weldtech ATP160 Inverter Plasma Cutter Instruction Manual

Instruction Manual for weldtech models including: ATP160 Inverter Plasma Cutter, ATP160, Inverter Plasma Cutter, Plasma Cutter

AW ATP160 MANUAL 2024 email

ATP160

Operational manuals

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Weldtech ATP160 Manual Email 250924

ATP160
160A INVERTER PLASMA CUTTER /MMA(STICK)/TIG WELDER
OPERATING INSTRUCTIONS
www.weldtech.net.nz

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2

ATP160 Welding Machine
Contents
General Overview.......................................................5 Specifications.............................................................7 Box contents..............................................................8 Know your machine....................................................9 Plasma Cutting.........................................................10 Quick Setup Guide...................................................11 PT-31 Plasma Torch................................................12 Plasma Cutting Guide..............................................13 TIG welding..............................................................15 Expanded View of TIG Torch...................................16 TIG Basic Welding Guide.........................................17 TIG Welding Troubleshooting..................................19 MMA (Stick) Welding...............................................20 MMA (Stick) Basic Welding Guide...........................21 MMA (Stick) Troubleshooting..................................27 Care & Maintenance................................................28 Accessories & Consumables...................................28 Knowledge & Resources..........................................28 Change filter operation................................... .........29 Explosion Diagrams & Part List...............................30 Part List...................................................................31 Safety Warning........................................................32 Warranty..................................................................35
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ATP160
160A - INVERTER ARC-TIG -PLASMA CUTTER
The new Weldtech ATP160 Multi-process 3n1 ARC-TIG -PLASMA Cutting machine utilises the latest digital control technology to output an amazing 30 amps Plasma Cutting , 160 amps TIG and 140 amps Stick Arc power, all from a 10A single phase plug. Designed for portable repair work and small workshop use, the ATP160 is ideal for a welding enthusiast or hobbyist requiring a compact machine for basic repairs and general light welding requirements. The ATP160 Plasma Plasma Cutter is ideal for cutting steel up to 6mm thick, with a severance cut of 8mm. With the 160A TIG , you can weld Steel, Chrome Moly, Stainless, Titanium, or any other metal that can be welded with DC output, up to 3mm thickness. The 15-160A DC Stick/Arc output, with easy Arc start function precision welding Arc control, and super smooth inverter stabilised welding characteristics, is capable of welding like a pro with arc electrodes up to 3.2mm / 6mm steel thickness.
· ATP160 is the perfect choice for projects and repairs around the home , small workshop and auto repair tasks.
· Combination 3-in-1 multifunction Plasma Cutter/TIG Torch/ Stick Arc professional welding machine.
· Advanced IGBT technology, synergic controlled, very easy, precise and simple operation.
· Featured wave-form control system: perfect wave form of volts and amps during short circuits and Arc burning cycles.
· Automatic input voltage fluctuation controller, over-voltage protection, under voltage protection, over current protection, over load protection
· Automatic temperature control, fan on demand function · Generators protected and optimised · The ATP160 utilises cutting edge digital technology to deliver
a flawless weld, making spatter and post-weld clean-up almost non-existent.

Earth Clamp Include d

Specifications

Supply Power Plasma Cutter
Welding current Output: TIG Torch STICK ARC
Duty Cycle: Plasma Cutter TIG Torch STICK ARC
DC Open Circuit Voltage Efficiency Power factor Cooling Method Net Weight Product Size Package Weight

230V 60Hz / 10A Single Phase 10 - 30A
15A - 160A 15A - 140A
40% @30A, 100% @20A 50% @160A, 112A @100% 25% @140A 58V 85% 0.93 Fan Cooled 16kg 220x465x330mm 18kg

INCLUDES
5m Plasma Cutter Torch assembly, 4m (WP-17) TIG Torch Assembly,
4m 400A Electrode Holder with Cable, 3m 400A Earth Clamp with Cable,
2m Argon Gas Hose, Gas Regulator, TIG Consumables Starter Kit
& Plasma Consumables Starter Kit.

Welds up to 6 mm
Cuts up to 8 mm

MONTH TRADE WARRANTY

With 10A Plug - Ideal for a welding enthusiast or hobbyist requiring a compact machine!
4

General Overview
The new digitally controlled ATP160 is a DC TIG, stick and plasma purpose unit, designed for portable repair work and small project use. It is ideal for the welding enthusiast or hobbyist with basic non aluminum repair needs and general light welding requirements. The ATP160 features a lightweight IGBT inverter design and can provide capable service for small projects and repairs. The ATP160 is not intended for use in production or for heavy fabrication chores. NOTE: This unit is not suitable for welding aluminum.
General Use and Care: Care should be taken to keep the unit out of direct contact with water spray. The unit is rated IP21S, which rates it for light contact with dripping water but should never be used in the presence of water for safety. It is a good idea to remove the welder from the vicinity of any water or moisture source to reduce the possibility of electrocution or shock. Never operate in standing water.
Every 1-2 months, depending upon use, the welder should be unplugged, opened up and carefully cleaned with compressed air. Regular maintenance will extend the life of the unit.
IMPORTANT: Before opening the unit's case for any reason, make sure the unit has been unplugged for at least 10 minutes to allow time for the capacitors to fully discharge. Severe shock and/or death could occur.
Do not restrict air flow or movement of air around the welder. Allow a buffer distance of 60cm (2ft) from all sides if possible, with a minimum distance of at least 45cm (18") clearance. Do not operate the welder immediately in the weld area or the force of the fan will cause welding issues such as unstable arc, or porosity.
Do not mount in areas that are prone to severe shock or vibration. Lift and carry the welder by the handle.

