Comparc SINTESIS 160 User manual

PM1401 REV. 0
E.19-11-2021
CC - CD WELDER / 6200 WATTS GENERATOR
SINTESIS 160
DESCRIPTION
CONSTANTCURRENT(CC).
DIRECTCURRENT (CD)
PROCESS
STICK(SMAW)
TIG (GTAW).
OUTPUTTYPE:
304-878
OWNER´S MANUAL
T M
OWNER´S MANUAL
GIVETHISMANUALTOTHEOPERATOR
VISIT OUR WEBSITE AT: www.siisa-infra.com.mx

TABLE OF CONTENS
ARC WELDING SAFETY PRECAUTIONS .......................................................................................................... i
SECTION 1 SAFETY SIGNALS AND SYMBOLS ..............................................................................................1
SECTION 2 SPECIFICATIONS ...........................................................................................................................2
2 - 1 Specifications ..............................................................................................................................................2
2 - 2 Power supply electrical specifications.......................................................................................................2
2 - 3 Volt-Amperes Curves .................................................................................................................................3
2 - 4 Duty Cycle Curves.......................................................................................................................................3
2 - 5 Auxiliary Power Curves ...............................................................................................................................4
SECTION 3 INSTALLATION ...............................................................................................................................4
3 - 1 Selecting a location & moving welding source ..........................................................................................4
3 - 2 Engine prestart checks...............................................................................................................................5
3 - 3 Grounding connection .................................................................................................................................5
3 - 4 Grounding when supplying a building.........................................................................................................6
3 - 5 Selection of cable length. ...........................................................................................................................6
3 - 6 Selecting & preparing weld output cables .................................................................................................7
3 - 7 Connection of the welding power source to the engine generator............................................................8
3 - 8 Connection as an independent welding power source ..............................................................................8
3 - 9 Supply voltage 127 V a.c............................................................................................................................8
3 - 10 Supply voltage 220 V a.c..........................................................................................................................9
3 - 11 Recommended fuse sizes and minimum cable section ..........................................................................9
3 - 12 Weld output terminals...............................................................................................................................9
3 - 13 Weld cable size...................................................................................................................................... 10
SECTION 4 FUNCTION OF CONTROLS......................................................................................................... 10
Figure 4 - 1 Controls................................................................................................................................... 10
Figure 4 - 2 Engine controls....................................................................................................................... 10
SECTION 5 AUXILIARY POWER GUIDE ........................................................................................................ 11
5 - 1 How much power does equipment required? .......................................................................................... 11
5 - 2 How much power does supply the generator?........................................................................................ 11
5 - 3 Typical connection for emergency plant. ................................................................................................ 14
5 - 4 Equipment selection ................................................................................................................................ 14
5 - 5 Wiring of the 120 V.a.c. / 240 V a.c. plug. ............................................................................................ 15
5 - 6 Overload potection. .................................................................................................................................. 15
SECTION 6 MAINTENANCE AND TROUBLESHOOTING .............................................................................. 16
6 - 1 Routine maintenance ............................................................................................................................. 16
6 - 2 Routine power supply maintenance ...................................................................................................... 17
6 - 3 Power Supply Troubleshooting.............................................................................................................. 17
6 - 4 Engine Maintenance .............................................................................................................................. 18
SECTION 7 ELECTRICAL DIAGRAM ............................................................................................................. 19
SECTION 8 PART LIST.................................................................................................................................... 20

i
ARC WELDING SAFETY PRECAUTIONS
WARNING
- DANGER! - Indicates a hazardous situation which, if not avoided, will result in death or serious injury. The possible hazards
are shown in the adjoining symbols or explained in the text
- Indicates a hazardous situation which, if not avoided, could result in death or serious injury. The possible hazards are shown
in the adjoining symbols or explained in the text.
- The symbols shown below are used throughout this manual to call attention to and identify possible hazards. When you
see the symbol, watch out, and follow the related instructions to avoid the hazard. The safety information given below is
only a summary of the more complete safety information found in the Safety Standards.
- Only qualified persons should install, operate, maintain, and
repair this unit.
- During operation, keep everybody, especially children, away.
ARC WELDING can be hazardous.
ELECTRIC SHOCK can kill.
Touching live electrical parts can cause fatal shocks
or severe burns. The electrode and work circuit is
electrically live whenever the output is on. The input
power circuit and machine internal circuits are also
live when power is on. In semiautomatic or automatic
wire welding, the wire, wire reel, drive roll housing,
and all metal parts touching the welding wire are electrically live.
Incorrectly installed or improperly grounded equiment is a hazard.
1.- Do not touch live electrical parts.
2.- Wear dry, hole-free insulating gloves and body protection.
3.- Insulate yourself from work and ground using dry insulating
mats or covers.
4.- Disconnect input power or stop engine before installing or
servicing this equipment.
5.- Properly install and ground this equipment according to this
Owner's Manual and national, state, and local codes.
6.- Turn off all equipment when not in use.
7.- Do not use worn, damaged, undersized, or poorly spliced cables.
8.- Do not wrap cables around your body.
9.- Ground the workpiece to a good electrical (earth) ground.
10.- Do not touch electrode while in contact with the work (ground)
circuit.
11.- Use only well-maintained equipment. Repair or replace damaged
parts at once.
12.- Wear a safety harness to prevent falling if working above floor
level.
13.- Keep all panels and cover securely in place.
ARC RAYS can burn eyes and skin;
NOISE can damage hearing.
Arc rays from the welding process produce intense
heat and strong ultraviolet rays that can burn eyes and
skin. Noise from some processes can damage hearing.
1.- Wear a welding helmet fitted with a proper shade
of filter (see ANSIZ49.1 listed in Safety Standards) to protect
FUMES AND GASES can be hazardous
to your health.
Welding produces fumes and gases. Breathing these
fumes and gases can be hazardous to your health.
1.- Keep your head out of the fumes. Do not breath the fumes.
2.- If inside, ventilate the area and / or use exhaust at the arc to remove
welding fumes and gases.
3.- If ventilation is poor, use an approved air-supplied respirator.
4.- Read the Material Safety Data Sheets (MSDSs) and the
manufacturer´s instruction for metal, consumables, coatings, and
cleaners.
5.- Work in a confined space only if it is well ventilated, or while wearing
an air-supplied respirator. Shielding gases used for welding can
displace air causing injury or death. Be sure the breathing air is safe.
6.- Do not weld in locations near degreasing, cleaning, or spraying
operations. The heat and rays of the arc can react with vapors to
form highly toxic and irritating gases.
7.- Do not weld on coated metals, such as galvanized, lead, or cadmium
plated steel, unless the coating is removed from the weld area, the
area is well ventilated, and if necessary, while wearing an air-
supplied respirator. The coatings and any metals containing these
elements can give off toxic fumes if welded.
FLYING SPARK AND HOT METAL can
cause injury
Chipping and grinding cause flying metal . As welds
cool, they can throw off slag.
1.- Wear approved face shield or safety goggles. Side shields
recommended.
2.- Wear proper body protection to protect skin.
your face and eyes when welding or watching.
2.- Wear approvedsafety glasses. Side shields recommended.
3.- Use protective screens or barriers to protect others from flash and
glade; warn others not to watch the arc.
4.- Wear protective clothing made from durable, flame- resistant mate
rial (wool and leather) and foot protection.
5.- Use approved ear plugs or ear muffs if noise level is high.

