CARBONE TIG160PDCHF User manual

TIG160PDCHF IGBT INVERTER
DC TIG/PULSE TIG
WELDING MACHINE
(Suitable for 1x110V or 1x220V)
Operators’s Manual
Safety, Setup and General Use Guide
REV.2 0 00134-16
Issue Date: May.10,2016
Manual No.: 0-1524
EMPRESAS CARBONE S.A.
Calle 5ta. Rio Abajo, Panamá, Panamá
Telefonos: (507) 3916309 / 3916313
www.empresascarbone.com

Dear Customer,
Thank you for selecting the our machine. We appreciate you as a customer and hope that you
will enjoy years of use from your welder.
Please go directly to the our website to register your unit and receive your warranty information. Your
unit registration is important should any information such as product updates or re-calls be issued. It is also
important so that we may track your satisfaction with our products and services. If you are unable to register
by website, contact our directly through the sales department through the main customer service number in
your country. Your unit will be registered and warranty will be issued and in full effect. Keep all information
regarding your purchase. In the event of a problem you must contact technical support before your
welder can be a candidate for warranty service and returned.
Please review the current online warranty statement and information found on the website of the
our division located in or nearest to your country. Print it for your records and become familiar of its
terms and conditions.
We offers full technical support, in several different forms. We have online support available through
email, and a welding support forum designed for customers and noncustomer interaction. Technical advisors
are active on the forum daily. We also divide our support into two divisions: technical and welding
performance. Should you have an issue or question concerning your unit, please contact performance/
technical support available through the main company headquarters available in your country. For best
service call the appropriate support line and follow up with an email, particularly if off hours, or you cannot
reach a live person. In the event you do not reach a live person, particularly during heavy call volume times,
holidays, and off hours, leave a message and your call will normally be returned within 24 hours. Also for
quick answers to your basic questions, join the company owned forum available through the website.
Should you need to call or write, always know your model name, purchase date and welder manu-
facturing inspection date. This will assure the quick and accurate customer service. REMEMBER: Be as
specific and informed as possible. Technical and performance advisors rely upon you to carefully
describe the conditions and circumstances of your problem or question. Take notes of any issues
as best you can. You may be asked many questions by the advisors to clarify prob-lems or issues
that may seem very basic. However, diagnosis procedures MUST be followed to begin the warranty
process. Advisors can't assume anything, even with experienced users, and must cover all aspects
to properly diagnose the problem. Depending upon your issue, it is advisa-ble to have basic tools
handy such as screwdrivers, wrenches, pliers, and even an inexpensive test meter with volt/ohm
functions before you call.
Let us know how we may be of service to you should you have any questions.

We want you to take pride in operating our machine as much pride as we have taken in making this
product for you. Please read all information in this manual before operation
PLEASE EXAMINE CARTON AND EQUIPMENT FOR DAMAGE IMMEDIATELY
When this equipment is shipped, title passes to the purchaser upon receipt from the courier. Consequently
all claims for material damaged in shipment must be made by purchaser against the transportation company
used.
Please record your equipment identification below for future reference. This information can be
found on data plate at rear of machine.
：
Product TIG160PDCHF
Serial No. ___________________________________
Date of Purchase _____________________________
Where Purchased _____________________________
Whenever you request replacement parts or information on this equipment please always supply information
you have recorded above
This product is covered by 1 years parts and labour warranty, you are responsible for costs of shipping unit
to us, we will cover cost of returning item to you. External items, torch, earth lead etc are covered by 3
months warranty. Any faults/damage found caused by customer will be charged prorata.
Pay particular attention to the safety instructions we have provided you for your protection The level of
seriousness to be applied to each section is explained below
WARNING
This statement appears where the information must be followed exactly to avoid serious personal injury.
CAUTION
This statement appears where the information must be following to avoid a minor personal injury or damage
to this equipment.