Do not direct metallic dust or any dirt intentionally toward the machine, particularly in grinding and welding operations. Make sure the panel is protected from damage during welding and cutting operations.
Duty Cycle. This unit can be described as a general purpose, do it yourself type of multi process unit and is intended for hobby use and general small repair and build activities. Care should be taken not to exceed the duty cycle limit of the ATP160 for maximum servicelife. Once the duty cycle has been exceeded, heat may continue to build in the electronics. The duty cycle is based off a 10 minute duty cycle rating at 40° C. This means that the unit is capable of being operated at the maximum amps for the stated percent of time out of 10 minutes without a cool down break. For the balance of the 10 minute time period, the welder should rest without welding or cutting for maximum service life. The temperature light will come on and the welder will automatically stop welding or cutting when an overheat condition has occurred. If this occurs, stop and allow the unit to cool while switched on. Heat will continue to be generated by and transferred to the electronics after welding has ceased. Welding in humid, or hot conditions can affect duty cycle as well. Do not turn off the overheated welder until it has safely cooled for at least 15 minutes. Once the overheated condition has had time to clear, cycle the power switch off and back on to reset the unit. Do not operate the welder with the covers removed.

ATP160 Welding Machine

Over Current. Over currents can occur if there is a fault in the power supply system or inside the unit. If this occurs, and the LED lights up, turn the unit off, check for external causes and remedy the problem. If none is found, cycle the power switch off and then back on. If the over current light does not clear after cycling the power switch, contact Maintenance pesonnel for trouble shooting.
Blow Back and High Frequency Start. The welder uses High Frequency to start the TIG arc. HF is generated by a point gap system similar to an older automotive point/ coil system. A slight buzz, or hiss may be heard immediately upon start as the HF energizes. A bright blue light may be emitted from the front or side panel as the spark energizes. This is normal and safe as long as the covers are in place. Do not activate the HF unless you are in position and ready to weld to minimize point gap wear. Point gap should measure between 0.030"-0.045". The Plasma cutting torch is an improved blowback design which eliminates the need for High Frequency and its function is not dependent upon the HF points or point gap adjustment. Compared to older TIG/Stick Plasma designs, this helps to reduce point gap wear issues.

This manual has been compiled to give an overview of operation and is designed to offer information centered around safe, practical use of the welder. Welding is inherently dangerous. Only the operator of this welder, can ensure that safe operating practices are followed,through the exercise of common sense practices and training. Do not operate this machine until you have fully read the manual, including the safety section.

80 60
40

100 120
140

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Specifications

ATP160 (230V)

Plasma Cutter

Welding current Range(A)

TIG

MMA (stick)

Nominal DC Open Circuit Voltage (OCV)

Welding Output (230V)

Plasma Cutter TIG
MMA (stick)

Rated Input Current(A)

Plasma Cutter TIG

MMA (stick) Plasma Cutter

Duty Cycle (%)

TIG

MMA (stick)

Efficiency Power factor Welder Type Output Terminal Type Number of phases Nominal supply Voltage Nominal Supply Frequency Cooling Method Net Weight Dimensions (Height*Width*Depth)

10-30A 230V 15-160A 230V 15-140A 230V
58V
30A/92V 160A/16.4V 140A/25.6V
10A 230V 10A 230V 10A 230V 40% @30A 100% @20A 50% @160A 100% @112A 25% @140A 100% @70A 85% 0.93 Plasma Cutter/STICK/TIG WELDER 15-26 Dinse Style Connector Single Phase 230V 50Hz Fan Cooled 18kg 22x46.5x33CM

ATP160 Welding Machine Box contents
· ATP160 Plasma Cutter Cutter/TIG/Stick/Arc 3-in-1 Welding Machine. · 4 Meter Professional Plasma Cutter Torch with accessories. · 4 Meter Professional TIG Torch. · 3 Meter Electrode Holder with Cable. · 3 Meter Work Clamp with Cable. · 2 Pieces of Tungsten Electrode 1.6mm. · 2 Pieces of Tungsten Electrodes 2.4mm. · 2 pieces of Electrode 3.2mm. · 2 pieces of Electrode 2.4mm. · 1 piece of Argon regulator. · Owner's Manual.
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Know your machine

Plasma Cutter/ TIG/ MMA(stick) Selector
Power Switch
Current adjustment knob
1
Output connector (DC-)
2
TIG / CUT gun connection
Plasma Cutter/ TIG/ MMA(stick) Selector Switch.

80 60
40

100 120
160

Two-pin socket

Power Switch

ON OFF

CUTTER TIG STICK
A

Air Pressure Gauge
Current adjustment knob
Pressure regulating valve

Air Pressure Gauge Pressure regulating valve
Output connector (DC+)
Power input cable

Output connector (DC-)
TIG / CUT gun connection
9

Output connector (DC+)

Two-pin socket

Grounding screw

Drain

TIG ARGON IN CUT AIR IN

ATP160 Welding Machine

PLASMA Cutting

ON OFF

CUTTER TIG STICK
A

WARNING! High Voltage is present. Turn off the unit when changing or checking the torch and its consumables. Also turn the unit off while changing torches. Severe shock, burns or electrocution can occur if the plasma cutting torch is accidentally fired or if the switch is activated while the torch is being disassembled.

CUT gun(PT-31) connection

Earth clamp connection

Two-pin socket

Please connect the earth clamp to the positive polarity, and the Plasma Cutter welding torch to the negative polarity

1. Wear your safety gear. Generally you want the same type of protective gear as when welding. Plasma has high arc voltage if the job or bench is wet and you place your hand or arm on it you can become part of the circuit and receive a shock, be sure you are wearing leather gloves, Full length pants and covered shoes, Wear eye protection a #5 shade is the minimum eye protection with other shades
2. Connect the Earth Clamp securely to the work piece or the work bench.
3. Place and hold the torch vertical at the edge of the plate.

