Hobart Welders Inver-Tig 160i User manual
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TIG (GTAW) Welding
Stick (SMAW) Welding
Arc Welding Power Source
June 1999
Effective With Serial
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230 Volt -- 159 262
240 Volt -- 160 261
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OM-189 120 Page 1
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Means Warning! Watch Out! There are possible
hazards with this procedure! The possible hazards are
shown in the adjoining symbols.
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This group of symbols means Warning! Watch Out! possible
ELECTRIC SHOCK, MOVI G PARTS, and HOT PARTS hazards.
Consult symbols and related instructions below for necessary
actions to avoid the hazards.
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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 thewelding wire are electrically live. Incorrectly
installed or improperly grounded equipment is a hazard.
-
Do not touch live electrical parts.
-
Wear dry, hole-free insulating gloves and body protection.
-
Insulate yourself from work and ground using dry insulating mats
or covers big enough to prevent any physical contact with the
work or ground.
-
Do not use AC output in dampareas, if movementis confined, or if
there is a danger of falling.
-
Use AC output O LY if required for the welding process.
-
If AC output is required, use remote output control if present on
unit.
-
Disconnect input power or stop engine before installing or
servicing this equipment. Lockout/tagout input power according
to OSHA 29 CFR 1910.147 (see Safety Standards).
-
Properly install and ground this equipment according to its
Owner’s Manual and national, state, and local codes.
-
Always verify the supply ground -- check and be sure that input
power cord ground wire is properly connected to ground terminal
in disconnect box or that cord plug is connected to a properly
grounded receptacle outlet.
-
When making input connections, attach proper grounding
conductor first -- double-check connections.
-
Frequently inspect input power cord for damage or bare wiring --
replace cord immediately if damaged -- bare wiring can kill.
-
Turn off all equipment when not in use.
-
Do not use worn, damaged, undersized, or poorly spliced cables.
-
Do not drape cables over your body.
-
If earth grounding of the workpiece is required, ground it directly
with a separate cable.
-
Do not touch electrode if you are in contact with the work, ground,
or another electrode from a different machine.
-
Use only well-maintained equipment. Repair or replace damaged
parts at once. Maintain unit according to manual.
-
Wear a safety harness if working above floor level.
-
Keep all panels and covers securely in place.
-
Clamp work cable with good metal-to-metal contact to workpiece
or worktable as near the weld as practical.
-
Insulate work clamp when not connected to workpiece to prevent
contact with any metal object.
-
Do not connect more than one electrode or work cable to any
single weld output terminal.
2" 3 -4 5,-1 4
6 7 ,!
-
Turn Off inverter, disconnect input power, and discharge input
capacitors according to instructions in Maintenance Section
before touching any parts.
Welding produces fumes and gases. Breathing
these fumes and gases can be hazardous to your
health.
)80(6 $1' *$6(6 FDQ EH KD]DUGRXV
-
Keep your head out of the fumes. Do not breathe the fumes.
-
If inside, ventilate the area and/or use exhaust at the arc to
remove welding fumes and gases.
-
If ventilation is poor, use an approved air-supplied respirator.
-
Read the Material Safety Data Sheets (MSDSs) and the
manufacturer’s instructions for metals, consumables, coatings,
cleaners, and degreasers.
-
Work in a confined space only if it is well ventilated, or while
wearing an air-supplied respirator. Always have a trained watch-
person nearby. Welding fumes and gases can displace air and
lower the oxygen level causing injury or death. Be sure the
breathing air is safe.
-
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.
-
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.
OM-189 120 Page 2
Arc rays from the welding process produce intense
visible and invisible (ultraviolet and infrared) rays
that can burn eyes and skin. Sparks fly off from the
weld.
- 86 9 -. 0!
-
Wear a weldinghelmet fittedwith a proper shadeoffilter toprotect
your face and eyes when welding or watching (see A SI Z49.1
and Z87.1 listed in Safety Standards).
-
Wear approved safety glasses with side shields under your
helmet.
-
Use protective screens or barriers toprotectothers from flashand
glare; warn others not to watch the arc.
-
Wear protective clothing made from durable, flame-resistant
material (leather and wool) and foot protection.
Welding on closed containers, such as tanks,
drums, or pipes, can cause them to blow up. Sparks
can fly off from the welding arc. The flying sparks,
hot workpiece, and hot equipment can cause fires
and burns. Accidental contact of electrode to metal objects can
cause sparks, explosion, overheating, or fire. Check and be sure the
area is safe before doing any welding.
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-
Protect yourself and others from flying sparks and hot metal.
-
Do not weld where flying sparks can strike flammable material.
-
Remove all flammables within 35 ft (10.7 m) of the welding arc. If
this is not possible, tightly cover them with approved covers.
