Arc TOLWDRROBT16 ROSSI 160 Amp Inverter Welder User Manual

User Manual

[Revision 5.0]

READ THIS MANUAL CAREFULLY BEFORE USE – FAILURE TO DO SO MAY RESULT IN INJURY, PROPERTY DAMAGE AND MAY

VOID WARRANTY. • KEEP THIS MANUAL FOR FUTURE REFERENCE. • Products covered by this manual may vary in appearance,

assembly, inclusions, specifications, description, and packaging.

TIG160A MK III Inverter Welder

E&OE © Rossi 2

Safety

Safety messages are designed to alert you to possible dangers or hazards that could cause death, injury or

equipment or property damage if not understood or followed. Safety messages have the following symbols:

You WILL be KILLED or

SERIOUSLY INJURED if you do

not follow instructions.

You CAN be KILLED or

SERIOUSLY INJURED if you do

not follow instructions.

You CAN be INJURED if you do

not follow instructions or equipment

damage may occur.

It is vital that you read and understand this

user manual before using the product,

including safety warnings, and any assembly

and operating instructions. Keep the manual

for future reference.

Safety precautions and recommendations

detailed here must be fully understood and

followed to reduce the risk of injury, fire,

explosion, electrical hazard, and/or property

damage.

Safety information presented here is generic

in nature – some advice may not be

applicable to every product. The term

"equipment" refers to the product, be it

electrical mains powered, battery powered or

combustion engine powered.

• Before Use - If you are not familiar with the

safe operation/handling of the equipment or

are in any way unsure of any aspect of

suitability or correct use for your

application, you should complete training

conducted by a person or organization

qualified in safe use and operation of this

equipment, including fuel/electrical handling

and safety.

• Do NOT operate the equipment in

flammable or explosive environments, such

as in the presence of flammable liquids,

gases, or dust. The equipment may create

sparks or heat that may ignite flammable

substances.

• Keep clear of moving parts.

• Equipment may be a potential source of

electric shock or injury if misused.

• Do NOT operate the equipment if it is

damaged, malfunctioning or is in an

excessively worn state.

• Do NOT allow others to use the equipment

unless they have read this manual and are

adequately trained.

• Keep packaging away from children - risk

of suffocation! Operators must use the

equipment correctly. When using the

equipment, consider conditions and pay

due care to persons and property.

General Work Area Safety

•

Work areas should be clean and well it.

• Do not operate the equipment if

bystanders, animals etc are within

operating range of the equipment or the

general work area.

• If devices are provided for connecting dust

extraction / collection facilities, ensure

these are connected and used properly.

Dust collection can reduce dust-related

hazards.

General Personal Safety

•

Wear appropriate protective equipment

when operating, servicing, or when in the

operating area of the equipment to help

protect from eye and ear injury, poisoning,

burns, cutting and crush injuries. Protective

equipment such as safety goggles,

respirators, non-slip safety footwear, hard

hat, hearing protection etc should be used

for appropriate equipment / conditions.

Other people nearby should also wear

appropriate personal protective equipment.

Do not wear loose clothing or jewellery,

which can be caught in moving parts. Keep

hair and clothing away from the equipment.

• Stay alert and use common sense when

operating the equipment. Do not over-

reach. Always maintain secure footing and

balance.

• Do not use the equipment if tired or under

the influence of drugs, alcohol, or

medication.

• This equipment is not intended for use by

persons with reduced physical, sensory, or

mental capabilities.

General Fuel Safety

•

Petrol/fuel/gasoline is extremely flammable

– keep clear of naked flames or other

ignition sources.

• Do not spill fuel. If you spill fuel, wipe it off

the equipment immediately – if fuel gets on

your clothing, change clothing.

• Do NOT smoke near fuel or when

refuelling.

• Always shut off the engine before

refuelling.

• Do NOT refuel a hot engine.

• Open the fuel cap carefully to allow any

pressure build-up in the tank to release

slowly.

• Always refuel in well ventilated areas.

• Always check for fuel leakage. If fuel

leakage is found, do not start, or run the

engine until all leaks are fixed.