5. Correct amperage and travel speed are important and relevant to material thickness and are correct when sparks are exiting from the work piece. If sparks are spraying up from the work piece there is insufficient amps selected or the travel speed is too fast.
6. To finish the cutting, release the torch switch. The air flow will continue for 30 seconds to cool the torch head. Do not disconnect air until this cooling period has been completed. Failure to do this will result in torch head damage.

4. Pull the trigger to energise the arc and move the torch towards the plate. When the cutting arc has established and cut through the edge of the plate start moving evenly in the direction you wish to cut.

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QUICK SETUP GUIDE: REAR CONNECTIONS FOR PLASMA OPERATION Compressor and Dryer Diagram

Compressor and Air hose w fittings (Customer Supplied)

Regulator Assembly with built in water trap and dirt filter (Included)

Air Drying Filter Device (Customer Supplied)

Please Note: Plasma cutters require a dry, moisture free air supply. Ensure you have a dessicant dryer/filter or electric air drying system in place. Damage/faults caused due to moisture in the air supply will not be covered under the warranty of this machine.
11

ATP160 Welding Machine
PT-31 PLASMA TORCH
PLASMA TORCH: PT-31
1
2 3 4 5

NO.

Description

O-Ring

Electrode - Std.

Swirl Ring

Std. Cutting Tip

Shield Cap

Part Number QTY

WT45065

2pk

WT-WT18205 5pk

WT-WT18785 2pk

WT-WT18866 5pk

WT-WT18204 2pk

www.weldtech.net.nz 12

Plasma Cutting Guide
Amperage Guide
Thickness (mm) Output Current

TOO FAST

TOO SLOW

CORRECT

Piercing Technique

2. When the arc breaks through the work, bring the torch to an upright position and proceed to cut
1. To start a pierce, tilt the torch to prevent molten material from coming back against and damaging the torch.
NOTE: Keep moving while cutting. Cut at a steady
so that the arc lag is 10° to 20° behind the travel di-
of the cut.
Operating Techniques
1. Piercing may be pierced with the torch touching the work. When piercing thicker materials, position the torch 0.5mm (0.2") above the work piece.

It is advisable when piercing thicker materials to
which makes it a lot easier and gives increased
move the torch along the cut path. This will reduce the chance of spatter from entering the torch and prevent the possibility of welding the tip to the plate. The torch should be angled at about 30° when starting to pierce, and then straightened after accomplishing the pierce.
2. Grate Cutting or heavy mesh cutting, do not release the torch switch. This avoids the 2 second pre-start portion of the cutting cycle.
3. Edge Starting perpendicular to the work piece with the front of the tip near (not touching) the edge of the work piece at the point where the cut is to start. When starting at the edge of the plate, do not pause at the edge and force the arc to `reach' for the edge of the metal.
NOTE: The speeds given here are typical for best quality cuts. Your actual speeds may vary depending on material composition, surface condition, operator technique, etc.
If cutting speed is too fast, you may lose the cut. With slower speeds excessive dross may accumulate. If speed is too slow, the arc may extinguish. Air cutting typically produces a rough face on stainless steel and aluminium.
4. Drag Cutting - Position torch tip slightly above work piece, press torch switch and lower torch tip forward work piece until contact is made and cutting arc is established. After cutting arc is established, move the torch in the desired direction keeping the torch tip slightly angled, maintaining contact with the work piece.
Avoid moving too fast as would be indicated by sparks radiating from the topside of the work
tain sparks concentration at the underside of the work piece and making sure the material is completely cut through before moving on.

5. Direction of Cut - The plasma gas stream swirls as it leaves the torch to maintain a smooth col-

of a cut being more square than the other.

side of the cut is more square than the left.

ATP160 Welding Machine

Establish the Cutting Arc as Quickly as Possible.

Cutting Speed Guide

Material

Thickness Cutting Speed

(mm)

(mm/s)

Carbon

Steel

(AISI 1020)

6.4

Stainless

1.6

140

Steel

3.2

(AISI 304)

Aluminium

1.6

190

(6061)

6.4

To make a square-edged cut along an inside diameter of a circle, the torch should move counter clockwise around the circle. To keep the square edge along an outside diameter cut, the torch should travel in a clockwise direction.
6. Quality Cuts Dross (slag) is the excess material that spatters and builds up on the underside of the work-piece as you cut. Dross occurs when the operating procedure and technique is less than optimal. It will require practice and experience to obtain cuts without dross. Although less than optimal cuts will contain dross, it is relatively easy to remove by break-
is generally only a minor inconvenience.

A combination of factors contributes to the build-up of dross. They include; material type, material thickness , amperage used for the cut, speed of the torch across the work-piece, condition of the torch tip, in-
inversely proportional relationship between output current and speed of cut. Do not use more output current than is necessary and adjust speed of cut toward minimizing dross build-up on underside of cut. Experiment with adjusting current and speed to minimize dross.
When dross is present on carbon steel, it is commonly referred to as either `high speed, slow speed, or top dross'. Dross present on top of the plate is normally caused by too great a torch to plate distance.
`Top dross' is normally very easy to remove and can
dross' is normally present on the bottom edge of the plate. It can vary from a light to heavy bead, but does not adhere tightly to the cut edge, and can be easily
bead along the bottom of the cut edge and is very
it is sometimes useful to reduce the cutting speed to produce `slow speed dross'. Any resultant clean up can be accomplished by scraping, not grinding.

