INVERTER

ARC
WELDER
MODEL 160S DC CC
STICK
TIG - Lift Start

OPERATING MANUAL

November 5, 2003

Manual No. 430429-504

CONTENTS
SYMBOL LEGEND ............................................................................................................................................................ 5
STATEMENT OF WARRANTY ........................................................................................................................................ 6
1.0 GENERAL INFORMATION......................................................................................................................................... 7
1.01 Notes, Cautions and Warnings ................................................................................................................................. 7
1.02 Important Safety Precautions.................................................................................................................................... 7
1.03 Publications ............................................................................................................................................................. 8
1.04 Note, Attention et Avertissement.............................................................................................................................. 9
1.05 Precautions De Securite Importantes....................................................................................................................... 9
1.06 Documents De Reference ...................................................................................................................................... 11
2.0 INTRODUCTION AND DESCRIPTION ................................................................................................................... 13
2.01 Description ............................................................................................................................................................. 13
2.02 Functional Block Diagrams .................................................................................................................................... 14
2.03 Transporting Methods............................................................................................................................................. 14
2.04 Installation Recommendations................................................................................................................................ 15
2.04.01 Environment .................................................................................................................................................. 15
2.04.02 Location......................................................................................................................................................... 15
2.05 Electrical Input Connections................................................................................................................................... 16
2.05.01 Electrical Input Requirements ....................................................................................................................... 16
2.05.02 Input Power ................................................................................................................................................... 18
2.05.03 High Frequency Introduction......................................................................................................................... 19
2.05.04 High Frequency Interference ......................................................................................................................... 19
2.06 Specifications ......................................................................................................................................................... 21
2.07 Duty Cycle.............................................................................................................................................................. 22
3.0 OPERATOR CONTROLS ........................................................................................................................................... 23
3.01 P-Wee 160S Controls ............................................................................................................................................. 23
3.02 Weld Parameter Description for the 160S .............................................................................................................. 25
3.03 Power Source Features ........................................................................................................................................... 26
4.0 SET-UP FOR SMAW (STICK) AND GTAW (TIG) .................................................................................................. 27
5.0 SEQUENCE OF OPERATION.................................................................................................................................... 28
5.0 Stick Welding ........................................................................................................................................................... 29
5.02 DC LIFT TIG Welding........................................................................................................................................... 29
6.0 BASIC TIG WELDING GUIDE.................................................................................................................................. 31
6.01 Electrode Polarity ................................................................................................................................................... 31
6.02 Tungsten Electrode Current Ranges ....................................................................................................................... 31
6.03 Tungsten Electrode Types ...................................................................................................................................... 31
6.04 Guide for Selecting Filler Wire Diameter............................................................................................................... 32
6.05 Shielding Gas Selection.......................................................................................................................................... 32
6.06 TIG Welding Parameters for Low Carbon & Low Alloy Steel Pipe ...................................................................... 32
6.07 Welding Parameters for Steel ................................................................................................................................. 33
7.0 Basic Arc Welding Guide............................................................................................................................................. 34
7.01Electrode Polarity .................................................................................................................................................... 34
7.02 Effects of Stick Welding Various Materials ........................................................................................................... 34
8.0 ROUTINE MAINTENANCE ...................................................................................................................................... 36
9.0 BASIC TROUBLESHOOTING................................................................................................................................... 37
9.01 TIG Welding Problems........................................................................................................................................... 37
9.02 Stick Welding Problems ......................................................................................................................................... 39
8.03 Power Source Problems.......................................................................................................................................... 41
10.0 Voltage Reduction Device (VRD).............................................................................................................................. 42
10.01 VRD Specification................................................................................................................................................ 42
10.02 VRD Maintenance ................................................................................................................................................ 42
11.0 Power Source Error Codes ......................................................................................................................................... 43
12.0 PARTS LIST .............................................................................................................................................................. 45
APPENDIX A - INTERCONNECT DIAGRAM............................................................................................................... 48
APPENDIX B - AUTOMATION ...................................................................................................................................... 50

PAGE LEFT INTENTIONALLY BLANK

SYMBOL LEGEND
Amperage

STICK (Shielded Metal Arc

SMAW)

Voltage

Pulse Current Function

Hertz (frequency)

Spot Time (GTAW)

SEC

Seconds

Remote Control (Panel/Remote)

Percent

Remote Function

DC (Direct Current)

Arc Control (SMAW)

AC (Alternating Current

Gas Post-Flow

Standard Function

Gas Pre-Flow

Slope Function

VRD

Voltage Reduction Device

Circuit

Slope W/Repeat Function

Negative

Spot Function

Positive

Impulse Starting (High

Frequency GTAW)

Gas Input

Touch Start (Lift Start TIG

circuit GTAW)

Gas Output

STATEMENT OF WARRANTY
LIMITED WARRANTY: Thermal Arc, Inc., A Thermadyne Company, hereafter, Thermal Arc warrants to customers
of its authorized distributors hereafter Thermal; Arc that its products will be free of defects in workmanship or
material. Should any failure to conform to this warranty appear within the time period applicable to the Thermal Arc
products as stated below, Thermal Arc shall, upon notification thereof and substantiation that the product has been
stored, installed, operated, and maintained in accordance with Thermal Arcs specifications, instructions,
recommendations and recognized standard industry practice, and not subject to misuse, repair, neglect, alteration, or
accident, correct such defects by suitable repair or replacement, at Thermal Arcs sole option, of any components or parts
of the product determined by Thermal Arc to be defective.
THERMAL ARC MAKES NO OTHER WARRANTY, EXPRESS OR IMPLIED. THIS WARRANTY IS EXCLUSIVE
AND IN LIEU OF ALL OTHERS, INCLUDING, BUT NOT LIMITED TO ANY WARRANTY OF
MERCHANTABILITY OR FITNESS FOR ANY PARTICULAR PURPOSE.
LIMITATION OF LIABILITY: Thermal Arc shall not under any circumstances be liable for special, indirect or
consequential damages, such as, but not limited to, lost profits and business interruption. The remedies of the Purchaser
set forth herein are exclusive and the liability of Thermal Arc with respect to any contract, or anything done in connection
therewith such as the performance or breach thereof, or from the manufacture, sale, delivery, resale, or use of any goods
covered by or furnished by Thermal Arc whether arising out of contract, negligence, strict tort, or under any warranty, or
otherwise, shall not, except as expressly provided herein, exceed the price of the goods upon which such liability is based.
No employee, agent, or representative of Thermal Arc is authorized to change this warranty in any way or grant any
other warranty.
PURCHASER'S RIGHTS UNDER THIS WARRANTY ARE VOID IF REPLACEMENT PARTS OR ACCESSORIES
ARE USED WHICH IN THERMAL ARCS SOLE JUDGEMENT MAY IMPAIR THE SAFETY OR PERFORMANCE
OF ANY THERMAL ARC PRODUCT.
PURCHASER'S RIGHTS UNDER THIS WARRANTY ARE VOID IF THE PRODUCT IS SOLD TO PURCHASER BY
NON-AUTHORIZED PERSONS.
The warranty is effective for the time stated below beginning on the date that the authorized distributor delivers the
products to the Purchaser. Notwithstanding the foregoing, in no event shall the warranty period extend more than the
time stated plus one year from the date Thermal Arc delivered the product to the authorized distributor.
POWER SUPPLIES

POWER SUPPLIES & WIRE FEEDERS

LABOR

MAIN POWER MAGNETICS (STATIC & ROTATING)

3 YEAR

3 YEAR

ORIGINAL MAIN POWER RECTIFIER

3 YEAR

3 YEAR

POWER SWITCHING SEMI-CONDUCTORS & CONTROL PC BOARD

3 YEAR

3 YEAR

ALL OTHER CIRCUITS AND COMPONENTS INCLUDING

1 YEAR

1 YEAR

BUT NOT LIMITED TO, CONTACTORS, RELAYS,

SOLENOIDS, PUMPS, SWITCHES, MOTORS
ENGINES: ENIGINES ARE NOT WARRANTED BY THERMAL ARC, ALTHOUGH MOST ARE WARRANTED BY THE
ENGINE MANUFACTURER, SEE THE ENGINE MANUFACTURES WARRANTY FOR DETAILS.
CONSOLES, CONTROL EQUIPMENT, HEAT

1 YEAR

1 YEAR

PLASMA TORCH AND LEADS, AND REMOTE CONTROLS

180 DAYS

180 DAYS

REPAIR/REPLACEMENT PARTS

90 DAYS

90 DAYS

EXCHANGES, AND ACCESSORY EQUIPMENT

Warranty repairs or replacement claims under this limited warranty must be submitted to Thermal Arc by an authorized
Thermal Arc repair facility within thirty (30) days of purchasers notice of any Warranty Claim. No transportation costs
of any kind will be paid under this warranty. Transportation charges to send products to an authorized warranty repair
facility shall be the responsibility of the Purchaser. All returned goods shall be at the Purchasers risk and expense. This
warranty supersedes all previous Thermal Arc warranties.
Thermal Arc is a Registered Trademark of Thermadyne Industries Inc.

