufacturer. Negative Output Terminal (Dinse™ 50) Secure the gas cylinder in an Positive Output... -
Page 24: Victor Regulator
THERMAL ARC 161 S INSTALLATION 2. The regulator body will be stamped “IN” or “HP” 9. Set the “Process Selection Switch” to LIFT TIG at the inlet port. Attach the inlet port to the system 10. Set the weld current control knob to the desired supply pressure connection. amperage. 3. Wrap pipe threads with Teflon tape 1 1/2 to 2 11. - Page 25 INSTALLATION THERMAL ARC 161 S WARNING DO NOT attach or use the regulator if oil, grease, flamma ble substances or damage is present! Have a qualified repair technician clean the regulator or repair any damage. Art # A-09828 Figure 3-6: Open Cylinder Valve 10.
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Page 26: Leak Testing The System
THERMAL ARC 161 S INSTALLATION 3.09 Leak Testing the System 3.10 When You Finish Using the Regulator Leak test the system before putting into operation. 1. Close the cylinder valve. 1. Be sure that there is a valve in the downstream 2. -
Page 27: Operation
If the Fault Indicator lights up continuously then the primary current into the main transformer has been ex- Front Panel ceeded. Have an Accredited Thermal Arc Service Provider The welding power source is protected by a self re-setting inspect then repair the welder. -
Page 28: Welding Current Control Explanation
THERMAL ARC 161 S OPERATION 4.02 Welding Current Control Output Scale for 115V Explanation The inside number scale identifies the available 15 Amp Outlet output weld current for STICK or LIFT TIG weld modes. The mains power 15 Amp circuit breaker or fuse should... -
Page 29: Stick (Smaw) Electrode Polarity
OPERATION THERMAL ARC 161 S Cast Iron 4.03 STICK (SMAW) Electrode Polarity Most types of cast iron, except white iron, are weldable. Stick electrodes are generally connected to the "+" Posi- White iron, because of its extreme brittleness, generally tive Output Terminal and the work lead to the "−" Nega- cracks when attempts are made to weld it. Trouble may... -
Page 30: Gtaw Electrode Polarity
THERMAL ARC 161 S OPERATION 4.05 GTAW Electrode Polarity Connect the TIG torch to the "-" Negative Output Terminal and the work lead to the "+" Positive Output Terminal for direct current straight polarity. Direct current straight polarity is the most widely used polarity for DC TIG welding. It allows limited wear of the electrode since 70% of the heat is concentrated at the work piece. -
Page 31: Tig Welding Parameters For Steel
OPERATION THERMAL ARC 161 S 4.10 TIG Welding Parameters for Steel DC Current Stainless Base Metal Electrode Filler Rod Argon Gas Flow Mild Steel Steel Thickness Diameter Diameter Rate Joint / Type 35-45 20-30 Butt/Corner 0.040" 1/16" 10 CFH 0.040"... -
Page 32: Welding Position
THERMAL ARC 161 S OPERATION 4.12 Welding Position The electrodes dealt with 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. -
Page 33: Joint Preparations
OPERATION THERMAL ARC 161 S 4.13 Joint Preparations In many cases, it will be possible to weld steel sections without any special preparation. For heavier sections and for repair work on castings, etc., it will be necessary to cut or grind an angle between the pieces being joined to ensure proper penetration of the weld metal and to produce sound joints. -
Page 34: Arc Welding Technique
THERMAL ARC 161 S OPERATION Another difficulty you may meet is the tendency, after the 4.14 Arc Welding Technique arc is struck, to withdraw the electrode so far that the arc A Word to Beginners is broken again. A little practice will soon remedy both of these faults. -
Page 35: Making Welded Joints
OPERATION THERMAL ARC 161 S 4.19 Making Welded Joints Heavy plate will require several runs to complete the joint. After completing the first run, chip the slag out and clean Having attained some skill in the handling of an electrode, the weld with a wire brush. - Page 36 THERMAL ARC 161 S OPERATION Art # A-07700_AB Art # A-07701 Figure 4-16: Multi-runs in HV fillet weld C. Vertical Welds 1. Vertical Up Figure 4-17: Single run vertical fillet weld Tack weld a three feet length of angle iron to your Art # A-07702 work bench in an upright position. Use a 1/8"...
