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IM737-A
August, 2007
™
INVERTEC V160-S
For use with machines having Code Numbers: 10877; 11031
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
andbecareful.
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i i SAFETY WARNING CALIFORNIA PROPOSITION 65 WARNINGS Diesel engine exhaust and some of its constituents The engine exhaust from this product contains are known to the State of California to cause can- chemicals known to the State of California to cause cer, birth defects, and other reproductive harm. cancer, birth defects, or other reproductive harm. The Above For Diesel Engines The Above For Gasoline Engines ARC WELDING CAN BE HAZARDOUS. PROTECT YOURSELF AND OTHERS FROM POSSIBLE SERIOUS INJURY
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ii ii SAFETY ELECTRIC SHOCK can ARC RAYS can burn. 4.a. Use a shield with the proper filter and cover kill. plates to protect your eyes from sparks and 3.a. The electrode and work (or ground) circuits the rays of the arc when welding or observing are electrically “hot” when the welder is on. open arc welding. Headshield and filter lens Do not touch these “hot” parts with your bare should conform to ANSI Z87. I standards. skin or wet clothing. Wear dry, hole-free gloves to insulate hands. 4.b. Us
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iii iii SAFETY WELDING SPARKS can CYLINDER may explode cause fire or explosion. if damaged. 6.a. Remove fire hazards from the welding area. 7.a. Use only compressed gas cylinders If this is not possible, cover them to prevent containing the correct shielding gas for the the welding sparks from starting a fire. process used and properly operating Remember that welding sparks and hot regulators designed for the gas and materials from welding can easily go through small cracks pressure used. All ho
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iv iv SAFETY PRÉCAUTIONS DE SÛRETÉ 6. Eloigner les matériaux inflammables ou les recouvrir afin de prévenir tout risque dʼincendie dû aux étincelles. Pour votre propre protection lire et observer toutes les instructions et les précautions de sûreté specifiques qui parraissent dans ce 7. Quand on ne soude pas, poser la pince à une endroit isolé de manuel aussi bien que les précautions de sûreté générales suiv- la masse. Un court-circuit accidental peut provoquer un antes: échauffement et un risqu
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v v for selecting a QUALITY product. We want you to take pride in operating this product ••• as much pride as we have in bringing Thank You this product to you! CUSTOMER ASSISTANCE POLICY The business of The Lincoln Electric Company is manufacturing and selling high quality welding equipment, consumables, and cutting equip- ment. Our challenge is to meet the needs of our customers and to exceed their expectations. On occasion, purchasers may ask Lincoln Electric for advice or information about t
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vi vi TABLE OF CONTENTS Page Installation.......................................................................................................................Section A Technical Specifications .......................................................................................................A-1 Safety Precautions.................................................................................................A-1 Select Suitable Location.....................................................
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A-1 A-1 INSTALLATION TECHNICAL SPECIFICATION V160-S INPUT - SINGLE PHASE ONLY Input Voltages / 50 /60 Hz. Max. Input Current at rated Output 115 V (20 A Plug and branch) 20 A 115 V (30 A branch) 25 A 230 V 34 A RATED OUTPUT Output Amps Duty Cycle Output Volts Input Circuit 60 (Stick) 22.4 115V (20A Plug and Branch) 90 (TIG) 13.6 100% 80 (Stick) 23.2 115V (30A Branch) 110 (TIG) 14.4 160 (Stick) 26.4 230V (30A Branch) 35% 160 (TIG) 16.4 130 (Stick) 25.2 230V (30A Branch) 100% 130 (TIG) 15.2
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A-2 A-2 INSTALLATION Read entire installation section before starting TILTING installation. Place the machine directly on a secure, level surface. The machine may topple over if this procedure is not SAFETY PRECAUTIONS followed. WARNING INPUT CONNECTIONS ELECTRIC SHOCK can kill. WARNING • Only qualified personnel should per- form this installation. ELECTRIC SHOCK can kill. •Disconnect input power by removing • Have a qualified electrician install plug from receptacle before working and servi
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A-3 A-3 INSTALLATION Fuse the input circuit with time delay fuses marked “D” When the ARFU has been activated due to an input 1 or delay type circuit breakers. Using fuses or circuit over current condition, the output will be turned off and breakers smaller than recommended may result in the green Power LED will blink indicating an over-cur- “nuisance” shut-offs from welder inrush currents even rent condition. This condition usually occurs when the if not welding at high currents. unit is op
