Thermal Arc 160 TS ARCMASTER User manual

50
60Hz
1
PHASE
SMAW
GTAW
INVERTER
DC CC
115
V
230
V
160 TS
ARCMASTER®
INVERTER ARC WELDER
Service Manual
Revision: AB Issue Date: June 16, 2006 Manual No: 0-4881B
Operating Features:

WE APPRECIATE YOUR BUSINESS!
Congratulations on your new Thermal Arc®product. We are proud to
have you as our customer and will strive to provide you with the best
service and reliability in the industry. This product is backed by our
extensive warranty and world-wide service network. To locate your
nearest distributor or service agency call 800-752-7621, or visit us
on the web at www.thermalarc.com.
This Operating Manual has been designed to instruct you on the correct
use and operation of your Thermal Arc®product. Your satisfaction with
this product and its safe operation is our ultimate concern. Therefore,
please take the time to read the entire manual, especially the Safety
Precautions. They will help you to avoid potential hazards that may
exist when working with this product.
YOU ARE IN GOOD COMPANY!
The Brand of Choice for Contractors and Fabricators Worldwide.
Thermal Arc®is a Global Brand of Arc Welding Products for Thermadyne
Industries Inc. We manufacture and supply to major welding industry
sectors worldwide including; Manufacturing, Construction, Mining,
Automotive, Aerospace, Engineering, Rural and DIY/Hobbyist.
We distinguish ourselves from our competition through market-
leading, dependable products that have stood the test of time. We
pride ourselves on technical innovation, competitive prices, excellent
delivery, superior customer service and technical support, together
with excellence in sales and marketing expertise.
Above all, we are committed to develop technologically advanced
products to achieve a safer working environment within the welding
industry.

i
!
WARNINGS
Read and understand this entire Manual and your employer’s safety practices before installing, operating,
or servicing the equipment.
While the information contained in this Manual represents the Manufacturer’s best judgment, the
Manufacturer assumes no liability for its use.
Service Manual Number 0-4881B for:
ArcMaster 160 TS Inverter Welding Power SupplyPart No. 10-3067
Published by:
Thermadyne Industries, Inc.
82 Benning Street
West Lebanon, New Hampshire, USA 03784
[phone]
www.thermalarc.com
Copyright © 2006, 2007, 2008 by
Thermadyne Industries, Inc.
® All rights reserved.
Reproduction of this work, in whole or in part, without written permission of the publisher
is prohibited.
The publisher does not assume and hereby disclaims any liability to any party for any loss
or damage caused by any error or omission in this Manual, whether such error results
from negligence, accident, or any other cause.
Publication Date: June 16, 2006
Revision AB Date: June 5, 2008
Record the following information for Warranty purposes:
Where Purchased: _______________________________
Purchase Date: _______________________________
Equipment Serial #: _______________________________

