SanRex SANARG 160P User manual

SanRex
SANARG
160P
DC INVERTER
ARC WELDER
Operators
Manual
Version No: C Issue Date: AUG. 21, 2019
Manual No: K00A031700

Welcome to the SanRex Family Welding
Team!
Dear Welding Professional,
We would like to take this opportunity to thank you, and congratulate you on procuring a SanRex SANARG
160P DC STICK/TIG Welding Machine.
Welding Professional, now that is a term that we do not take lightly. The welding machine that you
purchased is a full function, portable unit that was designed with the Welding Professional in mind. The unit
is suitable for use as a portable welder on the job site, to a unit utilized in an industrial manufacturing setting.
This unit will perform and is truly a welder for the Professional Welder. As you review this manual, you will
be provided with information regarding the use and functionality of the unit. What you will not see is
information or instruction on “how to weld”, as this is appropriately left to the vast array of Vocational, Trade
and other institutions that provide proper instructional education in welding.
This manual also contains sections that are dedicated solely to the safety of you and others in the work area.
It is highly recommended that this information be reviewed and that this manual be kept in a secure but
accessible location for reference of these import safety and well-being notices. Remember, the number one
requirement in performing any job is safety.
Sansha Electric of Osaka Japan and its “SanRex” brand name of products has specialized in the power supply
and power semiconductor manufacturing business for over 80 years. With over 55 years producing welding
power supplies and over 30 years producing inverter based welding and plasma cutting power supplies, you
can be assured that you have purchased one of the best welding machines on the market today.
The superior Arc Characteristics that you will experience is achieved through our dedication and commitment
to research and development as well as developing smart solutions for safe, reliable and environmentally
friendly welding machines.
We value long term relationships with our customers and strive to provide the most cost effective solutions
that support this philosophy.
We thank you for choosing SanRex equipment.
SanRex Family Welding Team

INTRODUCTION
PURPOSE OF THIS MANUAL
This manual has been prepared to present the safety, installation/operation and maintenance
instructions for the SanRex SANARG 160P, hereby referred to as 160P, a DC Stick, TIG and MIG welding
machine manufactured by the Sansha Corporation of Osaka, Japan. The manual contains the information
necessary for the Professional Welder to correctly use and operate the 160P. It is not the intent of this
manual, and does not, instruct or offer information on how to weld.
This operation manual includes an introduction followed by detailed information sections.
The information in this operating manual is generic to this model line of the welding machine and
must be supplemented with the application specific data, environment condition (location), electrical input
connections, limitations, and principal safety standards.
SECTION 1 - SAFETY REGULATIONS
AND REQUIREMENTS
This section contains the leading
particulars and descriptions of the welding
symbols, safety, warning instructions;
additional symbols for a complete
understanding and safe use of the
equipment are also included.
SECTION 2 –INTRODUCTION AND
DESCRIPTION
This section includes descriptions and
features of the product, V-A curves and the
block diagram of the product.
SECTION 3 - INSTALLATION
RECOMMENDATIONS
Describing the transportation, working
environment, electrical hook-up with
consideration for grounding and high
frequency interference. Also input power,
connections and specifications.
SECTION 4 –OPERATOR CONTROLS,
DIMENSIONS AND OUTLINE
Included in this section is a sequence of
operation, welding process selection, 160P
attributes and model features, plus torch
switch receptacle specifications.
SECTION 5 –SET-UP FOR BASIC STICK
AND TIG OPERATION.
Basic STICK and TIG set –up shown in a
simple pictorial manner.
SECTION 6 - SEQUENCE OF OPERATION
This section describes the sequence to set-
up the machine to perform STICK, TIG
and HF-TIG welding operations.
SECTION 7 –VOLTAGE REDUCTION
DEVICE (VRD)
This section includes information in the
Voltage Reduction device that is built-in
to the unit. This device lowers the Open
Circuit Voltage in STICK welding. This
function is useful in applications where a
high OCV could be dangerous. The 160P
is shipped from the factory with the VRD
in the disabled state.
SECTION 8 –TROUBLESHOOTING
This section provides information on
Power Source problems and Power Source
Error Codes.
SECTION 9 –ROUTINE MAINTENANCE
This section describes basic maintenance
for the welding power source.
SECTION 10 –PARTS LIST
This section contains the basic schematic,
exploded view and a listing of the spare
parts and order numbers.