General Carbon-Monoxide Safety

•

Using a combustion engine indoors CAN

KILL IN MINUTES. Engine exhaust

contains carbon-monoxide – a poison you

cannot smell or see.

• Use combustion engines OUTSIDE only,

and far away from windows, doors, and

vents.

General Equipment Use and Care

•

The equipment is designed for domestic

use only.

• Handle the equipment safely and carefully.

• Before use, inspect the equipment for

misalignment or binding of moving parts,

loose components, damage, or any other

condition that may affect its operation. If

damaged, have the equipment repaired by

an authorised service centre or technician

before use.

• Prevent unintentional starting of the

equipment - ensure equipment and power

switches are in the OFF position before

connecting or moving equipment. Do not

carry equipment with hands or fingers

touching any controls. Remove any tools or

other items that are not a part of the

equipment from it before starting or

switching on.

• Do not force the equipment. Use the

correct equipment for your application.

Equipment will perform better and be safer

when used within its design and usage

parameters.

• Use the equipment and accessories etc. in

accordance with these instructions,

considering working conditions and the

work to be performed. Using the equipment

for operations different from those intended

could result in hazardous situations.

• Always keep equipment components

(engines, hoses, handles, controls, frames,

housings, guards etc) and accessories

(cutting tools, nozzles, bits etc) properly

maintained. Keep the equipment clean and,

where applicable, properly lubricated.

• Store the equipment out of reach of

children or untrained persons. To avoid

burns or fire hazards, let the equipment

cool completely before transporting or

storing. Never place or store the equipment

near flammable materials, combustible

gases, or liquids etc.

• The equipment is not weather-proof, and

should not be stored in direct sunlight, at

high ambient temperatures or locations that

are damp or humid.

• Do not clean equipment with solvents,

flammable liquids, or harsh abrasives.

• For specific equipment safety use and care,

see Equipment Safety.

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General Electrical Safety

•

Inspect electrical equipment, extension

cords, power bars, and electrical fittings for

damage or wear before each use. Repair or

replace damaged equipment immediately.

• Ensure all power sources conform to

equipment voltage requirements and are

disconnected before connecting or

disconnecting equipment.

• When wiring electrically powered

equipment, follow all electrical and safety

codes.

• Always use a Residual Current Device

(RCD) (GFCI) / Earth Leakage Circuit

Breaker / Safety Switch when operating this

item (electrical items only).

• High voltage / high current power lines may

be present. Use extreme caution to avoid

contact or interference with power lines.

Electrical shock can be fatal.

General Electrical Safety

•

Electrically grounded equipment must have

an approved cord and plug and be

connected to a grounded electrical outlet.

• Do NOT bypass the ON/OFF switch and

operate equipment by connecting and

disconnecting the electrical cord.

• Do NOT use equipment that has exposed

wiring, damaged switches, covers or

guards.

• Do NOT use electrical equipment in wet

conditions or in damp locations.

• Do NOT use electrical cords to lift, move or

carry equipment.

• Do NOT coil or knot electrical cords, and

ensure electrical cords are not trip hazards.

General Service Information

•

The equipment must be serviced or

repaired at authorised service centres by

qualified personnel only.

• Replacement parts must be original

equipment manufacturer (OEM) to ensure

equipment safety is maintained.

• Do NOT attempt any maintenance or repair

work not described in this manual.

• After use, the equipment and components

may still be hot – allow the equipment to

cool and disconnect spark plugs and/or

electrical power sources and/or batteries

from it before adjusting, changing

accessories, or performing repair or

maintenance.

• Do NOT adjust while the equipment is

running.

• Perform service-related activities in suitable

conditions, such as a workshop.

• Replace worn, damaged or missing

warning/safety labels immediately.

Child Choking Hazard!

• W

ARNING: CHOKING HAZARD - CHILDREN UNDER 8 YRS. CAN CHOKE OR SUFFOCATE ON SMALL PARTS. ADULT

SUPERVISION REQUIRED.

• Carefully inspect anything a baby or child could gain access to, including this product & packaging.

• Dangers include anything of a size that could become stuck or lodged in a baby or child's airway.

