Firepower TIG 160S, Service Manual

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TABLE OF CONTENTS
SECTION 1:
SAFETY INSTRUCTIONS AND WARNINGS ....................................................... 1-1
1.01 Arc Welding Hazards ....................................................................................... 1-1
1.02 General Safety Information for Firepower CS Regulator ................................. 1-4
1.03 Principal Safety Standards .............................................................................. 1-5
1.04 Symbol Chart .................................................................................................. 1-6
1.05 Servicing Hazards ........................................................................................... 1-7
1.06 EMF Information ............................................................................................. 1-8
SECTION 2: INTRODUCTION ............................................................................. 2-1
2.01 How to Use This Manual ................................................................................. 2-1
2.02 Equipment Identification ................................................................................. 2-1
2.03 Receipt of Equipment ...................................................................................... 2-1
2.04 Description ..................................................................................................... 2-1
2.05
Transportation Methods .................................................................................. 2-1
SECTION 3:
SAFETY AND INSTALLATION ....................................................................... 3-1
3.01 Duty Cycle ....................................................................................................... 3-1
3.02 Specifications ................................................................................................. 3-3
3.03 Environment ................................................................................................... 3-5
3.04 Location .......................................................................................................... 3-5
3.05
Electrical Input Connections ........................................................................... 3-6
3.06 Electromagnetic Compatibility ........................................................................ 3-8
3.07 Volt-Ampere Curves ...................................................................................... 3-10
SECTION 4:
OPERATION ........................................................................................... 4-1
4.01 Front Panel ..................................................................................................... 4-1
4.02 Setup for Welding ........................................................................................... 4-2
4.03 Welding Current Control Explanation (US Version) ......................................... 4-2
4.04 Welding Current Control Explanation (UK Version) ......................................... 4-4
4.05 STICK (SMAW) Setup ..................................................................................... 4-5
4.06 LIFT TIG (GTAW) Setup................................................................................... 4-6
4.07 Firepower Regulator (US Version Only) .......................................................... 4-7
4.08 Leak Testing the System ................................................................................. 4-8
4.09 Lift Start TIG with the Firepower 160S ............................................................ 4-8
SECTION 5:
THEORY OF OPERATION ............................................................................ 5-1
5.01 Inverter Design ............................................................................................... 5-1
SECTION 6:
TROUBLESHOOTING ................................................................................ 6-1
6.01 Basic Troubleshooting .................................................................................... 6-1
6.02 Checking Unit Before Applying Power ............................................................ 6-2
6.03 Tools Needed for Troubleshooting and Servicing ............................................ 6-2
6.04 Case Removal ................................................................................................. 6-3