Table of Contents
1.0 SAFETY REGULATIONS AND REQUIREMENTS............................................................. 9
1.1 NOTES, CAUTIONS AND WARNING ANNOTATIONS................................................. 9
1.2 SAFETY RECOMMENDATIONS..................................................................................... 10
1.3 WELDING SYMBOLS ....................................................................................................... 11
1.3.1 SAFETY SYMBOL LEGEND..................................................................................... 11
1.3.2 GRAPHIC SYMBOL LEGEND .................................................................................. 15
1.4 SAFETY PRECAUTIONS................................................................................................. 16
1.5 SAFE OPERATION OF THE WELDER AND PERSONAL PROTECTION................... 17
1.5.1 IMPORTANT SAFETY PRECAUTIONS.................................................................. 17
1.5.2 ELECTRIC SHOCK............................................................................................................ 18
1.5.3 GASES AND FUMES.................................................................................................. 19
1.5.4 FIRE AND EXPLOSIONS........................................................................................... 20
1.5.5 ARC WELDING RAYS, NOISE AND SPATTER OR SLAG................................... 21
1.5.6 GAS CYLINDERS....................................................................................................... 22
1.6 REFERENCE PUBLICATIONS......................................................................................... 23
2.0 INTRODUCTION AND DESCRIPTION.............................................................................. 25
2.1 GENERAL........................................................................................................................... 25
2.2 WELDING MACHINE DESCRIPTION............................................................................. 25
2.3 160P POWER SOURCE FEATURES................................................................................. 25
2.4 WELDING OUTPUT VOLTAGE AND AMPERAGE CURVES..................................... 27
2.4.1 160P V/A OUTPUT CURVES..................................................................................... 27
2.5 FUNCTIONAL BLOCK DIAGRAM.................................................................................. 28
3.0 INSTALLATION RECOMMENDATIONS.......................................................................... 29
3.1 TRANSPORTATION METHODS...................................................................................... 29
3.2 ENVIRONMENT................................................................................................................. 30
3.3 MACHINE GROUNDING & HIGH FREQUENCY INTERFERENCE ........................... 30
3.3.1 GROUNDING .............................................................................................................. 30
3.3.2 HIGH FREQUENCY INTRODUCTION .................................................................... 30
3.3.3 HIGH FREQUENCY INTERFERENCE..................................................................... 31
3.4 LOCATION ......................................................................................................................... 32
3.5 ELECTRICAL INPUT CONNECTIONS & REQUIREMENTS ....................................... 32
3.5.1 INPUT POWER............................................................................................................ 32
3.5.1.1 160P Input Power.......................................................Error! Bookmark not defined.
3.5.2 FUSING........................................................................................................................ 33
3.5.3 ELECTRICAL INPUT CONNECTIONS.................................................................... 34
3.5.3.1 160P Input Power Connections...................................................................................... 34
3.6 SPECIFICATIONS.............................................................................................................. 36
3.7 DUTY CYCLE..................................................................................................................... 37
4.0 OPERATOR CONTROLS, DIMENSIONS & OUTLINE.................................................... 39
4.1 DIMENSIONS AND OUTLINE......................................................................................... 39
4.2 OPERATOR CONTROLS, LOCATION AND FUNCTIONALITY ................................. 40
4.3 8-PIN REMOTE CONTROL RECEPTACLE .................................................................... 42
4.4 PARAMETER DISPLAY PANEL...................................................................................... 43
4.5 FUNCTION SELECTION................................................................................................... 45
4.6 PARAMETER SELECTION............................................................................................... 46
5.0 SET-UP FOR BASIC STICK (SMAW) AND TIG (GTAW) WELDING............................ 48
6.0 SEQUENCE OF OPERATION.............................................................................................. 49
6.1 STICK WELDING............................................................................................................... 50