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TIG welding

ON OFF

CUTTER TIG STICK
A

TIG gun connection

Earth clamp connection

Two-pin socket

Please connect the earth clamp to the positive polarity, and the TIG welding torch to the negative polarity

1. Turn on the power switch at the front panel, digital current meter is normal, fan begins to rotate.
2. Open the valve of argon cylinder , adjust the volume of flow meter and make it is adequate to welding.
3. Press switch of torch, electromagnetic valve is started. Sound of HF arc striking can be heard, at the same time argon is flowing from torch burner.
NOTES:When welding is first operated, user must press switch of torch several seconds and begin to weld until all of air is be drained out. When welding is over, argon will still flow out in

several seconds in order to protect welding spot before cooled down. So torch must be kept welding place some time before arc has been extinguished.
4. Set suitable welding current and make sure welding current is adequate to thickness of work piece and process demand.
5. It is 2-4 mm from welding tungsten electrode to work piece, press control knob of torch, burn and strike arc, sound of HF arc-striking will be diminished. The welding machine can be operated now.

ATP160 Welding Machine
EXPANDED VIEW OF TIG TORCH
(Actual appearance may vary slightly from what is listed.)
TIG TORCH: 38419
1
2 3 8 5 4 6 7

NO.

Long Back Cap with O-Ring

Short Back Cap

Torch Head

Insulator

Collet 1/16'' , 5/64'' or 3/32''

Collet Holder

Ceramic Cup #4,5, or 6

Tungsten

QTY
1 Opt. 1 1 1 1 1 4
www.weldtech.net.nz 16

TIG Basic Welding Guide

electrode since 70% of the heat is concentrated at the work piece.

TIG Welding is a fusion procedure that uses an electric ARC created between an infusible tungsten electrode and base material to be welded. For TIG welding an inert gas must be used (Argon) which protects
up of rods suitable to the material to be welded (steel, stainless steel, copper etc).

TIG Welding (Fig 15)
Torch

Electric Current Inert Gas

Rod Protective Gas

Tungsten Electrode Deposit
Melted Area
Penetration Base Material

In TIG mode, welding is possible in all positions: angle, on the edge, vertical and overhead. Furthermore, with respect to other types of welding, the welding joint has greater mechanical resistance, greater corrosion resistance and limited heating in the welded area which limits distortion. Welding can be done even without weld material, guaranteeing a smooth, shiny weld with no impurities or slag.

Preparing Tungsten for DC Electrode Negative (DCEN) Welding

(Fig 16-1)

Tungsten Electrode Tapered End

2.5 x Electrode Diameter

Tig Electrode Selection and Preparation
Electrode Polarity Connect the TIG torch to the negative (-) torch terminal and the work lead to the positive (+) work terminal for direct current straight polarity. Direct current straight polarity is the most widely used polarity for DC TIG welding. It allows limited wear of the

2.5 x Electrode Diameter Grind end of tungsten on grit, hard abrasive wheel before welding. Do not use wheel for other jobs or tungsten can become contaminated causing lower weld quality.

(Fig 16-2) Straight Ground

Stable ARC Flat
Grinding Wheel

Ideal Tungsten Preparation - Stable ARC

ATP160 Welding Machine

(Fig 16-3)

ARC Welder

Point

Radial Ground

Grinding Wheel

Wrong Tungsten Preparation - Wandering ARC

(Fig 17)

Pointing the Electrode The electrode should be pointed according to the welding current.

www.weldtech.net.nz 18

TIG Welding Troubleshooting
19

ATP160 Welding Machine MMA (Stick) Welding

ON OFF

CUTTER TIG STICK
A

Earth clamp connection

Electrode holder connection

NOTE: When changing from MMA (Stick) to Plasma cutting or TIG, don't forget to change polarity of the torch and the work clamp. If polarity is not correct, welding and cutting problems will result. Also, change the Plasma Torch, TIG torch and stick connections with the machine turned off for safety and to prevent accidental firing of the torches.

Please connect the electrode holder to the positive polarity and the earth clamp to the negative polarity, which is commonly used for MMA (Stick) welding on most materials, such as low carbon steel and low alloy steel.

3. Make sure welding current is adequate to thickness of work piece.

1. Activate power switch on front panel, fan will begin to work.

2. Make sure the function switch of front panel is on arc setting.

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MMA (Stick) Basic Welding Guide
Size of Electrodes
The electrode size is determined by the thickness of metals being joined and can also be governed by the type of welding machine available. Small welding machines will only provide current (amperage) to run smaller sized electrodes.
For thin sections, it is necessary to use smaller electrodes otherwise the arc may burn holes through the job. A little practice will soon establish the most suitableelectrode for a given application.
Storage of Electrodes
Always store electrodes in a dry place and in their original containers.
Electrode Polarity
Electrodes are generally connected to the electrode holder with the electrode holder connected positive polarity. The work lead is connected to the negative polarity and is connected to the work piece. If in doubt consult the electrode data sheet.

Flat Position, Down Hand Butt Weld (Fig 1-11)
Flat Position, Gravity Fillet Weld (Fig 1-12)
Horizontal Position, Butt Weld (Fig 1-13)
Horizontal-Vertical (HV) Position (Fig 1-14)
Vertical Position, Butt Weld (Fig 1-15)

Various Materials
High Tensile and Alloy Steels
steels are the formation of a hardened zone in the weld area, and, if suitable precautions are not taken, the occurrence in this zone of under-bead cracks. Hardened zone and underbead cracks in the weld area may be reduced by using the correct electrodes, preheating, using higher current settings, using larger electrodes sizes, short runs for larger electrode deposits or tempering in a furnace.
Manganese Steels
high temperatures causes embrittlement. For this reason it is absolutely essential to keep manganese steelcool during welding by quenching after each weld or skip welding to distribute the heat.
Cast Iron Most types of cast iron, except white iron, are weldable. White iron, because of its extreme brittleness,
21

Vertical Position, Fillet Weld (Fig 1-16)
Overhead Position, Butt Weld (Fig 1-17)
Overhead Position, Fillet Weld (Fig 1-18)