Effective April 1, 2002

 Use an air-supplied respirator if ventilation is

not adequate to remove all fumes and gases.

1.0 GENERAL INFORMATION

The kinds of fumes and gases from the arc

welding/cutting depend on the kind of
metal being used, coatings on the metal, and
the different processes. You must be very
careful when cutting or welding any metals
which may contain one or more of the
following:

1.01 Notes, Cautions and Warnings

Throughout this manual, notes, cautions, and
warnings are used to highlight important
information. These highlights are categorized as
follows:
NOTE

Antimony
Arsenic
Barium
Beryllium
Cadmium
Vanadium

An
operation,
procedure,
or
background
information
which
requires additional emphasis or is
helpful in efficient operation of the
system.

Chromium
Cobalt
Copper
Lead
Manganese

Mercury
Nickel
Selenium
Silver

Always read the Material Safety Data Sheets

(MSDS) that should be supplied with the
material you are using. These MSDSs will
give you the information regarding the kind
and amount of fumes and gases that may be
dangerous to your health.

CAUTION
A procedure which, if not properly
followed, may cause damage to the
equipment.
WARNING

For information on how to test for fumes and

gases in your workplace, refer to item 1 in
Subsection 1.03, Publications in this manual.

A procedure which, if not properly

followed, may cause injury to the
operator or others in the operating
area.

Use special equipment, such as water or

down draft welding/cutting tables, to
capture fumes and gases.
Do not use the welding torch in an area
where combustible or explosive gases or
materials are located.

1.02 Important Safety Precautions

WARNING

Phosgene, a toxic gas, is generated from the

vapors of chlorinated solvents and cleansers.
Remove all sources of these vapors.

OPERATION
AND
MAINTENANCE
OF
ARC
WELDING EQUIPMENT CAN BE
DANGEROUS AND HAZARDOUS
TO YOUR HEALTH.

ELECTRIC SHOCK

To prevent possible injury, read,

understand and follow all warnings,
safety precautions and instructions
before using the equipment. Call 1800-462-2782 or your local distributor
if you have any questions.

Electric Shock can injure or kill. The arc welding

process uses and produces high voltage electrical
energy. This electric energy can cause severe or
fatal shock to the operator or others in the
workplace.
Never touch any parts that are electrically
live or hot.
Wear dry gloves and clothing. Insulate
yourself from the work piece or other parts
of the welding circuit.

GASES AND FUMES

Gases and fumes produced during the Arc
welding/cutting process can be dangerous and
hazardous to your health.

Repair or replace all worn or damaged parts.

Extra care must be taken when the workplace
is moist or damp.

Keep all fumes and gases from the breathing

area. Keep your head out of the welding
fume plume.

 Install and maintain equipment according to

NEC code, refer to item 4 in Subsection 1.03,
Publications.

ARC WELDING RAYS

Disconnect power source before performing

any service or repairs.

Arc Welding/Cutting Rays can injure your eyes

and burn your skin. The arc welding/cutting
process produces very bright ultra violet and infra
red light. These arc rays will damage your eyes
and burn your skin if you are not properly
protected.

Read and follow all the instructions in the

Operating Manual.

To protect your eyes, always wear a welding

helmet or shield. Also always wear safety
glasses with side shields, goggles or other
protective eye wear.

FIRE AND EXPLOSION

Fire and explosion can be caused by hot slag,
sparks, or the arc weld.

Wear welding gloves and suitable clothing to

protect your skin from the arc rays and
sparks.

Be sure there is no combustible or flammable

material in the workplace. Any material that
cannot be removed must be protected.

Keep helmet and safety glasses in good

condition. Replace lenses when cracked,
chipped or dirty.

Ventilate all flammable or explosive vapors

from the workplace.
Do not cut or weld on containers that may
have held combustibles.

Protect others in the work area from the arc

rays. Use protective booths, screens or
shields.

Provide a fire watch when working in an

area where fire hazards may exist.

Use the shade of lens as recommended in

Subsection 1.03, item 4.

Hydrogen gas may be formed and trapped

under aluminum workpieces when they are
cut underwater or while using a water table.
DO NOT cut aluminum alloys underwater
or on a water table unless the hydrogen gas
can be eliminated or dissipated. Trapped
hydrogen gas that is ignited will cause an
explosion.

1.03 Publications
Refer to the following standards or their latest
revisions for more information:
1. OSHA, SAFETY AND HEALTH STANDARDS,
29CFR
1910,
obtainable
from
the
Superintendent
of
Documents,
U.S.
Government Printing Office, Washington, D.C.
20402
2. ANSI Standard Z49.1, SAFETY IN WELDING
AND CUTTING, obtainable from the American
Welding Society, 550 N.W. LeJeune Rd, Miami,
FL 33126

NOISE
Noise can cause permanent hearing loss. Arc
welding/cutting processes can cause noise levels
to exceed safe limits. You must protect your ears
from loud noise to prevent permanent loss of
hearing.

3.

To protect your hearing from loud noise,

wear protective ear plugs and/or ear muffs.
Protect others in the workplace.

NIOSH, SAFETY AND HEALTH IN ARC

WELDING AND GAS WELDING AND
CUTTING, obtainable from the Superintendent
of Documents, U.S. Government Printing
Office, Washington, D.C. 20402

4. ANSI Standard Z87.1, SAFE PRACTICES FOR

OCCUPATION AND EDUCATIONAL EYE
AND FACE PROTECTION, obtainable from
American National Standards Institute, 1430
Broadway, New York, NY 10018

Noise levels should be measured to be sure

the decibels (sound) do not exceed safe
levels.
For information on how to test for noise, see
item 1 in Subsection 1.03, Publications, in
this manual.

5. ANSI Standard Z41.1, STANDARD FOR MENS

SAFETY-TOE FOOTWEAR, obtainable from
the American National Standards Institute,
1430 Broadway, New York, NY 10018

NOTE

6. ANSI Standard Z49.2, FIRE PREVENTION IN

THE USE OF CUTTING AND WELDING
PROCESSES, obtainable from American
National Standards Institute, 1430 Broadway,
New York, NY 10018
7.

8.

Toute opration, procdure ou

renseignement gnral sur lequel il
importe dinsister davantage ou qui
contribue

lefficacit
de
fonctionnement du systme.

AWS Standard A6.0, WELDING AND

CUTTING CONTAINERS WHICH HAVE
HELD COMBUSTIBLES, obtainable from
American Welding Society, 550 N.W. LeJeune
Rd, Miami, FL 33126

ATTENTION
Toute procdure pouvant rsulter
lendommagement du matriel en cas
de non-respect de la procdure en
question.

NFPA Standard 51, OXYGEN-FUEL GAS

SYSTEMS FOR WELDING, CUTTING AND
ALLIED PROCESSES, obtainable from the
National
Fire
Protection
Association,
Batterymarch Park, Quincy, MA 02269

AVERTISSEMENT

9. NFPA Standard 70, NATIONAL ELECTRICAL

CODE, obtainable from the National Fire
Protection Association, Batterymarch Park,
Quincy, MA 02269
10.

Toute procdure pouvant provoquer

des blessures de loprateur ou des
autres personnes se trouvant dans la
zone de travail en cas de non-respect
de la procdure en question.

NFPA Standard 51B, CUTTING AND

WELDING PROCESSES, obtainable from the
National
Fire
Protection
Association,
Batterymarch Park, Quincy, MA 02269

1.05 Precautions De Securite

Importantes

11.CGA Pamphlet P-1, SAFE HANDLING OF

COMPRESSED GASES IN CYLINDERS,
obtainable from the Compressed Gas
Association, 1235 Jefferson Davis Highway,
Suite 501, Arlington, VA 22202

AVERTISSEMENT
LOPRATION
ET
LA
MAINTENANCE DU MATRIEL
DE SOUDAGE LARC AU JET
DE
PLASMA
PEUVENT
PRSENTER DES RISQUES ET
DES DANGERS DE SANT.

12. CSA Standard W117.2, CODE FOR SAFETY IN

WELDING AND CUTTING, obtainable from
the Canadian Standards Association, Standards
Sales, 178 Rexdale Boulevard, Rexdale, Ontario,
Canada M9W 1R3
13.

Il faut communiquer aux oprateurs et

au personnel TOUS les dangers
possibles. Afin dviter les blessures
possibles, lisez, comprenez et suivez
tous les avertissements, toutes les
prcautions de scurit et toutes les
consignes avant dutiliser le matriel.
Composez le + 1-800-462-2782 ou
votre distributeur local si vous avez
des questions.