-
Be alert that welding sparks and hot materials from welding can
easily go through small cracks and openings to adjacent areas.
-
Watch for fire, and keep a fire extinguisher nearby.
-
Be aware that welding on a ceiling, floor, bulkhead, or partition
can cause fire on the hidden side.
-
Do not weld on closed containers such as tanks, drums, or pipes,
unless they are properly prepared according to AWS F4.1 (see
Safety Standards).
-
Connect work cable to the work as close to the welding area as
practical to prevent welding current from traveling long, possibly
unknown paths and causing electric shock and fire hazards.
-
Do not use welder to thaw frozen pipes.
-
Remove stick electrode from holder or cut off welding wire at
contact tip when not in use.
-
Wear oil-free protective garments such as leather gloves, heavy
shirt, cuffless trousers, high shoes, and a cap.
-
Remove any combustibles, such as a butane lighter or matches,
from your person before doing any welding.
" " - :6 9!
-
Welding, chipping, wire brushing, and grinding
cause sparks and flying metal. As welds cool,
they can throw off slag.
-
Wear approved safety glasses with side
shields even under your welding helmet.
" - :6 011!
-
Shut off shielding gas supply when not in use.
-
Always ventilate confined spaces or use
approved air-supplied respirator.
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-
Do not touch hot parts bare handed.
-
Allow cooling period before working on gun or
torch.
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-
Pacemaker wearers keep away.
-
Wearers should consult their doctor before
going near arc welding, gouging, or spot
welding operations.
- .-5-; <-;!
oise from some processes or equipment can
damage hearing.
-
Wear approved ear protection if noise level is
high.
Shielding gas cylinders contain gas under high
pressure. If damaged, a cylinder can explode.
Since gas cylinders are normally part of the welding
process, be sure to treat them carefully.
" - 31. 4 .-5-;.!
-
Protect compressed gas cylinders from excessive heat,
mechanical shocks, slag, open flames, sparks, and arcs.
-
Install cylinders in an upright position by securing to a stationary
support or cylinder rack to prevent falling or tipping.
-
Keep cylinders away from any welding or other electrical circuits.
-
ever drape a welding torch over a gas cylinder.
-
ever allow a welding electrode to touch any cylinder.
-
ever weld on a pressurized cylinder -- explosion will result.
-
Use only correct shielding gas cylinders, regulators, hoses, and
fittings designed for the specific application; maintain them and
associated parts in good condition.
-
Turn face away from valve outlet when opening cylinder valve.
-
Keep protective cap in place over valve except when cylinder is in
use or connected for use.
-
Read and follow instructions on compressed gas cylinders,
associated equipment, and CGA publication P-1 listed in Safety
Standards.
OM-189 120 Page 3
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-
Do not install or place unit on, over, or near
combustible surfaces.
-
Do not install unit near flammables.
-
Do not overload building wiring -- be sure power supply system
is properly sized, rated, and protected to handle this unit.
"" - -6 :69!
-
Use lifting eye to lift unit only, OT running
gear, gas cylinders, or any other accessories.
-
Use equipment of adequate capacity to lift and
support unit.
-
If using lift forks to move unit,be sure forks are
longenoughtoextendbeyondoppositesideof
unit.
2 - -6 2&
-
Allow cooling period; follow rated duty cycle.
-
Reduce current or reduce duty cycle before
starting to weld again.
-
Do not block or filter airflow to unit.
-
Put on grounded wrist strap BEFORE
handling boards or parts.
-
Use proper static-proof bags and boxes to
store, move, or ship PC boards.
2 - -6 :69!
-
Keep away from moving parts.
-
Keep away from pinch points such as drive
rolls.
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-
Do not press gun trigger until instructed to do
so.
-
Do not point gun toward any part of the body,
other people, or any metal when threading
welding wire.
2 - -6 :69!
-
Keep away from moving parts such as fans.
-
Keep all doors, panels, covers, and guards
closed and securely in place.
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-
High-frequency (H.F.) can interfere with radio
navigation, safety services, computers, and
communications equipment.
-
Have only qualified persons familiar with
electronic equipment perform this installation.
-
The user is responsible for having a qualified electrician
promptly correct any interference problem resulting from the
installation.
-
If notified by the FCC about interference, stop using the
equipment at once.
-
Have the installation regularly checked and maintained.
-
Keep high-frequency source doors and panels tightly shut,
keep spark gaps at correct setting, and use grounding and
shielding to minimize the possibility of interference.
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-
Electromagnetic energy can interfere with
sensitive electronic equipment such as
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 any sensitive elec-
tronic equipment.
-
Be sure this welding machine is installed and grounded
according to this manual.
