Lincoln Electric V160-S Service Manual
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Lincoln Electric V160-S Service Manual

Lincoln electric welder user manual
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See also: Operator's Manual
RETURN TO MAIN MENU
V160-S & -T
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.

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Summary of Contents for Lincoln Electric V160-S

  • Page 1 RETURN TO MAIN MENU V160-S & -T 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...
  • Page 6 RETURN TO MAIN MENU...

  • Page 11: Output Connections

    OUTPUT CONNECTIONS...
  • Page 12 BOOT WELDING CABLE .75 in. TRIM, IF REQ'D 19 mm TO FIT OVER CABLE WELDING CABLE .25 in. 6 mm COPPER FERRULE WELDING CABLE .50 in. max 12 mm max. SET SCREW BRASS PLUG COPPER TUBE Accessories Section...
  • Page 15 (See Figure B.2)
  • Page 22 WARNING WARNING WARNING...
  • Page 23 FIGURE E.1 – V160-S BLOCK LOGIC DIAGRAM BLUE WHITE 115/230/1/50/60 BROWN BLACK GREEN INPUT BOARD W05X0250 (SCHEMATIC X0203) 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 26 25 24 23 22 21 20 19 18 17 16 15 14 13 12 11...

  • Page 24: General Description

    FIGURE E.2 – GENERAL DESCRIPTION WHITE 115/230/1/50/60 BLACK GREEN DISPLAY BOARD W05X0245 (SCHEMATIC X0245) WARNING HIGH VOLTAGE CAN KILL • Do not operate with coers removed. • Disconnect input power by unplugging power cord before servicing. • Do not touch electrically live parts. •...

  • Page 25: Input Board

    BLUE WHITE 115/230/1/50/60 BROWN BLACK GREEN DISPLAY BOARD W05X0245 (SCHEMATIC X0245) WARNING HIGH VOLTAGE CAN KILL • Do not operate with coers removed. • Disconnect input power by unplugging power cord before servicing. • Do not touch electrically live parts. •...

  • Page 26: Theory Of Operation

    THEORY OF OPERATION BLUE WHITE 115/230/1/50/60 BROWN BLACK GREEN DISPLAY BOARD W05X0245 (SCHEMATIC X0245) WARNING HIGH VOLTAGE CAN KILL • Do not operate with coers removed. • Disconnect input power by unplugging power cord before servicing. • Do not touch electrically live parts. •...

  • Page 27: Display Board

    FIGURE E.5 – CONTROL/DISPLAY BOARD BLUE WHITE 115/230/1/50/60 BROWN BLACK GREEN DISPLAY BOARD W05X0245 (SCHEMATIC X0245) WARNING HIGH VOLTAGE CAN KILL • Do not operate with coers removed. • Disconnect input power by unplugging power cord before servicing. • Do not touch electrically live parts. •...

  • Page 28: Insulated Gate Bipolar Tran- Sistor (Igbt) Operation

    INSULATED GATE BIPOLAR TRAN- SISTOR (IGBT) OPERATION SOURCE DRAIN A. PASSIVE F F I I G G U U R R E E E E . . 6 6 - - I I G G B B T T GATE SOURCE BODY REGION DRAIN DRIFT REGION...

  • Page 34: Output Connections

    OUTPUT CONNECTIONS INITIALISATION DE PASSE-FILS ADAPTEUR DE TIG COMPOSÉ DE RETENUE LE TIG INCENDIENT LE CABLE ÉLECTRIQUE AVEC LE GAZ FITING...
  • Page 35 BOOT WELDING CABLE .75 in. TRIM, IF REQ'D 19 mm TO FIT OVER CABLE WELDING CABLE .25 in. 6 mm COPPER FERRULE WELDING CABLE .50 in. max 12 mm max. SET SCREW BRASS PLUG COPPER TUBE...
  • Page 39 (See Figure BB.2)
  • Page 45 POST-FLOW POST-FLOW ––GAS ON–– (3A) TORCH BUTTON OUTPUT CURRENT POST-FLOW ––GAS 0N–– (3A) TORCH BUTTON OUTPUT CURRENT POST-FLOW ––GAS ON––...
  • Page 46 TORCH BUTTON OUTPUT CURRENT POST-FLOW ––GAS ON–– TORCH BUTTON OUTPUT CURRENT (3A) POST-FLOW TORCH BUTTON OUTPUT CURRENT (3A) ––GAS ON–– (3A) POST-FLOW ––GAS ON––...
  • Page 52 WARNING WARNING WARNING...
  • Page 55 BLUE WHITE 115/230/1/50/60 BROWN BLACK GREEN INPUT BOARD W05X0250 (SCHEMATIC X0203) 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 26 25 24 23 22 21 20 19 18 17 16 15 14 13 12 11 DISPLAY BOARD W05X0245 (SCHEMATIC X0245)
  • Page 56 FIGURE EE.2 – GENERAL DESCRIPTION, WELDING CAPABILITY & LIMITATIONS BLUE WHITE 115/230/1/50/60 BLACK BROWN GREEN DISPLAY BOARD W05X0245 (SCHEMATIC X0245) WARNING HIGH VOLTAGE CAN KILL • Do not operate with coers removed. • Disconnect input power by unplugging power cord before servicing. •...

