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THERMAL ARC 161STL, 201TS

ASSEMBLY PROCEDURES

Assembly Procedures

8-2

Manual 0-5148

8.02 Installing Back Panel

1.  Install ON/OFF switch.
2.  Install power cord.
3.  Reconnect Input Wire on the ON/OFF switch.
4.  Reinstall Magnet onto Ground Wire.
5.  Install fan.
6.  Reconnect power ON/OFF switch to terminals on Main Power PCB.
7.  Reconnect Ground Wire to Main PCB.
8.  Reconnect Rear Panel screws.

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Art # A-10182

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Summary of Contents for 161 STL

Page 1: ...Art A 10144 50 60 Hz 50 60 Hz THERMAL ARC Inverter Arc Welder 161 STL Service Manual Revision AC Issue Date Dec 03 2012 Manual No 0 5148 Operating Features 201 Ts...

Page 2: ...re any contained in this manual Due to our constant effort to bring you the best products we may make an improvement that does not get reflected in the manual If you are ever in doubt about what you s...

Page 3: ...echnologies International Inc 16052 Swingley Ridge Road Suite 300 St Louis Mo 63017 USA www thermalarc com Copyright 2011 2012 by Victor Technologies International Inc All rights reserved Reproduction...

Page 4: ...ION 3 SAFETY AND INSTALLATION 3 1 3 01 Duty Cycle 3 1 3 02 Specifications 161STL 3 3 3 03 Specifications 201TS 3 4 3 04 Environment 3 5 3 05 Location 3 5 3 06 Electrical Input Connections 3 5 3 07 Ele...

Page 5: ...6 SECTION 7 DISASSEMBLY PROCEDURE 7 1 7 01 Safety Precautions for Disassembly 7 1 7 02 Control Board Removal 7 2 7 03 Front Panel Assembly Removal 7 4 7 04 Front Panel Operator Interface Circuit Board...

Page 6: ......

Page 7: ...ent with DC output 14 Wear a safety harness to prevent falling if working above floor level 15 Keep all panels and covers securely in place WARNING ARC RAYS can burn eyes and skin NOISE can damage hea...

Page 8: ...2 Do not weld where flying sparks can strike flammable material 3 Remove all flammables within 35 ft 10 7 m of the welding arc If this is not possible tightly cover them with approved covers 4 Be ale...

Page 9: ...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 ENGIN...

Page 10: ...ve procedures are among those also normally recommended for pacemaker wearers Consult your doctor for complete information 1 02 General Safety Information for Victor CS Regulator A Fire Prevention Wel...

Page 11: ...y Use a suitable hand truck to move cylin ders 3 Store empty cylinders away from full cylinders Mark them EMPTY and close the cylinder valve 4 NEVER use compressed gas cylinders without a pressure red...

Page 12: ...Frequency Negative Positive Direct Current DC Protective Earth Ground Line Line Connection Auxiliary Power Receptacle Rating Auxiliary Power Art A 04130_AB 115V 15A t t1 t2 X IPM MPM t V Fuse Wire Fe...

Page 13: ...hooting Section before touching any parts WARNING STATIC ESD can damage PC boards Put on grounded wrist strap BEFORE handling boards or parts Use proper static proof bags and boxes to store move or sh...

Page 14: ...TIONS Use Testing Booklet Part No 150 853 when servicing this unit Consult the Owner s Manual for welding safety precautions Use only genuine replacement parts from the manufacturer 1 06 EMF Informati...

Page 15: ...inspect the equipment for possible damage due to shipping If there is any damage notify the carrier immediately to file a claim Furnish complete information concerning damage claims or shipping error...

Page 16: ...THERMAL ARC 161STL 201ts INTRODUCTION Introduction 2 2 Manual 0 5148 Notes...

Page 17: ...gned to operate with a 30 duty cycle at 160 amperes and 26 4 volts This means that it has been designed and built to provide the rated amperage 160A for 3 minutes i e arc welding time out of every 10...

Page 18: ...al 0 5148 230VAC Input 0 20 40 60 80 100 120 0 50 100 150 200 250 AMPS Duty Cycle percentage 40 C Lift TIG HF TIG Stick Art A 10145 115VAC Input 0 20 40 60 80 100 120 0 50 100 150 200 250 AMPS Duty Cy...

