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IM10060
September, 2010
®
INVERTEC 100S
For use with machines having Code Numbers: 11673
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 thoughtful operation on
your part. DO NOT INSTALL,
OPERATE OR REPAIR THIS
EQUIPMENT WITHOUT READ-
ING THIS MANUAL AND THE
SAFETY PRECAUTIONS CON-
TAINED THROUGHOUT. And,
most importantly, think before
you act and be careful.
OP
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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 ARC RAYS can burn. ELECTRIC SHOCK can 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 and CUTTING CYLINDER may explode SPARKS can if damaged. cause fire or explosion. 7.a. Use only compressed gas cylinders 6.a. Remove fire hazards from the welding area. containing the correct shielding gas for the If this is not possible, cover them to prevent process used and properly operating the welding sparks from starting a fire. regulators designed for the gas and Remember that welding sparks and hot pressure used. All hoses, fittings, etc. should be suitable for mat
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iv iv SAFETY PRÉCAUTIONS DE SÛRETÉ 6. Eloigner les matériaux inflammables ou les recouvrir afin de prévenir tout risque d’incendie 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 SAFETY Electromagnetic Compatibility (EMC) Conformance Products displaying the CE mark are in conformity with European Community Council Directive of 15 Dec 2004 on the approximation of the laws of the Member States relating to electromagnetic compatibility, 2004/108/EC. It was manufactured in conformity with a national standard that implements a harmonized standard: EN 60974-10 Electromagnetic Compatibility (EMC) Product Standard for Arc Welding Equipment. It is for use with other Lincoln E
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vi vi SAFETY Electromagnetic Compatibility (EMC) The size of the surrounding area to be considered will depend on the structure of the building and other activities that are taking place. The surrounding area may extend beyond the boundaries of the premises. Methods of Reducing Emissions Mains Supply Welding equipment should be connected to the mains supply according to the manufacturer’s recommenda- tions. If interference occurs, it may be necessary to take additional precautions such as filter
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vii vii for selecting one of our QUALITY products. We want you to take pride in operating this product ••• as much pride as we have in T h a n k bringing this product to you! CUSTOMER ASSISTANCE POLICY The business of our company is manufacturing and selling high quality welding equipment. Our challenge is to meet the needs of our customers and to exceed their expectations. On occasion, purchasers may ask us for advice or information about their use of our products. We respond to our customers b
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viii viii TAbLE OF CONTENTS Page Installation.......................................................................................................................Section A Technical Specifications .......................................................................................................A-1 Safety Precautions .................................................................................................A-2 Select Suitable Location.................................................
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A-1 A-1 INSTALLATION ® TECHNICAL SPECIFICATION INVERTEC 100S INPUT - SINGLE PHASE ONLY Input Voltages 60 Hz. Rated Input Current 120Vac ± 15% 20 Amps @ Rated Output RATED OUTPUT Output Amps Output Volts Input Circuit Duty Cycle 80A (Stick) 23.2 Vdc 120 Vac 20% OUTPUT Output Current Range Type of Output Maximum Open Circuit Voltage 10-100 Amps 45 Volts Max. DC RECOMMENDED INPUT WIRE AND FUSE SIzES FOR MAXIMUM RATED OUTPUT TYPE SJT OR HARD USAGE INPUT MAXIMUM TIME-DELAY CIRCUIT INPUT VOLTAG
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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. Do not place or operate this machine on a surface SAFETY PRECAUTIONS with an incline greater than 15° from horizontal. The machine may topple over if this procedure is not fol- WARNING lowed. ELECTRIC SHOCK can kill. INPUT CONNECTIONS • Only qualified personnel should per- form this installation. WARNING • Disconnect input power by removing plug fr
