Lincoln Electric INVERTEC V160-S manual

INVER TEC V160-S ™ OPERA TOR’S MANUAL IM737-A August, 2007 Safety Depends on Y ou Lincoln arc welding and cutting equipment is designed a nd built with s afety in mind. Ho wever , y our ov erall safety can be increased by pr oper installatio n ... and thought- ful opera tion o n your part. DO NOT INST ALL, OPERA TE OR REP AIR THIS EQUIPMENT WIT[...]

FOR ENGINE powered equipment. 1.a. T urn the engine off before troubleshooting and maintenance work unless the maintenance work requires it to be running. ____________________________________________________ 1.b. Operate engines in open, well-ventilated areas or vent the engine exhaust fumes outdoors. _______________________________________________[...]

ii SAFETY ii ARC RA YS can burn. 4.a. Use a shield with the proper filter and cover plates to protect your eyes from sparks and the rays of the arc when welding or observing open arc welding. Headshield and filter lens should conform to ANSI Z87. I standards. 4. b. Use suitable clothing made from durable flame-resistant material to protect your ski[...]

iii SAFETY iii FOR ELECTRICALL Y powered equipment. 8.a. T urn off input power using the disconnect switch at the fuse box before working on the equipment. 8 .b . Install equipment in accordance with the U.S. National Electrical Code, all local codes and the manufacturer ʼs recommendations. 8.c. Ground the equipment in accordance with the U.S. Nat[...]

iv SAFETY iv Mar . ʻ93 PRÉCAUTIONS DE SÛRETÉ Pour votre propre protection lire et observer toutes les instructions et les précautions de sûreté specifiques qui parraissent dans ce manuel aussi bien que les précautions de sûreté générales suiv- antes: Sûreté Pour Soudage A L ʼArc 1. Protegez-vous contre la secousse électrique: a. Les[...]

v v Thank You for selecting a QUALITY product. We want you to take pride in operating this product ••• as much pride as we have in bringing this product to you! Read this Operators Manual completely before attempting to use this equipment. Save this manual and keep it handy for quick reference. Pay particular attention to the safety instructi[...]

vi vi T ABLE OF CONTENTS Page Installation ................................................................................................................... ....Section A T echnical Specifications ....................................................................................................... A-1 Safety Precautions.........................[...]

A-1 INST ALLA TION V160-S A-1 Input Circuit 1 15V (20A Plug and Branch) 1 15V (30A Branch) 230V (30A Branch) 230V (30A Branch) Maximum Open Circuit V oltage 48 V olts Max. Duty Cycle 100% 35% 100% Output Current Range 5-160 Amps INPUT - SINGLE PHASE ONL Y RA TED OUTPUT OUTPUT Height Widt h Depth Weight 12.6 in. 7.9 in. 16.9 in. Approx. 24.2lbs. 320[...]

A-2 INST ALLA TION V160-S A-2 Read entire installation section before starting installation. SAFETY PRECAUTIONS ELECTRIC SHOCK can kill. • Only qualified personnel should per- form this installation. • Disconnect input power by removing plug from receptacle before working inside V160-S. Allow machine to sit for 5 minutes minimum to allow the po[...]

A-3 INST ALLA TION V160-S A-3 Fuse the input circuit with time delay fuses marked “D” or delay type 1 circuit breakers. Using fuses or circuit breakers smaller than recommended may result in “nuisance” shut-offs from welder inrush currents even if not welding at high currents. 1 Also called “inverse time” or “thermal/magnetic” circu[...]

A-4 INST ALLA TION V160-S A-4 OUTPUT CONNECTIONS ELECTRIC SHOCK can kill. • Keep the electrode holder and cable insulation in good condition. • Do not touch electrically live parts or electrode with skin or wet cloth- ing. • Insulate yourself from work and gr ound. • T urn the input line Switch on the Invertec V160- S “off” befor e conn[...]

A-5 INST ALLA TION V160-S A-5 QUICK DISCONNECT PLUG (FOR STICK ELEC- TRODE CABLE) A quick disconnect system is used for the welding cable connections. The stick electrode cable will need to have a plug attached. 1. Cut off welding cable lug, if present. 2. Remove .75 in. (19mm) of welding cable insulation. 3. Slide rubber boot onto cable end. The b[...]

B-1 OPERA TION V160-S B-1 Read and understand this entire section before operating your machine. SAFETY INSTRUCTIONS ELECTRIC SHOCK can kill. • Do not touch electrically live parts such as output terminals or internal wiring. • Insulate yourself from the work and ground. • Always wear dry insulating gloves. ___________________________________[...]

B-2 OPERA TION B-2 REAR CONTROL P ANEL 1 . Power Switch: Controls the input power to the machine. Make sure the machine is properly con- nected to the input supply before turning the machine on.(See Figure B.1) 2. F a n : The cooling fan will turn ON when the machine is turned ON and it will continue to run whenever the output of the machine is ON.[...]