Page 19: ...Type Inverter Power Source Output Terminal Type Heavy Duty DinseTM 50 Classification Protection Class IP23S Standards EN 60974 1 EN50199 Cooling Method Fan Cooled Dimensions and Weight Welding Power...

Page 20: ...der Type Inverter Power Source Output Terminal Type Heavy Duty DinseTM 50 Classification Protection Class IP23S Standards EN 60974 1 EN50199 Cooling Method Fan Cooled Dimensions and Weight Welding Pow...

Page 21: ...es In areas not subjected to abnormal vibration or shock In areas not exposed to direct sunlight or rain Place at a distance of 12 300mm or more from walls or similar that could restrict natural air f...

Page 22: ...a de energized line disconnect switch 3 Use Table 3 1 as a guide to select line fuses for the disconnect switch Input Voltage Circuit Breaker or Fuse Size 115V 30A 208 230V 50A Table 3 1 Fuse Guide C...

Page 23: ...ting voltage after approximately 5 seconds NOTE Damage to the PCA could occur if 253 VAC or higher is applied to the Primary Power Cable Model Primary Supply Lead Size Factory Fitted Minimum Primary C...

Page 24: ...s may require additional protection measures The size of the surrounding area to be considered will depend on the structure of the building and other activities that are taking place The surrounding a...

Page 25: ...rthing of the work piece increasing the risk of injury to users or damage to other electrical equipment Where necessary the connection of the work piece to earth should be made by direct connection to...

Page 26: ...ge and amperage output capabilities of welding power source Curves of other settings fall between curves shown A 09949 230VAC Input 0 10 20 30 40 50 60 70 80 0 50 100 150 200 AMPS VOLTS Stick Max Lift...

Page 27: ...Safety and Installation Art A 10158 230VAC Input 0 10 20 30 40 50 60 70 80 0 50 100 150 200 250 AMPS VOLTS Stick Max Lift TIG Max Art A 10159 115VAC Input 0 10 20 30 40 50 60 70 80 0 50 100 150 200 AM...

Page 28: ...THERMAL ARC 161STL 201ts SAFETY AND INSTALLATION Safety and Installation 3 12 Manual 0 5148 Notes...

Page 29: ...rent classes of electrode welding current at any one setting would vary according to the type of electrode in use The operator should use the welding current range values as a guide then fine tune the...

Page 30: ...ing welding A POWER Indicator The POWER Indicator illuminates when the ON OFF switch is in the ON position and the correct mains voltage is present B FAULT Indicator The welding power source is protec...

Page 31: ...G GTAW modes Refer to Section 4 03 Setup for STICK SMAW Welding and 4 04 Setup for TIG Welding 201TS Switches between STICK SMAW LIFT TIG GTAW and HF TIG GTAW modes Refer to Section 4 03 Setup for STI...

Page 32: ...ding current 3 Torch Switch Input 0V to energize weld current connect pin 2 3 to turn on welding current 4 5 5k ohm maximum connection to 5k ohm remote control potentiometer 6 Zero ohm minimum connect...

Page 33: ...as a guide only Current delivered to the arc is dependent on the welding arc voltage and as welding arc voltage varies between different classes of electrodes welding current at any one setting would...

Page 34: ...any welding is to begin be sure to wear all appropriate and recommended safety equipment 1 Switch the ON OFF Switch located on the rear panel to OFF 2 Connect the work lead to the negative output ter...

Page 35: ...m 10 provides a hard arc deep penetration 8 Install a stick electrode in the electrode holder 9 You are now ready to begin STICK Welding NOTE Gently strike the electrode on the work piece to generate...

Page 36: ...may be around the valve regulator seat area 5 Install the regulator for details of VICTOR regulator please refer to 3 08 and tighten with a wrench 6 Connect one end of the supplied gas hose to the out...

Page 37: ...g it to a stationary support to prevent falling or tipping Switch to 2T 4T Set DOWN Slope Figure 4 5 Setup for HF TIG GTAW Welding of 201TS HF TIG GTAW Sequence of Operation CAUTION Before any welding...

Page 38: ...g wheel is turning 13 Install the tungsten with approximately 1 8 to sticking out from the gas cup ensuring you have correct sized collet 14 Tighten the back cap then open the valve on the torch 15 Pl...

