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

5
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

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Controls and settings
Fig 4
1. Up slope
Adjustment 0-5 seconds. The main welding current raises from minimum amperage to
main current selected in time selected when weld started
2. Down slope
Down-Slope adjustment 0-5 seconds. The main welding current decreases from main
amperage to minimum amperage in time selected when weld finished
3. Main current control
This adjusts the main welding current and is shown in L.E.D (Fig 4.9) when welding is
in process.
4. Pulse frequency adjustment
This sets how often pulse will occur and is adjustable from 0.5Hz to 25Hz.
5. Gas post flow adjustment
Adjustable from 1 – 10 seconds. The gas keeps flowing after weld has finished, this cools
& stops tungsten from getting contaminated. Note: Gas pre-flow time is fixed at 0.5
seconds in TIG mode but no pre-flow time will occur if the arc is restarted during post
flow time as gas is already flowing.
6. MMA-TIG mode switch.
Switches between TIG (GTAW) & MMA STICK (SMAW) welding.

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7. Pulse On/Off switch
This turns the pulse welding on and off.
8. 2/4 Way selector switch
2/4 Step trigger mode switch – tig welding can either be done in 2 or 4 step mode.
When the trigger mode is in the 2 step position the following sequence will occur
Press and hold the Tig torch switch to start sequence.
The machine will open gas valve to start flow of shield gas, after a 0.5 seconds pre-
flow time to purge air from torch hose the welding output of machine will be turned on
and the arc will be started. After the arc is started the output current will increase from
the start (min) current to base (main) current in time selected by slope-up.
Release the Tig torch switch to end sequence.
The machine will now decrease output to finish (min) current in time set by slope-down,
once at finish (min) current the machine will stop output and the gas valve will continue
to operate for the selected time (post flow)
Possible variations of this standard sequence are shown in diagram below. It is possible
to press and hold tig torch switch a second time during down slope time to restart. After
the switch is pressed the output current will raise to base (main) current
When the trigger mode is in the 4 step position the following sequence will occur

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Press and hold the tig torch switch to start sequence.
The machine will open gas valve to start flow of shield gas, after a 0.5 seconds pre-flow
time to purge air from torch hose the welding output of machine will be turned on and the
arc will be started. After the arc is started the output current will be at start (min) current
This condition can be maintained as long as required.
Release the tig torch switch to go to step 2
The machine will now increase output to base (main) current in time set by slope-up.
Press and hold the tig torch switch when main weld is complete
The machine will now decrease the welding output current to finish (min) in down-slope
time set. Once at finish (min) output you can release the Tig torch switch to end weld the
gas post-flow will continue to run for set time.
9. LED Display
3 digit LED meter is used to display the actual amperage (when welding).

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Operating machine
SAFETY PRECAUTIONS
WARNING!
ELECTRIC SHOCK CAN KILL
Do not touch electrically live parts or electrode with skin or wet clothing.
Insulate yourself from work and ground
Always wear dry insulating gloves
WARNING!
FUMES AND GASES can be dangerous
Keep your head out of fumes & gases produced from welding.
Use ventilation or exhaust to remove fumes & gases from breathing zone and general area.
WARNING!
WELDING SPARKS can cause fire or explosion
Keep flammable material away from work area.
Do not weld on containers that have held combustibles
WARNING!
ARC RAYS can burn
Wear eye, ear and body protection – Make sure work area is protected by proper shielding to
avoid injury to passers by.

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Welding in TIG mode – No Pulse
1. Connect the Tig Torch to machine, connect earth lead to machine & work piece.
2. Set the TIG/MMA switch to TIG
3. Set Pulse Switch to Off position
4. Select 2 or 4 way torch operation
5. Connect Argon gas and set flow to approx 8-12 LPM
6. Set Gas post flow to 3 x diameter of tungsten width
7. Adjust Base current to desired welding current
8. Press the Tig torch switch to start welding
Welding in TIG mode – with Pulse
1. Connect the Tig Torch to machine, connect earth lead to machine & work piece.
2. Set the TIG/MMA switch to TIG
3. Select 2 or 4 way torch operation
4. Connect Argon gas and set flow to approx 8-12 LPM
5. Set Gas post flow to 3 x diameter of tungsten width
6. Set Pulse On/Off switch to ON
7. Adjust Pulse freq. to desired setting (how often pulse happens)
8. Press the Tig torch switch to start welding
The benefits of pulse welding is the ability to control the weld pool and amount of heat absorbed by
work resulting in a smaller heat affected zone which results in fewer deformations and reduced
chance of cracking. There are no set rules for pulse welding as this is down to personal choice by
the welder.
Tig tungsten size / amperage guide
All values below are based on using pure argon shielding gas. Other current values may be
employed depending on the shielding gas and application
ELECTRODE RATINGS
Electrode Diameter (mm) 2% Thoriated on DC
(amps)
Red Tip – Grind to point
Pure Tungsten on DC
(amps)
Zirconiated 0.8% Tungsten
on AC (amps)
White Tip – No need to grind
1.0mm / 0.040” 5 - 80 30 20 - 60
1.6mm / 1/16” 40- 150 80 40 - 100
2.4 mm/ 3/32” 140 - 250 130 80 - 180
3.2mm / 1/8” 240 - 400 180 160 - 250
4.0mm / 5/32” 380- 500 240 220 - 320
4.8mm / 3/16” 500- 750 300 280 - 390
6.4mm / 1/4” 750 - 1000 400 360 - 525

