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Lincoln Electric INVERTEC V160-S Operator's Manual

Lincoln electric welder user manual.

 
RETURN TO MAIN MENU
IM737-A
INVERTEC V160-S
August, 2007
10877; 11031
For use with machines having Code Numbers:
Safety Depends on You
Lincoln arc welding and cutting
equipment is designed and built
with safety in mind. However, your
overall safety can be increased by
proper installation ... and thought-
ful operation on your part. DO
NOT INSTALL, OPERATE OR
REPAIR THIS EQUIPMENT
WITHOUT
READING
THIS
MANUAL AND THE SAFETY
PRECAUTIONS CONTAINED
THROUGHOUT. And, most
importantly, think before you act
and be careful.
OPERATOR'S MANUAL
Copyright © 2007 Lincoln Global Inc.
• World's Leader in Welding and Cutting Products •
• Sales and Service through Subsidiaries and Distributors Worldwide •
Cleveland, Ohio 44117-1199 U.S.A. TEL: 216.481.8100 FAX: 216.486.1751 WEB SITE: www.lincolnelectric.com

Summary of Contents

  • Page 1

    RETURN TO MAIN MENU IM737-A ™ INVERTEC V160-S August, 2007 10877; 11031 For use with machines having Code Numbers: Safety Depends on You Lincoln arc welding and cutting equipment is designed and built with safety in mind. However, your overall safety can be increased by proper installation ...

  • Page 2

    351040, Miami, Florida 33135 or CSA Standard W117.2-1974. A Free copy of “Arc Welding Safety” booklet E205 is available from the Lincoln Electric Company, 22801 St. Clair Avenue, Cleveland, Ohio 44117-1199. BE SURE THAT ALL INSTALLATION, OPERATION, MAINTENANCE AND REPAIR PROCEDURES ARE PERFORMED ONLY BY QUALIFIED INDIVIDUALS.

  • Page 3

    ELECTRIC SHOCK can kill. 3.a. The electrode and work (or ground) circuits are electrically “hot” when the welder is on. Do not touch these “hot” parts with your bare skin or wet clothing. Wear dry, hole-free gloves to insulate hands.

  • Page 4

    WELDING SPARKS can cause fire or explosion. 6.a. Remove fire hazards from the welding area. If this is not possible, cover them to prevent the welding sparks from starting a fire. Remember that welding sparks and hot materials from welding can easily go through small cracks and openings to adjacent areas.

  • Page 5

    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 LʼArc 1. Protegez-vous contre la secousse électrique: a.

  • Page 6

    Electric for advice or information about their use of our products. We respond to our customers based on the best information in our posses- sion at that time. Lincoln Electric is not in a position to warrant or guarantee such advice, and assumes no liability, with respect to such infor- mation or advice.

  • Page 7: Table Of Contents

    TABLE OF CONTENTS Installation...Section A Technical Specifications ...A-1 Safety Precautions...A-1 Select Suitable Location ...A-2 Stacking...A-2 Tilting ...A-2 Input Connections ...A-2 Ground Connection...A-2,A-3 ARFU (Auto-Restore Fuse) ...A-3 Output Connections...A-4 Output and Gas Connection for Tig Welding ...A-4 Output Connection for Stick Welding...A-4 Quick Disconnect Plug ...A-5 Output Connection for Tig Welding Remote Control Connection ...A-5...

  • Page 8: Technical Specifications

    TECHNICAL SPECIFICATION V160-S Input Voltages / 50 /60 Hz. 115 V (20 A Plug and branch) 115 V (30 A branch) 230 V Output Amps Duty Cycle 100% 160 (Stick) 160 (TIG) 130 (Stick) 100% 130 (TIG) Output Current Range 5-160 Amps RECOMMENDED INPUT WIRE AND FUSE SIZES FOR MAXIMUM RATED OUTPUT INPUT VOLTAGE /...

  • Page 9: Safety Precautions, Select Suitable Location, Stacking, Tilting, Input Connections

    • When operated in ambient temperatures greater than 40°C, the output duty cycle may be reduced. • Do not mount over combustible surfaces. STACKING The Invertec V160-S cannot be stacked. INSTALLATION TILTING Place the machine directly on a secure, level surface.