Page 39: ...AUGE SUPPLY INLET CONNECTION OUTLET CONNECTION PRESSURE ADJUSTING SCREW A 09414_AB Figure 4 8 Victor CS Regulator WARNING Use the regulator for the gas and pressure for which it is designed NEVER alte...

Page 40: ...ielding gas set up attach the shielding gas hose from the torch to a flow meter regulator on the cylinder In this case we will be using Argon set at a flow rate of around 20 CFH You will need to use a...

Page 41: ...er main transformer than in a conventional power supply The AC is then rectified to extremely smooth DC The diagram to the below shows the basic electrical wiring of a DC output inverter power supply...

Page 42: ...THERMAL ARC 161Stl 201ts THEORY OF OPERATION Theory of Operation 5 2 Manual 0 5148 Notes...

Page 43: ...B3 Step 3 If above voltage is incorrect disconnect the harness of J11 connector and re measure according to step 1 If still incorrect replace Main Power PCB 1 Cannot adjust Weld Current Check Control...

Page 44: ...ore working on unit Significant DC voltage can remain on capacitors after unit is Off Wait until all front panel LED s are off before removing case Check DC bus voltage according to Section 6 07 after...

Page 45: ...5148 6 3 Troubleshooting 6 04 Case Removal Read and follow safety information in Section 6 02 before proceeding 1 Cover 2 Screws Remove the 4 screws 2 on each side of the unit Remove 2 screws from bot...

Page 46: ...w Carefully lift the case to access and remove the screw which connects the ground wire to the cover 3 Art A 09851_AB 6 05 Clear Cover Sheet Removal Read and follow safety information in Section 6 02...

Page 47: ...TROUBLESHOOTING THERMAL ARC 161stl 201ts Manual 0 5148 6 5 Troubleshooting 6 06 Pre Power Check Measure Points for following tests 3 4 9 2 12 11 8 13 16 7 6 5 10 17 18 14 15 1 Art A 10161...

Page 48: ...sitive Probe Negative Probe Measure Point 6 Measure Point 5 Measure Point 8 Measure Point 7 If reading is out of voltage drop range replace main board 3 Measurement of PFC IGBT Set multimeter to diode...

Page 49: ...ure Point 17 Measure Point 18 If reading is not 4ohms within 5 replace Resistor R1 7 Power Switch S1 Continuity Check 1 Art A 09854_AB Read and follow safety information in Section 6 02 before proceed...

Page 50: ...voltage reading with multimeter before inspection Set multimeter to DC voltage mode Read and follow safety information in Section 6 02 before proceeding 1 DC Positive 2 DC Negative Check and make sur...

Page 51: ...G THERMAL ARC 161stl 201ts Manual 0 5148 6 9 Troubleshooting 6 08 Installing Clear Cover Sheet Read and follow safety information in Section 6 02 before proceeding 1 Replace the clear protective sheet...

Page 52: ...THERMAL ARC 161Stl 201TS troubleshooting Troubleshooting 6 10 Manual 0 5148 6 09 Waveforms for Section 6 10 A OCV Waveform of Transformer primary Art A 09858...

Page 53: ...THERMAL ARC 161stl 201ts Manual 0 5148 6 11 Troubleshooting B Output 160A 26 4V transformer primary waveform under input 230VAC Art A 09859 C Output 160A 26 4 V output voltage waveform under input 230...

Page 54: ...61Stl 201TS troubleshooting Troubleshooting 6 12 Manual 0 5148 D Output 125A 25V transformer primary waveform under input 115VAC Art A 09894 E Output 125A 25V output voltage waveform under input 115VA...

Page 55: ...ARC 161stl 201ts Manual 0 5148 6 13 Troubleshooting 6 10 Troubleshooting Circuit Diagram 161STL V1 Details refer to 6 09 A B and D waveforms V2 Details refer to 6 09 C and E waveforms INPUT 230VAC 115...

Page 56: ...THERMAL ARC 161Stl 201TS troubleshooting Troubleshooting 6 14 Manual 0 5148 6 11 161STL Connector Diagram...

Page 57: ...TROUBLESHOOTING THERMAL ARC 161stl 201ts Manual 0 5148 6 15 Troubleshooting 6 12 Troubleshooting Circuit Diagram 201TS Art A 11277 INPUT 230VAC 115VAC 50 60Hz...