We are dedicated to providing you with the best possible equipment and service to meet the demanding
jobs that you have. We want to go beyond delivering a satisfactory product to you. That is the reason we
offer technical support to assist you with your needs should an occasion occur. With proper use and care
your product should deliver years of trouble free service.
Safe operation and proper maintenance is your responsibility.
We have compiled this operator's manual, to instruct you in basic safety, operation and maintenance of
our product to give you the best possible experience. Much of welding and cutting is based upon
experience and com-mon sense. As thorough as this welding manual may be, it is no substitute for either.
Exercise extreme caution and care in all activities related to welding or cutting. Your safety, health and even
life depends upon it. While accidents are never planned, preventing an accident requires careful planning.
Please carefully read this manual before you operate machine.
This manual is not only for the use
of the machine, but to assist in obtaining the best performance out of your unit. Do not operate the unit
until you have read this manual and you are thoroughly familiar with the safe operation of the unit. If you feel
you need more information please contact our Support.
The warranty does not cover improper use, maintenance or consumables. Do not attempt to alter or
defeat any piece or part of your unit, particularly any safety device. Keep all shields and covers in
place during unit operation should an unlikely failure of internal components result in the possible presence
of sparks and explosions. If a failure occurs, discontinue further use until mal-functioning parts or
accessories have been repaired or replaced by qualified personnel.
Note on High Frequency electromagnetic disturbances:
Certain welding and cutting processes generate High Frequency (HF) waves. These
waves may disturb sensitive electronic equipment such as televisions, radios, computers, cell
phones, and related equipment. High Frequency may also interfere with fluorescent lights.
Consult with an electrician if disturb-ance is noted. Sometimes, improper wire routing or poor
shielding may be the cause.
HF can interfere with pacemakers.See EMF warnings in following safety sec-tion for
further information. Always consult your physician before entering an area known to have
welding or cutting equipment if you have a pacemaker.
MOVING PARTS can cause injury.
Moving parts, such as fans, rotors, and belts can cut fingers and hands and catch loose
clothing.
Do not put your hands near the engine fan. Do not attempt to override the governor or idler by
pushing on the throttle control rods while the engine is running.
SAFETY PRECAUTIONS

These safety precautions are for protection of safety and health. Failure to follow these
guidelines may result in serious injury or death. Be careful to read and follow all cautions and
warnings. Protect yourself and others.
Welding and cutting processes produce high levels of ultraviolet (UV) radiation that can
cause severe skin burn and damage.There are other potential hazards involved with welding
such as severe burns and respiratory related illnesses. Therefore ob-serve the following to
minimize potential accidents and injury:
Use appropriate safety glasses with wrap around shields while in the work area, even
under welding helmets to protect your eyes from flying sparks and debris.When chip-ping
slag or grinding, goggles and face shields may be required.
When welding or cutting, always use an approved shielding device, with the correct
shade of filter installed. Always use a welding helmet in good condition. Discard any broken
or cracked filters or helmets. Using broken or cracked filters or helmets can cause severe eye
injury and burn. Filter shades of no less than shade 5 for cutting and no less than shade 9 for
welding are highly recommended. Shades greater than 9 may be required for high amperage
welds. Keep filter lenses clean and clear for maxi-mum visibility. It is also advisable to consult with your eye
doctor should you wear contacts for corrective vision before you wear them while welding.
Do not allow personnel to watch or observe the welding or cutting operation unless fully
protected by a filter screen, protective curtains or equivalent .protective equip-ment. If no
protection is available, exclude them from the work area. Even brief expo-sure to the rays from
the welding arc can damage unprotected eyes.
Always wear hearing protection because welding and cutting can be extremely noisy. E
ar protection is necessary to prevent hearing loss. Even prolonged low levels of noise has
been known to create long term hearing damage. Hearing protection also further protects
against hot sparks and debris from entering the ear canal and doing harm.
Always wear personal protective clothing. Flame proof clothing is required at all times.
Sparks and hot metal can lodge in pockets, hems and cuffs. Make sure loose clothing is tucked
in neatly. Leather aprons and jackets are recommended. Suitable welding jackets and coats
may be purchased made from fire proof material from welding supply stores. Discard any
burned or frayed clothing. Keep clothing away from oil, grease and flammable liquids.
Leather boots or steel toed leather boots with rubber bottoms are required for ade-quate
foot protection. Canvas, polyester and other man made materials often found in shoes will
either burn or melt. Rubber or other non conductive soles are necessary to help protect from
electrical shock.
Flame proof and insulated gauntlet gloves are required whether welding or cutting or
handling metal. Simple work gloves for the garden or chore work are not sufficient. Gauntlet
type welding gloves are available from your local welding supply companies. Never attempt to
weld with out gloves. Welding with out gloves can result in serious burns and electrical shock.
If your hand or body parts comes into contact with the arc of a plasma cutter or welder, instant
and serious burns will occur. Proper hand protection is required at all times when working
with welding or cutting machines!
SAFETY PRECAUTIONS