NWSA booklet, WELDING SAFETY

BIBLIOGRAPHY obtainable from the National
Welding Supply Association, 1900 Arch Street,
Philadelphia, PA 19103

14. American Welding Society Standard AWSF4.1,

RECOMMENDED SAFE PRACTICES FOR
THE PREPARATION FOR WELDING AND
CUTTING OF CONTAINERS AND PIPING
THAT
HAVE
HELD
HAZARDOUS
SUBSTANCES, obtainable from the American
Welding Society, 550 N.W. LeJeune Rd, Miami,
FL 33126
15. ANSI Standard Z88.2, PRACTICE FOR
RESPIRATORY PROTECTION, obtainable
from American National Standards Institute,
1430 Broadway, New York, NY 10018

FUME et GAZ
La fume et les gaz produits par le procd de jet
de plasma peuvent prsenter des risques et des
dangers de sant.

1.04 Note, Attention et Avertissement

Eloignez toute fume et gaz de votre zone de

respiration. Gardez votre tte hors de la
plume de fume provenant du chalumeau.

Dans ce manuel, les mots note, attention, et

avertissement sont utiliss pour mettre en relief
des informations caractre important. Ces mises
en relief sont classifies comme suit :

Utilisez un appareil respiratoire

alimentation en air si laration fournie ne
permet pas dliminer la fume et les gaz.

Prenez des soins particuliers lorsque la zone

de travail est humide ou moite.

Les sortes de gaz et de fume provenant de

larc de plasma dpendent du genre de mtal
utilis, des revtements se trouvant sur le
mtal et des diffrents procds. Vous devez
prendre soin lorsque vous coupez ou soudez
tout mtal pouvant contenir un ou plusieurs
des lments suivants:
antimoine
argent
arsenic
baryum
bryllium
vanadium

cadmium
chrome
cobalt
cuivre
manganse

Montez et maintenez le matriel

conformment au Code lectrique national
des Etats-Unis. (Voir la page 5, article 9.)

Dbranchez lalimentation lectrique avant

tout travail dentretien ou de rparation.

mercure
nickel
plomb
slnium

Lisez et respectez toutes les consignes du

Manuel de consignes.

INCENDIE ET EXPLOSION
Les incendies et les explosions peuvent rsulter
des scories chaudes, des tincelles ou de larc de
plasma. Le procd larc de plasma produit du
mtal, des tincelles, des scories chaudes pouvant
mettre le feu aux matires combustibles ou
provoquer lexplosion de fumes inflammables.

Lisez toujours les fiches de donnes sur la

scurit des matires (sigle amricain
MSDS); celles-ci devraient tre fournies
avec le matriel que vous utilisez. Les MSDS
contiennent des renseignements quant la
quantit et la nature de la fume et des gaz
pouvant poser des dangers de sant.

Soyez certain quaucune matire combustible

ou inflammable ne se trouve sur le lieu de
travail. Protgez toute telle matire quil est
impossible de retirer de la zone de travail.
Procurez une bonne aration de toutes les
fumes inflammables ou explosives.

Pour des informations sur la manire de

tester la fume et les gaz de votre lieu de
travail, consultez larticle 1 et les documents
cits la page 5.

Utilisez un quipement spcial tel que des

tables de coupe dbit deau ou courant
descendant pour capter la fume et les gaz.

Ne coupez pas et ne soudez pas les

conteneurs ayant pu renfermer des matires
combustibles.

Prvoyez une veille dincendie lors de tout

travail dans une zone prsentant des dangers
dincendie.

Nutilisez pas le chalumeau au jet de plasma

dans une zone o se trouvent des matires
ou des gaz combustibles ou explosifs.

Le phosgne, un gaz toxique, est gnr par la

fume provenant des solvants et des
produits de nettoyage chlors. Eliminez
toute source de telle fume.

CHOC ELECTRIQUE
Les chocs lectriques peuvent blesser ou mme
tuer. Le procd au jet de plasma requiert et
produit de lnergie lectrique haute tension. Cette
nergie lectrique peut produire des chocs graves,
voire mortels, pour loprateur et les autres
personnes sur le lieu de travail.

Le gas hydrogne peut se former ou

saccumuler sous les pices de travail en
aluminium lorsquelles sont coupes sous
leau ou sur une table deau. NE PAS couper
les alliages en aluminium sous leau ou sur
une table deau moins que le gas
hydrogne peut schapper ou se dissiper.
Le gas hydrogne accumul explosera si
enflamm.

RAYONS DARC DE PLASMA

Les rayons provenant de larc de plasma peuvent
blesser vos yeux et brler votre peau. Le procd
larc de plasma produit une lumire infra-rouge et
des rayons ultra-violets trs forts. Ces rayons darc
nuiront vos yeux et brleront votre peau si vous
ne vous protgez pas correctement.

Ne touchez jamais une pice sous tension

ou vive; portez des gants et des vtements
secs. Isolez-vous de la pice de travail ou des
autres parties du circuit de soudage.

Pour protger vos yeux, portez toujours un

casque ou un cran de soudeur. Portez
toujours des lunettes de scurit munies de

Rparez ou remplacez toute pice use ou

endommage.

10

parois latrales ou des lunettes de protection

ou une autre sorte de protection oculaire.

Superintendent
of
Documents,
U.S.
Government Printing Office, Washington,
D.C. 20402

Portez des gants de soudeur et un vtement

protecteur appropri pour protger votre
peau contre les tincelles et les rayons de
larc.

2. Norme ANSI Z49.1, LA SCURIT DES

OPRATIONS
DE
COUPE
ET
DE
SOUDAGE, disponible auprs de la Socit
Amricaine de Soudage (American Welding
Society), 550 N.W. LeJeune Rd., Miami, FL
33126

Maintenez votre casque et vos lunettes de

protection en bon tat. Remplacez toute
lentille sale ou comportant fissure ou
rognure.

3. NIOSH, LA SCURIT ET LA SANT LORS

DES OPRATIONS DE COUPE ET DE
SOUDAGE LARC ET AU GAZ,
disponible auprs du Superintendent of
Documents, U.S. Government Printing
Office, Washington, D.C. 20402

Protgez les autres personnes se trouvant sur

la zone de travail contre les rayons de larc
en fournissant des cabines ou des crans de
protection.
Respectez le teint de lentille recommand
dans le article 4, page 5.

4. Norme ANSI Z87.1, PRATIQUES SURES

POUR LA PROTECTION DES YEUX ET DU
VISAGE AU TRAVAIL ET DANS LES
ECOLES, disponible de lInstitut Amricain
des Normes Nationales (American National
Standards Institute), 1430 Broadway, New
York, NY 10018

Hydrogen gas may be present under

aluminum workpieces during the cutting
process when being cut underwater or using
a water table. DO NOT cut aluminum
underwater or on a water table unless the
hydrogen gas can be eliminated as the
hydrogen gas may detonate.

5. Norme ANSI Z41.1, NORMES POUR LES

CHAUSSURES PROTECTRICES, disponible
auprs de lAmerican National Standards
Institute, 1430 Broadway, New York, NY
10018

BRUIT
Le bruit peut provoquer une perte permanente de
loue. Les procds de soudage larc de plasma
peuvent provoquer des niveaux sonores
suprieurs aux limites normalement acceptables.
Vous d4ez vous protger les oreilles contre les
bruits forts afin dviter une perte permanente de
loue.

6. Norme ANSI Z49.2, PRVENTION DES

INCENDIES LORS DE LEMPLOI DE
PROCDS DE COUPE ET DE SOUDAGE,
disponible auprs de lAmerican National
Standards Institute, 1430 Broadway, New
York, NY 10018
7. Norme A6.0 de lAssociation Amricaine du
Soudage (AWS), LE SOUDAGE ET LA
COUPE
DE
CONTENEURS
AYANT
RENFERM
DES
PRODUITS
COMBUSTIBLES, disponible auprs de la
American Welding Society, 550 N.W.
LeJeune Rd., Miami, FL 33126

Pour protger votre oue contre les bruits

forts, portez des tampons protecteurs et/ou
des protections auriculaires. Protgez
galement les autres personnes se trouvant
sur le lieu de travail.
Il faut mesurer les niveaux sonores afin
dassurer que les dcibels (le bruit) ne
dpassent pas les niveaux srs.

8. Norme 51 de lAssociation Amricaine pour

la Protection contre les Incendies (NFPA),
LES
SYSTEMES

GAZ
AVEC
ALIMENTATION EN OXYGENE POUR LE
SOUDAGE, LA COUPE ET LES PROCDS
ASSOCIS, disponible auprs de la National
Fire Protection Association, Batterymarch
Park, Quincy, MA 02269

Pour des renseignements sur la manire de

tester le bruit, consultez larticle 1, page 5.