Page 58: ...6 2 J 2 1 J 9 J 1 2 J22 J18 1 5 J5 J13 1 5 6 10 J8 J24 1 2 J7 J19 1 2 J30 1 8 6 1 J20 201 CONNECTOR KEY J1 15 J2 power J3 OT2 J4 OT1 J5 SOU HF QF J6 GUN J7 WV J8 MB J9 WA J10 IN J11 DY2 J12 FJ QF J13...

Page 59: ...l 201TS Manual 0 5148 7 1 Disassembly Procedure 7 01 Safety Precautions for Disassembly Read and follow safety information in Section 6 02 before proceeding Unplug unit before beginning Disassembly pr...

Page 60: ...nel 2 Disconnect J8 harness from J8 connector 3 Disconnect J7 harness from J7 connector 4 Disconnect J2 harness from J2 connector 5 Disconnect J6 harness from J6 connector 6 Disconnect J5 harness from...

Page 61: ...ocedure CONNECTOR LAYOUT DIAGRAM J1 J3 J5 J6 J7 J8 J9 NO 1 2 3 Control PCB2 J4 J2 Art A 10164 POWER OT1 OT2 SOU HF QF GUN V W B M WA 161STL Control PCB CONNECTOR LAYOUT DIAGRAM 1 2 3 J1 J2 J3 J4 J5 J6...

Page 62: ...information in Section 6 02 before proceeding with disassembly 1 Power supply output Negative 2 Power supply output Positive 3 Output terminal bolts Unscrew power supply output terminal bolts 4 Disco...

Page 63: ...disassembly procedure THERMAL ARC 161stl 201TS Manual 0 5148 7 5 Disassembly Procedure 3 Art A 10167 4 Art A 10168...

Page 64: ...6 02 before proceeding with disassembly 1 PROCESS Selector Switch Boot Remove the rubber boot from the PROCESS Selector switch by turning the retaining nut counter clockwise 2 WELD CURRENT Control Kno...

Page 65: ...the Trigger Selector Switch by turning the retaining nut counter clockwise 7 Arc Force Down Slope Control Knob Remove the Arc Force Down Slope Control Knob by lossening the set screw 8 Arc Force Down...

Page 66: ...from Main PCB1 Disconnect the two wires from PCB1 3 Rear panel mounting SCREW Remove screw holding rear panel to chassis 4 Ground wire screw Disconnect Input cord ground wire from Main Power PCB1 usi...

Page 67: ...disassembly procedure THERMAL ARC 161stl 201TS Manual 0 5148 7 9 Disassembly Procedure 1 2 Art A 10173 3 Art A 10174...

Page 68: ...THERMAL ARC 161Stl 201ts disassembly procedure Disassembly Procedure 7 10 Manual 0 5148 4 Art A 10175 6 Art A 10176...

Page 69: ...locking tabs Squeeze the locking tabs and push SW1 out from the rear panel 3 Input Power Cord 4 Strain relief screws Remove the two 2 screws from the strain relief 5 Input Power Cord ground wire filt...

Page 70: ...THERMAL ARC 161Stl 201ts disassembly procedure Disassembly Procedure 7 12 Manual 0 5148 1 5 7 3 Art A 10178 6 2 Art A 10179...

Page 71: ...1TS Manual 0 5148 7 13 Disassembly Procedure 7 07 Base Panel Removal Read and follow safety information in Section 6 02 before proceeding with disassembly 1 Remove PCB1 assembly 2 Remove Base Panel Sc...

Page 72: ...THERMAL ARC 161Stl 201ts disassembly procedure Disassembly Procedure 7 14 Manual 0 5148 Notes...

Page 73: ...01TS Manual 0 5148 8 1 Assembly Procedures SECTION 8 ASSEMBLY PROCEDURES 8 01 Installing Base Board 1 Base Panel 2 Panel screws Secure the Main Power PCB1 to the Base Panel with the Panel Screws 3 Mai...

Page 74: ...ack Panel 1 Install ON OFF switch 2 Install power cord 3 Reconnect Input Wire on the ON OFF switch 4 Reinstall Magnet onto Ground Wire 5 Install fan 6 Reconnect power ON OFF switch to terminals on Mai...

Page 75: ...ASSEMBLY PROCEDURE THERMAL ARC 161stl 201TS Manual 0 5148 8 3 Assembly Procedures 6 7 Art A 10183 8 Art A 09883...