ii
CYLINDERS can explode if damaged.
Shieldinggas cylinders contain gas under highpressure.
If damaged, a cylinder can explode. Since gas cylinders
are normally part of the welding process, be sure to
treat them carefully.
1.- Protect compressed gas cylinders from excessive heat, mechanical
shocks, and arcs.
2.- Install and secure cylinders in an upright position by chaining them
to a stationary support or equipment cylinder rack to prevent falling
or tipping.
3.- Keep cylinders away from any welding or other electrical circuits.
4.- Never allow a welding electrode to touch any cylinder.
5.- Use only correct shielding gas cylinders, regulators, hoses, and
fittings designed for the specific application; maintain them and
associated parts in good condition.
6.- Turn face away from valve outlet when opening cylinder valve.
7.- Keep protective cap in place over valve except when cylinder is in
use or connected for use.
8.- Readand follow instructions on compressed gas cylinders, associated
equipment, and CGA publication P-1 listed in Safety Standards.
ENGINES can be hazardous.
WARNING
ENGINE EXHAUST GASES can kill.
Engines produce harmful exhaust gases.
1.- Use equipment outside in open, well-ventilated
areas.
2.- If used in a closed area, vent engine exhaust outside and away from
any building air intakes.
ENGINE FUEL can cause fire or
explosion.
Engine fuel is highly flammable.
1.- Stop engine before checking or adding fuel.
2.- Do not add fuel while smoking or if unit is near any sparks or open
flames.
3.- Allow engine to cool before fueling. If possible, check and add fuel
to cold engine before beginning job.
4.- Do not overfill tank - allow room for fuel to expand.
5.- Do not spill fuel. If fuel is spilled, clean up before starting engine.
MOVING PARTS can cause injury.
Moving parts, such as fans, rotors, and belts can cut
fingers and hands and catch loose clothing.
1.- Keep all doors, panels, covers, and guards closed
and securely in place.
2.- Stop engine before installing or connecting unit.
3.- Have only qualified people remove guards or covers for maintenance
and troubleshooting as necessary.
4.- To prevent accidental stating during servicing, disconnect negative
(-) battery cable from battery.
5.- Keep hands, hair, loose clothing, and tools away from moving parts.
6.- Reinstall panels or guards and close doors when servicing is finished
and before starting engine.
SPARKS can cause BATTERY GASES
TO EXPLODE; BATTERY ACID can
burn eyes and skin.
Batteries contain acid and generate explosive gases.
1.- Always wear a face shield when working on a
battery.
2.- Stop engine before disconnecting or connecting battery cables.
3.- Do not allow tools to cause sparks when working on a battery.
4.- Do not use welder to charge batteries or jump start vehicles.
5.- Observe correct polarity (+ and -) on batteries.
WELDING can cause fire or explosion.
Sparks and spatter fly off from the welding arc. The
flying sparks and hot metal, weld spatter, hot workpiece,
and hot equipment can cause fires and burns. Acciden-
tal contact of electrode or welding wire to metal objects
can cause sparks, overheating, or fire.
1.- Protect yourself and others from flying sparks and hot metal.
2.- Do not weld where flying sparks can strike flammable material.
3.- Remove all flammables within 35ft (10.7 m) of the welding arc. If
this is not possible, tightly cover them with approved covers.
4.- Be alert that welding sparks and hot materials from welding can
easily go through small cracks and openings to adjacent areas.
5.- Watch for fire, and keep a fire extinguisher nearby.
6.- Be aware that welding on a ceiling, floor, bulkhead, or partition can
cause fire on the hidden side.
7.- Do not weld on closed containers surch as tanks or drums.
8.- Connect work cable to the work as close to the welding areas as
practical to prevent welding current from traveling long, possibly
unknown paths and causing electric shock and fire hazards.
9.- Do not use welder to thaw frozen pipes.
10.- Remove stick electrode from holder or cut off welding wire at
contact tip when not in use.
11.- Wear oil-free protective garments such as leather gloves, heavy
shirt, cuffless trousers, high shoes, and a cap.