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Welding in STICK MMA (SMAW) Mode
1. Fit MMA electrode holder to machine
2. Fit earth lead to machine and to work piece
3. Select MMA on MMA/TIG switch
4. Place electrode in holder
5. Select desired welding base current
6. Strike arc and weld
WARNING!
ELECTRIC SHOCK CAN KILL
When machine is switched to MMA mode, output terminals are always live, take care and do not
touch electrode and earth by person at same time, otherwise electric shock will occur.
The foot pedal has no affect on welding current in MMA mode and the gas flow and high frequency
starting circuit is disabled.

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Maintenance
Routine and periodic maintenance
WARNING!
ELECTRIC SHOCK CAN KILL
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
1. Periodically remove the side/top panels of machine and clean out machine with a low
pressure dry air line paying particular attention to PC Boards, Fan blades, HF points
2. Inspect input and output cables & hoses for fraying, cuts & bare spots
3. Keep tig torch and cables in good condition
4. Clean air vents to ensure proper air flow and cooling
5. The fan motor has sealed bearings which requires no maintenance
Troubleshooting
Service & repair should only be performed by R-Tech welding trained personnel. Un-authorised
repairs performed on this welding equipment may result in danger or injury to the technician and
machine operator and will invalidate your warranty.
For your safety and to avoid electric shock, please observe all safety notes and precautions detailed
throughout this manual
The troubleshooting guide is provided to help you locate possible machine malfunctions
If fault/problem is not listed below check our Tig Welder Support page on our website
www.r-techwelding.co.uk/support.php or contact R-Tech by phone. Contact details can
be found on front of this manual and our website

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Tig welding problems
• No output - Power light is not lit
Check machine on/off switch is in the ‘on’ position
Check Input power to machine
Check plug wiring
Check mains trip / fuses
• No output - Fan runs - Power light is lit
Check torch connections are secure and torch switch operation, try replacing tig torch.
If you have a multi-meter check continuity between pins 1 and 2 on torch switch plug when
pressing torch switch
• No output - Power light is lit - Warning light is lit
Welding application may have exceeded recommended duty cycle, allow machine to cool
down until the warning light goes out.
• No output – Power light is lit – Gas at torch end when trigger pressed
Check torch condition – possible break in torch power cable – replace torch
• Machine keeps overheating - Warning light is lit on machine
Check if fan is running – if not contact R-Tech for repair
Check the cooling vents for obstruction, blow out machine with clean dry low pressure air
supply. Check for adequate ventilation around machine
• Porosity in weld – No / low gas at torch tip
Check gas supply from gas bottle
Check flow rate on regulator
Check gas hose for restrictions
Check for draughts in local area, open doors etc
Replace TIG torch – may have gas restriction

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• Poor weld penetration
Check condition of earth lead and clamp and ensure clamp is connection via a clean area
on work piece
Check condition of TIG torch, try other TIG torch
• Machine stuck on minimum amps when welding although higher amperage has been
set
Make sure machine has not been set to 4-way operation as when in this mode when you
press torch switch you get minimum amps and when you let go of switch machine will go to
maximum amps set.
• Arc ‘Flutters’ when TIG welding
1. Tungsten electrode may be too large in diameter for the current setting.
2. Tungsten not sharp when in DC mode
3. Gas shielding flow may be low or high, check gas flow , reduce tungsten stick out
beyond ceramic
4. Check for leaks in torch & gas hoses
• Black areas along weld bead
1. Clean any oily or organic contamination from the work piece
2 Tungsten electrode contaminated. Replace or sharpen
3 Check for leaks or contamination on gas hoses & connections.
4 Gas flow may be insufficient, Increase gas flow, reduce tungsten stick out from ceramic
• Weak HF – Poor arc striking – welding output normal
1 Check torch and earth connections – is torch cable insulation in good condition.
2 Check for leaks or contamination on gas hoses & connections.
3 Gas flow may be insufficient, increase gas flow, reduce tungsten stick out from ceramic
4 Keep output cables short as possible
• HF spark is present at the tungsten electrode but unable to start welding arc,
Machine has normal welding output
1 Tungsten may be contaminated - replace or sharpen
2 The current may be set too low
3 Tungsten may be to large for process

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4 Gas flow may be insufficient, increase gas flow, reduce tungsten stick out from ceramic
• No HF when torch trigger pressed, no blue spark between HF points
Examine and clean HF points with clean dry low pressure air line
HF PCB faulty – Contact R-Tech for repair
MMA Stick welding problems
• Stick electrode ‘blasts off’ when arc is struck
Welding current set to high, reduce amperage or use thicker electrode
Contaminated electrodes or material
• Electrode sticks in weld puddle
Welding current is set too low
Arc is too short, keep electrode further away from work
• Excessive splatter
Too long an arc, keep electrode closer to work
• Poor penetration
Travel speed too fast
Too much welding current, reduce welding amperage
• Porosity in weld
Electrodes are damp
Arc too long, get electrode closer to work