• Dangers include things like raw, hard fruit and vegetable pieces, large pieces of meat, bones or sausage skins, popcorn, nuts,

hard lollies and corn chips, small magnets and batteries, coins, beads, marbles and small uninflated balloons, broken toys and smaller toys,

buttons, keys and coins. But there are also many more.

• Pay particular attention to accessories, nuts, bolts, screws, washers, caps, covers, loose parts, parts that could be removed or break off, pieces

of packaging, staples, tape etc.

• In the case of any doubt, secure the item of concern in an appropriate manner, or completely remove the possibility of access by a baby or child.

Inverter Welder Safety

• W

ARNING! READ ALL SAFETY WARNINGS, INSTRUCTIONS, ILLUSTRATIONS AND SPECIFICATIONS PROVIDED WITH THIS

MACHINE. FAILURE TO FOLLOW ALL INSTRUCTIONS LISTED BELOW MAY RESULT IN ELECTRIC SHOCK, FIRE AND/OR SERIOUS

INJURY. ONLY QUALIFIED PERSONS SHOULD INSTALL, OPERATE, MAINTAIN, AND REPAIR THIS UNIT.

Electric Shock

•

Touching live electrical parts can cause fatal shocks or severe burns. The electrode and work circuit are electrically live whenever the output is

on. Incorrectly installed or improperly grounded equipment is a hazard.

• Insulate yourself from work and ground using dry insulating mats or covers, big enough to prevent any physical contact with the work or ground.

• Do not connect more than one electrode or work cables to any single weld output terminal.

• Always verify the supply ground – check and be sure that input power cord-ground wire is properly connected to ground terminal in disconnect

box or that cord plug is connected to a properly grounded receptacle outlet.

Fumes and Gases

•

Welding produces fumes and gases. Breathing these fumes and gases can be hazardous to your health. Keep your head out of the fumes. Do

not breathe the fumes.

• 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, Wear an air-supplied respirator if necessary.

Arc Rays

•

Arc rays from the welding process produce intense visible and invisible (ultraviolet and infrared) rays that can burn eyes and skin. Sparks may fly

off from the weld.

• Wear a welding helmet fitted with a proper shade of filter to protect your face and eyes when welding or watching.

• Wear approved safety goggles with side shields under your helmet.

Additional Safety Reminders

•

Accidental contact of electrode to metal objects can cause sparks, explosion, overheating, or fire.

• Hot parts can cause severe burns. Do not touch hot parts bare handed. Wait for the cooling period before working on gun or torch.

• Overuse can cause overheating. Allow cooling period and follow rated duty cycle. Reduce the current before starting to weld again. Do not block

or filter airflow.

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• Moving parts can cause injury. Keep away from moving parts such as fans. Keep all doors, panels, covers, and guards closed and securely in

place.

• High-frequency due to welding can cause interference. It can interfere with radio navigation, safety services, sensors computers, and/or

communications equipment.

• Electro-static discharge can damage printed circuit boards. Put on grounded wrist strap before handling boards or parts.

• Cylinders can explode if damaged; Shielding gas cylinders contain gas under high pressure and damaged cylinder can explode, so be sure to

treat them carefully.

• Keep cylinders away from any welding or other electrical circuits.

• Never hang a welding torch over a gas cylinder.

• Never allow a welding electrode to touch any cylinder. Never weld on a pressurized cylinder – explosion will result.

• When working with cylinders or operating cylinder valves, ensure that you wear appropriate protectives, boots, clothing, gloves and safety

glasses. When moving cylinders, ensure that the valve is not accidentally opened in transit.

• Before operating a cylinder valve: Ensure that the system you are connecting the cylinder into is suitable for the gas and pressure involved.

Ensure that any accessories (such as hoses attached to the cylinder valve, or the system being connected to) are securely connected.

• Do not, in any manner, come into physical contact with any part of the welding current circuit, which includes:

• Workpiece or any conductive material in contact with it.

• Ground clamp.

• Electrode or Welding Flux-cored Wire.

• Any metal parts on the electrode holder or TIG Torch.

• All the equipment should be kept in good working condition, inspected and, when defective, promptly repaired or withdrawn from service.

• Training should be sought out in the safe use of this equipment, the processes and the emergencies.