ATP160 Welding Machine

generally cracks when attempts are made to weld it. Trouble may also be experienced when welding white-heart malleable, due to the porosity caused by gas held in this type of iron.
Copper and Alloys The most important factor is the high rate of heat conductivity of copper, making pre-heating of heavy sections necessary to give proper fusion of weld and base metal.
Types of Electrodes
of groups depending on their applications. There are a great number of electrodes used for specialised industrial purposes which are not of particular interest for everyday general work. These include some low hydrogen types for high tensile steel, cellulose types for welding large diameter pipes, etc. The range of electrodes dealt with in this publication will cover the vast majority of applications likely to be encountered; are all easy to use.

tions without any special preparation. For heavier sections and for repair work on castings, etc., it will be necessary to cut or grind an angle between the pieces being joined to ensure proper penetration of the weld metal and to produce sound joints. In general, surfaces being welded should be clean and free of rust, scale, dirt, grease, etc. Slag should be removed from oxy-cut surfaces. Typical joint designs are shown in Figure 1-19.
Open Square Butt Joint (Fig 1-19a)
Gap varies from1.6mm (1/16") to 4.8mm (3/16") depending on plate thickness
Single Vee Butt Joint (Fig 1-19b) Not less than 45°

MILD STEEL : E6011 - This electrode is used for all-position welding or for welding on rusty, dirty, less-than- new metal. It has
repair or maintenance work.
E6013 - This all-position electrode is used for welding clean, new sheet metal. Its soft arc has minimal spatter, moderate penetration and an easy-to-clean slag.
E7014 - All positional, ease to use electrode for use on thicker steel than E6013. Especially suitable for sheet metal
E7018 - A low-hydrogen, all-position electrode used when quality is an issue or for hard-to-weld metals. It has the capability of producing more uniform weld metal, which has better impact properties at low temperatures.
CAST IRON: ENI-CL - Suitable for joining all cast irons except white cast iron.
STAINLESS STEEL: E318L-16 - High corrosion resistances. Ideal for dairy work etc.
Joint Preparations
In many cases, it will be possible to weld steel sec-

Single Vee Butt Joint

(Fig 1-19c)

Not less than 70°

1.6mm (1/16")

1.6mm (1/16") max.

Double Vee Butt Joint

(Fig 1-19d)

Not less than 70°

1.6mm (1/16")

1.6mm (1/16") max.

Lap Joint (Fig 1-19e) Fillet Joint (Fig 1-19f)

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Corner Weld (Fig 1-19g) Tee Joints (Fig 1-19h) Edge Joint (Fig 1-19i)
Plug Welds (Fig 1-19j)
23

MMA Welding Techniques - A Word for Beginners
For those who have not yet done any welding, the simplest way to commence is to run beads on a piece of scrap plate. Use mild steel plate about 6.0mm thick and a 3.2mm electrode.

be carried out in the down hand position. Make sure that the Work Lead/Clamp is making good electrical contact with the work, either directly or through the work table. For light gauge material, always clamp the work lead directly to the job, otherwise a poor circuit will probably result.

The Welder
Place yourself in a comfortable position before beginning to weld. Get a seat of suitable height and do as much work as possible sitting down. Don't hold your body tense. A taut attitude of mind and a tensed body will soon make you feel tired. Relax
You can add much to your peace of mind by wearing a leather apron and gauntlets. You won't be worrying then about being burnt or sparks setting alight to your clothes.
Place the work so that the direction of welding is across, rather than to or from, your body. The electrode holder lead should be clear of any obstruction so that you can move your arm freely along as the electrode burns down. If the lead is slung over your shoulder, it allows greater freedom of movement and takes a lot of weight your hand. Be sure the insulation on your cable and electrode holder is not faulty; otherwise you are risking an electric shock.

Striking the Arc

Practice this on a piece of scrap plate before going

ence

due to the tip of the electrode "stick-

ing" to the work piece. This is caused by making too

heavy a contact with the work and failing to with-

draw the electrode quickly enough. A low amper-

age will accentuate it. This freezing-on of the tip may

be overcome by scratching the electrode along the

plate surface in the same way as a match is struck. As

soon as the arc is established, maintain a 1.6mm to

3.2mm gap between the burning electrode end and

ATP160 Welding Machine

the parent metal. Draw the electrode slowly along as it melts down.
ter the arc is struck, to withdraw the electrode so far that the arc is broken again. A little practice will soon remedy both of these faults.

Striking an Arc

(Fig 1-20)

20o

1.6mm (1/16")

Arc Length
The securing of an arc length necessary to produce a neat weld soon becomes almost automatic. You will
A very long arc produces a crackling or spluttering noise and the weld metal comes across in large, ir-
increases. A short arc is essential if a high quality weld is to be obtained although if it is too short there is the danger of it being blanketed by slag and the elec-
give the electrode a quick twist back over the weld to detach it. Contact or "touch-weld" electrodes such as E7014 Stick electrodes do not stick in this way, and make welding much easier.
Rate of Travel
After the arc is struck, your next concern is to maintain it, and this requires moving the electrode tip towards the molten pool at the same rate as it is melting away. At the same time, the electrode has to move along the plate to form a bead.
The electrode is directed at the weld pool at about 20º from the vertical. The rate of travel has to be adjusted so that a well-formed bead is produced.
If the travel is too fast, the bead will be narrow and strung out and may even be broken up into individual globules. If the travel is too slow, the weld metal piles up and the bead will be too large.