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Page 37: Distortion
OPERATION THERMAL ARC 161 S 4.20 Distortion 3. Overhead Welds Apart from the rather awkward position necessary, Distortion in some degree is present in all forms of overhead welding is not much more difficult that welding. In many cases it is so small that it is barely downhand welding. -
Page 38: Overcoming Distortion Effects
THERMAL ARC 161 S OPERATION The metal in the weld area is stretched (plastic deforma- D. Presetting tion), the job may be pulled out of shape by the powerful It is possible in some cases to tell from past experience or... - Page 39 OPERATION THERMAL ARC 161 S Art # A-07710_AB Block Sequence. The spaces between the welds are filled in when the welds are cool. Figure 4-26: Welding sequence Art # A-07711_AB Figure 4-27: Step back sequence Art # A-07712 Figure 4-28: Chain intermittent welding...
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Page 41: Service
SERVICE THERMAL ARC 161 S SECTION 5: SERVICE 5.01 Maintenance and Inspection To clean the unit, open the enclosure and use a vacuum cleaner to remove any accumulated dirt and dust. The unit The only routine maintenance required for the power should also be wiped clean, if necessary;... -
Page 42: Stick (Smaw) Welding Problems
THERMAL ARC 161 S SERVICE 5.02 STICK (SMAW) Welding Problems Description Possible Cause Remedy 1. Gas pockets or voids in weld metal Electrodes are damp. A. Dry electrodes before use. (Porosity). Welding current is too high. B. Reduce welding current. -
Page 43: Tig Welding Problems
SERVICE THERMAL ARC 161 S 5.03 TIG Welding Problems Weld quality is dependent on the selection of the correct consumables, maintenance of equipment and proper welding technique. Description Possible Cause Remedy 1. Excessive bead build-up or poor Welding current is too low... -
Page 44: Power Source Problems
There are extremely dangerous voltages and power levels present inside this product. Do not attempt to repair unless you are an Accredited Thermal Arc Service Agent and you have had training in power mea- surements and troubleshooting techniques. If major complex subassemblies are faulty, then the Welding Power Source must be returned to an Accredited Thermal Arc Service Agent for repair. -
Page 45: Replacement Parts
There are extremely dangerous voltages and power levels present inside this product. Do not attempt to repair unless you are an Accredited Thermal Arc Service Agent and you have had training in power measurements and troubleshooting techniques. If major complex subassemblies are faulty, then the Welding Power Source must be returned to an Accredited Thermal Arc Service Agent for repair. - Page 46 THERMAL ARC 161 S REPLACEMENT PARTS Art # A-09896_AB Replacement Parts Manual 0-5199...
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Page 47: Appendix 1: Options And Accessories
APPENDIX THERMAL ARC 161 S APPENDIX 1: OPTIONS AND ACCESSORIES Description Part Number 17V style TIG Torch with 12.5ft lead, gas valve, 50mm dinse connection and accessory kit W4012600 with 1/16", 3/32", 1/8" thoriated tungstens; 1/16", 3/32", 1/8" collets; 1/16", 3/32", 1/8" collet bodies; No. 5, 6, 7 Alumina nozzle; short back cap; long back cap VICTOR AF210-580 Regulator, Argon-CO2 Flowgauge with 5/8" - 18 UNF connection... -
Page 48: Appendix 2: System Schematic
THERMAL ARC 161 S APPENDIX APPENDIX 2: SYSTEM SCHEMATIC J1-2 J9-1 J9-2 J1-1 -24V J2-1 J3-1 J2-2 J3-2 +15V J2-3 J3-3 IGBT Driver A J2-4 J3-4 IGBT Driver B J2-5 J3-5 J2-6 J3-6 Over Current Signal J2-7 J3-7 Over Current Signal... - Page 49 This page intentionally blank.
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Page 50: Limited Warranty
No employee, agent, or representative of Thermal Arc is authorized to change this warranty in any way or grant any other warranty, and Thermal Arc shall not be bound by any such attempt. Correction of non-conformities, in the manner and time provided herein, constitutes fulfillment of thermal’s obligations to purchaser with respect to the product. - Page 51 WARRANTY SCHEDULE This information applies to Thermal Arc products that were purchased in the USA and Canada. August 2011 SAFETY EQUIPMENT ARRANTY ERIOD ABOR Auto-Darkening Welding Helmet (Electronic Lens) 2 year 2 year Harness Assembly 1 Month 1 Month ENGINE DRIVEN WELDERS...
- Page 52 U.S. Customer Care: 800-426-1888 / 800-535-0557 Canada Customer Care: 905-827-4515 / 800-588-1714 • International Customer Care: 940-381-1212 / 940-483-8178 www.thermalarc.com • A Global Cutting & Welding Market Leader ™ W O R L D H E A D Q U A R T E R S : 1 6 0 5 2 S w i n g l e y R i d g e R o a d , S u i t e 3 0 0 •...
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