• WARNING! THE PRODUCT MUST BE FULLY ASSEMBLED BEFORE OPERATION! DO NOT USE A PRODUCT THAT IS ONLY PARTLY

ASSEMBLED OR ASSEMBLED WITH DAMAGED PARTS! FOLLOW THE ASSEMBLY INSTRUCTIONS STEP-BY-STEP.

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Safety Symbols

The product may have safety warning labels attached to it, explained below. Understand the symbols on your

product and their meanings. If any stickers become unreadable, unattached etc., replace them.

Flammable Material Hazard

Flammable liquids, gases, or

substances etc may present.

Avoid ignition sources and open

flames. Danger of fire.

Read User Manual

Read and fully understand

product safety warnings,

operation, procedures etc before

using the product.

Use Hand Protection

Wear appropriate hand protection

and take due care as the product

or use of the product may present

hand hazards.

Carbon-Monoxide Hazard

Do not use the product in

confined areas or without

adequate ventilation. Carbon-

monoxide poisoning can be fatal.

Electrocution / Electrical Shock

Hazard

High voltage or high current

electricity may be present or

required by the product. Take

due care when handling electrical

products, cables, plugs and

leads. Electrical shock can be

fatal.

Toxic Fumes / Dust Hazard

Using the product or by-products

from use may produce fumes,

smoke or particles that could be

harmful if inhaled. Wear

appropriate breathing protection

and have adequate ventilation.

Explosive Material Hazard

Combustible liquids, gases, or

substances etc may be present.

Avoid ignition sources and open

flames. Danger of explosion.

Cutting / Amputation Hazard

The product may have blades,

edges or mechanical devices that

can cause severe cut injury to

fingers, limbs etc. Take due care

when handling and using the

product.

Crush Hazard

The product may have blades,

edges or mechanical devices that

can cause severe crush injury to

fingers, limbs etc. Take due care

when handling and using the

product.

Single Operator Only

The product must be operated by

a single person only. More than

one person operating the product

may introduce additional hazards.

Use Face Protection

Wear appropriate full-face

protection and take due care as

the product or use of the product

may present face and eye

hazards.

Use Foot Protection

Wear appropriate foot protection

and take due care as the product

or use of the product may present

foot hazards.

Use Eye / Ear / Head Protection

Wear appropriate eye and / or

ear and / or head protection and

take due care as the product or

use of the product may present

eye, hearing, and head hazards.

Running Hazard

Do not run on or near the product

as doing so may present a fall

hazard.

Diving Hazard

Do not dive into the product as

doing so may present a neck /

head injury hazard.

Adult Supervision Required

Always supervise children and

other users of a product to

prevent drowning or injury.

Skin Penetration / Puncture

Hazard

The product may produce

pressure, emit liquids or objects

that can cause severe injury to

fingers, limbs, blood etc. Take

due care when handling and

using the product.

Hot Surface Hazard

Be aware that the product may

produce high temperatures and

hot surfaces that can cause burn

injuries.

Flying Debris Hazard

Be aware that the product or use

of the product may present

hazards produced by flying

debris. Wear appropriate clothing

and protective devices.

Moving Parts Hazard

Be aware that the product

contains or uses mechanical

devices that move or rotate.

Always wait for moving parts to

stop fully before handling the

product, adjusting, maintenance

etc.

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Carbon-Monoxide Hazard

Do not use the product in

confined areas or without

adequate ventilation. Carbon-

monoxide poisoning can be fatal.

Pull Hazard

Be aware that the product

contains or uses mechanical

devices that can pull in objects

and can cause severe injury to

fingers, limbs etc. Take due care

when handling and using the

product.

Slope / Fall Injury Hazard

Be aware that using the product

on sloping surfaces or in slippery

conditions may present additional

dangers from falls and contact

with blades, moving parts, hot

surfaces etc.

"Slam Dunk" Warning

Do NOT attempt "slam dunk"

manoeuvres as this may result in

severe injury due to falling,

product breakage or collapse etc.

Electrocution / Electrical Shock

Hazard - Outdoor

High voltage or high current

electricity may be present or

required by the product. Do NOT

use in rain, damp, or wet

conditions. Electrical shock can

be fatal.