6.1.1 STICK SEQUENCE WITH VOLTAGE REDUCTION DEVICE DISABLED......... 51
6.1.2 STICK SEQUENCE WITH VOLTAGE REDUCTION DEVICE ENABLED ......... 51
6.2 DC HF TIG & LIFT TIG WELDING.................................................................................. 52
6.3 LIFT TIG SEQUENCE........................................................................................................ 53
6.3.1 STANDARD MODE.................................................................................................... 53
6.3.2 SLOPE MODE.............................................................................................................. 53
6.3.3 REPEAT MODE........................................................................................................... 53
6.4 HF TIG SEQUENCE........................................................................................................... 54
6.4.1 STANDARD MODE.................................................................................................... 54
6.4.2 SLOPE MODE.............................................................................................................. 54
6.4.3 REPEAT MODE........................................................................................................... 54
6.4.4 SPOT MODE................................................................................................................ 55
7.0 VOLTAGE REDUCTION DEVICE (VRD).......................................................................... 56
7.1 VRD SPECIFICATIONS..................................................................................................... 56
7.2 SWITCHING VRD ON/OFF............................................................................................... 56
8.0 TROUBLE SHOOTING......................................................................................................... 59
8.1 POWER SOURCE PROBLEMS......................................................................................... 59
8.2 POWER SOURCE ERROR CODES................................................................................... 61
9.0 ROUTINE MAINTENANCE................................................................................................. 65
9.1 OPENING THE ENCLOSURE........................................................................................... 66
10.0 PARTS LIST 160P ................................................................................................................ 69
10.1 INTERCONNECT DIAGRAM 160P.............................................................................. 76
10.2 EXPLODED VIEW –COMPONENT LAYOUT 160P.................................................. 78
10.3 EXPLODED VIEW –WIRING LAYOUT 160P............................................................ 81

9
SECTION 1 –SAFETY REGULATIONS AND REQUIREMENTS
1.0 SAFETY REGULATIONS AND REQUIREMENTS
Throughout this manual, notes, cautions, danger, attention and warnings are used to highlight
important information. These highlights are categorized as follows:
1.1 NOTES, CAUTIONS AND WARNING ANNOTATIONS
NOTE: An operation, procedure, or background information which requires additional
emphasis or is helpful in efficient operation of the system.
CAUTION: A procedure which, if not properly followed, may cause damage to the equipment.
WARNING: A procedure which, if not properly followed, may cause injury to the operator or
others in the operating.
DANGER: Procedures, which if not properly followed, may lead to death or serious injury.
Please read this operating manual thoroughly before utilizing the equipment.
Wherever welding equipment is used, safety is always our concern.
PROTECT yourself and others.

10
1.2 SAFETY RECOMMENDATIONS
For the purpose of safety, it is recommended that this welding equipment be installed, maintained,
inspected, and repaired by appropriable qualified person or persons who are well familiarized
with welding equipment.
As for safety training, it is recommended to avail yourselves of various seminars and
qualifying examinations for welding engineers and welding technicians sponsored by the
Welding Society, the Welding Engineering Society, and the headquarters or branch offices
of societies or associations concerned.
For the purpose of safety, it is recommended that this welding equipment should be operated by
persons who have enough knowledge and skill to understand all safety precautions and
instructions in the Operating Manual and to be able handle the equipment safely.
After reading this Operating Manual, please store it carefully with guarantee where it will be
made accessible to all personnel dealing with the equipment
.
Please call your local distributors, business offices, or service agents if you have any
questions