WARNING! Persons with pacemakers should not weld, cut or be in the welding area
until they consult with their physician. Some pacemakers are sensitive to EMF radiation and
could severely malfunction while welding or while being in the vicinity of someone welding.
Serious injury or death may occur!
Welding and plasma cutting processes generate electro-magnetic fields and
radiation. While the effects of EMF radiation are not known, it is suspected that there may be
some harm from long term exposure to electromagnetic fields. Therefore, certain pre-cautions
should be taken to minimize exposure:
* Lay welding leads and lines neatly away from the body.
* Never coil cables around the body.
* Secure cables with tape if necessary to keep from the body.
* Keep all cables and leads on the same side the body.
* Never stand between cables or leads.
* Keep as far away from the power source (welder) as possible while welding.
* Never stand between the ground clamp and the torch.
* Keep the ground clamp grounded as close to the weld or cut as possible.
Welding and cutting processes pose certain inhalation risks. Be sure to follow any
guidelines from your chosen consumable and electrode suppliers regarding possible need for
respiratory equipment while welding or cutting. Always weld with adequate ventilation. Never weld
in closed rooms or confined spaces. Fumes and gases re-leased while welding or cutting may be
poisonous. Take precautions at all times.
Any burning of the eyes, nose or throat are signs that you need to increase ventilation.
* Stop immediately and relocate work if necessary until adequate ventilation is ob-tained.
* Stop work completely and seek medical help if irritation and discomfort persists.
WARNING! Do not weld on galvanized steel, stainless steel, beryllium, titanium, cop-per,
cadmium, lead or zinc without proper respiratory equipment and or ventilation.
WARNING! This product when used for welding or cutting produces fumes and gas-es
which contains chemicals known to the State of California to cause birth defects and in some
§
cases cancer. (California Safety and Health Code 25249.5 et seq.)
WARNING! Do not weld or cut around Chlorinated solvents or degreasing areas. Release
of Phosgene gas can be deadly. Consider all chemicals to have potential deadly results if welded
on or near metal containing residual amounts of chemicals.
Keep all cylinders upright and chained to a wall or appropriate holding pen. Certain
regulations regarding high pressure cylinders can be obtained from OSHA or local regulatory
agency. Consult also with your welding supply company in your area for further recommendations.
The regulatory changes are frequent so keep informed.
All cylinders have a potential explosion hazard. When not in use, keep capped and closed.
Store chained so that overturn is not likely. Transporting cylinders incorrectly can lead to an
explosion. Do not attempt to adapt regulators to fit cylinders. Do not use faulty regulators. Do
not allow cylinders to come into contact with work piece or work. Do not weld or strike arcs on
cylinders. Keep cylinders away from direct heat, flame and sparks.
SAFETY PRECAUTIONS

WARNING! Electrical shock can kill. Make sure all electrical equipment is properly
grounded. Do not use frayed, cut or otherwise damaged cables and leads. Do not stand, lean
or rest on ground clamp. Do not stand in water or damp areas while weld-ing or cutting. Keep
work surface dry. Do not use welder or plasma cutter in the rain or in extremely humid
conditions. Use dry rubber soled shoes and dry gloves when welding or cutting to insulate
against electrical shock. Turn machine on or off only with gloved hand. Keep all parts of the
body insulated from work, and work tables. Keep away from direct contact with skin against
work. If tight or close quarters ne-cessitates standing or resting on work piece, insulate with
dry boards and rubber mats designed to insulate the body from direct contact.
All work cables, leads, and hoses pose trip hazards. Be aware of their location and
make sure all personnel in area are advised of their location. Taping or securing ca-bles with
appropriate restraints can help reduce trips and falls.
WARNING! Fire and explosions are real risks while welding or cutting. Always keep
fire extinguishers close by and additionally a water hose or bucket of sand. Periodi-cally check
work area for smoldering embers or smoke. It is a good idea to have someone help watch for
possible fires while you are welding. Sparks and hot metal may travel a long distance. They
may go into cracks in walls and floors and start a fire that would not be immediately visible.
Here are some things you can do to reduce the possibility of fire or explosion:
* Keep all combustible materials including rags and spare clothing away from area.
* Keep all flammable fuels and liquids stored separately from work area.
* Visually inspect work area when job is completed for the slightest traces of smoke or embers.
* If welding or cutting outside, make sure you are in a cleared off area, free from dry tender and
debris that might start a forest or grass fire.
* Do not weld on tanks, drums or barrels that are closed, pressurized or anything that held
flammable liquid or material.
Metal is hot after welding or cutting! Always use gloves and or tongs when handling hot
pieces of metal. Remember to place hot metal on fire-proof surfaces after han-dling. Serious
burns and injury can result if material is improperly handled.
WARNING! Faulty or poorly maintained equipment can cause injury or death. Prop-
er maintenance is your responsibility. Make sure all equipment is properly maintained and
serviced by qualified personnel. Do not abuse or misuse equipment.
Keep all covers in place. A faulty machine may shoot sparks or may have exploding parts.
Touching uncovered parts inside machine can cause discharge of high amounts of electricity.
Do not allow employees to operate poorly serviced equipment. Always check
condition of equipment thoroughly before start up. Disconnect unit from power source before
any service attempt is made and for long term storage or electrical storms.
Further information can be obtained from The American Welding Society (AWS) that
relates directly to safe welding and plasma cutting. Additionally, your local welding supply
company may have additional pamphlets available concerning their products. Do not operate
machinery until your are comfortable with proper operation and are able to assume inherent
risks of cutting or welding.
SAFETY PRECAUTIONS