iii
STEAM AND PRESSURIZED HOT
COOLANT can burn face, eyes, and
skin.
The coolant in the radiator can be very hot and under
pressure.
1.- Do not remove radiator cap when engine is hot. Allow engine to cool.
2.- Wear gloves and put a rag over cap area when removing cap.
3.- Allow pressure to escape before completely removing cap.
- Additional Symbols For Installation, Operation, And Maintenance
NOISE can damage hearing.
Noise from some processes or equipment can damage hearing.
- Wear approved ear protection if noise level is high.
FALLING EQUIPMENT can injure
-Use lifting eye to lift unit and properly installed
accessories only, NOT gas cylinders. Do not
exceed maximum lift eye weight rating (see
Specifications).
-Use equipment of adequate capacity to lift and support unit.
-If using lift forks to move unit, be sure forks are long enough to extend
beyond opposite side of unit.
-Keep equipment (cables and cords) away from moving vehicles
when working from an aerial location.
OVERUSE can cause OVERHEATING
-Allow cooling period; follow rated duty cycle.
-Reduce current or reduce duty cycle before starting to
weldagain.
-Do not block or filter airflow to unit.
STATIC (ESD) can damage PC boards.
-Put on grounded wrist strap BEFORE handling boards or parts.
-Use proper static-proof bags and boxes to store, move, or ship PC boards.
ARC WELDING can cause interference.
-Electromagnetic energy can interfere with sensitive
electronic equipment such as microprocessors, computers,
and computer-driven equipment such as robots.
-Be sure all equipment in the welding area is
electromagnetically compatible.
- To reduce possible interference, keep weld cables as short as possible, close
together, and down low, such as on the floor.
-Locate welding operation 100 meters from anysensitiveelectronic equipment.
-Besurethisweldingmachineisinstalledandgroundedaccordingtothismanual.
-If interference still occurs, the user must take extra measures such as moving
thewelding machine,using shieldedcables, usingline filters, or shieldingthe work
area.
-Read and follow all labels and the Owner’s Manual carefullybefore installing, operating, or servicing unit.
Read the safety information at the beginning of the manual and in each section.
- Definitions

1
1-2 Symbol usage and definition.
Start
Engine
Do not switch
while welding
Welding Arc
(Electrode) Stick
(SMAW)
Engine
Choke Read
operator´s
Manual
Stop
Engine
Engine
oil
Fast
(Run, weld / Power)
Fuel
Hours
Seconds
Time
Ground
Positive
Negative
Alternating
Current
MIG (GMAW)
Wire
Battery
Volts Amperes Circuit Breaker
Slow (Idle)
Fast/slow
Output
Work
Connection
Check Valve
Clearance
TIG (GTAW)
1-1 Safety signal words.
SECTION 1 - SAFETYSIGNALSAND SYMBOLS
WARNING
CAUTION
IMPORTANT: Statements identify special instructionsnecessaryforthemostefficientoperationofthisequipment.
WARNING statements identify procedures or practices which must be followed to
avoid seriuos personal injuryor loss of life.
CAUTIONstatementsidentifyproceduresorpracticeswhichmustbefollowedtoavoid
minor personal injury or damage to this equipment.
Thefollowingsafetyalertsymbolandsignalwordsareusedthroughoutthismanualtocallattentiontoandidentifydifferent
levelsof hazardandspecialinstructions.

SECCION 2 SPECIFICATIONS
Table 2-2. Power supply specifications
DESCRIPTION
2-2. POWER SUPPLY ELECTRICAL SPECIFICATIONS
2-1. SPECIFICATIONS
Table 2-1. Engine - generator specifications
Engine Power Type Generatorpowerrating,
1phase,60Hz Fuelcapacity Oil capacity Start
KohlerCH440 14Hp@3600rpm 1Cylinder,
Aircooled
6500Wmax
6200Wcontinuos
7l 0.980l Electric
weight,kg(lb): 105(12.7) Ship, kg(lb): 120(21.2)
Dimensions,mm(pulg): high: 640(25.2) width:660 (26) Length830(33)
The design of this machine is based on Inverter Technology. This allowsan arc dinamical time response extremely
low (around 0.5 microseconds), aproaching excelent characteristics of weld, with any elctrode type. The high
frequency of INVERTER system eliminates totally any annoying hum caused by the traditional power supplies.
A
kVA
kW
Stick 160@24.4 15- 160 85 N/A N/A N/A
TIG 160@16.4 15- 160 85 N/A N/A N/A
127 120@22.8 15- 120 33.6 4.2 3
220 160@24.4 15- 160 38.4 8.5 5.3
127
120@14.8
15- 120
25
3.1
2.2
220
160@16.4
15- 160
30
6.6
4.1
Supply
voltage (V
a.c.)
ProcessOutputtype Rated load consumption , 50Hz- 60Hz
Open circuit
voltage (V)
Range current
(A)
Duty cycle
(%)
Rated weld
output(A@V)
c. d.
Motor-
generator
(220V)
85
85
40
40
Stick
TIG
c.d.
2

