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11) Slope Down (TIG Mode) Arc Force (Stick)

In the TIG welding mode, this control adjusts the slope down.
The slope down is the amount of time it takes your MTS 160 
to go from the preset welding current to off.  A longer slope
down time will gradually cool your weld and help to prevent
“cratering”.  The slope down is adjustable from .1 sec to 10 sec.

In the Stick welding mode, this control adjusts the Arc Force.
The arc force is how “hard” or “soft” the welding arc is.  The
minimum setting produces a softer arc, while the maximum
setting produces a “harder” arc with more “driving” force
behind it.  The “harder” arc may produce more spatter.

Front Panel Receptacles

1) Adapter Block

This is where the MIG welding gun or the TIG torch 
connects to the machine.  This single connection houses the 
power, welding wire, shield gas, and the trigger wires.

To install the welding gun or TIG torch, simply insert the 
male central adapter block (on welding gun) into the female 
central adapter block (on welding machine).  These will only
fit together in one way.  Tighten the adapter nut securely 
by hand.

2/3) Power Output Receptacles

3 is the positive power output receptacle and 2 is the 
negative power output receptacle.  These control the polarity
of the machine.  For most MIG welding applications with 
shield gas, the ground cable will be connected to the 
negative receptacle (2).  For most MIG welding applications 
with flux cored wire and most TIG welding applications, the
ground cable will be connected to the positive receptacle (3).

If you have burn-through problems when welding on 
extremely thin material with a solid wire and shielding gas, 
you may want to reverse the polarity as this will reduce the 
penetration and make it easier for you to weld thin material.

This is also where you will install your optional electrode 
holder if you are arc welding.  If you will be arc welding DC
electrode positive, then the electrode holder will go in the 
positive receptacle (3) and the ground will be installed in the
negative receptacle (2).  If you will be arc welding DC 
electrode negative, then the electrode holder will go in the 
negative receptacle (2) and the ground will be installed in 
the positive receptacle (3). 

When inserting the end of the ground cable into either 
power output receptacle, secure the ground cable by twisting
it clockwise 1/2 turn.  It is important that the ground clamp 
be connected to a good, clean, surface.  Failure to do so will 
cause poor quality welds.  Place the ground clamp as close 
as possible to the area to be welded.

Polarity Adjustment

The polarity must be adjusted correctly for MIG welding with
shielding gas, flux cored MIG welding, and TIG welding.  This
connection is located in the wire feed compartment.  The wire
connected to the polarity terminal goes to the adapter block and
determines the polarity of the adapter block.

For most MIG welding applications using shielding gas, the
polarity wire will be connected to the positive terminal (1) as
shown.  This would make the welding gun positive and the
ground cable would be plugged into the negative output
receptacle on the front of the welder (see Fig 3).

For most flux cored MIG welding and TIG welding, the polarity
wire will be connected to the negative terminal (2).  This will
make the torch negative.  The ground cable would be connected
to the positive output receptacle on the front of the welder (see
Fig 3).

To change the polarity from positive to negative, unplug the
welder from the power supply.  Remove the insulated nut.
Remove the polarity wire from the positive terminal, and install
it on the negative terminal.  Tighten the insulated nut securely
on the negative terminal.

6

Figure 3

Figure 2

1

2

3

Summary of Contents for MTS 160

Page 1: ...MTS 160 Owner s Manual HTP America Inc 3200 Nordic Road Arlington Heights IL 60005 4729 1 800 USA WELD 847 357 0700 FAX 847 357 0744 www usaweld com...

Page 2: ...er the discovery actual or construction alleged breach of warranty specifying the claimed defect HTP America Inc has reserved the right to make changes in design or add any improvements to its product...

Page 3: ...ur new HTP MIG Welder will deliver years of trouble free service However it is very important that you read the following manual completely Safety Suggestions ELECTRIC ARC WELDING PRODUCES ULTRA VIOLE...

Page 4: ...Note the welding wire will only feed with the side panel closed 5 Post Gas Flow The post gas flow is adjustable from 1 sec to 4 sec Post gas flow is necessary during TIG welding because after the arc...

Page 5: ...optional TIG welding torch must be attached to the central adapter block on the front panel of the welder Stick Welding Mode When the MTS 160 is in the stick welding mode it is possible to perform DC...

Page 6: ...aterial This is also where you will install your optional electrode holder if you are arc welding If you will be arc welding DC electrode positive then the electrode holder will go in the positive rec...