1
CONTENTS
SECTION 1: SAFETY INSTRUCTIONS AND WARNINGS....................................................................................................3
1.01 Arc Welding Hazards ...........................................................................................................................................3
1.02 PRINCIPAL SAFETY STANDARDS .......................................................................................................................7
1.03 PRECAUTIONS DE SECURITE EN SOUNDAGE A L’ARC.......................................................................................8
1.04 Dangers relatifs au soudage à l’arc......................................................................................................................8
1.05 PRINCIPAL SAFETY STANDARDS .....................................................................................................................12
SECTION 2: INTRODUCTION ..........................................................................................................................................13
2.01 How To Use This Manual....................................................................................................................................13
2.02 Equipment Identification.....................................................................................................................................13
2.04 Symbol Chart......................................................................................................................................................14
2.05 Description.........................................................................................................................................................15
2.06 Functional Block Diagrams .................................................................................................................................16
2.07 Transporting Methods ........................................................................................................................................16
SECTION 3: INSTALLATION ..........................................................................................................................................17
3.01 Environment .......................................................................................................................................................17
3.02 Location .............................................................................................................................................................17
3.03 Electrical Input Connections ...............................................................................................................................17
3.04 Electrical Input Requirement...............................................................................................................................18
3.05 Input Power........................................................................................................................................................19
3.06 High Frequency Introduction ..............................................................................................................................19
3.07 High Frequency Interference...............................................................................................................................20
3.08 Duty Cycle ..........................................................................................................................................................20
3.09 Specifications .....................................................................................................................................................21
SECTION 4: OPERATOR CONTROLS .............................................................................................................................23
4.01 ARC MASTER 160TS Controls............................................................................................................................23
4.02 Weld Process selection for 160TS......................................................................................................................25
4.03 Weld Parameter Descriptions for ARC MASTER 160TS......................................................................................26
4.04 Weld Parameters for ARC MASTER 160TS.........................................................................................................29
4.05 Power Source Features.......................................................................................................................................30
SECTION 5: SET-UP FOR SMAW (STICK) AND GTAW (TIG)..........................................................................................31
SECTION 6: SEQUENCE OF OPERATION........................................................................................................................32
6.01 Stick Welding .....................................................................................................................................................33
6.02 HF TIG & Lift TIG Welding ..................................................................................................................................33
6.03 Slope Mode Sequence ........................................................................................................................................34
6.04 Slope Mode with repeat sequence ......................................................................................................................34
6.05 Pulse Controls ....................................................................................................................................................35
SECTION 7: ROUTINE MAINTENANCE...........................................................................................................................36
SECTION 8: BASIC TROUBLESHOOTING.......................................................................................................................38
8.01 TIG Welding Problems........................................................................................................................................38
8.02 Stick Welding Problems .....................................................................................................................................41
8.03 Power Source Problems.....................................................................................................................................44
SECTION 9: VOLTAGE REDUCTION DEVICE (VRD)..........................................................................................46
9.01 VRD Specification...............................................................................................................................................46
9.02 VRD Maintenance...............................................................................................................................................46
9.03 Switching VRD On/Off ........................................................................................................................................49
SECTION 10: POWER SOURCE ERROR CODE .....................................................................................................50