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A-3 A-3 INSTALLATION 120V INPUT STICK WELDING (SMAW) First determine the proper electrode polarity for the elec- The rated output of the Invertec® 100S is available trode to be used. Consult the electrode data for this when connected to a 20A branch circuit. When con- information. Then connect the output cables to the out- nected to a branch circuit with lower ampacity, lower put terminals of the machine for the selected polarity. welding current and duty cycle must be used. An out- Shown h
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b-1 b-1 OPERATION Read and understand this entire section before WELDING CAPAbILITY operating your machine. The INVERTEC® 100S is rated at 80 amps, 23.2 SAFETY INSTRUCTIONS volts, at 20% duty cycle on a ten minute basis. It is capable of higher duty cycles at lower output currents. WARNING If the duty cycle is exceeded, a thermal protector will shut off the output until the machine cools. See Table ELECTRIC SHOCK can kill. A.1 in the INSTALLATION Section for other rated out- puts. • Do not touc
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b-2 b-2 OPERATION CONTROLS AND OPERATIONAL ARC-WELDING CIRCUIT (See Figure B.3) FIGURE b.3 MACHINE START-UP: When the machine is turned ON, an auto-test is exe- cuted; during this test only the Thermal LED is ON; after few seconds the Thermal LED turns OFF and the Power ON/OFF LED lights up. The Machine is ready to operate when the POWER ON LED on the Front Control Panel illuminates green. FRONT PANEL CONTROLS Output Current Knob: Potentiometer used to set the output current used during welding.
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b-3 b-3 OPERATION This figure closely resembles what is actually seen 4. Immediately after striking the arc try to maintain a during welding. The “arc stream’’ is seen in the middle distance from the workpiece that is equivalent to of the figure. This is the electric arc created by the the diameter of the electrode used. Maintain this electric current flowing through the space between the distance as constantly as possible during the weld. end of the electrode and the work. Whenever possible, we
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b-4 b-4 OPERATION 7. Once the electrode is burned down move the elec- TIG welding also requires 100% Argon shielding gas trode quickly from the weld to extinguish the arc. to shield the arc, preventing porosity in the weld. This is different than stick welding which has a coating on 8. Turn the machine off and remove the stub by open- the electrode to produce its own shielding. In addition, ing the jaws of the electrode holder and insert a a gas regulator, a manual gas valve TIG torch, torch new
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C-1 C-1 ACCESSORIES CAbLE PLUGS OPTIONAL ACCESSORIES AND COMPATIbLE EQUIPMENT K852-25 - Cable Plug Kit attaches to welding cable to provide quick disconnect from machine. Factory Installed TIG Torch Parts Kit - A Parts kit is available for the Electrical Holder and Cable Assembly PTA-17 TIG torch. This kit includes back cap, collets, Work Cable and Clamp collet bodies, nozzles, and tungtens. Strap Packet Instruction Manual Order KP508 for PTA-17 torches See publication E12.150 for parts kit
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D-1 D-1 MAINTENANCE SAFETY PRECAUTIONS WARNING WARNING Do not open this machine and do not introduce any- thing into its openings. Power supply must be discon- ELECTRIC SHOCK can kill. nected from the machine before each maintenance • Have an electrician install and serv- and service. After each repair, perform proper tests to ice this equipment. ensure safety. • Turn the input power off at the fuse box, disconnect supply lines and allow machine to sit for five minutes CAUTION minimum to allow
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E-1 E-1 TROUbLESHOOTING HOW TO USE TROUbLESHOOTING GUIDE WARNING Service and Repair should only be performed by 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. __________________________________________________________________________ This
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E-2 E-2 TROUbLESHOOTING Observe all Safety Guidelines detailed throughout this manual PRObLEMS POSSIbLE RECOMMENDED (SYMPTOMS) CAUSE COURSE OF ACTION WELDING PRObLEMS Excessive spatter 1. Long arc 2. High current Craters 1. Fast movement of the electrode away from piece. Inclusions 1. Poor cleanliness or distribution of the Welding passes. 2. Improper movement of the elec- trode. Insufficient penetration 1. High progression speed. 2. Welding current too low. 3. Narrow chamfering. Sticking 1. Arc