1.06 Documents De Reference

Consultez les normes suivantes ou les rvisions les
plus rcentes ayant t faites celles-ci pour de
plus amples renseignements :
1.

9. Norme 70 de la NFPA, CODE ELECTRIQUE

NATIONAL, disponible auprs de la
National
Fire
Protection
Association,
Batterymarch Park, Quincy, MA 02269

OSHA, NORMES DE SCURIT DU

TRAVAIL ET DE PROTECTION DE LA
SANT, 29CFR 1910, disponible auprs du

11

10. Norme 51B de la NFPA, LES PROCDS

DE COUPE ET DE SOUDAGE, disponible
auprs de la National Fire Protection
Association, Batterymarch Park, Quincy, MA
02269

auprs de lAssociation Nationale de

Fournitures de Soudage (National Welding
Supply Association), 1900 Arch Street,
Philadelphia, PA 19103
14.

11. Brochure GCA P-1, LA MANIPULATION

SANS RISQUE DES GAZ COMPRIMS EN
CYLINDRES,
disponible
auprs
de
lAssociation
des
Gaz
Comprims
(Compressed
Gas
Association),
1235
Jefferson Davis Highway, Suite 501,
Arlington, VA 22202
12. Norme CSA W117.2, CODE DE SCURIT
POUR LE SOUDAGE ET LA COUPE,
disponible auprs de lAssociation des
Normes Canadiennes, Standards Sales, 178
Rexdale Boulevard, Rexdale, Ontario,
Canada, M9W 1R3

Norme
AWSF4.1
de
lAssociation
Amricaine
de
Soudage,
RECOMMANDATIONS DE PRATIQUES
SURES POUR LA PRPARATION LA
COUPE
ET
AU
SOUDAGE
DE
CONTENEURS ET TUYAUX AYANT
RENFERM DES PRODUITS DANGEREUX
, disponible auprs de la American Welding
Society, 550 N.W. LeJeune Rd., Miami, FL
33126

15. Norme ANSI Z88.2, PRATIQUES DE

PROTECTION RESPIRATOIRE, disponible
auprs de lAmerican National Standards
Institute, 1430 Broadway, New York, NY
10018

13. ivret NWSA, BIBLIOGRAPHIE SUR LA

SCURIT DU SOUDAGE, disponible

12

2.0 INTRODUCTION AND DESCRIPTION

2.01 Description
The Thermal Arc Model P-Wee 160S is a self contained single-phase DC arc welding power source
with Constant Current (CC) output characteristics. This unit is equipped with a Digital Volt/Amperage
Meter and lift arc starter, for use with Gas Tungsten Arc Welding (GTAW) and Shielded Metal Arc
Welding (SMAW) processes. The power source is totally enclosed in an impact resistant, flame resistant
and non-conductive plastic case.

(V)

(V)

OCV

OCV

18V
10V
160A
5A

160A 210A (A)

25A

STICK Process

160A

(A)

LIFT-TIG Process

Figure 1. Model 160S Volt-Ampere curve

Note 1
Volt-Ampere curves show the maximum Voltage and Amperage output capabilities of the
welding power source. Curves of other settings will fall between the curves shown.

13

2.02 Functional Block Diagrams

Figure 2 illustrates the functional block diagram of the 160S-power supply.

Figure 2. Model 160S Functional Block Diagram

2.03 Transporting Methods
These units are equipped with a handle for carrying purposes.

WARNING 1
ELECTRIC SHOCK can kill. DO NOT TOUCH live electrical parts. Disconnect input
power conductors from de-energized supply line before moving the welding power source.

WARNING 2
FALLING EQUIPMENT can cause serious personal injury and equipment damage.

Lift unit with handle on top of case.

Use handcart or similar device of adequate capacity.
If using a fork lift vehicle, place and secure unit on a proper skid before transporting.

14

2.04 Installation Recommendations

2.04.01 Environment
The P-Wee 160S is designed for use in hazardous environments.
Examples of environments with increased hazardous environments are a.

b.
c.

In locations in which freedom of movement is restricted, so that the operator is forced

to perform the work in a cramped (kneeling, sitting or lying) position with physical
contact with conductive parts;
In locations which are fully or partially limited by conductive elements, and in which
there is a high risk of unavoidable or accidental contact by the operator, or
In wet or damp hot locations where humidity or perspiration considerably reduces the
skin resistance of the human body and the insulation properties of accessories.

Environments with hazardous environments do not include places where electrically conductive
parts in the near vicinity of the operator, which can cause increased hazard, have been
insulated.
2.04.02 Location
Be sure to locate the welder according to the following guidelines:

In areas, free from moisture and dust.

Ambient temperature between 0 degrees C

to 40 degrees C.

In areas, free from oil, steam and

corrosive gases.

In areas, not subjected to abnormal

vibration or shock.

In areas, not exposed to direct sunlight or

rain.

Place at a distance of 12 (304.79mm) or

more from walls or similar that could
restrict natural airflow for cooling.

WARNING 3
Thermal Arc advises that this equipment be electrically connected by a qualified
electrician.

15

2.05 Electrical Input Connections

WARNING 4
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. Lockout/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.
2.05.01 Electrical Input Requirements
Operate the welding power source from a single-phase 50/60 Hz, AC power supply. The input
voltage must match one of the electrical input voltages shown on the input data label on the unit
nameplate. Contact the local electric utility for information about the type of electrical service
available, how proper connections should be made, and inspection required.
The line disconnect switch provides a safe and convenient means to completely remove all
electrical power from the welding power supply whenever necessary to inspect or service the unit.

Note 2
These units are equipped with a two-conductor with earth power cable that is connected at
the welding power source end for single phase electrical input power.

Do not connect an input (WHITE or BLACK) conductor to the ground terminal.

Do not connect the ground (GREEN) conductor to an input line terminal.

16

Refer to figure 3 and:

1. Connect end of ground (GREEN) conductor to a suitable ground. Use a grounding method that
complies with all applicable electrical codes.
2. Connect ends of line 1 (BLACK) and line 2 (WHITE) input conductors to a de-energized line
disconnect switch.
3. Use Table 1 and Table 2 as a guide to select line fuses for the disconnect switch.
Input Voltage
115 VAC
208-230 VAC

Fuse Size
40 Amps
45 Amps

Table 1 Electrical Input Connections

Note 3
Fuse size is based on not more than 200 percent of the rated input amperage of the welding power
source (Based on Article 630, National Electrical Code).

Figure 3. Electrical Input Connections

17

2.05.02 Input Power

Each unit incorporates an INRUSH circuit and input voltage sensing circuit. When the MAIN
CIRCUIT SWITCH is turned on, the inrush circuit provides a pre-charging of the input capacitors.
SCRs in the Power Control Assembly (PCA) will turn on after the input capacitors have charged
to full operating voltage (after approximately 5 seconds).

Note 4
Note the available input power. Damage to the PCA could occur if 460VAC or higher is
applied.
The following 115/230V Primary Current recommendations are required to obtain the
maximum welding current and duty cycle from this welding equipment:
Model

P-Wee 160S

Primary Supply Minimum Primary

Current & Duty Cycle
Lead Size
Current Circuit Size
(Factory Fitted)
(Vin/Amps)
TIG
STICK
115/22
85A @ 100%
208/25
160A @ 35%
230/23
12/3 AWG
minimum
115/38
85A @ 100%
208/42
160A @ 35%
230/38
-

Table 2 115/230V Primary Current Circuit sizes to achieve maximum current

18

2.05.03 High Frequency Introduction

The importance of correct installation of high frequency welding equipment cannot be overemphasized. Interference due to high frequency initiated or stabilized arc is almost invariably
traced to improper installation. The following information is intended as a guide for personnel
installing high frequency welding machines.
Warning
Explosives
The high frequency section of this machine has an output similar to a radio transmitter. The
machine should NOT be used in the vicinity of blasting operations due to the danger of
premature firing.
Computers
It is also possible that operation close to computer installations may cause computer
malfunction.
2.05.04 High Frequency Interference
Interference may be transmitted by a high frequency initiated or stabilized arc welding
machine in the following ways:
Direct Radiation
Radiation from the machine can occur if the case is metal and is not properly grounded. It
can occur through apertures such as open access panels. The shielding of the high frequency
unit in the Power Source will prevent direct radiation if the equipment is properly grounded.
Transmission via the Supply Lead
Without adequate shielding and filtering, high frequency energy may be fed to the wiring
within the installation (mains) by direct coupling. The energy is then transmitted by both
radiation and conduction. Adequate shielding and filtering is provided in the Power Source.
Radiation from Welding Leads
Radiated interference from welding leads, although pronounced in the vicinity of the leads,
diminishes rapidly with distance. Keeping leads as short as possible will minimize this type
of interference. Looping and suspending of leads should be avoided where possible.
Re-radiation from Unearthed Metallic Objects
A major factor contributing to interference is re-radiation from unearthed metallic objects
close to the welding leads. Effective grounding of such objects will prevent re-radiation in
most cases.

