Summary of Contents for flopower FLOW160DA000
- Page 1 160 DualArc AC Stick Welder FLOW160DA000) (Model # Operator’s Manual and Parts List Florida Power & Welding International, LLC +1. 305. 698. 2220 www.flopower.com...
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Page 2: Table Of Contents
CONTENTS INTRODUCTION ………………………………………………………………………………………………………………………… DESCRIPTION AND SPECIFICATIONS ………………………………………………………………………………………………………………………… FLOPOWER LIMITED WARRANTY ………………………………………………………………………………………………………………………… SAFETY PRECAUTIONS ………………………………………………………………………………………………………………………… COMPONENTS/ACCESSORIES ………………………………………………………………………………………………………………………… ASSEMBLY AND INSTALLATION ………………………………………………………………………………………………………………………… OPERATION ………………………………………………………………………………………………………………………… ARC WELDING BASICS ………………………………………………………………………………………………………………………… 10-12 BASIC CARE ………………………………………………………………………………………………………………………… TECHNICAL SPECIFICATIONS ………………………………………………………………………………………………………………………… WIRING SCHEMATIC ………………………………………………………………………………………………………………………… PARTS LIST ………………………………………………………………………………………………………………………… TROBLESHOOTING …………………………………………………………………………………………………………………………... -
Page 3: Introduction
It is designed for use with 220V and 110V circuits, making it a versatile and low-cost choice. Before attempting to use the welder, please make sure to read this manual carefully! Should you have any technical problems or questions regarding this unit, contact us by email at sales@flopower.com or by telephone at (800) 535 1185 -- from outside the USA +1 305 698 2220. -
Page 4: Flopower Limited Warranty
FLOPOWER warrants to its original retail purchaser that this unit is is free of defects in material and workmanship at the time it is shipped by FLOPOWER. Within one year after the date of purchase, FLOPOWER will repair or replace any warranted parts or components that fail due to defects in material or workmanship, determined at FLOPOWER’s discretion through an inspection conducted by the technical staff of FLOPOWER or its authorized resellers or repair service providers. -
Page 5: Safety Precautions
SAFETY PRECAUTIONS HEALTH HAZARDS: Welding produces intense electric and magnetic emissions that may interfere with the proper functioning of cardiac pacemakers, hearing aids, or other electronic health equipment. If you use such devices, you should consult your medical health professional and the manufacturer of the health device before using the welder. GASES AND FUMES: Gases and fumes produced during welding can be dangerous and hazardous to your health. - Page 6 Replace or repair all worn or damaged parts. Disconnect the power source before performing any service or repairs. Read and follow all the instructions in this Operator’s Manual. FIRE AND EXPLOSION: Fire and explosion can be caused by hot slag, sparks, or the welding arc. ...
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Page 7: Components/Accessories
COMPONENTS/ACCESSORIES Below is a list of the components of the 160 DualArc stick welder by Work cable/clamp (to be connected to weld piece). Electrode cable/holder (holds welding electrode). Input power cable (comes without plug). Rotating Amperage control knob. Power selector switch (to choose between OFF, 110V and 220V input). Power indicator light (green - lights when machine is connected to electricity). -
Page 8: Assembly And Installation
ASSEMBLY AND INSTALLATION Carefully unpack the product and verify that all the parts and accessories identified earlier are present in the machine and do not appear to have been broken during transportation. If a missing or defective part is found, please contact your retailer to obtain a replacement. The 160 DualArc welding machine comes without a power plug. -
Page 9: Operation
OPERATION You must identify whether your input power circuit is 110V or 220V (+/- 10%). This will determine whether you will choose to weld in the 110V or 220V mode. Selecting the wrong welding voltage will result in damage to the welding machine. If you are not certain of the voltage provided by the circuit, do not operate the welder, and seek assistant from a qualified electrician. All metals that are welded must be properly cleaned of any rust, moisture, grease, plastic or other non-metal external agents before welding. -
Page 10: Arc Welding Basics
ARC WELDING BASICS Arc welding is a process in which metals are joined together using heat developed by a welder. Current passes through the metals via the work clamp and the electrode (and the electrode holder), thus forming intense heat which results in a weld. The incandescent space between the weld area and the burning electrode is commonly referred to as the arc. This unit is an AC (alternating current) welder, which means that current travels in both directions of the welding circuit, in quick alternations (50 or 60 times per second, for 50Hz and 60Hz frequencies). - Page 11 Starting: Initiating the arc may be challenging, especially to the novice welder. It is recommended that users practice and familiarize themselves with the machine by welding some scrap metals before starting a job. An arc can be initiated by either scratching or tapping the electrode onto the weld metals. After the arc is started, it is important to swiftly leave a slight gap, or the electrode will weld itself onto the metal. However, the gap must not be too large;...
- Page 12 Arc speed: Because the electrode is melted continuously into the weld, it is important to continue feeding the electrode accordingly. However, this must be done at the right speed. When the travel speed is too fast, the resulting bead is narrow and penetration is poor. When the speed is too slow, the bead is high and wide and the metal tends to overheat. Overheat protection: The unit will automatically shut down once the duty cycle is reached.
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Page 13: Basic Care
BASIC CARE Always unplug the welder when it is not being used. Worn parts or damaged parts (cables, switches, plugs, handle) should be replaced promptly (see Parts List). When the welder is used outdoors, it should be kept from rain or long exposure to the sun. Inspect the welding cables from time to time to ensure that they are in good condition. -
Page 14: Technical Specifications
TECHNICAL SPECIFICATIONS / WIRING SCHEMATIC Welding Input Duty Cycle Rated Input Input Power Input Open Circuit Rated Insulation Case Overload Cooling Current Current Cable Capacitance Voltage Output Grade Protection Protection Range Voltage Grade 55-160A, AC 110VAC or 160A at 10% 38A or 76A at 16mm 7.7 KVA... -
Page 15: Parts List
PARTS LIST Exploded View Descriptions Part Numbers 1. Handle FLOW160DA001 2. Amperage/current indicator FLOW160DA002 3. Heat Relay FLOW160DA003 4. Secondary Winding FLOW160DA004 5. Inset FLOW160DA005 6. Indicator (amperage) FLOW160DA006 7. Sliding iron-core bracket FLOW160DA007 8. Rotating Amperage control FLOW160DA008 9. Power indicator light (green) FLOW160DA009 10. -
Page 16: Trobleshooting
TROUBLESHOOTING Problem Possible Fault Correction Welder does not power up (indicator light is not on). No power is available at receptacle. Check fuses or breakers. The input power cable is damaged or broken. Have cable replaced or repaired. Welder stops working during welding operation. Unit has reached or exceeded its duty cycle –... - Page 17 Unit overheats prematurely. An extension cord is being used. Relocate the welder or use a thicker extension cord. Electrode being used is too thick. Use smaller diameter electrode. It is difficult to start the arc. Electrode diameter is too large for the Amperage Reduce electrode size or increase Amperage.
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Page 18: Reference Publications
REFERENCE PUBLICATIONS Refer to the following standards or their latest revisions for more information on safety during welding operations: 1. OSHA, SAFETY AND HEALTH STANDARDS, 29CFR 1910, obtainable from the Superintendent of Documents, U.S. Government Printing Office, Washington, D.C. 20402. 2.