Electrocution / Electrical Shock

Hazard - Disconnect

High voltage or high current

electricity may be present or

required by the product. Always

disconnect the product from the

electrical supply before handling

the product, adjusting,

maintenance etc.

Power Line Electrocution

Hazard

High voltage / high current power

lines may be present. Use

extreme caution to avoid contact

or interference with power lines.

Electrical shock can be fatal.

"Kick-Back" Hazard

High level of "kick-back" hazard

that can cause the machine to

suddenly rotate towards operator.

Kick-back injury can be fatal.

Winch Operator Position

Hazard

Do NOT stand between winch

and load. Do NOT use winch to

move people.

Winch Lift Hazard

Do NOT LIFT load vertically. Use

machine to PULL only.

Cable Hazard

Ensure that load bearing cable is

not kinked or knotted.

Winch Cable Hazard

Ensure that there is a minimum

number of cable coils on

winching mechanism.

Winch Hook Hazard

Carry hook to load – do NOT

throw or run.

Flash / Blinding Hazard

Wear appropriate eye protection

for welding. Direct exposure to

weld arcs may cause permanent

eye injury.

Laser Hazard

Laser may be in use – do NOT

look directly at laser or allow

others to.

Choking Hazard

Children under 8 yrs. Can choke

or suffocate on small parts. Adult

supervision required.

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Table of Contents

Safety ............................................................................................................................................................. 2

Safety Symbols ........................................................................................................................................................... 5

Parts Identification ....................................................................................................................................... 8

Installation ..................................................................................................................................................... 9

Parameters ............................................................................................................................................................... 11

Operation ..................................................................................................................................................... 12

Product Description .................................................................................................................................................. 12

Operating Instructions .............................................................................................................................................. 12

DC Tig Welding .................................................................................................................................................. 12

AC Tig Welding .................................................................................................................................................. 13

General Operation .................................................................................................................................................... 13

MMA Welding ..................................................................................................................................................... 13

TIG Welding ....................................................................................................................................................... 13

TIG Welding Fusion Technique ......................................................................................................................... 14

TIG Welding with Filler Wire Technique ............................................................................................................. 15

Storage and Maintenance .......................................................................................................................... 16

Specifications ............................................................................................................................................. 17

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Parts Identification

No. Name No. Name

1 Quick Connector Socket: Welding Machine Output (-) 10 110V Power LED

2 Quick Connector Socket: Welding Machine Output (+) 11 220V Power LED

3 TIG Torch Switch Socket 12 Function Select Button

4

TIG torch Socket

13

MMA Function

5

Clean Welding Adjustment

14

TIG DC Function

6

Current Adjustable Knob

15

TIG AC Function

7

Current Display

16

Power Cord Anchorage

8 Overheating LED 17 Power Switch

9 QC LED 18 Gas Inlet

•

Overheat protection indicator: When machine works for a continuous, extended period and at large

currents, to prevent component from burning out, the overheat protection function is set. When the LED

indicator is lit, work must be stopped, but no need to turn OFF the machine. After 2-3 minutes, it will resume.

•

Abnormality indicator: The LED indicator will light-up when there is anything abnormal inside the machine.

When it is lit, please turn OFF the power switch and restart the machine after the indicator is OFF. It can

continue to work if the machine returns to normal. If indication occurs again, please have it checked by

professionals or the manufacturer.

Spare parts available

for purchase, scan QR

code below:

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Installation

1. Connect the welding tongs (grounding clamp and electrode holder) correctly according to the image below.

First, make sure that the cable, welding tongs and quick plugs are connected reliably.

2. Connect the electrode holder in the quick socket with the ‘-‘ polarity, and then tighten it. A suitable electrode

is connected to the holder.

3. Connect the grounding clamp into the quick socket with the ‘+’ polarity, and then tighten it. The grounding

clamp connects to the workpiece.

(Reverse polarity is acceptable).

IMPORTANT! Ensure that all cables and the earth cable connections are tight. If a connection is slack, it will

result in a voltage drop that will cause the connections to overheat.