19

PAGE LEFT INTENTIONALLY BLANK

20

2.06 Specifications
Parameter
Rated Output
Amperes
Volts
Duty Cycle
Duty Cycle

TIG

STICK

Output Current TIG

Range
STICK
Open Circuit Voltage
Dimensions
Width
Height
Length
Weight
Output @ Rated Load
Output Amperes
Output Volts
Duty Cycle
KVA
KW
Output @ No Load
KVA
KW
Input Volts Single Phase
115V
208V
230V

160S
115VAC
230VAC
85
160
23
26
100%
35%
160A / 16V @ 35% 230VAC
130A / 15V @ 60% 230VAC
100A / 14V @ 100% 230VAC
85A / 13V @ 100% 115VAC
160A / 26V @ 35% 230VAC
130A / 25V @ 60% 230VAC
100A / 24V @ 100% 230VAC
85A/23V @ 100% 115VAC
5 160 (230V), 5 - 85 (115V)
5 160 (230V), 5 85 (115V)
64V
5.12 (130mm)
10.24 (260mm)
12.60 (320mm)
18.95 lb. 8.6 kg
115V 230V
85A 160A
23V 26V
100% 35%
4.4
8.7
2.4
5.2
0.2
0.1
Amperage Draw @ Rated Load
38
42
38

No Load
1.5
1.1
1.0

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.

21

2.07 Duty Cycle

The duty cycle of a welding power source is the percentage of a ten (10) minute period that it can
be operated at a given output without causing overheating and damage to the unit. If the welding
amperes decrease, the duty cycle increases. If the welding amperes are increased beyond the
rated output, the duty cycle will decrease.

WARNING 5
Exceeding the duty cycle ratings will cause the thermal overload protection circuit to
become energized and shut down the output until the unit has cooled to normal operating
temperature.

CAUTION 1
Continually exceeding the duty cycle ratings can cause damage to the welding power
source and will void the manufactures warranty.

NOTE 5
Due to variations that can occur in manufactured products, claimed performance, voltages, ratings,
all capacities, measurements, dimensions and weights quoted are approximate only. Achievable
capacities and ratings in use and operation will depend upon correct installation, use, applications,
maintenance and service.

22

3.0 OPERATOR CONTROLS

3.01 P-Wee 160S Controls

Figure 4 P-Wee 160S Power Source

1 Control Knob
This control sets the selected weld parameter, rotating it clockwise increases the parameter
and is indicated on the digital meter. Pushing the knob inward displays the actual welding
voltage.
2 Remote Control Socket
The 8 pin Remote Control Socket is used to connect remote current control devices to the
welding Power Source. To make connections, align keyway, insert plug, and rotate threaded
collar fully clockwise.

Gnd.
2

12345678

6
5k Ohms

Front view of 8-Socket Receptacle

23

Socket Pin

Function

1
2

Earth (Ground)
Torch Switch Input (24V) to energize weld current.
(connect pins 2 & 3 to turn on welding current)
Torch Switch Input (0V) to energize weld current
(connect pins 2 & 3 to turn on welding current)
Connect pin 4 to pin 8 to instruct machine that a remote current control
device is connected (12V DC supply)
5k ohm (maximum) connection to 5k ohm remote control potentiometer
Zero ohm (minimum) connection to 5k ohm remote control
potentiometer
Wiper arm connection to 5k ohm remote control potentiometer
Connect pin 4 to pin 8 to instruct machine that a remote current control
device is connected (0V)

3
4
5
6
7
8

3 Positive Terminal
Welding current flows from the Power Source via heavy duty Dinse type terminal. It is
essential, however, that the male plug is inserted and turned securely to achieve a sound
electrical connection.
4 Negative Terminal
Welding current flows from the Power Source via heavy duty Dinse type terminal. It is
essential, however, that the male plug is inserted and turned securely to achieve a sound
electrical connection.
CAUTION 2
Loose welding terminal connections can cause overheating and result in the male plug
being fused in the bayonet terminal.
5 ON/OFF Switch
This switch connects the Primary supply voltage to the inverter when in the ON position.
This enables the Power Supply.
WARNING 6
When the welder is connected to the Primary supply voltage, the internal electrical
components maybe at 230V potential with respect to earth.
6 Input Cable
The input cable connects the Primary supply voltage to the equipment.

24

3.02 Weld Parameter Description for the 160S

Figure 5. P-Wee 160S Front Panel with Parameter Description

Parameter

HOT START

Description
This parameter operates in STICK weld mode and is used to improve the
start characteristics for stick electrodes. e.g. low hydrogen electrodes. It
sets the peak start current on top of the (WELD) current.
Weld Current (Amperage)- sets the STICK and TIG WELD current.
ARC CONTROL - This parameter provides a suitable short circuit current
in STICK welding to improve electrode sticking and arc stability.
LIFT TIG mode of operation. A remote control device is required for use
during LIFT TIG operation. See section 3.01, section 2 Remote Control
Socket, for complete details of the remote device.
STICK Mode of operation.

Weld
Parameter
HOT START
WELD CUR
ARC CONTROL

Table 3 Weld Parameter Descriptions for P-Wee 160S

Weld Mode
Parameter
Factory Incremental
LIFT TIG
Range
Setting
Unit
STICK
0 to 70A
20A
1A
Yes
No
5 to 85A 115V
1A
Yes
Yes
5 to 160A 230V
80A
1A
Yes
Yes
0 to 100%
10%
1%
Yes
No

25

3.03 Power Source Features

Feature
New Digital Control

Description
Almost all welding parameters are adjustable

Touch Panel Switches

Touch switches eliminate mechanical damage

Front Control Cover

Protects front panel controls

Digital Meter

Displays selected weld parameter value

Displays weld current when welding
Displays weld current for 20 seconds after weld
has been completed
A selected weld parameter value can be adjusted at
any time even while welding

ON/OFF switch
Voltage Reduction Device (VRD)

Primary voltage Supply ON/OFF switch located

on rear panel
Reduces the OCV when the power supply is not in
use. Eliminates the need for add on voltage reducers
and has no effect on arc starting.
VRD fully complies to IEC 60974-1
When Stick mode is selected the green VRD light
is ON when not welding and red when welding.
When in TIG modes VRD is off.

Control Knob

For the selected weld parameter, rotating the knob

clockwise increases the parameter
Rotating the knob counterclockwise decreases the
parameter
A selected weld parameter value can be adjusted at
any time even while welding
Pushing the knob in displays actual arc voltage.

Self Diagnosis Using Error Codes

An error code is displayed on the Digital Meter

when a problem occurs with Primary supply
voltage or internal component problems. Refer to
troubleshooting guide.

26

4.0 SET-UP FOR SMAW (STICK) AND GTAW (TIG)

Conventional operating procedures apply when using the Welding Power Source, i.e. connect work
lead directly to work piece and electrode lead is used to hold electrode. Wide safety margins
provided by the coil design ensure that the Welding Power Source will withstand short-term
overload without adverse effects. The welding current range values should be used as a guide
only. Current delivered to the arc is dependent on the welding arc voltage, and as welding arc
voltage varies between different classes of electrodes, welding current at any one setting would
vary according to the type of electrode in use. The operator should use the welding current range
values as a guide, then finally adjust the current setting to suit the application.
Figure 6 160S Set-up
WARNING 7
Before connecting the work clamp to the
work and inserting the electrode in the
electrode holder make sure the Primary
power supply is switched off.
CAUTION 3
Remove any packaging material prior to use.
Do not block the air vents at the front or rear
or sides of the Welding Power Source.

27

5.0 SEQUENCE OF OPERATION

NOTE: Scroll Buttons are used to select the parameters to be set. The
LEDs show which function is being adjusted on the weld sequence graph.
Refer to Symbols Table located in the front of the manual for Symbol
descriptions.

5
1
2
3
Figure 7 160S Front Panel

1. Scroll Buttons used to select the parameters to be set. The LEDs show which function is
being adjusted on the weld sequence graph.
2. Digital LED display Welding amperage and parameter values are displayed in this window.
Internal warnings such as over temperature, low or high input voltage applied are signaled to the
operator by a warning sound and error message on the screen.
3. Control knob allows the operator to adjust the output amperage within the entire range of the
power source also used to set each parameter value. Pushing the knob inward displays the actual
welding voltage.
4. Process Button This button selects between STICK or Lift TIG mode.
5. 8 pin remote control receptacle for connecting remote devices.