3FIGURE2-2.DUTYCYCLECHART
2-4 DUTY CYCLE CURVES
FIGURE2-1.VOLTS-AMPERESCURVES
Thevolt-amperescurvesshowtheminimum andmaximumv ol tageandamperageoutput capabilitiesof the welding
power source. Curvesof other settings fall between the curves shown.
2-3. VOLTS-AMPERES CURVES
Duty cycle is a percentage of a 10-minute interval during
whichthe unit canweldat rated loadwithout overheating.
With 220 VAC supply power, this unit can run at 40% duty
cyclewhenoperatedat160amperes,allowing4minutesof
each10minuteperiodtobewelded,withthenext6minutes
resting.
With120VACsupplyvoltage, thisunitcanrun at40%duty
cycle when operated at 130 amps, allowing welding for 4
minutesoutofevery10minuteperiodwitharestforthenext
6 minutes.
Whenunitoverheats,theoutputstops,theover-temperature
indicatorlightcomesonandthecoolingfancontinuestorun.
Wait 15 minutes for the unit to cool down. Reduce the
amperageor duty cycle before startingto weldagain.
WARNING:byweldingbeyondthespecifieddutycycle,may
damagetheunitandvoidthewarranty.
Exceeding duty cycle can damage unit and void warranty.
PRECAUCIÓN
0
10
20
30
40
50
60
70
80
0 20 40 60 80 100 120 140 160 180 200
0
10
20
30
40
50
60
70
80
90
-10 10 30 50 70 90 110 130
0
10
20
30
40
50
60
70
80
-10 10 30 50 70 90 110 130 150 170 190
0
10
20
30
40
50
60
70
80
90
-10 10 30 50 70 90 110 130 150 170
MAX.
MÍN.
MAX.
MAX.
MAX.
MÍN. MÍN.
MÍN.
ELECTRODE(120Va.c.) ELECTRODE(220Va.c.)
TIG (120 V a.c.) TIG (220 V a.c.)
Volts Volts Volts
Volts
Amperes Amperes
AmperesAmperes
Duty cycle (%)
W
e
l
d
A
m
p
e
r
e
s
127V
220V
RATED OUTPUT

FIGURE 3-1 LOCATION OF WELDING GENERATOR
1Keep free 1000 mm ( 40" ) around the
aquipment for good air flux
Do not operate the generator in enclosed or
poorly ventilated areas.
3.1 SELECTINGALOCATION WELDING SOURCE.
SECTION 3 INSTALLATION
CAUTION READ SAFETY BLOCKS at beginning of manual before proceeding.
2-5 AC AUXILIARY POWER
Theacgeneratorpowercurves
showthegeneratorpoweravailable
inamperesatthe120and240 V
receptacles.
FIGURE 2-4 120/240 Vac AUXILIARY POWER OUTPUT
100
10
110
125
130
120
20 30 40
200
220
250
260
240
0 10
Amperes
a 120 V a.c.
V
o
l
t
s
a
.
c
.
15 20
Amperes a 240 V a.c.
50
25
1.0 F.P.
60 80
30 40
AIR
AIR
A
I
R
E
AIRE
A
I
R
AIR
A
I
R
E
A
I
R
1
4
Rear
Left
Front Right
Top

5
3-2 ENGINE PRESTART CHECKS
PRECAUCION SEE SAFETY SIGNAL AT THE BEGINING THIS
MANUAL
2
3
FIGURE 3-2 OIL AND FUEL LEVEL
1
FIGURE 3-3 GROUND CONNECTION
3-3 GROUND CONNECTION
1.- TERMINAL TO GROUND THE GENERATOR.
The neutral point of the auxiliary output of
the generator is connected to the
structure of the machine (Chassis).
2.- LANDING CABLE. Use lime insulated
copper wire. 10 or greater.
3.- TRUCK CHASSIS OR TRAILER.
7/16" (11.1 mm)
TOOL NEEDED
1
23
Electrical Connection
Metal to Metal.
Chassis
generator
TIERRA
Calle plásticos No. 17, Colonia San Francisco Cuautlalpan,
Naucalpan deJuárez, Estado de México, C.P. 53569
2 Fuel tank. Check fuel level before starting engine, add
if necessary.
Caution, Do not overfill fuel tank, leave 1/2 "(12.7mm)
space to allow expansion of fuel gases.
3Oil. After checking the fuel in the machine, check the
oil level, with the unit level horizontally. If the oil is not in
the bayonet mark, add oil. See the oil specifications for
use (Section 6-2).
Check the oil and fuel level daily. The motor must be cold
and the machine must be horizontally leveled.
1Fuel Valve. Open the fuel valve to start at engine start.
Close the fuel valve before moving the unit or carburetor,
as this may cause problems starting.