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A-4 A-4 INSTALLATION OUTPUT CONNECTION FOR STICK The following Lincoln engine drives meet these condi- tions when run in the high idle mode: WELDING (FIGURE A.2) • Ranger 250,305 FIGURE A.2 • Commander 300, 400, & 500 Many engine drives do not meet these conditions (eg WORK CLAMP 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. WORK CABLE OUTPU
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A-5 A-5 INSTALLATION REMOTE CONTROL CONNECTION QUICK DISCONNECT PLUG (FOR STICK ELEC- A remote control receptacle is provided on the lower TRODE CABLE) center case front of the welder for connecting a A quick disconnect system is used for the welding remote control to the machine. The V160-S will auto- cable connections. The stick electrode cable will need matically sense if a remote control connection is to have a plug attached. made. In Lift TIG mode (GTAW), WITHOUT a remote 1. Cut off weld
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B-1 B-1 OPERATION Read and understand this entire section before GENERAL DESCRIPTION operating your machine. The Invertec V160-S is an industrial 160 amp arc SAFETY INSTRUCTIONS welding power source which utilizes single phase input power, to produce constant current output. The welding response of this Invertec has been optimized WARNING for stick (SMAW) and Touch Start TIG (GTAW). The unit is ideal for industrial applications where portability is important. ELECTRIC SHOCK can kill. The Inverte
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B-2 B-2 OPERATION REAR CONTROL PANEL 4. Arc Control: The Arc Control simultaneously adjust the level at Hot Start and Arc Force. Increasing the Arc 1. Power Switch: Controls the input power to the Control setting increases both Hot Start and Arc Force. machine. Make sure the machine is properly con- nected to the input supply before turning the • Hot Start: This is a temporary increase in the output machine on.(See Figure B.1) current during the start of the stick welding process. This helps ign
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B-3 B-3 OPERATION 9. Output Current Control: This controls the output 7. Remote LED: This indicator will turn on when a or welding current of the machine. remote control is connected to the machine via the remote control connector. Using a remote control The function of this control knob is changed if a will change the function of the output current con- remote control is connected. If the Remote LED is trol, refer to the output current control section ON, this indicates that a remote control is
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B-4 B-4 OPERATION DIP Switch 1: Machine Type DIP SWITCH FUNCTIONS This controls the output of the V160-S and some welding waveform functions. It configures the V160-S This section has 8 DIP switch functions of the V160- to automatically turn ON depending on the position of S. Read and understand the functions before making the Welding Mode switch. Refer to DIP Switch 6 for any changes because abnormal operation can occur more information. with the wrong settings. The machine must be turned
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B-5 B-5 OPERATION 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 configuration also depends on the position of DIP Switch 1 which selects the machine type. This setting can be changed but only if the following functions are cl
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C-1 C-1 ACCESSORIES CABLE PLUGS OPTIONAL ACCESSORIES AND COMPATIBLE EQUIPMENT K852-50 - Cable Plug Kit for #1-#2 cable. Attaches to welding cable to provide quick disconnect from Factory Installed machine. Electrical Holder and Cable Assembly TIG Torch Parts Kits - Parts kits are available for the Work Cable and Clamp PTA-17 TIG torch. This kit includes back cap, collets, Strap Packet collet bodies, nozzles and tungstens. Instruction Manual Order KP508 for PTA-17 torches See publication E1
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D-1 D-1 MAINTENANCE SAFETY PRECAUTIONS CAUTION WARNING ELECTRIC SHOCK can kill. • Disconnect the power supply before every oper- • Have an electrician install and serv- ation. ice this equipment. ------------------------------------------------------------------------ • Always use gloves in compliance with the safety • Turn the input power off at the fuse standards. box, disconnect supply lines and allow machine to sit for five minutes minimum to allow the power capaci- tors to discharge before
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E-1 E-1 TROUBLESHOOTING HOW TO USE TROUBLESHOOTING GUIDE WARNING 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. _______________________________________________________________