-
If interference still occurs, the user must take extra measures
such as moving the welding machine, using shielded cables,
using line filters, or shielding the work area.
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, A SI Standard Z49.1, from American
Welding Society, 550 .W. LeJeune Rd, Miami FL 33126
6DIHW\ DQG +HDOWK 6WDQGDUGV
, OSHA 29 CFR 1910, from Superinten-
dent of Documents, U.S. Government Printing Office, Washington,
D.C. 20402.
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American Welding Society Standard AWS F4.1, from American
Welding Society, 550 .W. LeJeune Rd, Miami, FL 33126
1DWLRQDO (OHFWULFDO &RGH
, FPA Standard 70, from ational Fire
Protection Association, Batterymarch Park, Quincy, MA 02269.
6DIH +DQGOLQJ RI &RPSUHVVHG *DVHV LQ &\OLQGHUV
, CGA Pamphlet
P-1, from Compressed Gas Association, 1235 Jefferson Davis
Highway, Suite 501, Arlington, VA 22202.
&RGH IRU 6DIHW\ LQ :HOGLQJ DQG &XWWLQJ
, CSA Standard W117.2, from
Canadian Standards Association, Standards Sales, 178 Rexdale
Boulevard, Rexdale, Ontario, Canada M9W 1R3.
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, A SI Standard Z87.1, from American ational Standards
Institute, 1430 Broadway, ew York, Y 10018.
&XWWLQJ $QG :HOGLQJ 3URFHVVHV
, FPA Standard 51B, from ational
Fire Protection Association, Batterymarch Park, Quincy, MA 02269.
OM-189 120 Page 4
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Considerations About Welding And The Effects Of Low Frequency
Electric And Magnetic Fields
Welding current, as it flows through welding cables, will cause electro-
magnetic fields. There has been and still is some concern about such
fields. However, after examining more than 500 studies spanning 17
years of research, a special blue ribbon committee of the ational
Research Council concluded that: “The body of evidence, in the
committee’s judgment, has not demonstrated that exposure to power-
frequency electric and magnetic fields is a human-health hazard.”
However, studies are still going forth and evidence continues to be
examined. Until the final conclusions of the research are reached, you
may wish to minimize your exposure to electromagnetic fields when
welding or cutting.
To reduce magnetic fields in the workplace, use the following
procedures:
1. Keep cables close together by twisting or taping them.
2. Arrange cables to one side and away from the operator.
3. Do not coil or drape cables around your body.
4. Keep welding power source and cables as far away from opera-
tor as practical.
5. Connect work clamp to workpiece as close to the weld as
possible.
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Pacemaker wearers consult your doctor first. If cleared by your doctor,
then following the above procedures is recommended.
OM-189 120 Page 5
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160 A @ 16.4 Volts DC,
60% Duty Cycle 5--160 90 IP22 18 17 4 33 lb
(15 kg)
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Height: 10-3/4 in (270 mm); Width: 9-1/8 in (230 mm); Length: 15-3/4 in (400 mm)
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6 Minutes Welding 4 Minutes Resting
Duty Cycle is percentage of 10
minutes that unit can weld at rated
load without overheating.
If unit overheats, thermostat(s)
opens, output stops, and cooling
fan runs. Wait fifteen minutes for
unit to cool. Reduce amperage or
duty cycle before welding.
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OM-189 120 Page 6
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Volt-ampere curve shows mini-
mum and maximum voltage and
amperage output capabilities of
unit.
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1 Rating Label
Use rating label to determine input
power needs.
2 Line Disconnect Device
Locate unit near correct input pow-
er supply.
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18 in
(460 mm)
18 in
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OM-189 120 Page 7
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And Current Control
Receptacle
OM-189 120 Page 8
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Positive
250 2 1 1/0 2/0 3/0 4/0 2-2/0 2-2/0
Weld cable size (AWG) is based on either a 4 volts or less drop or a current density of at least 300 circular mils per ampere.
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Reference: 1997 ational Electrical Code ( EC)
OM-189 120 Page 9
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1 Rating Label
Supply correct input power. See
Section 2-8.
2 Line Disconnect Device
Check input voltage available at
site.
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OM-189 120 Page 10
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1 Machine On Indicator Light
2 Welding On Indicator Light
3 Thermal Cutout Warning
Indicator Light
4 Welding Current Control
5 Down Slope And Up Slope
Time Control
6 Base Current Control
7 Post-Gas time Control
8 Pulse Frequency Control
9 HF Or Lift-Arc Selector
10 Control Panel Or Remote
Control Selector
11 Function selector
(Electrode, 2T, 4T, Spot
Welding, Repeat Cycle)
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Replace
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Labels
Replace Cracked
Torch Body
Repair Or
Replace
Cracked
Cables
Repair Or Replace
Cracked Cables
And Cords
Clean
And
Tighten
Weld
Connections
. *
Blow Out Inside
OM-189 120 Page 11
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Trouble Remedy
o weld output; unit completely inop-
erative. Be sure Power switch is On (see Section 3-1).