3-4 GROUNDING WHEN SUPPLYING A BUILDING.
FIGURE 3-4 GROUNDING WHEN SUPPLYING A BUILDING.
3
2
2
1
TIERRA
Calle plásticos No. 17, ColoniaS an Francisco Cuautlalpan,
Naucalpan de Juárez, Estado de México,C.P. 53569
6
1.- EARTH TERMINAL OF TEAM.
2.- LANDING CABLE. Use an insulated
copper cable # 10 AWG or greater.
3.- LANDING DEVICE.
Ground the generator to a physical ground
system (metal pipe, metal structure), when
the generator suppliespower to premises
(houses, warehouses, etc.) with wiring
system.
3-5 SELECTING THE CABLE LENGTH. (Use the cable as short as possible).
TABLE 3-1 SELECTION OF CABLES AT 120Vac
CABLE LENGTH FOR LOADSAT 120 Vca
Current
(Amp.) Load (Watts)
MAXIMUM PERMISSIBLE CABLE LENGTH IN Ft (m)
FOR DIFFENENTS CALIBRES*
4AWG 6 AWG 8 AWG 10 AWG 12 AWG 14 AWG
5
7
10
15
20
25
30
35
40
45
50
600
840
1200
1800
2400
3000
3600
4200
4800
5400
6000
400 (122)
300 ( 91)
225 ( 68)
175 ( 53)
150 ( 46)
125 ( 38)
112 ( 34)
100 ( 31)
87 ( 26)
* Based on maximum valtage of 2%
400 (122)
275 ( 84)
175 ( 53)
137 ( 42)
112 ( 34)
87 ( 26)
75 ( 23)
62 ( 19)
62 ( 19)
50 ( 15)
350 (106)
250 ( 76)
175 ( 53)
112 ( 34)
87 ( 26)
62 ( 19)
50 ( 15)
50 ( 15)
37 ( 11)
225 ( 68)
150 ( 46)
112 ( 34)
75 ( 23)
50 ( 15)
37 ( 11)
37 ( 11)
137 ( 42)
100 ( 30)
62 ( 19)
37 ( 11)
30 ( 9)
100 ( 30)
62 ( 19)
50 ( 15)
30 ( 9)

7
FIGURE 3-6 SELECTING & PREPARING WELD OUTPUT CABLES.
3-6 SELECTING & PREPARING WELD OUTPUT CABLES
2
1
34
TABLE 3-2 SELECTION OF CABLES AT 120 Vac
1 Weld Output Cable Determine Total
Cable Length In Weld Circuit And
Maximum WeldingAmperes.USe Table
3-1 To Select Proper Cable Size.
Use shortest cables possibles . Do not
Use Damages Cables.
2 Terminal Lug. Use Lugs of Proper
Amperage Capacity And Hole Size For
Connecting To Work Clamp, Electrode
Holder, And Weld Output Terminals.
3 Insulated Electrode Holder Install
According to ManufacturerInstructiions
4 Works Clamp Install Onto Works
Cable.
For Example To-
tal Cable Length
in Weld Circuit =
6 m (20 Ft).
CABLE LENGTH FOR LOAD 240 Vac
Current
(Amp.) Load (Watts) 4 AWG 6 AWG 8 AWG 10 AWG 12 AWG 14 AWG
5
7
10
15
20
25
30
35
40
45
50
1200
1680
2400
3600
4800
6000
7000
8400
9600
10,800
12,000
800 (244)
600 (183)
450 (137)
350 (107)
300 ( 91)
250 ( 76)
225 ( 69)
200 ( 61)
175 ( 53)
800 (244)
550 (168)
350 (107)
275 ( 84)
225 ( 69)
175 ( 53)
150 ( 46)
125 ( 38)
125 ( 38)
100 ( 31)
700 (213)
500 (152)
350 (107)
225 ( 69)
175 ( 53)
125 ( 38)
100 ( 31)
100 ( 31)
75 ( 23)
450 (137)
300 ( 91)
225 ( 69)
150 ( 46)
100 ( 31)
75 ( 23)
75 ( 23)
225 ( 69)
200 ( 61)
125 ( 38)
75 ( 23)
60 ( 18)
200 ( 61)
125 ( 38)
100 ( 31)
75 ( 23)
60 ( 18)
MAXIMUM PERMISSIBLE CABLE LENGTH IN Ft (m)
FOR DIFFENENTS CALIBRES*
* Based on maximum valtage of 2%

- The power supply voltage of the power source should be 220 VAC +/- 10% or 127VAC +/- 10%, too low a supply
voltagemaycause erraticweldingoperation,toohigha supplyvoltagemaycauseoverheatingof thecomponentsand
possibledamagetotheequipment.
3-8. CONNECTION AS AN INDEPENDENT WELDING POWER SOURCE.
CAUTION
3-9. SUPPLY VOLTAGE AT 127 V a.c.
CAUTION THE EQUIPMENT MUST BE CONNECTED TO THE MAINS SUPPLY IN COMPLIANCE WITH
SAFETY STANDARDS AND INCONDITIONS THAT DONOT EXPOSE THE USER TO RISKS OR
VOLTAGE DISCHARGES. MUST ALWAYS BEGROUNDED WHEN USING THIS PRODUCT.
127 V, 20 A
127 V, 15 A
Unplug the power cord with plug from the 220V
receptacle located inside the side box. Use the
adapter provided to connect to 127V power
voltage.
3-7.CONNECTION OF THE WELDING POWER SOURCE TO THE ENGINE-
GENERATOR.
The power supply is factory connected to the engine-
generator by means of a half turn plug in the 250 V, 20 A.
receptacle located in the side box of the chassis, see
picture.
CAUTION
Detail of the power connection to the
motor-generator.
CAUTION
8
SEE SAFETY SIGNAL AT THE BEGINING THIS
MANUAL
SEE SAFETY SIGNAL AT THE BEGINING THIS
MANUAL
SEE SAFETY SIGNAL AT THE BEGINING THIS
MANUAL

