Comparc SINTESIS 160 Owner'S Manual Download

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PM1401 REV. 0
E. 19-11-2021

CC - CD WELDER / 6200 WATTS GENERATOR

SINTESIS 160

DESCRIPTION

CONSTANT CURRENT (CC).

DIRECT CURRENT ( CD)

PROCESS

STICK (SMAW)

TIG (GTAW).

OUTPUT TYPE :

304-878

OWNER´S MANUAL

T M

OWNER´S MANUAL

GIVE THIS MANUALTO THE OPERATOR

VISIT OUR W EBSITE AT:

www.siisa-infra.com.mx

Summary of Contents for SINTESIS 160

Page 1: ...ER 6200 WATTS GENERATOR SINTESIS 160 DESCRIPTION CONSTANTCURRENT CC DIRECTCURRENT CD PROCESS STICK SMAW TIG GTAW OUTPUTTYPE 304 878 OWNER S MANUAL T M OWNER S MANUAL GIVETHISMANUALTOTHEOPERATOR VISIT OUR WEBSITE AT www siisa infra com mx ...

Page 2: ...an independent welding power source 8 3 9 Supply voltage 127 V a c 8 3 10 Supply voltage 220 V a c 9 3 11 Recommended fuse sizes and minimum cable section 9 3 12 Weld output terminals 9 3 13 Weld cable size 10 SECTION 4 FUNCTION OF CONTROLS 10 Figure 4 1 Controls 10 Figure 4 2 Engine controls 10 SECTION 5 AUXILIARY POWER GUIDE 11 5 1 How much power does equipment required 11 5 2 How much power doe...

Page 3: ...amaged parts at once 12 Wear a safety harness to prevent falling if working above floor level 13 Keep all panels and cover securely in place 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 burn eyes and skin Noise from some processes can damage hearing 1 Wear a welding helmet fitted with a proper s...

Page 4: ...alling or connecting unit 3 Have only qualified people remove guards or covers for maintenance and troubleshooting as necessary 4 To prevent accidental stating 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 SPARKS can ...

Page 5: ...ng period follow rated duty cycle Reduce current or reduce duty cycle before starting to weld again Do not block or filter airflow to unit 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 ship PC boards ARC WELDING can cause interference Electromagnetic energy can interfere with sensitive electronic ...

Page 6: ...Safety signal words SECTION 1 SAFETY SIGNALS AND SYMBOLS WARNING CAUTION IMPORTANT Statements identify special instructions necessary for the most efficient operation of thisequipment WARNING statements identify procedures or practices which must be followed to avoid seriuos personal injury or loss of life CAUTIONstatementsidentifyproceduresorpracticeswhichmustbefollowedtoavoid minor personal inju...

Page 7: ...based on Inverter Technology This allows an arc dinamical time response extremely low around 0 5 microseconds aproaching excelent characteristics of weld with any elctrode type The high frequency of INVERTER system eliminates totally any annoying hum caused by the traditional power supplies A kVA kW Stick 160 24 4 15 160 85 N A N A N A TIG 160 16 4 15 160 85 N A N A N A 127 120 22 8 15 120 33 6 4 ...

Page 8: ...inutesout of every10minute periodwitharest forthenext 6 minutes Whenunit overheats theoutput stops theover temperature indicatorlight comesonandthecoolingfancontinuestorun Wait 15 minutes for the unit to cool down Reduce the amperage or duty cycle before starting to weld again WARNING byweldingbeyondthespecifieddutycycle may damage the unit and void the warranty Exceeding duty cycle can damage uni...

Page 9: ...N READ SAFETY BLOCKS at beginning of manual before proceeding 2 5 AC AUXILIARY POWER Theacgeneratorpower curves showthegeneratorpoweravailable in amperesat the120 and240 V receptacles FIGURE 2 4 120 240 Vac AUXILIARY POWER OUTPUT 100 10 110 125 130 120 20 30 40 200 220 250 260 240 0 10 Amperes a 120 V a c Volts a c 15 20 Amperes a 240 V a c 50 25 1 0 F P 60 80 30 40 A IR A IR A IR E A IR E A IR A ...

Page 10: ...alle plásticos No 17 Colonia San Francisco Cuautlalpan Naucalpan de Juárez Estado de México C P 53569 2 Fuel tank Check fuel level before starting engine add if necessary Caution Do not overfill fuel tank leave 1 2 12 7mm space to allow expansion of fuel gases 3 Oil After checking the fuel in the machine check the oil level with the unit level horizontally If the oil is not in the bayonet mark add...