  • Page 10: Arfu (auto-restore Fuse)

    Also called “inverse time” or “thermal/magnetic” circuit breakers. These circuit breakers have a delay in tripping action that decreases as the magnitude of the current increases. The Invertec V160-S is recommended for use on an individual branch circuit. 115V INPUT The rated output of the V160-S is available when con- nected to a 30A branch circuit.

  • Page 11: Output Connections, Output And Gas Connection For Tig Welding, Output Connection For Stick Welding

    • Ranger 250,305 • Commander 300, 400, & 500 Many engine drives do not meet these conditions (eg Miller Bobcats, etc). Operation of the Invertec V160-S is not recommended on engine drives not conforming to these conditions. Such combinations may overvolt- age the Invertec V160-S power source.

  • Page 12: Quick Disconnect Plug, Output Connection For Tig Welding, Remote Control Connection

    INSTALLATION REMOTE CONTROL CONNECTION A remote control receptacle is provided on the lower center case front of the welder for connecting a remote control to the machine. The V160-S will auto- matically sense if a remote control connection is made. In Lift TIG mode (GTAW), WITHOUT a remote control device connected to the V160-S, the output will come on automatically.

  • Page 13: General Description, Welding Capability, Limitations

    The Invertec V160-S performs DC Touch Start Tig Starting with excellent results. WELDING CAPABILITY The Invertec V160-S is rated at 160 amps, 26.4 volts, at 35% duty cycle on a ten minute basis. It is capable of higher duty cycles at lower output currents. It is capable of 130 amps, 25.2 volts at at 100% duty...

  • Page 14: Rear Control Panel

    REAR CONTROL PANEL 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. Fan: 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.

  • Page 15

    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.

  • Page 16: Dip Switch 1: Machine Type

    ELECTRIC SHOCK CAN KILL: Be sure that all installation, opera- tion, maintenance and repair proce- dures are performed only by qualified individuals. Lincoln Electric is not responsible for damages caused by improper installation, improper care or abnormal operation. Before opening the machine to make changes to the DIP Switches it must first be turned OFF and disconnected from the input source.

  • Page 17

    Switch European/USA 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.

  • Page 18

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

  • Page 19: Input Filter Capacitor Discharge Procedure, Routine Maintenance

    SAFETY PRECAUTIONS WARNING ELECTRIC SHOCK • Have an electrician install and serv- ice this equipment. • Turn 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.

  • Page 20

    HOW TO USE TROUBLESHOOTING GUIDE Service and Repair should only be performed by Lincoln Electric Factory Trained Personnel. Unauthorized repairs performed on this equipment may result in danger to the technician and machine operator and will invalidate your factory warranty. For your safety and to avoid Electrical Shock, please observe all safety notes and precautions detailed throughout this manual.

  • Page 21

    Observe all Safety Guidelines detailed throughout this manual PROBLEMS (SYMPTOMS) PROBLEMS IN STICK WELDING Excessive spatter Craters Inclusions Insufficient penetration Sticking Porosity Cracks 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.

  • Page 22

    Observe all Safety Guidelines detailed throughout this manual PROBLEMS (SYMPTOMS) PROBLEMS IN TIG WELDING Oxidation Tungsten inclusions Porosity Hot cracking 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.

  • Page 23

    Observe all Safety Guidelines detailed throughout this manual PROBLEMS (SYMPTOMS) ELECTRICAL FAILURES 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 (Thermal LED on) 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.

  • Page 24

    DIAGRAMS V160-S...

  • Page 25

    DIAGRAMS W07X0261rev03 V160-S...

  • Page 26

    NOTES V160-S...

  • Page 27

    ● WARNING ● Spanish ● AVISO DE PRECAUCION ● French ● ATTENTION ● ● German WARNUNG ● Portuguese ● ATENÇÃO ● Japanese Chinese Korean Arabic ● ● ● ● ● ● ● ● ● ●...

  • Page 28

    ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● Spanish ● PRECAUCION French ● ATTENTION ● German WARNUNG Portuguese ● ● Japanese Chinese Korean Arabic WARNING AVISO DE ATENÇÃO...

  • Page 29

    • World's Leader in Welding and Cutting Products • • Sales and Service through Subsidiaries and Distributors Worldwide • Cleveland, Ohio 44117-1199 U.S.A. TEL: 216.481.8100 FAX: 216.486.1751 WEB SITE: www.lincolnelectric.com...

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