9
3-11. RECOMMENDED FUSE SIZES AND MINIMUM CABLE SECTION.
3-10. SUPPLY VOLTAGE AT 220 V a.c.
CAUTION
250 V, 20A
220 V a. c.
CAUTION THE EQUIPMENT MUST BE CONNECTED TO THE MAINS SUPPLY IN COMPLIANCE WITH
SAFETY STANDARDSAND INCONDITIONS THAT DO NOT EXPOSE THE USER TO RISKS OR
VOLTAGE DISCHARGES. MUST ALWAYS BEGROUNDED WHEN USING THIS PRODUCT.
L1 L2
3-12. WELD OUTPUT TERMINALS.
WARNING
1 ELECTRODETERMINAL
2 WORKTERMINAL
NEVER touch ELECTRODE and WORK terminals at SAME TIME. READ
SAFETY BLOCK at beginning of manual before proceeding.
FIGURE 3-7 WELD OUTPUT TERMINALS
1
2
TIERRA
Calle plásticos No. 17, ColoniaSan FranciscoCuautlalpan,
Naucalpan de Juárez, Estado de México, C.P. 53569
SEE SAFETY SIGNAL AT THE BEGINING THIS
MANUAL
Unplug the power cord from the 220 V receptacle
located inside the side box. Connect it to the 220
V power supply voltage.
M axim u m reco m m en d ed len g th o f
exten sio n cab le
8 m (25 ft) 15 m (50 ft)
R ec om m en d ed m in im u m g ro u n d in g
co n d u cto r size
12 AW G (4 m m 2) 12 A W G (4 m m 2)
M axim u m reco m m en d ed fu se cap acity:
N o rm al o p eratio n fu se
50 50
R ec om m en d ed m in im u m cab le size 12 AW G (4 m m 2) 12 A W G (4 m m 2)
P RO T EC T IO N A T M A XIM U M O U T PU T IN P U T V O L T A G E
127 V a.c. 220 V a.c.
M axim u m reco m m en d ed fu se cap acity:
D elay fu se
30 40

4-2 ENGINE CONTROLS
STARTENGINE
A. Movechokecontrol (1) to "CHOKE" position.
B. Move the fuel and ignition lever (2) to the "ON"
position.
C. Pull hard on the handle (3)to start the engine,
repeat this operation if necessary.
STOPENGINE
A. Placetheignitionhandle(2)intheposition"OFF"(0).
1 CHOKE. Choke control is provided for
varying the fuel-air mixture to the engine
2 ACELERATION LEVER. Use this lever to select
enginespeeds:
3 STARTING HANDLE. Use this handle to start
engine.
CAUTION
SECTION 4 FUNCTION OF CONTROLS
FIGURE 4-1 CONTROLS
1 INTERRUPTOR DE ENCENDIDO PARA LA FUENTE DE PODER
2 120 V.c.a. RECEPTACLE RC1
3 120 V.c.a.RECEPTACLE RC2.
4 240 V.c.a. RECEPTACLE RC3.
5 240 V.c.a. RECEPTACLE RC4.EXCLUSIVE TO THE POWER
SOURCE (Not shown, located in chassis side case)
6 RESET CB1 FOR RC1, RC3 AND RC4.
7 RESET CB2 FOR RC2, RC3 AND RC4.
8 CURRENT ADJUSTMENT
8 4
4-1 CONTROLES
32
76
TIERRA
Calle plásticos No. 17, Colonia San Francisco Cuautlalpan,
Naucalpan de Juárez, Estadod e México, C.P. 53569
10 to 60%
1
Use this control (knob) to select the welding current according to the
application need, turn the knob clockwise to increase the current
and turn counterclockwise to decrease the current by referring to
the current indicator scale (machine cover).
5
1
3
2
10
* Weld cablesize (AWG) is based on eithera 4 volts or lessdrop or a current density of not more than 300 circular mils
perampere
3-13. WELD CABLES SIZE.
100
150
200
4
3
3
4
3
2
4
2
1
3
1
1/0
2
1/0
2/0
1
2/0
3/0
1/0
3/0
4/0
1/0
3/0
4/0
WELDING
AMPERES 10 to 60%
Duty Cycle.
60 Thru
100%
Duty Cycle.
100 Ft (30 m) or less 150Ft (45 m) 200Ft (60 m) 250Ft (70 m) 300Ft (90 m) 400Ft (120 m)
350Ft (105 m)
10 thru 100% Duty Cycle
TOTALCABLE(COPPER)LENGHTINWELDCIRCUITNOTEXCEEDING.*
SEE SAFETY SIGNAL AT THE BEGINING THIS
MANUAL

11
5-2 HOW MUCH POWER DOES SUPPLY THE GENERATOR
1.-LIMITLOADTO90%OFGENERATOR
OUTPUT.
Always start non-resistive (motor)
loads in order from largest to smallest,
and add resistive load last.
2.- 5 SECONDS RULE.
If motor doesnot start within 5Seconds,
turnoff power toprevent motor damage.
Motor requires more power than
generator can supply.
1
2
TIERRA
Calle plásticos No. 17, Colonia San Francisco Cuautlalpan,
Naucalpan de Juárez, Estado de México, C.P. 53569
SECTION 5 AUXILIARY POWER GUIDE
5-1 HOW MUCH POWER DOES EQUIPMENT REQUIRED?
FIGURE 5-1 POWER REQUIRED BY DIFFEREN TYPES OF EQUIPMENT (LOADS).
VOLTS x AMPERES = WATTS
This equation provides an actual power requirement for resistive loads, or an approximate running
requirement for non-resistive loads.
EXAMPLE 1: If a drill requires 4.5Amp. at 120V calculate its running power requirement in watts.
120 V x 4.5 A = 540 W
Therefor, the individual load applied by the drill is 540Watts.
EXAMPLE 2: If a flood lamp is rated at 200W. the individual load applied by the lamp is 200W. if three
200W flood lamps are used with the drill form example 1 add the individual loads to calculate total load.
( 200 W + 200 W + 200 W ) + 540 W = 1140 W
Therefor, the total load applied by the three flood lamps and drill is 1140 watts.
FIGURE 5-2 CALCULATING POWER REQUIRED TO RUN EQUIPMENT.
1.- RESISTIVE LOAD.
Alightbulbisaresistiveloadandrequires
a constant amount of power.
2.-NON-RESISTIVE LOAD.
Equipment with a motor, such as a drill,
isa non-resistive load and requires more
power while starting the motor than when
running (See figure 7-3).
3.- RATING DATA.
Volts and amperes, or watts required to
runequipment.Determinepowerrequired
as shown in figure 7-2.
60 W
VOLTS 120
AMPS 4.5
3
12
3
WARNING READ SAFETY BLOCKS at beginning of manual before proceeding.