Making Welded Joints
Having attained some skill in the handling of an electrode, you will be ready to go on to make up welded joints.
A. Butt Welds
Set up two plates with their edges parallel, as shown in Figure 1-21, allowing 1.6mm to 2.4mm gap between them and tack weld at both ends. This is to prevent contraction stresses from the cooling weld metal pulling the plates out of alignment.
Plates thicker than 6.0mm should have their mating edges bevelled to form a 70º to 90º included angle. This allows full penetration of the weld metal to the root. Using a 3.2mm E7014 Stick electrode at 100 amps, deposit a run of weld metal on the bottom of the joint.
Do not weave the electrode, but maintain a steady

for undercut to form, but keeping the arc length short, the angle of the electrode at about 20º from vertical, and the rate of travel not too fast, will help eliminate this.
The electrode needs to be moved along fast enough to prevent the slag pool from getting ahead of the arc. To complete the joint in thin plate, turn the job over, clean the slag out of the back and deposit a similar weld.

Butt Weld (Fig 1-21)

20o- 30o

Electrode

Tack Weld

Tack Weld
Weld Build Up Sequence (Fig 1-22)

www.weldtech.net.nz 24

Heavy plate will require several runs to complete the
and clean the weld with a wire brush. It is important to do this to prevent slag being trapped by the second run. Subsequent runs are then deposited using either a weave technique or single beads laid down in the sequence shown in Figure 1-22. The width of weave should not be more than three times the core wire diameter of the electrode.

machined, ground or gouged out to remove slag which may be trapped in the root, and to prepare a suitable joint for depositing the backing run. If a backing bar is used, it is not usually necessary to remove this, since it serves a similar purpose to the backing run in securing proper fusion at the root of the weld.

B. Fillet Welds
These are welds of approximately triangular crosssection made by depositing metal in the corner of two faces meeting at right angles. Refer to Figure 1-14, 1-23 and 1-24.

Electrode Position for HV Fillet Weld (Fig 1-23)

45o from vertical
60o-70o from line of weld

A piece of angle iron is a suitable specimen with which to begin, or two lengths of strip steel may be tacked together at right angles. Using a 3.2mm E7014 Stick electrode at 100 amps, position angle iron with one leg horizontal and the other vertical. This is known as a horizontal-vertical (HV)
Strike the arc and immediately bring the electrode to
about 45º from the vertical. Some electrodes require being sloped about 20º away from the perpendicular position to prevent slag from running ahead of the weld. Refer to Figure 1-23.
Do not attempt to build up much larger than 6.4mm width with a 3.2mm electrode, otherwise the weld metal tends to sag towards the base, and undercut forms on the vertical leg. Multi-runs can be made as shown in Figure 1-24. Weaving in HV welds is undesirable.

Multi-Runs in HV Fillet Weld (Fig 1-24)
C. Vertical Welds
1. Vertical Up Tack weld a three feet length of angle iron to your work bench in an upright position. Use a 3.2mm E7014 Stick electrode and set the current at 100 amps. Make yourself comfortable on a seat in front of electrode needs to be about 10º from the horizontal to enable a good bead to be deposited. Refer Fig. 1-25.
Single Run Vertical Fillet Weld (Fig 1-25)
Use a short arc, and do not attempt to weave on the slag the weld deposit and begin the second run at the bottom. This time a slight weaving motion is necat the edges.
Multi Run Vertical Fillet Weld (Fig 1-26)
Weaving motion for second and subsequent runs
Pause at edge of weave
At the completion of each side motion, pause for a moment to allow weld metal to build up at the edges, otherwise undercut will form and too much metal will accumulate in the centre of the weld. Figure 1-26 illustrates multi-run technique and Figure 1-27 and of weaving too rapidly.

ATP160 Welding Machine

Examples of Vertical Fillet Welds (Fig 1-27)
CORRECT

INCORRECT

Pause at edge of weave allows weld metal to build up and eliminates undercut

Note: Weld contour at edge of weave

2. Vertical Down
The E7014 Stick electrode makes welding in this position particularly easy. Use a 3.2mm electrode at 100 amps. The tip of the electrode is held in light contact with the work and the speed of downward travel is regulated so that the tip of the electrode just keeps ahead of the slag. The electrode should point upwards at an angle of about 45º.

waste pipe. Then tack this to the work bench or hold in a vice so that the specimen is positioned in the overhead position as shown in the sketch.
The electrode is held at 45º to the horizontal and tilted 10º in the line of travel (Figure 1-28). The tip of the electrode may be touched lightly on the metal, which helps to give a steady run. A weave technique
Use a 3.2mm E6013 Stick electrode at 100 amps, and
along at a steady rate. You will notice that the weld
before the metal freezes.
Overhead Fillet Weld (Fig 1-28)

3. Overhead Welds Apart from the rather awkward position necessary, down hand welding.Set up a specimen for overhead angles to another piece of angle iron or a length of

45o to plate

Tilted 10o in line of travel

Angle tacked to pipe

www.weldtech.net.nz 26

MMA (Stick) Troubleshooting
27

ATP160 Welding Machine

Care & Maintenance

Keep your Welding Machine in Top Condition
The ATP160 does not require any special maintenance, however the user should take care of the ma chine as follows:
· Regularly clean the ventilation slots.
· Keep the casing clean.
· Check all cables before use.
· Check electrode holders, work lead/clamps and welding torches before use.
· Replace worn electrode holders and earth clamps, which do not provide a good connection.
· Replace worn torch consumable parts in a timely manner.
· Replace worn wire drive components in a timely manner
· Use a soft cloth or brush to clean electrical components. Do not use liquid cleaning products, water or especially solvents.
· Do not use compressed air to clean electrical components as this can force dirt and dust further into components, causing electrical short circuits.
· Check for damaged parts. Do not use the welder with damaged parts.

Storing the Welder
When not in use the welder should be stored in the dry and frost-free environment.
WARNING! Before performing cleaning/ma-in tenance, replacing cables / connections , make
disconnected from the power supply.