2
CONTENTS
SECTION 11: ADVANCED TROUBLE SHOOTING............................................................................................... 52
11.01 System-Level Fault Isolation ............................................................................................................................ 52
1. Opening the Enclosure ....................................................................................................................................... 53
11.02 Verification and Remedy to the Indicated Error Codes ..................................................................................... 56
1. E01 “Over-Temperature at the primary side”...................................................................................................... 57
2. E02 “Over-Temperature at the secondary side”.................................................................................................. 57
3. E03 “Primary Over-Current Failure” .................................................................................................................. 58
4. E94 “Thermistor malfunction”............................................................................................................................ 58
5. E99 “Initial Power Receiving”............................................................................................................................. 58
11.03 Verification and Remedy to Failures without Indication Codes .........................................................................59
1. “Cooling Fan (FAN1) Failure” (Fan is not rotating.).............................................................................................59
2. “Gas Valve Failure” (No Gas flow through unit)..................................................................................................59
3. “No Weld Output” .............................................................................................................................................. 60
4. “Operating Panel Failure” (LED’s do not light properly or welding setting cannot be established.)..................... 61
5. “High Frequency Output Failure” (Unit does not generate High Frequency.)....................................................... 61
11.04 Fault Isolation Tests ......................................................................................................................................... 62
11.05 Verification of the Power Input Circuitry........................................................................................................... 63
1. Verification of the AC input voltage using an AC voltmeter................................................................................. 63
2. Verification of the Power Supply Voltage ........................................................................................................... 65
3. Verification of the Cooling Fan, FAN1, Drive Circuitry......................................................................................... 67
4. Verification of the Gas Valve, SOL1, Drive Circuitry............................................................................................ 68
5. Verification of the primary Diode (D1)................................................................................................................69
6. Verification of the secondary Diode (D2, D3) ..................................................................................................... 70
7. Verification of the primary IGBT (Q1A-Q4C)....................................................................................................... 71
8. Verification of No-load Voltage (OCV) ................................................................................................................ 72
9. Output Load Test ............................................................................................................................................... 73
SECTION 12: MAINTENANCE ................................................................................................................................ 74
12.01 Maintenance List.............................................................................................................................................. 74
12.02 Service Tools ................................................................................................................................................... 77
12.03 Replacement Procedure................................................................................................................................... 78
1. PCB1 (WK-5466) and Primary Diode D1............................................................................................................ 78
2. PCB2 (WK-5467), Capacitor C1 and Resistor R1 ............................................................................................... 81
3. PCB3 (WK-5609) and T1 “Transformer” ............................................................................................................ 82
4. PCB4 (WK-5449) ............................................................................................................................................... 83
5. PCB5 (WK-5448) ............................................................................................................................................... 84
6. PCB6 (WK-5460) and Q1A-Q2C “Primary IGBT”................................................................................................ 85
7. PCB7 (WK-5460) and Q3A-Q4C “Primary IGBT”................................................................................................ 86
8. D2 and D3 “Secondary Diode” ........................................................................................................................... 86
9. C.C. “Coupling Coil”* and FCH1 “Reactor” *160TS only................................................................................... 87
10. CT1 “Hole Current Trans”................................................................................................................................. 88
11. FAN1 “Cooling Fan” .........................................................................................................................................89
12. HF UNIT1 “High Frequency Unit” *160TS only................................................................................................ 90
13. SOL1 “Solenoid GAS Valve” *160TS only ....................................................................................................... 90
14. S1 “Switch” ..................................................................................................................................................... 91
15. CON1 “Remote Receptacle” ............................................................................................................................. 92
16. TH1 “Primary Thermistor” ............................................................................................................................... 93
17. TH2 “Secondary Thermistor” ........................................................................................................................... 93
APPENDIX A: PARTS LIST....................................................................................................................................... 95
APPENDIX B: CONNECTION WIRING GUIDE.................................................................................................... 100
1. Connection Guide................................................................................................................................................. 100
2. Connection Wire List............................................................................................................................................ 101
APPENDIX C: CONNECTION DIAGRAM............................................................................................................. 103
APPENDIX D: DIODE TESTING BASICS............................................................................................................... 105

ARCMASTER 160TS
3
SECTION 1:
SAFETY INSTRUCTIONS AND WARNINGS
WARNING
PROTECT YOURSELF AND OTHERS FROM POSSIBLE SERIOUS INJURY OR DEATH. KEEP CHILDREN AWAY.
PACEMAKER WEARERS KEEP AWAY UNTIL CONSULTING YOUR DOCTOR. DO NOT LOSE THESE INSTRUCTIONS. READ
OPERATING / INSTRUCTION MANUAL BEFORE INSTALLING, OPERATING OR SERVICING THIS EQUIPMENT.
Welding products and welding processes can cause serious injury or death, or damage to other equipment or property, if
the operator does not strictly observe all safety rules and take precautionary actions.
Safe practices have developed from past experience in the use of welding and cutting. These practices must be learned
through study and training before using this equipment. Some of these practices apply to equipment.
CONNECTED TO POWER LINES; other practices apply to engine driven equipment. Anyone not having extensive training in
welding and cutting practices should not attempt to weld.
Safe practices are outline in the American National Standard Z49.1 entitled: SAFETY IN WELDING AND CUTTING. This
publication and other guides to what you should learn before operating this equipment are listed at the end of these safety
precautions. HAVE ALL INSTALLATION, OPERATION, MAINTENANCE, AND REPAIR WORK PERFORMED ONLY BY
QUALIFIED PEOPLE.
1.01 Arc Welding Hazards
WARNING
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 equipment 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. Lock input
power disconnect switch open, or remove line fuses
so power cannot be turned on accidentally.
5. Properly install and ground this equipment according
to its Owner’s Manual and national, state, and local
codes.
6. Turn off all equipment when not in use. Disconnect
power to equipment if it will be left unattended or out
of service.
7. Use fully insulated electrode holders. Never dip holder
in water to cool it or lay it down on the ground or the
work surface. Do not touch holders connected to two
welding machines at the same time or touch other
people with the holder or electrode.
8. Do not use worn, damaged, undersize, or poorly
spliced cables.
9. Do not wrap cables around your body.
10. Ground the workpiece to a good electrical (earth)
ground.
11. Do not touch electrode while in contact with the work
(ground) circuit.
12. Use only well-maintained equipment. Repair or
replace damaged parts at once.
13. In confined spaces or damp locations, do not use a
welder with AC output unless it is equipped with a
voltage reducer. Use equipment with DC output.

