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Thermal Arc 161 S User Manual

Thermal Arc 161 S
56 pages
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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:

Table of Contents

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Thermal Arc 161 S Specifications

General IconGeneral
Input Phase1
Input Frequency50/60 Hz
Output Current Range10 - 160 A
Input Voltage115/230 VAC
Duty Cycle30% at 160A
Welding ProcessMIG, TIG, Stick

Summary

SAFETY INSTRUCTIONS AND WARNINGS

Arc Welding Hazards

Details hazards, warnings, and precautions related to electric shock and arc welding processes.

General Safety Information

Covers fire prevention, housekeeping, ventilation, personal protection, and handling of hazardous substances.

Principal Safety Standards

Lists key ANSI, OSHA, NFPA, and other safety standards relevant to welding and cutting operations.

Symbol Chart

Explains various symbols used on the welding equipment and within the manual for clarity.

INTRODUCTION

How to Use This Manual

Provides guidance on understanding the manual's structure, including warnings, cautions, and notes.

Equipment Identification and Receipt

Explains how to identify the unit and what to do upon receiving the equipment, checking for damage.

Equipment Description and Features

Details the welding machine's compact design, current range, and TIG/STICK capabilities.

Transportation and Handling

Offers guidance on safely moving and lifting the welding unit to prevent injury or damage.

Specifications

Provides technical data including voltage, current, duty cycle, dimensions, and weight of the power source.

INSTALLATION

Environment and Location Requirements

Specifies suitable environmental conditions and placement for safe welder operation.

Electrical Input Connections and Grounding

Details how to properly connect the welder to the power supply and ensure correct grounding.

Electromagnetic Compatibility

Discusses precautions for reducing electromagnetic emissions when using the welder.

Setup for Welding

Provides general guidance on connecting the work lead and electrode for welding operations.

STICK and TIG Setup Procedures

Step-by-step instructions for setting up the welder for both STICK (SMAW) and TIG (GTAW) welding modes.

Gas Regulator and Leak Testing

Covers the installation and use of the gas regulator and how to perform essential leak testing.

Regulator Usage and Storage

Explains how to finish using the regulator and proper procedures for storing it.

OPERATION

Front Panel Controls and Indicators

Explains the function of buttons, switches, and indicators on the welding machine's front panel.

Welding Current Control Explanation

Details how to set the welding current and explains the outlet scales for different voltages.

STICK and GTAW Polarity and Materials

Explains electrode polarity for STICK and GTAW welding and the effects of stick welding on various materials.

TIG Welding Parameters and Practice

Covers filler wire selection, tungsten ranges, gas selection, TIG parameters for steel, and general arc welding practices.

Joint Preparation and Distortion Control

Provides guidance on preparing joints for welding and methods to minimize or overcome distortion.

SERVICE

Routine Maintenance and Inspection

Outlines the necessary cleaning and inspection procedures for the welding power source.

Troubleshooting STICK (SMAW) Welding Problems

Addresses common issues encountered during STICK welding, providing possible causes and remedies.

Troubleshooting TIG Welding Problems

Addresses common issues encountered during TIG welding, providing possible causes and remedies.

Power Source Problem Diagnosis

Helps identify and resolve problems related to the welding arc not establishing or output current issues.

APPENDIX 1: REPLACEMENT PARTS

APPENDIX 2: OPTIONS AND ACCESSORIES

APPENDIX 3: SYSTEM SCHEMATIC

LIMITED WARRANTY

WARRANTY SCHEDULE

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