TABLEOFCONTENTS
Page
SAFETY PRECAUTIONS................................................. .
Installation.....................................................Section A
Technical Specifications...............................................A-1
Output Amps %duty cycle ...............................................A-2
Select Suitable Location...............................................A-3
Stacking ..............................................................A-3
TRANSPORT - UNLOADING ............................................A-3
Tilting. ..............................................................A-3
Environmental Area ....................................................A-3
Machine Grounding and High Frequency Interference Protection .........A-4
Input Connections ...................................................A-4
Reconnect Procedure....................................................A-5
220/230/240V Input.....................................................A-5
110/115/120V Input.....................................................A-5
Attachment Plug Installation, Engine Driven Generator..................A-5
Output Connections.....................................................A-6
Output and Gas Connection for Tig Welding..............................A-6
Work Cable Connection .................................................A-6
Output Connection for Stick Welding ...................................A-6
Quick Disconnect Plug .................................................A-6
Shielding Gas Connection...............................................A-6
Remote Control Connection..............................................A-6
Operation.......................................................Section B
Safety precautions.....................................................B-1
Product Description....................................................B-2
Welding Capability.....................................................B-2
Limitations ...........................................................B-2
Control Panel .....................................................B-3
Controls and Settings, 2 Step and 4 Step Tig Sequence .............B-3,B-5
Operating steps........................................................B-6
Welding in Tig mode....................................................B-6
Welding Polarity ......................................................B-6
DC Electrode Negative Polarity.........................................B-6
DC Electrode Positive Polarity ........................................B-6
D.C.-Pulsed TIG .......................................................B-6
Steel Tig Welding .....................................................B-7
Copper Tig Welding.....................................................B-7
GTAW Process...........................................................B-8
Protective Gas ........................................................B-8
DC Tig Welding Quick Start Up .........................................B-9
Remote Control operation ..............................................B-9
Welding in Stick mode .................................................B-13
Maintenance .....................................................Section C
Safety Precautions ....................................................C-1
Routine and periodic Maintenance.......................................C-1
Troubleshooting .................................................Section D
How to Use Troubleshooting Guide ......................................D-1
Input Filter Capacitor Discharge Procedure ............................D-1
Troubleshooting Guide.........................................D-2 thru D-7
Wiring Diagram...................................................Section E
Main circuit wiring Diagram............................................E-1
Accessories......................................................Section F
Parts Lists(COMPONENT LISTS)..................................... Appendix

A-1 INSTALLATION A-1
TECHNICAL SPECIFICATIONS -
max. rated Output Amps @% Duty Cycle (Based on a 10 minute cycle) (Example; 130A@35% for DC Stick
and 160A@35% for DC TIG)
Model TIG 160PDCHF
Power Supply Voltage 1x110V 50/60Hz 1x220V 50/60Hz
Fuse rating 27A 24A
No-load Voltage 70V 70V
Rated Output Current 100A(TIG)
80A(MMA)
160A(TIG)
130A(MMA)
Rated Duty Cycle 35% 35%
Welding Cur. Adjusting Range 5-100A(TIG)
10-80A(MMA)
5-160A(TIG)
10-130A(MMA)
base Current 5A
Initial current(fixed) 15A
crater-fill current(fixed) 15A
Pulse Width Ratio 0.5
Pulse Frequency 0.5 - 25Hz
TIG Arc starting mode high frequency arc striking
Up-slope,Down-slope time 0-5 Sec
After Flow Time 1 - 10 Sec
Mass 9kg
Protection Class of enclosure I P21S
outline Dimensions (mm3) 310×155×290

A-2 INSTALLATION A-2
Chart gives max. rated Output Amps @% Duty Cycle (Based on a 10 minute cycle) (Example; 130A@35%
for DC Stick and 160A@35% for DC TIG)
TIG
STICK(MMA)
(1)
Wiring and protection based on the IEC60974.1 National Electric Code: Use a Super Lag type fuse or circuit
breaker with a delay in tripping action. Models with NEMA 6-50P plug may be used with a 50 amp protected
6-50R receptacle, or with a maximum 70 amp protected 6-50R receptacle if dedicated for the welder.
40 60 80 100 120 140 160 180A
100%
90%
80%
70%
60%
50%
40%
30%
20%
10%
0
OUTPUT AMPS
OUTPUT AMPS %DUTY CYCLE
Using standard input cable for protected input supply