Page 76: ...and tighten 5 WELD CURRENT knob Install knob onto potentiometer shaft Align the knob pointer to line up with maximum current calibration mark on the panel then tighten the set screw 6 Arc Force Down...

Page 77: ...ASSEMBLY PROCEDURE THERMAL ARC 161stl 201TS Manual 0 5148 8 5 Assembly Procedures 4 Art A 10185 6 7 8 5 Art A 10186...

Page 78: ...Procedures 8 6 Manual 0 5148 9 Reinstall output terminals on front panel with 27mm wrench 10 Reconnect wires to their respective terminals using the bolts 11 Reconnect Output Terminal Bolts and tight...

Page 79: ...ASSEMBLY PROCEDURE THERMAL ARC 161stl 201TS Manual 0 5148 8 7 Assembly Procedures 11 10 Art A 10188 12 Art A 10189...

Page 80: ...arness into connector J7 4 Plug harness into connector J2 5 Plug harness into connector J6 6 Plug harness into connector J5 7 Plug harness into connector J4 8 Plug harness into connector J3 9 Plug har...

Page 81: ...ASSEMBLY PROCEDURE THERMAL ARC 161stl 201TS Manual 0 5148 8 9 Assembly Procedures 11 Art A 10190...

Page 82: ...Stl 201ts ASSEMBLY PROCEDURES Assembly Procedures 8 10 Manual 0 5148 8 05 Installing Case 1 Install Case 2 Install Screws Eight 8 screws 4 on both side panels of case 2 on front panel 2 on rear panel...

Page 83: ...ASSEMBLY PROCEDURE THERMAL ARC 161stl 201TS Manual 0 5148 8 11 Assembly Procedures 2 Art A 10192...

Page 84: ...THERMAL ARC 161Stl 201ts ASSEMBLY PROCEDURES Assembly Procedures 8 12 Manual 0 5148 Notes...

Page 85: ...tapping screw GB T13806 2 AST4 2 13 Bracket 3 EACH locking washer external serrated GB862 2 87 4 Base Panel Solenoid valve 4 EACH Screw spring washer flat washer M4 16 Rectifier bridge 2 EACH Flat was...

Page 86: ...161STL W7003204 PCB3 10 Front Panel W7003205 11 Front Panel Label W7003206 12 Rubber Boot W7003064 13 Knob control Red 21 ODx6 ID W7003079 14 Output Terminal 50mm dinse W7003020 15 Socket 8 Pin w cab...

Page 87: ...replacement parts THERMAL ARC 161stl 201TS Manual 0 5148 9 3 Replacement Parts 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 Art A 10022_AB 25 26...

Page 88: ...10 Output Inductor Magnetic Core W7003210 11 Front Control PCB3 W7003218 PCB3 12 Front Panel W7003205 13 Front Panel Label W7003219 14 Rubber Boot W7003064 15 Knob control Red 21 ODx6 ID W7003079 16 C...

Page 89: ...replacement parts THERMAL ARC 161stl 201TS Manual 0 5148 9 5 Replacement Parts 2 5 3 4 6 7 8 9 10 11 12 13 14 15 16 17 18 19 21 20 22 23 24 25 26 Art A 10104_AB 27 5 1...

Page 90: ...THERMAL ARC 161Stl 201TS replacement parts Replacement Parts 9 6 Manual 0 5148 Notes...

Page 91: ...8 18 UNF connection 0781 4169 Power Adapter 230V 50A Socket Nema 6 50R to 115V 15A Plug Nema 5 15P W4014000 USA Graphics Auto Darkening welding helment spare cover lens and operating manual W4011700 C...

Page 92: ...THERMAL ARC 161Stl 201TS accessories Accessories 10 2 Manual 0 5148 Notes...

Page 93: ...ising out of contract tort including negligence or strict liability or under any warranty or otherwise shall not exceed the price of the goods upon which such liability is based No employee agent or r...

Page 94: ...ars All other original circuits and components including but not limited to relays switches contactors solenoids fans electric motors 1 year 1 year PLASMA WELDING EQUIPMENT WARRANTY PERIOD LABOR Ultim...

Page 95: ......

Page 96: ...Cikarang Indonesia Customer Care Ph 6221 8990 6095 Fax 6221 8990 6096 Rawang Malaysia Customer Care Ph 603 6092 2988 Fax 603 6092 1085 Melbourne Australia Australia Customer Care Ph 1300 654 674 toll...

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