Page 11: ...stem 3 5 SELECTING THE CABLE LENGTH Use the cable as short as possible TABLE 3 1 SELECTION OF CABLES AT 120Vac CABLE LENGTH FOR LOADS AT 120 Vca Current Amp Load Watts MAXIMUM PERMISSIBLE CABLE LENGTH IN Ft m FOR DIFFENENTS CALIBRES 4 AWG 6 AWG 8 AWG 10 AWG 12 AWG 14 AWG 5 7 10 15 20 25 30 35 40 45 50 600 840 1200 1800 2400 3000 3600 4200 4800 5400 6000 400 122 300 91 225 68 175 53 150 46 125 38 1...

Page 12: ...to Manufacturer Instructiions 4 Works Clamp Install Onto Works Cable For Example To tal Cable Length in Weld Circuit 6 m 20 Ft CABLE LENGTH FOR LOAD 240 Vac Current Amp Load Watts 4 AWG 6 AWG 8 AWG 10 AWG 12 AWG 14 AWG 5 7 10 15 20 25 30 35 40 45 50 1200 1680 2400 3600 4800 6000 7000 8400 9600 10 800 12 000 800 244 600 183 450 137 350 107 300 91 250 76 225 69 200 61 175 53 800 244 550 168 350 107 ...

Page 13: ...OR VOLTAGE DISCHARGES MUST ALWAYS BE GROUNDED WHEN USING THIS PRODUCT 127 V 20 A 127 V 15 A Unplug the power cord with plug from the 220V receptacle located inside the side box Use the adapter provided to connect to 127V power voltage 3 7 CONNECTION OF THE WELDING POWER SOURCE TO THE ENGINE GENERATOR The power supply is factory connected to the engine generator by means of a half turn plug in the ...

Page 14: ...alle plásticos No 17 Colonia San Francisco Cuautlalpan Naucalpan de Juárez Estado de México C P 53569 SEE SAFETY SIGNAL AT THE BEGINING THIS M A NU AL Unplug the power cord from the 220 V receptacle located inside the side box Connect it to the 220 V power supply voltage M a xim u m reco m m en d ed len g th o f exten sio n c ab le 8 m 25 ft 15 m 50 ft R ec o m m en d ed m in im u m g ro u n d in ...

Page 15: ...1 RC3 AND RC4 7 RESET CB2 FOR RC2 RC3 AND RC4 8 CURRENT ADJUSTMENT 8 4 4 1 CONTROLES 3 2 7 6 TIERRA Calle plásticos No 17 Colonia San Francisco Cuautlalpan Naucalpan de Juárez Estado de México C P 53569 10 to 60 1 Use this control knob to select the welding current according to the application need turn the knob clockwise to increase the current and turn counterclockwise to decrease the current by...

Page 16: ... 120V calculate its running power requirement in watts 120 V x 4 5 A 540 W Therefor the individual load applied by the drill is 540Watts EXAMPLE 2 If a flood lamp is rated at 200W the individual load applied by the lamp is 200W if three 200W flood lamps are used with the drill form example 1 add the individual loads to calculate total load 200 W 200 W 200 W 540 W 1140 W Therefor the total load app...

Page 17: ...HP 1 HP 1 1 2 HP 2 HP 3 HP 5 HP 2020 3075 4500 6100 8200 10550 15900 23300 720 975 1400 1600 2200 2850 3900 6800 Capacitor Start Induction Run 1 1 2 HP 5 HP 7 1 2 HP 10 HP 8100 23300 35000 46700 2000 6000 8000 10700 Fan Duty 1 8 HP 1 6 HP 1 4 HP 1 3 HP 1 2 HP 1000 1400 1850 2400 3500 400 550 650 800 1100 Contractor Rating Starting Watts Running Watts Hand Drill 1 4 3 8 1 2 350 400 600 350 400 600 ...

Page 18: ... starting current as shown in Figure 5 4 3 Operating current nominal If the code is not present multiply the operating rated current by six The generator output current must be at least twice the rated motor current 2 3 FIG 5 5 POSSIBLE LOAD COMBINATIONS 40 13 4 3 2 3 1 examples of typical electrical appliances that can be connected to the generators considering power values at sea level We recomm...

Page 19: ...rting or stopping the engine slowing the engine speed causes low voltage and frequency FIGURE 5 7 CONNECTING TO ELECTRICAL EQUIPMENT 1 Receptacles with neutral connected to the chassis 2 3 terminal plug of the equipment with the chassis grounded 3 Double insulated 2 terminal equipment plug 5 4 EQUIPMENT SELECTION Make sure that the equipment has this symbol or legend The customer shall supply the ...