28

5.0 Stick Welding

Connect work lead to negative terminal
Connect electrode lead to positive terminal
Switch machine on
Connect remote control device if required
Use the Scroll Buttons to move to the parameter to be set. The LED will show which
function is being adjusted on the weld sequence graph. Use the control knob to adjust each
parameter.
Set HOT START
Set WELD current
Set Arc Control
Commence welding
5.02 DC LIFT TIG Welding
Connect work lead to positive terminal
Connect TIG torch to negative terminal
Switch machine on
Set weld current.
Connect remote control device. A remote control device is required for use during LIFT
TIG operation. See section 3.01, section 2 Remote Control Socket, for complete details
of the remote device.

Use the Scroll Buttons to move to the parameter to be set. The LED will show which
function is being adjusted on the weld sequence graph. Use the control knob to adjust each
parameter.
Set WELD current
Commence welding

29

PAGE LEFT INTENTIONALLY BLANK

30

6.0 BASIC TIG WELDING GUIDE

6.01 Electrode Polarity
Connect the TIG torch to the - / TORCH terminal and the work lead to the + / WORK
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.
6.02 Tungsten Electrode Current Ranges
Electrode Diameter

DC Current (Amps)

0.040 (1.0mm)

30 60

1/16 (1.6mm)

60 115

3/32 (2.4mm)

100 165

1/8 (3.2mm)

135 200

5/32 (4.0mm)

190 280

3/16 (4.8mm)

250 340

Table 4 Current ranges for varies tungsten electrode sizes

6.03 Tungsten Electrode Types
Electrode Type
(Ground
Finish)

Thoriated 2%

Ceriated 2%

Welding Application

Features

DC welding of mild steel,

stainless steel and copper.

Excellent arc starting, Long

life, High current carrying
capacity.

DC welding of mild steel,

stainless steel, copper,
aluminium, magnesium and
their alloys

Longer life, More stable arc,

Easier starting, Wider current
range, Narrower more
concentrated arc.

Table 5 Tungsten electrode types

31

Color
Code

Red

Grey

6.04 Guide for Selecting Filler Wire Diameter

Filler Wire Diameter

DC Current Range
(Amps)

1/16 (1.6 mm)

20 - 90

3/32 (2.4 mm)

65 - 115

1/8 (3.2 mm)

100 - 165

3/16 (4.8 mm)

200-350

Table 6 Filler wire selection guide

NOTE 6
The filler wire diameter specified in Table 6 is a guide only, other diameter wires may
be used according to the welding application
.
6.05 Shielding Gas Selection
Alloy

Shielding Gas

Aluminium & alloys

Argon
Carbon Steel
Argon
Stainless Steel
Argon
Nickel Alloy
Argon
Copper
Argon
Titanium
Argon
Table 7 Shielding gas selection
6.06 TIG Welding Parameters for Low Carbon & Low Alloy Steel Pipe
Electrode Type &
Diameter

Current Range DC
Amperes

Filler Rod for

Root Pass

Thoriated 2%
3/32 (2.4 mm)

120 - 170

Yes

Thoriated 2%
3/32 (2.4 mm)

100 - 160

Yes

Thoriated 2%
3/32 (2.4 mm)

90 - 130

No

Joint Preparation

Table 8 TIG welding parameters for low carbon & low alloy steel pipe

32

6.07 Welding Parameters for Steel

Base Metal DC Current DC Current Tungsten Filler Rod
Thickness
for Mild
for Stainless Electrode
Diameter
Steel
Steel
Diameter (if required)
35-45
20-30
0.040
0.040
1/16
40-50
25-35
1.0mm
1.0mm
1.6mm
45-55
30-45
0.045
0.040
1/16
50-60
35-50
1.2mm
1.0mm
1.6mm
60-70
40-60
1/16
1/16
1/16
70-90
50-70
1.6mm
1.6mm
1.6mm

Argon Gas
Flow Rate
Liters/min

Joint Type

5-7

Butt/Corner
Lap/ Fillet

5-7

Butt/Corner
Lap/ Fillet

Butt/Corner
Lap/ Fillet

1/8
3.2mm

80-100
90-115

65-85
90-110

1/16
1.6mm

3/32
2.4mm

Butt/Corner
Lap/ Fillet

3/16
4.8mm

115-135
140-165

100-125
125-150

3/32
2.4mm

1/8
3.2mm

10

Butt/Corner
Lap/ Fillet

6.4mm

160-175
170-200

135-160
160-180

1/8
3.2mm

5/32
4.0mm

10

Butt/Corner
Lap/ Fillet

Table 9 DC TIG welding parameters

33

7.0 Basic Arc Welding Guide

7.01Electrode Polarity
Stick electrodes are generally connected to the + terminal and the work lead to the terminal
but if in doubt consult the electrode manufacturers literature.
7.02 Effects of Stick Welding Various Materials
High tensile and alloy steels
The two most prominent effects of welding these steels are the formation of a hardened zone in
the weld area, and, if suitable precautions are not taken, the occurrence in this zone of under-bead
cracks. Hardened zone and under-bead cracks in the weld area may be reduced by using the
correct electrodes, preheating, using higher current settings, using larger electrodes sizes, short
runs for larger electrode deposits or tempering in a furnace.
Manganese steels
The effect on manganese steel of slow cooling from high temperatures is to embrittle it. For this
reason it is absolutely essential to keep manganese steel cool during welding by quenching after
each weld or skip welding to distribute the heat.
Cast Iron
Most types of cast iron, except white iron, are weldable. White iron, because of its extreme
brittleness, generally cracks when attempts are made to weld it. Trouble may also be experienced
when welding white-heart malleable, due to the porosity caused by gas held in this type of iron.
Copper and alloys
The most important factor is the high rate of heat conductivity of copper, making preheating of
heavy sections necessary to give proper fusion of weld and base metal.
Types of Electrodes
Arc Welding electrodes are classified into a number of groups depending on their applications.
There are a great number of electrodes used for specialized industrial purposes which are not of
particular interest for everyday general work. These include some low hydrogen types for high
tensile steel, cellulose types for welding large diameter pipes, etc. The range of electrodes dealt
with in this publication will cover the vast majority of applications likely to be encountered; are all
easy to use and all will work on even the most basic of welding machines.

Metals being
joined

Electrode

Comments

Mild steel

6013

Ideal electrodes for all general

purpose work. Features include out
standing operator appeal, easy arc
starting and low spatter.

Mild steel

7014

All positional electrode for use on

mild and galvanized steel furniture,
plates, fences, gates, pipes and tanks
etc. Especially suitable for verticaldown welding.

Cast iron

99% Nickel

Stainless steel

318L-16

Suitable for joining all cast irons

except white cast iron.
High corrosion resistance. Ideal for
dairy work, etc. On stainless steels.

34

Metals being
joined
Copper, Bronze,
Brass, etc.

High Alloy Steels,

Dissimilar Metals,
Crack Resistance.
All Hard-To-Weld
Jobs.

Electrode

Comments

Bronze

Easy to use electrode for marine

fittings, water taps and valves, water
trough float arms, etc. Also for
joining copper to steel and for bronze
overlays on steel shafts.

5.7 ERCUSI-A

312-16

It will weld most problematical jobs

such as springs, shafts, broken joins
mild steel to stainless and alloy
steels.
Not suitable for Aluminum.

Table 10 - Types of Electrodes

35

8.0 ROUTINE MAINTENANCE

The only routine maintenance required for the power supply is a thorough cleaning and inspection,
with the frequency depending on the usage and the operating environment.

WARNING 8
Disconnect primary power at the source before opening the enclosure. Wait at least two
minutes before opening the enclosure to allow the primary capacitors to discharge.

To clean the unit, open the enclosure (please refer to Section 8.01.01, Opening the Enclosure in the
160S Service Manual P/N 430429-513) and use a vacuum cleaner to remove any accumulated dirt
and dust. The unit should also be wiped clean, if necessary; with solvents that are recommended
for cleaning electrical apparatus.
CAUTION 4
Do not blow air into the power supply during cleaning. Blowing air into the unit can
cause metal particles to interfere with sensitive electrical components and cause
damage to the unit.

36

9.0 BASIC TROUBLESHOOTING

WARNING 9
There are extremely dangerous voltages and power levels present inside this product. Do
not attempt to open or 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.
The basic level of troubleshooting is that which can be performed without special equipment or
knowledge.
9.01 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
penetration or poor
fusion at edges of
weld.