4. While using TIG welding, Take the TIG Torch and put the Gas-electricity plug of the welding gun to the Gas

Output (4) at the front panel, and fasten it securely. Put the Switch connection on the Torch to the trigger slot

(3) and secure it as well.

5. lace the fastening plug of the torch cable to the ‘+’ polarity socket and Earth clamp at the other terminal, for

the workpiece.

6. Connect the Shielding gas (Argon) cylinder to the gas inlet at the back panel of the machine.

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Parameters

Current setting: The correct current, or amperage setting primarily depends on the diameter and type of

electrode selected. Select an amperage based on the material thickness and welding position.

MMA

Diameter of welding rod (mm) φ1.6 φ2.0 φ2.5 φ3.2 φ4

Welding current (A) 20-60 60-100 80-120 120-140 140-200

TIG

Tungsten needle

(mm)

Current

(A)

Collet & its body size selection

i

s based on the needle size.

Φ1.0 20-80 Nozzle #4 Ø 6mm

Φ1.6 50-120 Nozzle #5 Ø 8mm

Φ2.0 100-140 Nozzle #6 Ø 10mm

Φ2.4 140-200 …

Argon Gas Flow with Current Adjustment and Material Thickness

Thickness (mm) Current (A)

(CFM) Gas Flow (l/min)

Stainless steel Aluminium Copper

0.3 - 0.5 10 - 40 4 6 6

0.5 - 1.0 20 - 40 4 6 6

1.0 - 2.0 40 - 70 4 – 6 8 - 10 8 - 10

2.0 - 3.0 80 - 130 8 - 10 10 - 12 10 - 12

3.0 - 4.0 120 - 170 10 – 12 10 - 15 10 - 15

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TIG160A MK III Inverter Welder

Operation

Product Description

TIG160A MK III Inverter Welder functions both as Tungsten Inert Gas (TIG) and MMA (Manual Metal Arc)

Machine.

In Tungsten Inert Gas (TIG) welding, a non-consumable tungsten electrode is used to produce the weld. The

weld area and electrode are protected by an inert shielding gas (argon) from oxidation or other atmospheric

contamination. A filler metal is normally used. A constant-current welding power supply produces electrical

energy, which is conducted across the arc through a column of highly ionized gas and metal vapours. TIG is

most used to weld thin sections of stainless steel and non-ferrous metals such as aluminium, magnesium, and

copper alloys.

In Manual Metal Arc Welding (MMA), with consumable, flux- covered electrode and a ground clamp, a short-

circuit is initially made on the weld piece. An electric arc forms between electrode and workpiece, which heats up

enough to melt both. As the electrode melts, the flux coating on the electrode develops gas and slag, which help

protect the weld pool. The gas keeps air and other pollutants away, while slag forms on top of the weld pool to

protect the weld seam.

The machine uses a high performance IGBT Technology, which is very useful as they give power that can be

used for different welding processes.

•

Hot Start provides excellent arc ignition without the electrode sticking and avoiding any metallurgical default

in the weld.

•

Anti-sticking feature minimizes the short circuit current in the event of the electrode sticking to the work

piece.

•

VRD (Voltage Reduction Device) in-built function provides an additional measure of safety.

•

Arc force in-built improves the weld performance on the specified size of electrodes to be used, making the

job easier.

Operating Instructions

DC Tig Welding

1. Turn ON the power switch, the fan will begin to rotate.

2. Open the Argon switch and adjust the gas flow to the rated standard.

3. Position the welding switch to the upper position/TIG WELDING.

4. When positioning the switch to the DC position, it is DC arc welding, which can be for stainless steel, iron,

copper and other metals.

5. Adjust the arc initiation current according to the welding requirement.

6. Set the suitable welding current according to the material’s thickness.

7. Press the torch switch and the electromagnetic valve will start. You will start to hear electricity-releasing HF

sparks and at the same time, Argon gets released from the torch.

8. Keep a 2-4mm space between the Tungsten pole and the workpiece. Press the torch control switch.

Between the electrode and the workpiece, HF electricity is released. After arc initiation, the HF sparks soon

disappears, and you can begin your work.