12
Starting
Watts Running Watts.
RatingFarm Equipment
1650
3400
4400
2900
650
1000
1400
1100
2800
2000
6000
8000
10700
Mixers
High Pressure .8 Gal/Min 3300 1000 950
6-1/2"
7-1/4"
8-1/4"
500
900
1400
9"
10" 4500 6300 1500 1800
Band Saw 14" 2500 1100
6"
8"
10"
1720
3900
5200
720
1400
1600
1/2 HP
1 HP
1-1/2 HP
2 HP
3000
6000
8200
10500
1000
1500
2200
2800
Electric Chain Saw 1-1/2 HP 12"
2 HP 14" 1100 1100 1100 1100
Standard
9" trabajo
pesado 12"
350
500 350 500
1/3 HP
18" 2100 400 700 400
125
313
1000
1400
1250
100
250
1000
400 GHP
Centrifugal Pump 900 GHP
3/4 HP, 16"
1 HP, 20"
1/2 HP
3/4 HP
1 HP
1/4 HP
1.7 HP
2-1/2 HP
600 200
500900
4500
6100 1400 1600
950
1400
1600
3150
4500
6100
700
900
1300
1900
900
1300
1750
1500
2100
1750 Tipica
1500
2100
Microwaves 6000
2800 6000 2000
100
300 100 300
50-200
3100 800
2150
2100 750 1000
2100
3200 800 1050
2100
2850 700 1450
1200 1200
300-1200 300-1200
1050
1650 1050 1645
As Indicated on Bulb
800
1100
1450 650
400
550
725
3700
5800
8750
11500
13800
1500
2500
3800
5000
6000
800
1250
1600
2100
3225
300
500
600
700
875
Automatic Washer 1150
2500
7550 700 5750
50-200
720
975
1400
1600
2200
2850
3900
6800
TABLE 5-3 APPROXIMATE POWER REQUIREMENTS FOR TIPICAL EQUIPMENT*
Industrials Motors Rating Starting
Watts
Split Phase
1/8 HP
1/6 HP
1/4 HP
1/3 HP
1/2 HP
800
1225
1600
2100
3175
300
500
600
700
875
Running
Watts.
Capacitor Start-
Induction Run.
1/3 HP
1/2 HP
3/4 HP
1 HP
1-1/2 HP
2 HP
3 HP
5 HP
2020
3075
4500
6100
8200
10550
15900
23300
720
975
1400
1600
2200
2850
3900
6800
Capacitor Start-
Induction Run.
1-1/2 HP
5 HP
7-1/2 HP
10 HP
8100
23300
35000
46700
2000
6000
8000
10700
Fan Duty.
1/8 HP
1/6 HP
1/4 HP
1/3 HP
1/2 HP
1000
1400
1850
2400
3500
400
550
650
800
1100
Contractor Rating Starting
Watts Running Watts.
Hand Drill 1/4"
3/8"
1/2"
350
400
600
350
400
600
Circular Saw 500
900
1400
High Pressure Washer
Floor Polisher
Submergible Pump
Flood Lights
Electric Trimmer
Air Compressor
Bench Grinder
Table Saw
Electric Cultivator
55 Gal Drum Mixer
Wet & Dry Vac
Mercurio
Sodio
Vapor
Grain Cleaner
Portable Conveyor
Grain Elevator
Milk Cooler
Milker (Vacuum Pump)
FARM DUTY MOTORS
std (e.g. Conveyors,
Feed Augers, Air
Compressors)
High Torque
Washers 2 Gal/Min 550 PSI
700 PSI
500 PSI 3150
4500
6100
1/2 HP
1/2 HP
5 HP
7-1/2 HP
10 HP
8100
23300
35000
46000
1/3 HP
1/2 HP
3/4 HP
1 HP
1-1/2 HP
2 HP
3 HP
5 HP
1720
2575
4500
6100
8200
10550
15900
23300
2 HP 10500
3/4 HP
1/2 HP
1/4 HP 1000 1000
1400
1600
Running
Watts.
Starting
Watts
RatingResidential
Coffe Maker
TV
Radio
Froster
Shallow Well Pump
Sump Pump
Dishwasher
Clothes Dryer
Furnance Blower
Air Aconditioned Central
Automatic Door Garage
Electric Blanket
Dehumidifier
Vacuum Cleaner
Lights
Toaster
Hair Dryer
Iron
2 Slice
4 Slice
Standard
Delux 800 1100
Portable 400
1/4 HP
1/3 HP 1650 2125
10,000 BTU
20,000 BTU
24,000 BTU
32,000 BTU
40,000 BTU
1/8 HP
1/6 HP
1/4 HP
1/3 HP
1/2 HP
3450
Gas
Electric
Cool Dry
Hot Dry
1/3 HP
1/2 HP
1/3 HP
1/2 HP
B & W
Color
Oven
625 W
6" Elements
8" Elements
Stock Tank De-Icer.