Welding current is too low

Increase weld current and/or

faulty joint preparation

2 Weld bead too

wide and flat or
undercut at edges
of weld or
excessive burn
through

Welding current is too high

Decrease weld current

3 Weld bead too

small or
insufficient
penetration or
ripples in bead are
widely spaced
apart

Travel speed too fast

Reduce travel speed

4 Weld bead too

wide or excessive
bead build up or
excessive penetration in butt joint

Travel speed too slow

Increase travel speed

5 Uneven leg length

in fillet joint

Wrong placement of filler rod

Re-position filler rod

6 Electrode melts
A Electrode is connected to the A Connect the electrode to the
when arc is struck.
+ terminal.
terminal.

37

Description
7 Dirty weld pool.

Possible Cause
A Electrode contaminated
through contact with work
piece or filler rod material.
B Gas contaminated with air.

Remedy
A Clean the electrode by
grinding off the contaminates.
B Check gas lines for cuts and
loose fitting or change gas
cylinder.

8 Electrode melts or A No gas flowing to welding

oxidizes when an
region.
arc is struck.
B Torch is clogged with dust.
C Gas hose is cut.
D Gas passage contains
impurities.

A Check the gas lines for kinks

or breaks and gas cylinder
contents.
B Clean torch
C Replace gas hose.
D Disconnect gas hose from
torch then raise gas pressure
and blow out impurities.
E Gas regulator turned off.
E Turn on.
F Torch valve is turned off.
F Turn on.
G The electrode is too small for G Increase electrode diameter
the welding current.
or reduce the welding current.

9 Poor weld finish.

Inadequate shielding gas.

Increase gas flow or check

gas line for gas flow
problems.

10 Arc flutters during A Tungsten electrode is too

A Select the right size electrode.
TIG welding.
large for the welding current.
Refer to Basic TIG Welding
guide.
B Absence of oxides in the
B Refer Basic TIG Welding
weld pool.
Guide for ways to reduce arc
flutter.
11 Welding arc can
A Work clamp is not connected A Connect the work clamp to
not be established.
to the work piece or the
the work piece or connect the
work/torch leads are not
work/torch leads to the right
connected to the right
welding terminals.
welding terminals.
B Torch lead is disconnected.
B Connect it to the terminal.
C Gas flow incorrectly set,
C Select the right flow rate,
cylinder empty or the torch
change cylinders or turn torch
valve is off.
valve on.

38

Description
12 Arc start is not
smooth.

Possible Cause

Remedy

A Tungsten electrode is too

A Select the right size electrode.
large for the welding current.
Refer to Basic TIG Welding
Guide.
B The wrong electrode is being B Select the right electrode
used for the welding job
type. Refer to Basic TIG
Welding Guide
C Gas flow rate is too high.
C Select the correct rate for the
welding job.
Refer to Basic TIG Welding
Guide.
D Incorrect shielding gas is
D Select the right shielding gas.
being used.
Refer to Basic TIG Welding
Guide.
E Poor work clamp connection E Improve connection to work
to work piece.
piece.

9.02 Stick Welding Problems

Description

Possible Cause

1 Gas pockets or
A Electrodes are damp.
voids in weld metal B Welding current is too high.
(Porosity).
C Surface impurities such as
oil, grease, paint, etc.
2 Crack occurring in A Rigidity of joint.
weld metal soon
after solidification
commences
B Insufficient throat thickness.

3 A gap is left by
failure of the weld
metal to fill the
root of the weld.

C Cooling rate is too high.

A Welding current is too low.
B Electrode too large for joint.
C Insufficient gap.
D Incorrect sequence.

Remedy
A Dry electrodes before use.
B Reduce welding current.
C Clean joint before welding.
A Redesign to relieve weld joint
of severe stresses or use crack
resistance electrodes.
B Travel slightly slower to allow
greater build up in throat.
C Preheat plate and cool slowly.
A Increase welding current
B Use smaller diameter
electrode.
C Allow wider gap.
D Use correct build-up sequence.

Figure 8 Example of insufficient gap or incorrect

sequence

39

4 Portions of the
weld run do not
fuse to the surface
of the metal or
edge of the joint.

A Small electrodes used on

heavy cold plate.
B Welding current is too low.

A Use larger electrodes and preheat the plate.

B Increase welding current

C Wrong electrode angle.

C Adjust angle so the welding

arc is directed more into the
base metal
D Travel speed of electrode is
D Reduce travel speed of
too high.
electrode
E Scale or dirt on joint surface. E Clean surface before welding.

Figure 9 Example of lack of fusion

5 Non-metallic parti- A Non-metallic particles may

cles are trapped in
be trapped in undercut from
previous run.
the weld metal
(slag inclusion).
B Joint preparation too
restricted.
C
D

E
F

A If bad undercut is present,

clean slag out and cover with a
run from a smaller diameter
electrode.
B Allow for adequate
penetration and room for
cleaning out the slag.
Irregular deposits allow slag C If very bad, chip or grind out
to be trapped.
irregularities.
Lack of penetration with slag D Use smaller electrode with
trapped beneath weld bead.
sufficient current to give
adequate penetration. Use
suitable tools to remove all
slag from corners.
E Clean joint before welding.
Rust or mill scale is
preventing full fusion.
Wrong electrode for position F Use electrodes designed for
in which welding is done.
position in which welding is
done, otherwise proper control
of slag is difficult.

Figure 10 Examples of slag inclusion

40

8.03 Power Source Problems

Description
1 The welding arc
cannot be
established

Possible Cause

Remedy

A The Primary supply voltage A Switch ON the Primary supply

has not been switched ON.
voltage.
B The Welding Power Source B Switch ON the Welding
switch is switched OFF.
Power Source.
C Loose connections internally. C Have an Accredited Thermal
Arc Service Agent repair the
connection.

2 Maximum output
Defective control circuit
Have an Accredited Thermal
welding current can
Arc Service Agent inspect
not be achieved
then repair the welder.
with nominal
Mains supply
voltage.
3 Welding current
Poor work lead connection to
Ensure that the work lead has
reduces when
the work piece.
a positive electrical
welding
connection to the work piece.
4 No gas flow when A Gas hose is cut.
A Replace gas hose.
the torch trigger
B Gas passage contains
B Disconnect gas hose from the
switch is
impurities.
rear of Power Source then
depressed.
raise gas pressure and blow
out impurities.
C Gas regulator turned off.
C Turn gas regulator on.

41

10.0 Voltage Reduction Device (VRD)

10.01 VRD Specification

Description
VRD Open Circuit Voltage
VRD Resistance
VRD Turn OFF Time

Notes

P-Wee 160S
15.3 to 19.8V

Open circuit voltage between welding

terminals
148 to 193 ohms The required resistance between welding
terminals to turn ON the welding power
0.2 to 0.3 seconds The time taken to turn OFF the welding
power once the welding current has
stopped

10.02 VRD Maintenance

Routine inspection and testing (power source)
An inspection of the power source, an insulation resistance test and an earth resistance test
shall be carried out.
a) For transportable equipment, at least once every 3 months; and
b) For fixed equipment, at least once every 12 months.
The owners of the equipment shall keep a suitable record of the periodic tests.
Note 7
A transportable power source is any equipment that is not permanently connected and
fixed in the position in which it is operated.
In addition to the above tests and specifically in relation to the VRD fitted to this machine,
the following periodic tests should also be conducted by an accredited Thermal Arc service
agent.
Description
VRD Open Circuit Voltage
VRD Turn ON Resistance
VRD Turn OFF Time

IEC 60974-1 Requirements

Less than 20V; at Vin=115V or 230V
Less than 200 ohms
Less than 0.3 seconds

If this equipment is used in a hazardous location or environments with a high risk of

electrocution then the above tests should be carried out prior to entering this location.

42

A Primary current is too high

because welding arc is too
long.
B Mains supply voltage is
more than 10% below
nominal voltage

Primary supply voltage is

greater than the nominal
voltage plus 10%

3 E11 error code displayed

Over Primary supply (input)
voltage at primary capacitors is
exceeded for one second

C Air flow is restricted by

vents being blocked

A The Welding Power

Sources duty cycle has
been exceeded.
B Fan ceases to operate.

Possible Cause

2 E03 error code displayed

Primary (input) current too high

1 E01 error code displayed

Temperature sensor TH1 (protects
IGBTs) is greater than 80C for
about 1 second

Description

11.0 Power Source Error Codes

43

Have an Accredited
Thermal Arc Service Agent
or a qualified electrician
check the Primary voltage.

B Have an Accredited
Thermal Arc Service Agent
or a qualified electrician
check for low Mains
voltage.

A Reduce length of welding

arc.

A Let Power Source cool

down then keep within its
duty cycle.
B Have an Accredited
Thermal Arc Service Agent
investigate
C
Unblock vents then let
Power Source cool down.

Remedy

Weld current ceases.

Buzzer sounds constantly.
Error code E11
automatically will reset
when the voltage reduces.

Weld current ceases.