If damaged, before further use, the welder must be
that it will operate properly. Check for breakage of parts, mountings and other conditions that may
Have your welder repaired by an expert. An authorised service centre should properly repair a damaged part.
This appliance is manufactured in accordance with relevant safety standards. Only experts must carry out repairing of electrical appliances, otherwise considerable danger for the user may result. Use only
non-genuine parts.

Accessories & Consumables
Visit www.weldtech.net.nz for a full range of consumables and accessories.
Knowledge & Resources
Please refer to Euroquip website www.euroquip.co.nz/ Downloads.html for knowledgebase articles & operation videos.

www.weldtech.net.nz 28

Change filter operation
THE AIR FILTER IS REQUIRED TO BE CHANGED ONCE EVERY THREE MONTHS.
1. Turn off the power and unplug the power cord. 2. Open the small side door of the machine and unplug the Pipe. 3. Remove the filter.

80 60
40

100 120
160

1 3 2

A Separate 1

and

B Unscrew

C Just need to change the Sintered Bronze Filter
29

yellow part
3
Sintered Bronze Filter

80 60
40

100 120
160

ATP160 Welding Machine Explosion Diagrams & Part List
www.weldtech.net.nz 30

Part List

NO.

Description

Housing

Handle

Plastic front panel

Bottom housing

CUTTER/TIG/STICK switch

ON/OFF switch

Air pressure gauge

Current Adjustment Knob

Air pressure regulator

Output connector (DC + / -)

NO.

Description

Gas-electric connector for CUT/TIG torch

Two-pin socket

Circuit Boards

Fan

Fan External Cover

Air supply connector

Primary power input cable.

Water drain

Grounding screw

Air filter

LED Meter

Safety Warning

ATP160 Welding Machine

IMPORTANT: BEFORE INSTALLING, OPERATING OR CARRYING OUT MAINTENANCE ON THE PLASMA CUTTER, READ THE CONTENTS OF THIS MANUAL CAREFULLY, WHICH MUST BE STORED IN A PLACE FAMILIAR TO ALL USERS FOR THE ENTIRE OPERATIVE LIFE-SPAN OF THE MACHINE. PAY PARTICULAR ATTENTION TO THE SAFETY RULES.THIS EQUIPMENT MUST BE USED SOLELY FOR PLASMA CUTTING.
MACHINE OPERATING
Plasma cutting equipment can be dangerous to both the operator and people in or near the surrounding working area, if the equipment is not correctly operated. Equipment must only be used under the strict and comprehensive observance of all relevant safety regulations. Read and understand this instruction manual carefully before the installation and operation of this equipment.
DANGER! People with pacemakers should not use this machine or be nearby during use. Plasma Cutter/TIG/Stick, such as this one, produce strong, fluctuating electromagnetic fields that can cause pacemaker interference or pacemaker failure. People with pacemakers should consult their physician(s) for advice.
Never leave the machine unattended when it is plugged into an electrical outlet.
Turn off the Plasma Cutter, and unplug it from its its electrial outlet before leaving.
Unplug the machine from its eletrial outlet before performing any inspection, maintenance,or cleaning procedures, including changing accessories.
Avoid unintentional starting. Make sure switch is in off position before plugging in. Make sure you are prepared to begin work before turning on the machine.

Electric shock:It can kill. Touching live electrical parts can cause fatal shocks or severe burns. The plasma nozzle and work circuit is electrically live whenever the output is on. The input power circuit and internal machine circuits are also live when power is on. Do not touch live electrical parts or electrodes with bare skin, gloves or wet clothing. Incorrectly installed or improperly grounded equipment is dangerous.
· Connect the primary input cable according to USA standards and regulations. · Disconnect power source before performing any service or repairs. · Avoid all contact with live electrical parts of the welding circuit, torch nozzle and work piece with bare hands. The operator must wear dry welding gloves while he/she performs the plasma cutting task. · Isolate yourselves from both the earth and the work piece. · Keep cords dry, free of oil and grease, and protected from hot metal and sparks. · Frequently inspect input power cable for wear and tear, replace the cable immediately if damaged, bare wiring is dangerous and can kill. · Do not use damaged, under sized, or badly joined cables. · Do not drape cables over your body. · We recommend(RCD)safety switch is used with this equipment to detect any leakage of current to earth.

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Fumes and gases are dangerous. Plasma cutting/TIG/STICK produces fumes and gases. Harmful fumes and metallic powders are produced during the cutting operation. Metals which are painted or coated or which contain mercury, zinc, lead and graphite may produce harmful concentrations of toxic fumes during cutting. Breathing these fumes and gases can be hazardous to your health.
· Do not breathe the smoke and gas generated whilst welding or cutting, keep your head out of the fumes. · Keep the working area well ventilated, use fume extraction or ventilation to remove welding fumes and gases. · In confined or heavy fume environments always wear an approved airsupplied respirator. · Cutting fumes and gases can displace air and lower the oxygen level causing injury or death. · Be sure the breathing air is safe. · Do not cut in locations near degreasing, cleaning, or spraying operations. The heat and rays of the arc can react with vapours to form highly toxic and irritating gases. · Materials such as galvanized, lead, or cadmium plated steel, containing elements th at can give off toxic fumes when cuttung. Do not cut these materials unless the area is very well ventilated, and or wearing an air supplied respirator. · Always read the material Safety Data Sheets(MSDS) that should be supplied with the material you are using. These MSDSs will give you the information regarding the kind and amount of fumes and gases that may be dangerous to your health.
Arc rays:harmful to people's eyes and skin. Arc rays from the plasma cutting process produce intense visible and invisible ultraviolet and infrared rays that can burn eyes and skin. Protect your eyes with welding masks or goggles fitted with filtered lenses, and protect your body with appropriate safety garments. Protect others by installing adequate shields or curtains.