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TIG160A MK III Inverter Welder

AC Tig Welding

Positioning the switch to the AC position will convert it to AC arc welding, which can be for aluminium materials.

NOTE: When using the AC TIG welding, the smallest current is not easy for arc initiation. Please set the current

to 20A.

General Operation

NOTE: It is recommended that you try welding and rate of welding current first on something else than the actual

work piece. You can start welding after having made the necessary selections.

The MMA/ TIG Switch (1) is used to switch between the two welding operations: MMA and TIG welding.

MMA Welding

1. Always secure the earth cable clamp directly on the welding piece. Turn the power switch to ‘ON’ position.

Cooling fan inside the machine should begin to work once welding starts.

2. Clamp the welding rod on the electrode holder, the machine is in the manual welding mode and in the

standby state.

3. Select a suitable welding current with the adjustment knob (2) according to the thickness of the welding

workpiece, diameter of welding rod, working position and technology needs (see Parameters

). If t

he current

is too high, intensified splashing occurs and if it’s too low, the melted welding stick becomes a fluid, drips

transfer and would not proceed smoothly.

For beginners, the first difficulty is priming the arc. For best results proceed as follows:

1. T

est the current intensity and the electrode on a piece of scrap material. Hold the electrode approx. 2cm

above the start of the joint. Touch the workpiece with the electrode and stroke it repeatedly on-off the

workpiece to start the arc.

2. Watch the arc only through a face shield and keep the arc length approximately 1–1.5 times the diameter of

the electrode. Hold the electrode at an angle approximately 70° – 80°.

3. Wait until the joint has cooled completely before removing the slag. If you wish to continue welding a joint

after taking a break, the slag at the end of the joint must be removed first. Prime the arc in the joint and melt

the electrode at the point where the two joints meet.

TIG Welding

TIG welding works on same principle of arc welding. In a TIG welding process, a high intense arc is produced

between tungsten electrode and work piece. A shielding gas (Argon) is also used which protect the weld surface

from oxidization.

1. Open the shielding cylinder and set the required gas flow using the pressure (flow) adjustment knob on the

regulator.

2. Press the switch of the TIG torch, and the electromagnetic valve will start. The sound of HF arc striking can

be heard, while at the same time Argon is flowing from the torch burner.

NOTE: Before welding, user must press the switch of the torch for several seconds until all the air is drained out.

When welding is over, Argon will still flow out for a few seconds to protect the welding spot before cooling down.

The torch must be kept on the welding place for a short time before the arc has been extinguished.

3. Set a suitable welding current and make sure that the welding current is adequate to the thickness of the

workpiece and the process demand.

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TIG160A MK III Inverter Welder

4. Maintain 2-4mm from the Tungsten electrode to the work piece. Press the switch of the torch, burn and strike

arc. The sound of the HF arc-striking will diminish. The welding machine can be operated now, and the

operation can be conducted with the help of a filler rod.

TIG Welding Fusion Technique

Some welds combining thin materials can be accomplished without filler metals like edge, corner, and butt joints.

This is known as Fusion welding, where the edges are melted together using only the heat and arc force. Once

the arc is started, the torch is held in place until a weld pool is created, a circular movement of the Tungsten will

assist in creating a weld pool. Once the pool is established, tilt the torch at about a 75°, then move smoothly and

evenly along the joint while fusing the materials together.

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TIG160A MK III Inverter Welder

TIG Welding with Filler Wire Technique

A filler rod is added to the weld pool to build up reinforcement and create a strong weld. The filler metal is

introduced to the leading edge of the weld pool formed by fusion. The rod is usually held at 15°, the arc will melt

the filler into the weld pool as the torch is moved forward.

Also, a dabbing technique can be used to control the amount of filler wire added, the wire is fed into the molten

pool and retracted in a repeating sequence as the torch is moved slowly and evenly forward.

It is important during the welding to keep the molten end of the filler wire inside the gas shield as this protects

the end of the wire from being oxidised and contaminating the weld pool.

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TIG160A MK III Inverter Welder

Storage and Maintenance

Storage

Store the equipment and accessories out of children’s reach in a dark and dry place at above freezing

temperature. The ideal storage temperature is between 5 and 30°C. Store the electric machine in its original

packaging.