Buzzer sounds constantly.
Switch machine off then on
to reset E03 error.

Weld current ceases.

Buzzer sounds constantly.
E01 resets when TH1
decreases to 70C for about
30 seconds.

Remarks

Have an Accredited
Weld current ceases.
Thermal Arc Service Agent Buzzer sounds constantly.
check or replace the
Switch machine off.
temperature sensors.

The Welding Power

Sources temperature
sensors have malfunctioned.

6 E94 error code displayed

Temperature sensor TH1 for
IGBTs is an open circuit.

44

Have an Accredited
Weld current ceases.
Thermal Arc Service Agent Buzzer sounds constantly.
check the control PCB
Switch machine off.

Memory chip (EEPROM)

error

Weld current ceases.

Buzzer sounds constantly.
Error code E12
automatically will reset
when the voltage increases.

Remarks

5 E93 error code displayed

Memory chip (EEPROM) on
control PCB can not read/write
weld parameters

A Have an Accredited
Thermal Arc Service Agent
or a qualified electrician
check the Mains voltage
B Have an Accredited
Thermal Arc Service Agent
or a qualified electrician
check the primary cable &
fuses.

Remedy

Mains supply voltage is

down to a dangerously low
level.

Possible Cause

4 E12 error code displayed

Under mains supply (input) voltage
primary capacitors is reduced for
one second

Description

Description
Capacitor
Capacitor
Capacitor
Capacitor
Capacitor
Remote Socket

Current Sensor
Diode
Diode
Fan
Inductor
Inductor
Printed Circuit Board

Printed Circuit Board

Printed Circuit Board

Printed Circuit Board
Printed Circuit Board
Printed Circuit Board
Printed Circuit Board

DWG. No.
C1
C2
C3
C4
C5-6
CON1

CT1
D1
D2-3
FAN1
L1
L104
PCB1

PCB2

PCB4
PCB5
PCB6
PCB7
PCB8

12.0 PARTS LIST

45

Type & Rating

SS351206PPQ1 DC 350V 20uF
ECKATS103MF
0.01uF
ECKATS103MF
0.01uF
ECW-H10H683JR DC1KV 0.068uF
ECW-H12H472JR 1200V .0047uF
206433-1 8P
(with Wiring Assembly)
HC-TN200V4B15M 200A 4V
GBPC3508
800V 35A
DBA200UA40
D12T24PS101 DC 24V
F2A753900 200A STICK FCH
1615MRE RING CORE
WK-4980 U01 MAIN2
with Thunder Label
WK-4977 U01 MAIN1
with Thunder Label
WK-4985 U07 STICK PANEL
WK-4986 U01 CNTL1
WK-4987 U01 CNTL2
WK-5015 U01 DIODE PCB
WK-5071 U01 CONNECT PCB
1
1
1
1
1

1
1
2
1
1
1
1

QTY.
1
1
1
1
2
1

P0A498507
P0A498601
P0A498701
P0A501501
P0A507101

U0A706400

11251003000
44913000100
4582A0040
U0A738100
F2A753900
63200006500
U0A706300

Code No.
42601003900
42442007100
42442007100
42421138500
42421141100
U0A706200

10-6691
10-6692
10-6693
10-6694
10-6695

10-6690

10-5003
10-6686
10-6687
10-6840
10-6688
10-6538
10-6689

Order No.
10-6685
10-2219
10-2219
10-5013
10-2216
10-6838

Description
Transistor

Resistor
Resistor
Resistor
Resistor
Resistor
Resistor
Switch
Transformer
Thermistor
Front Panel
Rear Panel
Side Panel
Front Control Cover
Rear Control Cover
Protection Cover
Encoder Cover
PCB Cover
Strap
Name Label
Side Label

DWG. No.
Q1

R1
R3A
R3B
R4A
R4B
R5
S1
T1
TH1

12.0 PARTS LIST Continued

46

Type & Rating

CM100DUS12F-2 600V 100A
(with WK-3367 U04)
ERG-3ANJ 472 3W 4.7k
ERG3SJ330
3 W 33
ERG3SJ330
3 W 33
ERG3SJ330
3 W 33
ERG3SJ330
3 W 33
ERG-3ANJ 103 3 W 10k
DCP-52SR50C-480V 2P-480V
F2A704300
ERTA53D203 20K"/25C B=3950K
E0D004500
E0D004600
E0D006000
J4B515400
JDA111800 (with Label)
E1B500700
EBA514400
E1B550900 (with Caution Label)
E5A937000
N4A007300
N4A009100
1
1
1
1
1
1
1
1
1
1
1
2
1
1
1
1
1
1
2
2

40305147200
40305010100
40305010100
40305010100
40305010100
40305110300
25850003500
F2A704300
U0A733200
U0A749600
U0A749700
E0D006000
J4B515400
U0A706800
E1B500700
EBA514400
U0A706700
E5A937000
N4A007300
N4A009100

QTY.
Code No.
1 U0A706500
10-5010
10-6697
10-6697
10-6697
10-6697
10-5009
10-6644
10-6698
10-6841
10-6880
10-6881
10-6701
10-6702
10-6703
10-6704
10-6654
10-6705
10-5069
10-6706
10-6707

Order No.
10-6696

DWG. No.

Description
Warning Label 1
Warning Label 2
Output Terminal Label
Output Terminal (female)
Input Cable
Input Cable Clamp
Heatsink
Knob
Knob Cap
Control Cover Sheet
Flat Cable (Long)
Flat Cable (Short)
Q-Post (M5)
D-T Bus Bar
Q Bus Bar1
Q Bus Bar2 (C2E1)
Diode Bus Bar
Clip
Front Chassis
Rear Chassis
Capacitor Chassis
HF. Unit Chassis
Output Terminal (male)
Operating Manual
Service Manual

12.0 PARTS LIST Continued

N4A072400
N4A072500
N4A057700
TRAK-BE10-25
132 12/3SOW BLK W/5-15P
SCLB18A
E1B575400
2615603
3015104
N0B883100
EAA547301
EBA420200
EBA436000
EBA447900
EBA448200
EBA551900
EBA508300
#74 NATURAL
J3C009200
J3C010800
JDA117700
J4B549700
TRAK-SK10-25

Type & Rating

47

QTY.
1
1
1
2
1
1
1
1
1
1
1
1
1
2
2
1
1
4
1
1
1
1
2
1

Code No.
N4A072400
N4A072500
N4A057700
26999025700
52031130100
53613021800
E1B575400
50990001500
50990003500
N0B883100
EAA547301
EBA420200
EBA436000
EBA447900
EBA448200
EBA551900
EBA508300
60602422000
J3C009200
J3C010800
JDA117700
J4B549700
26999025600

Order No.
10-6708
10-6709
10-6710
10-6711
N/A
10-6712
10-6713
10-6714
10-6715
10-6716
10-6668
10-6717
10-6674
10-6718
10-6719
10-6720
10-6721
10-5259
10-6722
10-6723
10-6724
10-6725
10-1068
430429-504
430429-513

APPENDIX A - INTERCONNECT DIAGRAM

48

49

APPENDIX B - AUTOMATION
SLIDE SWITCH SETTING FOR "OKTOMOVE". Models 160S/TS
Three slide switches (S1, S2 and S3) are provided on PC Board WK-4977 for automation purposes.
This PCB is the units right side main PCB. This PCB can be accessed by removing the side covers
by loosening 4 screws on each the front and rear panel, then removing the 4 side panel screws as
well as the 2 handle screws. Carefully pull the front and rear panels outward to release and remove
the side cover. Lift up the protective PCB cover sheet from the bottom and the slide switches will
be accessible through a slot in the PCB Board. See figure on next page for details.
All units are shipped from the factory with the slide switches set in position "A". This is for normal
semi-automatic operation utilizing a remote device, such as a foot control. The 8-pin remote
operates as described earlier in this manual.
Placing all slide switches in position "B" would be primarily used for automation with an arc
establish relay, remote amperage and contactor. An arc-establish signal is located from pins 4 and 8
when in this mode.
Placing slide switches S1 and S2 in "B" position and slide switch S3 in "A" position would have the
configuration of an arc-establish signal and remote contactor, but the units front panel would
control the amperage.
S1
A COM

B
WK-4977

S3

CN6

CON1

B
COM
S2
A COM

Set All "A" position : factory shipping

S1
S2
S3

OK-TO-MOVE
RELAY

POSITION
A
A
A

CN6

CON1

4
Remote : Short 4 to 8
Panel : Open

Use "OK TO MOVE signal"

S1
S2
S3
A/V

POSITION
B
B
B
B
B
A
REMOTE PANEL

CN6

CON1

4
Max Load:
24V 50ma.

OK TO MOVE
RELAY

50

Figure 11 Slide Switch Location

51