13
POWER
SINTESIS 160
TYPICALLY EXAMPLES OF HOUSEHOLD APPLIANCES
TABLE 5-2 SINGLE PHASE INDUCTION MOTOR STARTING REQUIREMENTS.
CODE
Volts = 230
HP = 1/4 , KVA / HP 11.2
11.2 x 1/4 x 1000 Starting the motor requires 12.2 amperes.
EXAMPLE 3: Calculate starting amperage required for a 230V, 1/4 HP motor with a motor start code of M.
KVA / HP x HP X 1000
VOLTS = Starting Amperage
VOLTS = 12.2 Amps.
FIG. 5-3 POWER REQUIRED TO START ENGINE
FIG. 5 -4 CALCULATE STARTING CURRENT
G
KVA/HP 6.3 H 7.1 J 8.0 K 9.0 L 10.0 M 11.2 N 12.5 P 14.0
1.- Motor data plate.
2.- Motor starting power code. Determinethe power
required to start the motor using Table 5-2.
Determine the required starting current as
shown in Figure 5-4.
3.- Operating current (nominal). If the code is not
present multiply the operating (rated) current by
six. The generator output current must be at least
twice the rated motor current.
23
FIG. 5 - 5 POSSIBLE LOAD COMBINATIONS
40 13 4 3 2 3 1
examples of typical electrical appliances that can be connected to the generators considering power values at
sealevel.
Werecommendverifying thedemandof your appliancesstartingpower andcontinuousoperation before
connecting.
Either of these devices can be connected alone, or in some combinations, as long as it does not exceed the
generatorpower.
30W
MOTOR AC
VOLTS 230 AMPS 2.5
CODIGO Hz 60
HP 1/4 FASE : 1
1
NOTE: It is not possible to obtain the entire load of the generator through a single contact. respect the maximum amperes of
each plug.
75W 200W 300W 450W 500W 700W

WARNING
5-3 TYPICAL CONNECTION FOR EMERGENCY PLANT.
FIGURE 5-6 AUXILIARY POWER TYPICAL CONNECTION.
1.- Utility meter.
2.- Main protection switch.
3.- 2-pole 2-throw transfer swit-
ch. Obtain and correctly install
the switch, it must be of equal or
greater capacity than the main
protection switch (2).
4.- Circuit breaker fuses or
thermal switches. Obtain and
install correctly.
5.- Connection cable. Select the
cable according to section 3-5.
6.- Generator Connections.
Connect the appropriate
terminals or plugs to the cables
according to the current
capacity.
7.- Load connections. Turn off
or disconnect equipment
connected to the generator
before starting or stopping the
engine; slowing the engine
speed causes low voltage and
frequency.
FIGURE 5-7 CONNECTING TO ELECTRICAL EQUIPMENT.
1.- Receptacles with neutral connected to the chassis.
2.-3-terminal plugof the equipment with the chassisgrounded.
3.- Double insulated 2-terminal equipment plug.
5-4 EQUIPMENT SELECTION.
Make sure that the
equipment has this
symbol or legend.
The customer shall supply the necessary equipment so that the
generator can be installed as an emergency plant.
1
2
3
Or
TIERRA
Calle plásticos No. 17, Colonia San Francisco Cuautlalpan,
Naucalpan de Juárez, Estado de México, C.P. 53569
14
SEE SAFETY SIGNAL AT THE BEGINING THIS
MANUAL
120/240V.c.a.
1 Phase- 3 wires.
Output generator
Load
120/240 Vac
60 Hz. 3wires
Service normal
Neutro
240Vac
240Vac
240Vac
120Vac
120Vac
120Vac
120Vac
120Vac
120Vac
ó
F1
CB
Ground

15
FIGURE 5-8 CONNECTION TO ELECTRICAL EQUIPMENT.
Be sure to connect both 120V and 240V plugs
as shown in the figure,
1.- The 120 Vac. 15 Amp. plug should be
connected in its flat terminals to the power
supply (Phase and Neutral) and the round
terminal to the ground system of your
equipment to avoid electric shocks.
2.- Additionally, the 240VAC plug shall be
connected to the 240VAC power at its plain
terminals. (Phase-Phase) and the terminal
with the protrusion should be connected to
ground.
5-5 WIRING OF THE 120 V.a.c. / 240 V. a.c. PLUG.
Consult sections 3-5 and 3-6
for information on cablegauge
and length.
1
2
FIGURE 5-9 OVERLOAD PROTECTION.
This generator is equipped with a protection system that
prevents damage to the generator windings when short
circuits or overloadsoccur at the auxiliary power receptacles
and at the welding source terminals.
1.- CIRCUIT BREAKER CB1. This breaker protects the
generator windings against overloads or short circuits
produced in the RC1, RC3 and RC4 receptacles.
2.- CIRCUIT BREAKER CB2. This breaker protects the
generator windings against overloads or short circuits
produced in the RC2, RC3 and RC4 receptacles.
Reset the breakers if necessary.
5-6 OVERLOAD PROTECTION.
1 2
The plug canbe wiredto supply 240V2-wire or
120/240V3-wire.Seeelectricaldiagram.
1.- Wired plugfor 120/240V 3wires.
When the plug is connected for 120V loads,
the load for each 120V output will be half of
the total maximum power.
2.- PLUG WIRED FOR 240V 2 WIRED LOAD.
3.-NEUTRAL(WHITE).
4.- LINE 1.
5.- LINE 2.
6.-GROUND(GREEN).
7.-Current available using 120/240Vplug
TIERRA
Calle plásticos No. 17, Colonia San Francisco Cuautlalpan,
Naucalpan de Juárez, Estado de México, C.P. 53569