Rtech TIG160PDC User manual

www.r-techwelding.co.uk
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TIG160PDC DC TIG WELDER
OPERATION INSTRUCTIONS
Version 2014-1

2

Thank you for selecting the R-Tech Tig160PDC Inverter DC Tig Welder.
The Tig160PDC has many benefits over traditional TIG welders, including pulse welding,
slope up/down and an industrial 35% duty cycle.
We want you to take pride in operating our Tig160PDC as much pride as we have taken in
making this product for you.
PLEASE EXAMINE THE 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 the data plate at rear of machine.
Product: TIG160PDC
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 a 2 year parts and labour warranty; we will cover cost of collecting,
repair and returning the item to you to for UK mainland (other areas are RTB). External items,
(torch, earth lead etc…) are covered by a 3 month warranty. Any faults/damage found caused
by a customer will be charged accordingly.
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.

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Introduction
The R-Tech Tig160PDC is a member of our field acclaimed family of welding products.
Premium features include:-
1. Inverter power source – more efficient to operate, provides smoother weld characteristics.
2. Pulse welding in DC Tig welding mode
3. HF Arc start – Easy arc striking and prolonged tungsten life
4. Slope up / slope down
5. Digital amp meter
6. Industrial 35% Duty cycle at 160 Amps @ 40C
Recommended Processes
The R-Tech Tig160PDC is recommended for the Tig welding processes within its output capacity of
160 Amps
Equipment Limitations
The R-Tech Tig160PDC is protected from overloads beyond the output ratings and duty cycle as
per machine specifications with thermostat protection of the output coils and rectifiers.
Welding Capability – Duty Cycle
The R-Tech Tig160PDC is rated at 160 Amps at 35% duty cycle on a ten minute basis. If the duty
cycle is exceeded a thermal protector will shut machine off until the machine cools.
Technical Specifications
Model No.
R-Tech TIG160PDC
Input
240V AC 50/60Hz
Fuse Slow-blow 13Amp
MMA
No-load Voltage
60V – 80V
Current Range
5A – 125A
Rated Output Current
125A
Duty Cycle
35%
DC TIG
No-load Voltage
60V – 80V
Current Range
5A – 160A
Rated Output Current
160A
Duty Cycle
35%
Up-Slope Time
5 Seconds
Down-Slope Time
5 Seconds
Pulse Frequency Range
0.5Hz – 25Hz
Gas Post Flow Time
1 – 10 Seconds
Arc Starting Mode
High Frequency
Gross Weight
12 KG
Insulation
IP21S
Dimensions mm
425 x 195 x 310

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Safety Precautions
Read entire section before starting installation
WARNING!
Electric Shock can kill – Only qualified personnel should perform this installation. Turn off input
power at the fuse box before working on this equipment. Do not touch electrically live parts. Always
connect the machine to an earthed mains supply as per national recommended standards.
Select suitable location
Place the welder where clean cooling air can freely circulate in and out of the front & rear louver
vents. Dirt, dust or any foreign material that can be drawn through vents into welder must be kept to
a minimum. Failure to observe these precautions can result in excessive operating temperatures
which can lead to plant failure.
Grinding
Do not direct grinding particles towards the welder. An abundance of conductive material can cause
plant failure.
Stacking
This machine cannot be stacked.
Transport – Unloading
Never underestimate the weight of equipment, never move or leave suspended in the air above
people. Use recommended lifting equipment at all times.
WARNING!
Falling Equipment can cause injury. Never lift welder with gas bottle attached. Never lift above
personnel.
Tilting
Machine must be placed on a secure level surface or on a recommended undercarriage/trolley.
This machine may topple over if this procedure is not followed.
Environmental Rating
The welding power source carries the IP21S rating. It may be used in normal industrial and
commercial environments. Avoid using in areas where water / rain is around.
Read and follow the ‘Electric Shock Warnings’ in the safety section if welding must be performed
under electrically hazardous conditions such as welding in wet areas or water on the work piece.