Be sure line disconnect switch is On (see Section 2-9).
Check line fuse(s) and replace if necessary (see Sections 2-9).
Check for proper input power connections (see Sections 2-8 and/or 2-9).
o weld output; fan motor FM running
and pilot light on. Thermostat(s) open (overheating). Allow fan to run; thermostat(s) closes when unit has cooled (see
Section 2-2).
Low weld output with no control. Check position of Amperage Control (see Section 3-1).
Have Factory Authorized Service Agent check control board PC1.
Limited output and low open-circuit
voltage. Check incoming power for correct voltage. Replace line fuse if open (see Section 2-9).
Check for proper input and output connections (see Sections 2-7 and/or 2-9).
Erratic or improper weld output. Tighten all welding cable connections (see Sections 2-7).
Check for proper size and type of cable (see Section 2-7).
Check for proper input and output connections (see Sections 2-7 and/or 2-9).
Replace electrode.
Arc not forming when using Lift-Arc. Check electrode and workpiece, clean as needed to allow good contact.
Fan motor FM does not run. Check and clear blocked fan blade; be sure blade is secure on shaft.
Have Factory Authorized Service Agent check fan motor FM.
Wandering arc; poor control of arc di-
rection. Reduce gas flow rate.
Select proper size tungsten (see Section 6-1).
Properly prepare tungsten (see Sections 6-2 and 6-3).
Tungsten electrode oxidizing and not
remaining bright after conclusion of
weld.
Shield weld zone from drafts.
Increase postflow time.
Check and tighten all gas fittings.
Water in torch. Refer to torch Owner’s Manual for part(s) requiring replacement, and repair torch as
necessary.
OM-189 120 Page 12
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.020” 5-20 * 5-20 10-20
.040” 15-80 * 10-60 20-30
1/16” 70-150 10-20 50-100 30-80
3/32” 125-225 15-30 100-160 60-130
1/8” 225-360 25-40 150-210 100-180
5/32” 360-450 40-55 200-275 160-240
3/16” 450-720 55-80 250-350 190-300
1/4” 720-950 80-125 325-450 250-400
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1/16” 50-160 10-20 50-150 60-120
3/32” 135-235 15-30 130-250 100-180
1/8” 250-400 25-40 225-360 160-250
5/32” 400-500 40-55 300-450 200-320
3/16” 500-750 55-80 400-500 290-390
1/4” 750-1000 80-125 600-800 340-525
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5/32” * * 300-450 200-320
3/16” * * 400-550 290-390
1/4” * * 600-800 340-525
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Typical argon shielding gas flow rates are 15 to 35 cfh (cubic feet per hour).
* ot Recommended.
The figures listed are intended as a guide and are a composite of recommendations from American Welding Society (AWS) and electrode
manufacturers.
OM-189 120 PAge 15
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1 Tungsten Electrode With
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2 Pointed Tungsten Electrode
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1 Tungsten Electrode
2 Tapered End
Grind end of tungsten on fine grit,
hard abrasive wheel before weld-
ing. Do not use wheel for other jobs
or tungsten can become contami-
nated causing lower weld quality.
3
Ideal Tungsten Preparation -- Stable Arc
2-1/2 Times
Electrode Diameter
12
1 Stable Arc
2 Flat
Diameter of this flat determines
amperage capacity.
3 Grinding Wheel
4 Straight Ground
3
1
2
1 Arc Wander
2 Point
3 Grinding Wheel
4 Radial Ground
2
1
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Wrong Tungsten Preparation -- Wandering Arc
4
OM-189 120 Page 16
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1 Workpiece
Make sure workpiece is clean before
welding.
2 Work Clamp
Place as close to the weld as possi-
ble.
3 Torch
4 Filler Rod (If Applicable)
5 Tungsten Electrode
Select and prepare tungsten
according to Sections 6-1, and 6-2 or
6-3.
Tungsten extension is the distance
the tungsten extends out gas cup of
torch.
Arc length is the distance from the
tungsten to the workpiece.
As a general guide, start with an
extension and arc length equal to
diameter of tungsten.
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Form pool Tilt torch Move torch to front
of pool. Repeat process.
75
G
75
G
Welding direction
Form pool Tilt torch Add filler metal
Move torch to front
of pool. Repeat process.
Remove rod
Welding direction 15
G
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