  • Page 57: Input Board

    BLUE WHITE 115/230/1/50/60 BLACK BROWN GREEN 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 DISPLAY BOARD W05X0245 (SCHEMATIC X0245) WARNING HIGH VOLTAGE CAN KILL • Do not operate with coers removed. • Disconnect input power by unplugging power cord before servicing.

  • Page 58: Inverter Board

    BLUE WHITE 115/230/1/50/60 BROWN BLACK GREEN DISPLAY BOARD W05X0245 (SCHEMATIC X0245) WARNING HIGH VOLTAGE CAN KILL • Do not operate with coers removed. • Disconnect input power by unplugging power cord before servicing. • Do not touch electrically live parts. •...

  • Page 59: Display Board

    BLUE WHITE 115/230/1/50/60 BLACK BROWN GREEN DISPLAY BOARD W05X0245 (SCHEMATIC X0245) WARNING HIGH VOLTAGE CAN KILL • Do not operate with coers removed. • Disconnect input power by unplugging power cord before servicing. • Do not touch electrically live parts. •...
  • Page 60 INSULATED GATE BIPOLAR TRAN- SISTOR (IGBT) OPERATION SOURCE DRAIN A. PASSIVE F F I I G G U U R R E E E E E E . . 6 6 - - I I G G B B T T GATE SOURCE BODY REGION...
  • Page 62 Step 1. LOCATE PROBLEM (SYMPTOM). Step 2. PERFORM EXTERNAL TESTS. Step 3. RECOMMENDED COURSE OF ACTION...
  • Page 64 Input oard Test Input oard Test IG T Inverter oard Test...
  • Page 65 Input oard Test Input oard Test Input oard Test Input oard Test Inverter oard Test Inverter oard Test...
  • Page 68 (CONTINUED) Four Screws Four Screws Input Filter Capacitor Discharge Procedure...

  • Page 69: Materials Needed

    WARNING DESCRIPTION MATERIALS NEEDED...
  • Page 70 INPUT CAPACITOR DISCHARGE PROCEDURE ( ontinued) DISCHARGE PROCEDURE INSULATED PLIERS INSULATED GLOVES...