11
1.3 WELDING SYMBOLS
1.3.1 SAFETY SYMBOL LEGEND
SYMBOL
SOURCE OF
HAZARD
HAZARD
HOW TO AVOID
Welding
Electrode
Electric Shock
Don’t weld on painted parts.
Remove the surface coating before
you begin welding. Keep your face
away from the welding plume.
Wiring
Electric Shock
Protect welding cables from
sparks, hot metal, open flames,
sharp edges, oil, and grease.
Do not use cables with frayed,
cracked or bare spots in the
insulation. Learn all you can
about safety. Your employer
must provide safety training.
Welding Arc
Arc Rays
Required protection varies with time
of exposure, distance from source,
and shielding used.
Follow recommended procedures in
AWS F2.1.
Engine Fuel
Fire
Develop adequate procedures, and
use proper equipment to do the job
safely.
When required obtain a Hot-Work
Permit (See NFPA 51B).
If relocation is not possible, protect
combustibles with fire resistant
covers.
Welding Fumes
and Gases
Fumes and Gases
Keep your head out of the fumes.
Do not breathe the fumes. Use
enough ventilation or exhaust at the
arc, or both, to keep fumes and
gases from your breathing zone and
general area.
Welding
Electrode and
Wiring
Electric Shock
Read all instructions, labels, and
installation manuals before
installing, operating, or servicing the
equipment.
Train all personnel involved in
welding operations to observe safe
electrical work practices according
to OSHA 1910.332.
Do not touch live electrical parts.

12
SYMBOL
SOURCE OF HAZARD
HAZARD
HOW TO AVOID
Chromium and Nickel
Fumes
Welding Fumes
Do not breathe fumes and gases.
Keep your head out of the fumes.
Use enough ventilation or exhaust
at the arc or both to keep fumes
and gases from your breathing
zone and general area.
Hazard Distances
Ultraviolet Radiation
Maintain proper distances from
the arc ray.
Review the “Safety and Health
Fact Sheet No. 26” from the
AWS for recommendations.
Falling Objects
Falling Objects
Be certain that material being
welded or cut is secured from
falling.
Do not permit loose objects near
the edge of overhead structures.
Confined Space
Fire, Exposure to
Hazardous Air
Contaminants
Determine if special training or a
permit is required to enter the
space.
Open all covers and secure them
from closing.
Test atmosphere for:
(1) suitable oxygen content
(2) combustibles or reactives
(3) toxics
Sparks, Radiation,
Hot Metal,
Slag, Heat
Electrical, Thermal
Wear a helmet with filter lens and
cover plate that complies with ANSI
Z87.1 for protection from radiant
energy, flying sparks, and spatter.
According to ANSI Z49.1 and OSHA
29 CFR 1910.252, "Helmets and
hand shields shall protect the face,
forehead, neck, and ears PPE.
Hot Metal, Slag, Arc
Rays, Hot Work Piece
Thermal
Use approved helmets or hand
shields that provide protection for
the face, neck, and ears, and wear
a head covering.
Wear approved safety goggles or
safety glasses with side shields,
even under your helmet.
Wear dry, hole-free insulating
gloves.

13
SYMBOL
SOURCE OF HAZARD
HAZARD
HOW TO AVOID
Optical Radiation and Arc
Heat
Thermal
Establish a written policy
documenting general safety
requirements for the wearing of
contact lenses. Conduct an eye
hazard evaluation in the
Workplace.
Cuts, Scrapes, Heat,
Flames, Molten Metal,
Wet Gloves, Insulation
Failure
Mechanical,
Thermal,
Electrical
Gloves should be:
Dry and moisture resistant.
In good condition, no holes or
tears.
Flame resistant.
Electrically and thermally insulated
to suit the process.
Coating of Steel
Fumes and
Gases
Obtain the Material Safety Data
Sheets (MSDSs) for all materials
used. Read and understand the
specification for coating type and
coating weights. Find out what
hazardous materials are present or
might be given off by the coating
when it is exposed to the arc of
high temperatures.
Reactive Force from Tools,
Tool Jammed or Coming
Loose
Mechanical
Wear proper head, eye and hand
protection.
Use face shields, safety glasses, and
goggles as appropriate.
Inspect tools before use.
Never use a tool that is in poor or
faulty condition.
Keep all tools in good condition.
Engine-Driven Generators,
power source Equipment
Health Hazard
Reduce the intensity of the source.
Shield the source where practical.
Use engineering control methods,
such as room acoustics, to control
noise.
Place Body Between
Welding Electrode and
Work Cables
Electric &
Magnetic Fields
Do not place your body between
the welding electrode and work
cables. Route cables on the same
side of your body.
Route the welding cables close
together. Secure them together
with tape or cable ties.