Maintenance

All the maintenance work must be conducted under the condition of turning OFF all power supply; please make

sure that the power switch is turned OFF and that the power plug is pulled out.

•

Regularly remove the dust on the welding machine with dry compressed air. When use it in heavy fume and

polluted air, do this job at least once a month. Compressed air should drop down to the required pressure to

prevent damaging the small parts and units in machine.

•

Avoid water or moisture from getting into the welding machine. If this happens, gently blow-dry the welding

machine immediately, then measure the insulation with an insulation resistance meter; it can only be used

when the measuring result is accepted.

•

If the welding machine will not be used for an extended period, it should be placed in its original packaging

and stored in a cool, dry place.

•

Any improper or incorrect operation may cause the welder’s failure and damage. Routine maintenance on

the power control switch, grounding device, welding electrode holder, coupling device and set screws should

be performed on a regular basis.

NOTE: Repairing welding equipment should be carried out by a qualified person using original spare parts. This

ensures the safety of the device as well as yourself. It is recommended that any maintenance work be performed

by qualified technicians. Before maintenance, please contact a qualified technician or service centre for

professional advice.

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TIG160A MK III Inverter Welder

Specifications

No-load Power 65-70V

Power Factor COS 0.93

Efficiency 85%

Output Current Range 15-160 Amps

Input voltage 240V AC

Power Plug 15A Australian Standard

Welding Polarity AC/DC

Duty Cycle

TIG: 60% @ 160A, 100% @ 140A. MMA:

60% @ 160A, 100% @ 140A

IP Rating IP21

Welder Type TIG/ARC

Weldable Metals

Aluminium, Bronze, Cast Iron, Chromoly,

Copper, Magnesium, Stainless Steel, Steel,

Zinc alloys

Suitable Electrodes 1.6-4mm

Electrode Cord Length 1.8m

Generator Recommended 8kVA

TIG Torch Length 4m

Earth Clamp Length 1.5m

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Some experts believe that the incorrect or prolonged use of almost any

product may cause serious injury or death. To help reduce your risk of

serious injury or death, refer to the information below. For more information,

see www.datastreamserver.com/safety



Consult all documentation, packaging,

and product labelling before use. Note

that some products feature

documentation available online. It is

recommended to print and retain the

documentation.



Before each use, check the product for

loose/broken/damaged/missing parts,

wear, or leaks (if applicable). Never use a

product with

loose/broken/damaged/missing parts,

wear, or leaks.



Products must be inspected and serviced

(if applicable) by a qualified technician

every 6 months. This is based on

average residential use by persons of

average size and strength, and on a

property of average metropolitan size.

Use beyond these recommendations may

require more frequent

inspections/servicing.



Ensure that all users of the product have

completed a suitable industry recognised

training course before being allowed

access to the product.



The product has been supplied by a general merchandise

retailer that may not be familiar with your specific

application or description of application. Be sure to attain

third-party approval from a qualified specialist for your

application before use, regardless of any assurances from

the retailer or its representatives.



This product is not intended for use where fail-safe

operation is required. As with any product (for example,

automobile, computer, toaster), there is the possibility of

technical issues that may require the repair or

replacement of parts, or the product itself. If the possibility

of such failure and the associated time it may take to

rectify could in any way inconvenience the user, business,

or employee, or financially affect the user, business, or

employee, then the product is not suitable for your

requirements. This product is not intended for use where

incorrect operation or a failure of any kind, including but

not limited to, a condition requiring product return,

replacement, parts replacement, or service by a

technician may cause financial loss, loss of employee

time or an inconvenience requiring compensation.



If this product has been purchased in error when

considering the information presented here, contact the

retailer directly for details of their returns policy, if

required.

diagrams, or images may be reproduced or transmitted in any form or by any means, electronic or

mechanical, including photocopying, scanning, or recording, or any information storage and retrieval system,

without express permission or consent from the publisher.

Arc TOLWDRROBT16 ROSSI 160 Amp Inverter Welder

Product's Documents

Product manual

Specifications

ROSSI TOLWDRROBT16 Questions and Answers