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Thermal Arc
Welding System
160 TS ARCMASTER
Thermal Arc 160 TS ARCMASTER User Manual
114 pages
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50
60
Hz
1
PHASE
SMAW
GTA
W
INVERTER
DC
CC
115
V
230
V
1
60 TS
ARCMASTER
®
INVER
TER ARC WELDER
Service Manual
Revision:
AB
Issue
Date:
June 16, 2006
Manual
No:
0-4881B
Operating Features:
2
Table of Contents
Service Manual
1
Table of Contents
4
Section 1: Safety Instructions and Warnings
7
Arc Welding Hazards
7
Principal Safety Standards
11
Precautions de Securite en Soundage a L'arc
12
Dangers Relatifs Au Soudage À L'arc
12
Principal Safety Standards
16
Section 2: Introduction
17
How to Use this Manual
17
Equipment Identification
17
Symbol Chart
18
Description
19
Functional Block Diagrams
20
Transporting Methods
20
Section 3: Installation
21
Environment
21
Location
21
Electrical Input Connections
21
Electrical Input Requirement
22
Input Power
23
High Frequency Introduction
23
High Frequency Interference
24
Duty Cycle
24
Specifications
25
Section 4: Operator Controls
27
ARC MASTER 160TS Controls
27
Weld Process Selection for 160TS
29
Weld Parameter Descriptions for ARC MASTER 160TS
30
Weld Parameters for ARC MASTER 160TS
33
Power Source Features
34
Section 5: Set-Up for Smaw (Stick) and Gtaw (Tig)
35
Section 6: Sequence of Operation
36
Stick Welding
37
HF TIG & Lift TIG Welding
37
Slope Mode Sequence
38
Slope Mode with Repeat Sequence
38
Pulse Controls
39
Section 7: Routine Maintenance
40
Section 8: Basic Troubleshooting
42
TIG Welding Problems
42
Stick Welding Problems
45
Power Source Problems
48
Section 9: Voltage Reduction Device (Vrd)
50
VRD Specification
50
VRD Maintenance
50
Switching VRD On/Off
51
Section 10: Power Source Error Code
54
Section 11: Advanced Trouble Shooting
56
System-Level Fault Isolation
56
Opening the Enclosure
57
Verification and Remedy to the Indicated Error Codes
60
E01 "Over-Temperature at the Primary Side
61
E02 "Over-Temperature at the Secondary Side
61
E03 "Primary Over-Current Failure
62
E94 "Thermistor Malfunction
62
E99 "Initial Power Receiving
62
Verification and Remedy to Failures Without Indication Codes
63
Cooling Fan (FAN1) Failure" (Fan Is Not Rotating.)
63
Gas Valve Failure" (no Gas Flow through Unit)
63
No Weld Output
64
Operating Panel Failure" (Led's Do Not Light Properly or Welding Setting Cannot be Established.)
65
High Frequency Output Failure" (Unit Does Not Generate High Frequency.)
65
Fault Isolation Tests
66
Verification of the Power Input Circuitry
67
Verification of the AC Input Voltage Using an AC Voltmeter
67
Verification of the Power Supply Voltage
69
Verification of the Cooling Fan, FAN1, Drive Circuitry
71
Verification of the Gas Valve, SOL1, Drive Circuitry
72
Verification of the Primary Diode (D1)
73
Verification of the Secondary Diode (D2, D3)
74
Verification of the Primary IGBT (Q1A-Q4C)
75
Verification of No-Load Voltage (OCV)
76
Output Load Test
77
Section 12: Maintenance
78
Maintenance List
78
Service Tools
81
Replacement Procedure
82
PCB1 (WK-5466) and Primary Diode D1
82
PCB2 (WK-5467), Capacitor C1 and Resistor R1
85
PCB3 (WK-5609) and T1 "Transformer
86
Pcb4 (Wk-5449)
87
Pcb5 (Wk-5448)
88
PCB6 (WK-5460) and Q1A-Q2C "Primary IGBT
89
PCB7 (WK-5460) and Q3A-Q4C "Primary IGBT
90
D2 and D3 "Secondary Diode
90
Coupling Coil"* and FCH1 "Reactor" *160TS Only
91
CT1 "Hole Current Trans
92
FAN1 "Cooling Fan
93
HF UNIT1 "High Frequency Unit" *160TS Only
94
SOL1 "Solenoid GAS Valve" *160TS Only
94
S1 "Switch
95
CON1 "Remote Receptacle
96
TH1 "Primary Thermistor
97
TH2 "Secondary Thermistor
97
Appendix A: Parts List
99
Appendix B: Connection Wiring Guide
102
Connection Guide
104
Connection Wire List
105
Appendix C: Connection Diagram
106
Appendix D: Diode Testing Basics
108
Limited Warranty
110
Warranty Schedule
111
Global Customer Service Contact Information
113
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Thermal Arc 160 TS ARCMASTER Specifications
General
Output Current Range
10 - 160 A
Duty Cycle
60% at 160 A
Open Circuit Voltage
70 V
Protection Class
IP23
Welding Process
TIG
TIG Start
Lift
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