Page 20: ... when short circuits or overloads occur at the auxiliary power receptacles and at the welding source terminals 1 CIRCUIT BREAKER CB1 This breaker protects the generator windings against overloads or short circuits produced in the RC1 RC3 and RC4 receptacles 2 CIRCUIT BREAKER CB2 This breaker protects the generator windings against overloads or short circuits produced in the RC2 RC3 and RC4 recepta...

Page 21: ...inals Change Oil Change Oil Filter Clean Cooling System 100 HOURS Clean and tighten Battery Connections Service Air Cleaner 50 HOURS Replace Fuel Filter Engine Manual Check Valve Clearance Repair Or Replace Damaged Cables Check Spark Plugs 1000 HOURS Blow out Or Vacuum Inside STOP ENGINE BEFORE MAINTAINING CAUTION Initial oil change should be performed after first twenty 20 hours of operation Ther...

Page 22: ...CTBETWEEN CONNECTIONS ERRATICWELDCURRENT WITHOUT CURRENT CONTROL OR WITH VERY LOWCURRENT FAN ROTATES NORMALLY BUT THERE IS NO OUTPUTCURRENT FAN NOT WORKING 6 3 POWER SUPPLY TROUBLESHOOTING AMBER ILLUMINATED LED MACHINEOVERHEATED ALLOW THEMACHINE TORUN15MINUTESWITHOUT WELDINGTOCOOLDOWN REMEDY TROUBLE The motor does not start The motor stops during nor mal operation TABLE 6 1 ENGINE TROUBLE Check th...

Page 23: ... recomendations Engine s Cooling temperature is greatest than a car the use of multigrade oil 10W 30 up 4 C cause a high oil consumption and oil level should be checked more frequently to avoid any damaged The oil with SAE 30 viscosity if is used below 4 C will causes dificult in start and a possible damage in engine due innadecuate lubrication Fuel capacity 1 85 Gal 7 Lt Any type of gasoline with...

Page 24: ...Primary Current Signal Ampli er Chassis Negative Positive Overtemperature detector Overload Energy Control panel card Bridge Recti er Capacitor Input lter Fast diodes Fan DC24 Fan Relay Power indicator or power on green Over Temperature Indicator Yellow Process Indicator Red TIG GREEN MMA Input voltage indicator Red 127 GREEN 220V Stabilizer Current transformer Temperature sensor Main switch Main ...

Page 25: ...E 1 MR10118 WHEEL 2 MR00905 FLAT WHASER 5 8 2 MC01268 CHAVETA DE 1 8 2 6 PB1572 BASE FOR DAMPER SUPPORT 1 PB1573 COMPLEMENT BASE 1 MS03957 SHOCK ABSORBER SUPPORT 4 7 PP4215 FRONT SUPPORT 1 8 MR09860 RAGATON RUBBER 1 9 CABINET ASSEMBLY SEE FIGURE 8 2 1 10 PA1178 ADAPTER 1 11 MR0530 THREE POLE RECEPTACLE 1 12 PC2082 WORK CABLE 1 13 PC2132 ELECTRODE HOLDER CABLE 1 14 MA00618 BATTERY 12V 1 15 PC3432 C...

Page 26: ...1 MC10508 CIRCUITBREAKER 40A 2 MR09889 RECEPTACLE 120V 2 MR00530 THREE POLE RECEPTACLE 1 MC11178 OUTPUT TERMINAL 2 PT2541 CONTROL PCB 1 MP08481 KNOB 1 MI01253 SWITCH 1 3 PT3225 REAR COVER 1 4 PC2951 COVER 1 5 PT3222 RIGHT SIDE COVER 1 6 PT3223 LEFT SIDE COVER 1 7 MV01115 FAN 1 8 MT08074 KULKA TERMINAL 1 9 CAPACITOR 1 10 PS0712 CAPACITOR CLAMP 1 11 PT2540 MAIN PCB 1 12 PC2954 POWER CORD 1 12 ...

Page 27: ...TY D E S C R I P T I O N 1 PK0050 IGBT 4 2 MT08647 MAIN TRANSFORMER 1 3 MD01908 HEAT SINK 4 4 MC11089 CAPACITOR 4 5 MT08648 CURRENT TRANSFORMER 1 6 MI01243 AUXILIARY INDUCER 1 7 MR10159 RECTIFIER 1 4 1 3 5 6 2 7 FIGURE 8 3 MAIN CARD ASSEMBLY 22 ...

Page 28: ...SERVICE CENTER FAX MAP CANADA LTD 325 Healey Road Unit 1 Bolton ON L7E 5C1 Canada Phone 905 951 2788 Toll Free 800 757 4445 Fax 905 951 6256 ...

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