14
SYMBOL
SOURCE OF HAZARD
HAZARD
HOW TO AVOID
Any Coatings on Base
Metal, Weld Process
Fumes and
Gases
Keep your head out of the fumes.
Do not breathe the fumes.
Use enough ventilation or exhaust
at the arc, or both, to keep fumes
and gases from your breathing
zone and general area.
Welding & Cutting
Toxic Fumes,
Electric Shock
Be alert, aware, and focused on the
job and the work area; notice any
changing conditions.
Wear and use only the correct,
approved equipment for the
specific job; be sure it is properly
installed and used.
Welding or its Allied
Processes
Pneumatic,
Electrical,
Gases,
Liquid
Employers must develop a written
lockout/tagout program and
procedure.
Employees must be trained in
these procedures, as well as the
purpose and methods of
lockout/tagout.

15
1.3.2 GRAPHIC SYMBOL LEGEND

16
1.4 SAFETY PRECAUTIONS
ATTENTION
FOR PROPER USE, PLEASE READ THIS
OPERATING MANUAL THOROUGHLY
PRIOR TO UTILIZING THE WELDING
MACHINE.
The safety precautions described in this
Operating Manual will give you the information
necessary for you to handle the equipment safely
and prevent any hazard or damage to you or
others.
Although this welding equipment is
designed and manufactured taking into account
all possible scenarios, be sure to observe the
safety precautions in this Operating Manual when
operating this welding equipment. Not doing so
may cause harm to the operator or others,
resulting in death or serious injury.
Improper use of the equipment may cause
various levels of damage. In this Operating
Manual, such damages are classified into two
ranks by combination of attention attracting
symbols and signal for the purpose of warning
indications. These attention attracting symbols
and signal terms have the same meanings as those
for warning labels on the equipment.
CAUTION
PROCEDURES, IF NOT PROPERLY
FOLLOWED, MAY CAUSE A RISK TO
OPERATORS RESULTING IN MEDIUM OR
SLIGHT INJURY AND/ OR DAMAGE
Serious or light injury includes loss of
sight, (high temperature and/or low temperature)
burns, electric shock, bone fracture, and
poisoning which may lead to hospitalization or
long-term hospital stay for treatment. Further,
medium and slight injury includes burns, and
electric shock, which do not require
hospitalization or long-term visit to hospital stays
for treatment. Damage to objects denotes
widespread damage to property or equipment.
DANGER
PROCEDURES NOT PROPERLY
FOLLOWED, MAY LEAD TO DEATH OR
SERIOUS INJURY.

17
1.5 SAFE OPERATION OF THE WELDER AND PERSONAL PROTECTION
1.5.1 IMPORTANT SAFETY PRECAUTIONS
To prevent serious injury to the operator or others, be sure to observe the following:
Never allow any unqualified
person to enter the surrounding
area of this welding equipment or
the welding area inadvertently.
Perform any work of power source
on the input side, select any
location, handle and store and pipe
high pressure gases, store work
pieces welded, and treat wastes in
accordance with legislations
and/or regulations, and your
company’s standards.
Although this welding equipment
is designed and manufactured
taking into account safety
adequately be sure to observe
safety precautions in this
Operating Manual when operating
this welding equipment.
Not doing so may cause fatal injury
to the operator or others, resulting
in death or serious injury.
Perform any work of power source
on the input side, select any
location, handle and store and pipe
high pressure gases, store work
pieces welded, and treat wastes in
accordance with legislations
and/or regulations, and your
company’s standard.
Those who use heart pacemakers
should not enter the surrounding
area of this welding equipment in
operation or the welding area
without permission of the doctor.
Welding equipment during
energizing produces a magnetic
field in the surrounding area which
adversely affects the operation of
such pacemakers
For the purpose of safety, it is
recommended that this welding
equipment should be installed,
maintained, inspected, and
repaired by appropriately qualified
personnel or persons who are well
familiarized with welding
equipment
For the purpose of safety, it is
recommended that this welding
equipment should be operated by
persons who have enough
knowledge and skill to understand
all safety precautions and
instructions in the Operating
Manual and to handle the
equipment safely.
Do not use this welding equipment
for applications other than
welding.