  • Page 71: Test Description

    WARNING TEST DESCRIPTION MATERIALS NEEDED...
  • Page 72 Input Board Case Removal Procedure Input Filter Capacitor Discharge Procedure...
  • Page 73 Input board checks Check Check the capacitors for Fuse F1 shorts Check the start resistor (20 Ohms) Check the input bridge for shorts or open...
  • Page 74 Voltage check on JP1 input board CONNECTOR JP1 PIN 15 PIN 1 PIN 16 Refer PIN 11 as ground Pin 5 = -5Vdc Pin 7 = +15Vdc PIN 2 Pin 9 = +5Vdc...
  • Page 75 115V or 230Vac 320 Vdc AC1 AC2 DC- DC+...
  • Page 76 F-16 INPUT BOARD TEST V160-S/T (continued) F2 0 Ohms Start Resistor 20 Ohms D11 Recti er 115VDC D20 Recti er 16VDC TEST PROCEDURE (NEW MODELS) 1. Locate connector JP1. See Figure F.6A. See Figure F.7. See Figure F.8. 2. Check pin 5 to pin 11 for -5vdc.
  • Page 77 V160 INPUT PCB INSIDE Revision Number -5 VDC Supply +5 VDC Supply +15 VDC Supply T2 Transformer 115 & 230 F1 Fuse Protects Reconnect Transformer F2 Thermostat Start Resistor Reconnect Relay Start Relay D11 Recti er Reconnect PCB Transformer Relay D20 Recti er...
  • Page 78 Input PCB 320 VDC Input DC- 320 VDC Input DC+ Output Same As Input PWM Drive PCB Inverter PCB V160 TOP VIEW V160 TOP VIEW 115AC or 230AC Input F2 Thermostat Input 115 or 230 Input Filter PCB Not On All Models...
  • Page 79 WARNING TEST DESCRIPTION MATERIALS NEEDED...
  • Page 80 Case Cover Removal Procedure Capacitor Discharge Procedure Inverter Board...
  • Page 81 VOLTAGE CHECKS ON JP1 INVERTER BOARD CHECK FOR 320 VDC REFER PIN 2 AS GROUND PIN 3 = 15 VDC PIN 7 = 15 VDC = INVERTER OFF PIN 7 = 0 VDC = INVERTER ON PIN 7 PIN 3 PIN 2...
  • Page 82 WAVEFORM ON EACH GATE 5us/div 10V/div Take note that you need an oscilloscope insulated from the supply line to do this measure 1 3 5 7 9 NUMBERING 2 4 6 8 10 GROUND...
  • Page 83 CHECK FOR THERMAL PROTECTION (~ 36 OHMS) CHECK THE OUTPUT DIODES FOR SHORTS CHECK FOR (~ 1K OHMS) CHECK THE IGBT S FOR SHORTS (AN OPEN STATUS NORMALLY IS EVIDENT) CHECK THE DIODES FOR SHORTS...
  • Page 84 VOLTAGE CHECKS ON JP1 INVERTER BOARD: REFER PIN 2 AS GROUND PIN 3 = 15 VDC PIN 7 = O VDC (INVERTER ON) PIN 7 = 15 VDC (INVERTER OFF) PIN 3 PIN 7 PIN 2 OUTPUT DIODES 1K BOTH WAYS CAN BE CHECKED AT OUTPUT STUDS ALSO...
  • Page 85 GATE DRIVE OUTPUT RECTIFIER IGBT IGB T SHUNT 1 Ohm OUTPUT TRANSFORMER T3 T3 INSIDE INVERTER PCB...
  • Page 87 WARNING DESCRIPTION MATERIALS NEEDED...
  • Page 88 Input Board Case Cover Removal Procedure. Capacitor Discharge Procedure. See Figure F.16. See Figure F.16. See Figure F.16. Figure F.16. See Figure F.16.
  • Page 89 Ground AC1 AC2 DC- DC+ Mounting Bolts...
  • Page 91 WARNING DESCRIPTION MATERIALS NEEDED...
  • Page 92 Case Cover Removal Procedure. Capacitor Discharge Procedure. See Figure F.19. See Figure F.18. See Figure F.19. Inverter Board...
  • Page 93 Ground...
  • Page 94 7MM SCREWS 10MM SCREWS...
  • Page 95 WARNING DESCRIPTION MATERIALS NEEDED...
  • Page 96 DISPLAY BOARD CONTROL KNOB 6MM NUT & WASHER Case Cover Removal Procedure. Capacitor Discharge Procedure. See Figure F.21. FOUR 2.5 MM ALLEN BOLTS FOUR 7MM MOUNTING SCREWS...
  • Page 97 7 MM CASEFRONT MOUNTING SCREWS...
  • Page 100 WIRING DIAGRAM - V160-S (CODE 10877) V160-S WIRING DIAGRAM WHITE 115/230/1/50/60 BLACK GREEN GREEN /YELLOW DISPLAY BOARD W05X0245 (SCHEMATIC: X0245) WARNING: HIGH VOLTAGE CAN KILL * Do not operate with covers removed. * Disconnect input power by unplugging power cord before servicing.

  • Page 101: Electrical Diagrams

    WIRING DIAGRAM - V160-S (CODE 11031) NOTE: DISPLAY PCB NOT ON ALL MODELS WARNING: HIGH VOLTAGE CAN KILL * Do not operate with covers removed. * Disconnect input power by unplugging power cord before servicing. * Do not touch electrically live parts.
  • Page 102 NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual. The wiring diagram specific to your code is pasted inside one of the enclosure panels of your machine. V160-S / T...
  • Page 103 24 23 22 21 20 19 18 13 12 DISPLAY BOARD W05X0370 (SCHEMATIC: X0370) WELD CONTROLLER W05X0233 (SCHEMATIC: X0233) REMOTE BOARD EARTH W05X0322 (SCHEMATIC: X0322) RIBBON CABLE HF TRANSFORMER INVERTER BOARD W05X0190 (SCHEMATIC: X0190) METER BOARD W05X0207 (SCHEMATIC: X0207) V160-S / T...
  • Page 104 SCHEMATIC - V160-S & -T (PAGE 1) DC+a 320V 1600V HGTP12N0604A 10nF 1600V 150K 400V MONTARE 400V VOLANTE NON MONTARE R7 STTA1206DI 1600V DC-a +15V 1N4148 1N4148 1N4148 200mA 1/4W 220µF COMPONENTI MECCANICI CONNESSI ELETTRICAMENTE ELECTRICAL DIAGRAMS STTA1206D MONTARE 10nF...
  • Page 105 SCHEMATIC - V160-S & -T (PAGE 2) MONTARE VOLANTE 4n7F 115V 4n7F BYV26C 1.5KE200V 100nF 630V TOP223Y NON MONTARE R11 +15Vdc 1N4148 RL3A RL3C 20mA RL3B ELECTRICAL DIAGRAMS W58X0220 W7165610 W7162430 RL2B RL1B RL1C + C12 + C15 1500µF 1500µF...
  • Page 106 HIGH FREQ CIRCUIT ONLY ON TIG VERSION NOT ON STICK VERSION ELECTRICAL DIAGRAMS PMW Controlled 100KZ to Maintain Proper supply NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual. 15VDC +5VDC -5VDC V160-S / T...
  • Page 107 12VDC For Fan Pins 1 & 2 Solenoid Circuit present on TIG machines only NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual. Supplies From Input Board JP1 To Control PCB V160-S / T...

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V160-t

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