ARCMASTER 160TS
4
14. Wear a safety harness to prevent falling if working
above fool level.
15. Keep all panels and covers securely in place.
WARNING
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 eyes and skin.
Noise from some processes can damage hearing.
1. Wear a welding helmet fitted with a proper shade of
filter (see ANSI Z49.1 listed in Safety Standards) to
protect your face and eyes when welding or watching.
2. Wear approved safety glasses. Side shields
recommended.
3. Use protective screens or barriers to protect others
from flash and flare; warn others not to watch the arc.
4. Wear protective clothing made from durable, flame-
resistant material (wool and lather) and foot
protection.
5. Use approved ear plugs or ear muffs if noise level is
high.
WARNING
FUMES AND GASES can be hazardous 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 metals,
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.
Eye protection filter shade selector for welding or cutting
(goggles or helmet), from AWS A6.2-73.
Welding or cutting Electrode Size Filter Welding or cutting Electrode Size Filter
Torch soldering 2 Gas metal-arc
Torch brazing 3 or 4 Non-ferrous base metal All 11
Oxygen Cutting Ferrous base metal All 12
Light Under 1 in., 25mm 3 or 4 Gas tungsten arc welding All 12
Medium 1 to 6 in., 25-150mm 4 or 5 (TIG) All 12
Heavy Over 6 in., 150mm 5 or 6 Atomic hydrogen welding All 12
Gas welding Carbon arc welding All 12
Light Under 1/8 in., 3mm 4 or 5 Plasma arc welding
Medium 1/8 to 1/2 in., 3-12mm 5 or 6 Carbon arc air gouging
Heavy Over 1/2 in., 12mm 6 or 8 Light 12
Shielded metal-arc Under 5/32 in., 4mm 10 Heavy 14
5/32 to 1/4 in., 12 Plasma arc cutting
Over 1/4 in., 6.4mm 14 Light Under 300 Amp 9
Medium 300 to 400 Amp 12
Heavy Over 400 Amp 14

ARCMASTER 160TS
5
6. Do not weld in locations near degreasing, cleaning, or
spraying operations. The heat and rays of the arc can
react with vapors to from 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.
WARNING
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. Accidental 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 35 ft (10.7m) 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 such as tanks or
drums.
8. 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.
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.
WARNING
FLYING SPARKS AND HOT METAL can cause injury.
Chipping and grinding cause flying metal. As weld
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.
WARNING
CYLINDERS can explode if damaged.
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.
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. Read and follow instructions on compressed gas
cylinders, associated equipment, and CGA publication
P-1 listed Safety Standards.

ARCMASTER 160TS
6
WARNING
Engines can be dangerous.
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.
WARNING
ENGINE FUEL can cause fire or explosion.
Engine fuse 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
stating engine.
WARNING
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 starting 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.
WARNING
SPARKS can cause BATTERY GASES TO EXPLODE;
BATTERY ACID can burn eyes and skin.
Batteries contain acid and generate explosive gases.
1. Always ware 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.
WARNING
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.