18
1.5.2 ELECTRIC SHOCK
To prevent electric shock, be sure to observe the following precaution:
Touching any parts that are
electrically “live” or “hot” may
cause fatal electric shock or burns.
Have a qualified electrician
connect the Welding Power
Source. Check the enclosure, base
metal and jig that they are
electrically connected in ordnance
with local regulations. (Electrical
Facilities Technical Standards)
Before installing, maintaining, or
inspecting this welding equipment,
leave the equipment for over 5
minutes after turning off power
supply at the distribution panel
switch.
Capacitors built-in may be
electrically charged even after the
power has been switched off.
Before performing works, make
sure that no charging voltage
should be applied to such parts.
Do not use cables which have
insufficient capacity, are damaged,
or in which any conductor is
exposed.
Tighten cable connections securely
and insulate properly.
Tighten cable connections securely
and insulate it.
Do not operate with welding
equipment with its cover or
enclosure loose or removed
Do not wear damaged, torn or wet
gloves. Always wear dry insulated
gloves
Use a lifeline harness when
performing works at any high
elevations.
Carry out maintenance and
inspection periodically and use it
after the repair of any and all
damaged parts.
Turn off both the Mains ON/OFF
switch on equipment and the
distribution panel switch when not
in use.

19
1.5.3 GASES AND FUMES
To protect you and others from fumes and gases produced during the welding processes, use
safeguards.
Inhalation of gases and fumes
produced during the welding
processes can be dangerous and
hazardous to your health.
Welding in confined spaces may
cause oxygen deficiency, resulting
in suffocation.
Never perform the welding work in
the vicinity of degreasing,
washing, and spraying operations.
Doing so may cause harmful gases
To prevent gas poisoning or
suffocation, use local ventilating
facilities set forth in legislations or
Regulations (Industrial Safety and
Health Law and Ordinance on
Prevention of Hazards Due to
Dusts and/or Fumes) or wear a
respirator.
When welding in confined spaces,
ensure that the welding area is
adequately ventilated, wear the
respirator, and perform the
welding work under
When welding a coated steel plate,
ensure that the welding area is
adequately ventilated or wear the
respirator. Welding the coated
steel plate may produce harmful
fumes or gases.

20
1.5.4 FIRE AND EXPLOSIONS
To prevent fire, explosion, or rupture, be sure to observe the following precautions.
Spatter or hot base metals produced
during and immediately after the
welding processes may cause fire.
Poor connections of cables or
defective contacts in any current
path on the base metal such as steel
frame may cause overheating due
to conducting current, resulting in
fire.
Explosion can be caused by the
welding arc produced on containers
that may have held combustibles
such as gasoline.
Rupture can be caused by welding
enclosed tanks or pipes.
Keep combustibles away from
scattered spatter. Cover
combustibles that cannot be
removed with incombustible
shields.
Do not weld in the vicinity of
flammable gases.
Keep hot base metals immediately
after the welding processes away
from combustibles.
When welding ceiling, floor or
wall, remove combustibles hidden
adjacent to them.
Tighten cable connections
securely and insulate them.
Connect work lead so that it is
positioned as close to the part
welded as possible.
Do not weld a gas pipe that may
have held any gas or an enclosed
tank or pipe
Have a fire extinguisher handy in
the vicinity of the welding area in
preparation for emergency.