Page 7: ...tighten the pressure roller adjusting screw until the wire feeds evenly without slipping Then tighten an additional 1 4 turn for steel No additional tightening is necessary for aluminum DO NOT OVERTIG...

Page 8: ...materials The flow rate should be set at 20 to 30 cfh depending on the welding conditions MIG WELDING WITHYOUR MTS 160 Connect the MIG welding gun to the adapter block Connect the proper shield gas t...

Page 9: ...our welder This is important to do prior to welding on your project so you will know which voltage setting to select for an application SEAM WELDING Install the conical nozzle Part 15105 on the weldin...

Page 10: ...dge of the first puddle Wait for the orange glow from the first puddle to disappear and deposit the second puddle of metal Continue this process until the seam is completed For a given thickness of me...

Page 11: ...aluminum welding kit 40011 or it may be necessary to use the RSG250 spool gun Pushing aluminum welding wire though a 10 ft welding gun is not a foolproof situation There is the possibility the welding...

Page 12: ...a problem The tendency for aluminum spatter to adhere to the swan neck contact tip and gas nozzle is much greater than that for steel Therefore use of the nozzle spray is extremely important However t...

Page 13: ...ht to see the welding process HTP has a flexible swan neck welding gun available Part 13510 available for welding muffler pipe The flexible swan neck makes it possible to bend the swan neck to get int...

Page 14: ...mended that you use TIG welding gloves like our BL25 gloves These are thinner than standard welding gloves and will give you a much better feel and make it easier to work the filler rod Grip the torch...

Page 15: ...This tungsten is the most common tungsten currently used Generally used for DC welding of steel and stainless steel Draw back is it has a low level radiation hazard Offers good overall performance 2...

Page 16: ...er rod for applications where the material is 1 8 and less Use a 3 32 diameter rod for 1 8 and thicker The following Filler Rod is available from HTP in 1 lb tubes which are tightly sealed to prevent...

Page 17: ...etting the tension on the drive roller does not remedy this problem then the liner should be replaced CHANGINGTHE CONTACTTIP The contact tip should be regarded as a wearing part and therefore requires...

Page 18: ...he wire in the groove DO NOT OVERTIGHTEN 4 Insert the wire protruding from the central adapter block into the end of the welding gun Install the welding gun on the welding machine 5 Remove the contact...

Page 19: ...n See Fig 18 3 Push the wire in and out of the welding gun as shown in Fig 19 The wire should move freely in the gun with little or no resistance If there is a great deal of friction the liner should...

Page 20: ...terial Also this is the only grade of welding wire that is compatible with the High Strength Low Alloy steels found in today s unibody vehicles 20 MONTHLY MAINTENANCE Your HTP MTS 160 is a very hardwo...

Page 21: ...21 Wiring Diagram MTS 160...

Page 22: ...Parts Breakdown MTS 160 22...

Page 23: ...ia 22mm 66121 14 Microswitch 64132 15 Label Front Panel 66619 16 Adapter Support 66462 17 Connections plate 66618 18 Male Plug 22312 19 Transformer 65844 20 Lable Control Panel 66617 21 Cabinet 62653...

Page 24: ...of the machine Is there about 12 Volts DC at the fan terminals Are the 3 secondary voltages present on T AUX Auxiliary Transformer 0 9V 0 12V 0 28V YES NO Change PCB 4 NO NO NO NO YES YES YES YES Go...

Page 25: ...roblem is in the plug or the panel Change the power cable NO NO YES C remove the torch Select TIG or MIG mode and simulate closing of the torch trigger short circuiting the 2 pins on the Euro coupling...

Page 26: ...14009 Trigger Switch 56 15062B Nozzle Springs 57 13002 DLT Gas Diffuser Left Hand Thread 58 14058 Head Insulator Std neck Illustration Part Description 59 15002 Swan Neck 63 15058 Head Insulator Flex...

Page 27: ...5 54N14 2A Gas Lens Collet Body 45V24 45V25 45V26 45V27 3 Collet 10N22 10N23 10N24 10N25 Short Configuration optional 1B Alumina Nozzle 13N08 13N09 13N10 13N11 2B Collet Body 17CB20 17CB20 17CB20 17CB...

Page 28: ...uty Cycle HTP MTS 160 0 10 20 30 40 50 60 70 80 90 100 110 120 130 140 150 160 Current Amps Duty Cycle Volt Amp Curve HTP MTS 160 0 5 10 15 20 25 30 0 50 100 150 200 250 300 350 Current A Voltage V 28...

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