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Electrical Installation
WARNING!
ELECTRIC SHOCK CAN KILL
Machine grounding and High Frequency Interference Protection
This welder must be grounded to earth. See national electrical codes fro proper grounding
methods.
The high frequency generator being similar to a radio transmitter may cause interference to radio,
TV and other electronic equipment. These problems may be the result of radiated interference.
Proper grounding methods can reduce or eliminate this.
Radiated interference can develop in the following ways
1. Direct interference from welder power source
2. Direct interference from the welding leads
3. Direct interference radiated from feedback into power lines
4. Interference from re-radiation by un-grounded metallic objects.
Keeping these contributing factors in mind, installing equipment as per following instructions should
minimize problems.
1. Keep the welder input power lines as short as possible and enclose as much of them as
possible in metal conduit or equivalent shielding. There should be a good electrical contact
between this conduit and ground (Earth).
2. Keep the work and electrode leads as short as possible. Tape the leads together where
practical.
3. Be sure the torch and earth leads rubber coverings are free from cuts and cracks that allow
welding power leakage
4. Keep earth lead connection to work in good condition – Clean area on workbench where
earth clamp is situated on a regular basis.

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Input Connections
Make sure the voltage, phase and frequency of input power is as specified on machine rating plate
located at rear of machine.
Have a qualified electrician provide suitable input power as per national electrical codes. Make sure
machine is earthed / grounded.
Make sure fuse or circuit breaker is correct rating for machine. Using fuses or circuit breakers
smaller than recommended will result in ‘nuisance’ shut off from welder inrush currents even if
welding at low amperages.
Failure to follow these instructions can cause immediate failure within the welder and void
machines warranty.
Turn the input power OFF at the mains switch & fuse box before working on this equipment.
Have a qualified electrician install & service this equipment.
Allow machine to sit for 5 minutes minimum to allow the power capacitors to discharge before
working inside this equipment. Do not touch electrically live parts
The TIG160PDC Inverter Tig Welder requires a 240V 50/60Hz 13amp fused supply. It comes with a
2 metre mains cable attached.
Connect wires according to national coding.
Brown wire – Live
Blue wire – Neutral
Green/Yellow Wire – Earth (Ground)
Connecting to an Engine Driven Generator
If connecting this machine to an engine driven generator please ensure the
following
Minimum Generator KVA Output – 5 KVA continuous
Generator to be fitted with AVR (automatic voltage regulation)
DO NOT USE ON A GENERATOR WITHOUT AVR
Connecting to a generator without the above minimum requirements will in-
validate your warranty.

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Connections for Tig160PDC
Rear machine connections
Fig 1
1. Mains input cable
Fit required plug as per your electrical installation
2. On/Off Switch
3. Gas input connector
Connect input gas hose ensuring connection is tight
4. Earth for chassis
If experiencing localized interference when using machine, connect workbench to this point
using correct graded earth wire (not normally used)

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Connections for TIG (GTAW) Welding
Fig 2
1. Negative power connector -
Connect Tig Torch Dinze to power connector by inserting and twisting until tight
2. Gas outlet
Connect the torch gas hose
3. Positive power connector +
Connect the earth lead to by inserting and twisting until tight and the earth clamp to
work/bench
4. Torch control socket 2-Pin
Connect torch control plug
To avoid a High Frequency shock keep the Tig torch in good condition and replace if any of the
insulation is damaged.
Connect the gas input hose to gas regulator and use ‘Pure Argon’ Gas, available from local
suppliers. Set gas flow/pressure to 8-12 LPM.
Make sure gas bottle is secured to avoid injury.

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Connections for STICK MMA (SMAW) Welding
Fig 3
1. Negative power connector -
Connect the earth lead to by inserting and twisting until tight and the earth clamp to
work/bench.
2. Gas Outlet – NOT used in MMA mode
3. Positive power connector +
Connect the electrode holder by inserting and twisting until tight
4. Torch switch plug – Not used in MMA mode