B-3 OPERA TION B-3 7. Remote LED: This indicator will turn on when a remote control is connected to the machine via the remote control connector . Using a remote control will change the function of the output current con- trol, refer to the output current control section below . 8. Output LED: This indicator turns on when the out- put of the machin[...]

B-4 OPERA TION B-4 V160-S DIP SWITCH FUNCTIONS T his section has 8 DIP switch functions of the V160- S. Read and understand the functions before making any changes because abnormal operation can occur with the wrong settings. The machine must be turned OFF when the DIP Switches are changed. ELECTRIC SHOCK CAN KILL: Be sure that all installation, op[...]

B-5 OPERA TION B-5 DIP Switch 6: European/USA Machine Configuration This configures several functions of the V160-S as required by the European and USA markets. For the European market it is OFF and for the USA market it is ON. Specifically , this configures the operation of the TIG slope timers, remote control, and trigger . However , this configu[...]

C-1 ACCESSORIES C-1 OPTIONAL ACCESSORIES AND COMP A TIBLE EQUIPMENT Factory Installed Electrical Holder and Cable Assembly Work Cable and Clamp Strap Packet Instruction Manual Field Installed K870 - Foot Amptrol tm for TIG welding. When the V160-Sʼs Output Control is in the “REMOTE” position, the foot Amptrol energizes the output and controls [...]

D-1 MAINTENANCE D-1 V160-S SAFETY PRECAUTIONS ELECTRIC SHOCK can kill. • Have an electrician install and serv- ice this equipment. • T urn the input power off at the fuse box, disconnect supply lines and allow machine to sit for five minutes minimum to allow the power capaci- tors to discharge before working inside this equipment. • Do not to[...]

E-1 TROUBLESHOOTING E-1 V160-S If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely , contact your Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed. CAUTION This T roubleshooting Guide is provided to help you locate and repair possibl[...]

E-2 TROUBLESHOOTING E-2 V160-S Observe all Safety Guidelines detailed throughout this manual PROBLEMS (SYMPTOMS) POSSIBLE AREAS OF MISADJUSTMENTS(S) RECOMMENDED COURSE OF ACTION Excessive spatter Craters Inclusions Insufficient penetration Sticking Porosity Cracks 1. Long arc 2. High current 1 . Fast movement of the electrode away from piece. 1. Po[...]

E-3 TROUBLESHOOTING E-3 V160-S If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely , contact your Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed. Observe all Safety Guidelines detailed throughout this manual PROBLEMS (SYMPTOMS) POS[...]

E-4 TROUBLESHOOTING E-4 V160-S Observe all Safety Guidelines detailed throughout this manual PROBLEMS (SYMPTOMS) POSSIBLE AREAS OF MISADJUSTMENT(S) RECOMMENDED COURSE OF ACTION Machine fails to come on (Power LED off) Power Input incorrect Input over-current (Power LED Flashing) No output current (Power LED on) (Output LED off) Thermal overload (Th[...]

F-1 DIAGRAMS F-1 V160-S NOTE: This diagram is for refer ence only . It may not be accurate for all machines covered by this manual. The specific diagram for a particular code is pasted inside the machine on one of the enclosure panels. If the diagram is illegible, write to the Service Department for a r eplacement. Give the equipment code number . [...]

F-2 DIAGRAMS F-2 V160-S NOTE: This diagram is for refer ence only . It may not be accurate for all machines covered by this manual. The specific diagram for a particular code is pasted inside the machine on one of the enclosure panels. If the diagram is illegible, write to the Service Department for a r eplacement. Give the equipment code number . [...]

NOTES V160-S[...]

W ARNING AV I S O D E PRECAUCION A TTENTION W ARNUNG A TENÇÃO Spanish French German Portuguese Japanese Chinese Korean Arabic READ AND UNDERST AND THE MANUF ACTURER’S INSTRUCTION FOR THIS EQUIPMENT AND THE CONSUMABLES TO BE USED AND FOLLOW YOUR EMPLOYER’S SAFETY PRACTICES. SE RECOMIENDA LEER Y ENTENDER LAS INSTRUCCIONES DEL F ABRICANTE PARA E[...]

W ARNING AV I S O D E PRECAUCION A TTENTION W ARNUNG A TENÇÃO Spanish French German Portuguese Japanese Chinese Korean Arabic LEIA E COMPREENDA AS INSTRUÇÕES DO F ABRICANTE PARA ESTE EQUIP AMENTO E AS P ARTES DE USO, E SIGA AS PRÁTICAS DE SEGURANÇA DO EMPREGADOR. ● Keep your head out of fumes. ● Use ventilation or exhaust to remove fumes [...]

• Sales and Service through Subsidiaries and Distributors Worldwide • Cleveland, Ohio 441 17-1 199 U.S.A. TEL: 216.481.8100 F AX: 216.486.1751 WEB SITE: www .lincolnelectric.com • World's Leader in W elding and Cutting Products •[...]