· Always wear a helmet or goggles with correct shade of filter lens and suitable protective clothing including welding gloves, appron, leg and foot protection whilst the plasma cutting operation is performed. Measures should be taken to protect people in or near the surrounding working area. Use protective · screens or barriers to protect others from flash, glare and sparks; warn others not to watch the arc.
Fire hazard. Plasma cutting on closed containers, such as tanks,drums, or pipes, can cause them to explode. Flying sparks from the welding arc, hot work piece, and hot equipment can cause fires and burns.Accidental contact of electrode to metal objects can cause sparks, explosion, overheating, or fire. Checkand be sure the area is safe before doing any cutting.
· The cutting sparks may cause fire, therefore remove any flammable materials well away from the working area.
Cover flammable materials and containers with approved covers if unable to be moved from the welding area. · Do not Plasma Cut closed containers such as tanks, drums, or pipes, unless they are properly prepared according to the required Safety Standards to insure that flammable or toxic vapors and substances are totally removed, these can cause an explosion even though the vessel has been "cleaned". Vent hollow castings or containers before heating, cutting or welding. They may explode.
· Do not cut where the atmosphere may containflammable dust, gas, or liquid vapours (such as petrol) · Have a fire extinguisher nearby and know how to use it. Be alert that cutting sparks and hot materialsfrom cutting can easily go through small cracks and openings to adjacent areas. Be aware that cutting on a ceiling, floor, bulkhead, or partition can cause fire on the hidden side.

ATP160 Welding Machine

Gas Cylinders. Do not cut in the vicinity of pressurised gas cylinders or in the presence of explosive dust, gases or fumes. Gas cylinders contain gas under high pressure. If damaged, a cylinder can explode. Because gas cylinders are normally part of the welding process, be sure to treat them carefully. CYLINDERS can explode if damaged.

· Wearers of Pacemakers and other Implanted Medical Devices should keep away. · Implanted Medical Device wearers should consult their doctor and the device manufacturer before going near any electric welding, cutting or heating operation.

proper cylinder care. Secure cylinders to a cart, wall, or post, to prevent them from falling.All cylinders should be used and stored in an upright position. Never drop or strike a cylinder. Do not use cylinders that have been dented.Cylinder caps should be used when moving or storing cylinders. Empty cylinders should be kept in specified areas and clearly marked "empty."
· Protect gas cylinders from excessive heat, mechanical shocks, physical damage, slag, open flames, sparks, and arcs. · Insure cylinders are held secure and upright to prevent tipping or falling over. · Never allow the plasma nozzle or earth clamp to touch the gas cylinder, do not drape welding cables over the cylinder. · Never plasma cut on a pressurised gas cylinder, it will explode and kill you. · Open the cylinder valve slowly and turn your face away from the cylinder outlet valve and gas regulator.

Noise can damage hearing. Noise from some processes or equipment can damage hearing. This machine does not directly produce noise exceeding 80dB. The plasma cutting/welding procedure may produce noise levels beyond said limit; users must therefore implement all precautions required by law. Wear approved ear protection if noise level is high.
Hot parts. Items being plasma cut generate and hold high heat and can cause severe burns. Do not touch hot parts with bare hands. Allow a cooling period before working on the plasma torch. Use insulated welding gloves and clothing to handle hot parts and prevent burns.

Electronic magnetic fields. The magnetic fields created by the high currents generated by plasma cutting may affect the operation of pacemakers and other vital electronic medical equipment.

www.weldtech.net.nz 34

Warranty

As part of an on-going commitment to excellence
product warranty program.
Warranty period for the ATP160: Commercial Use: 18 Month Domestic Use: 18 Month
Warranty covers failure caused by manufacturing and material defects in the product, during the war-
when the product is purchased by the end user. Warranty is not transferrable and is only claimable by the original purchaser.
Warranty does not cover parts that are subject to wear and tear from usage.
Warranty covers failure of a product caused by defective materials and/or manufacturing for the period
ranty period begins when the product is purchased by the end user. Warranty is not transferrable and is only claimable by the original purchaser.
Warranty also does not cover failure caused by the untimely replacement or service of the above wearing parts. Evidence must be provided that the product has been maintained and serviced suitably for a claim to be considered under warranty.
Failure caused by incorrect operation of the product, lack of proper care and maintenance of the product, external damage, external circumstances such as
tions to the product, attempted repair/ service by a party other than an Approved Service Agent, is not covered under warranty.

Warranty does not cover pre delivery service and adjustment, or failure that may occur as a result of lack of/ incorrect pre delivery service and adjustment.
Warranty does not cover any incidental, indirect or consequential loss, damage or expense that may result from any defect, failure or malfunction of a product.
Should any issue be found to be a combination of a warranty failure and a non-warranty issue, the repair cost component to rectify and repair the non-warranty failure is the customers' full responsibility.
a warranty claim is made at the sole jurisdiction of Euroquip.
No costs incurred will be considered under warranty if repairs are carried out by a party other than a Euroquip Approved Service Agent, unless with prior consent in writing from Euroquip.
It is the responsibility of the purchaser to deliver a product under warranty to the nearest relevant service agent or product reseller. Warranty does not cover call outs, mileage and freight costs.
If a product is repaired under warranty, parts and labour required for the repair will be supplied at no charge. Warranty assessment and repair will be scheduled and executed according to the normal
the availability of suitable replacement parts.
service agent.

Congratulations on your new WELDTECH product. We are proud to have you as our customer and will strive to provide you with the best service and reliability in the industry. This product is backed by our extensive warranty and service network. To locate your nearest distributor or service agency visit www.weldtech.net.nz, or email us at customerservice@euroquip.co.nz
www.weldtech.net.nz

References

Adobe PDF library 17.00 Adobe Illustrator 28.7 (Macintosh)