invertec 135s, 150s & 170s - Rapid Welding and Industrial Supplies
Contents
1. Use the illustration of assembly page and the table below to determine where the part is located for your particular code machine Use only the parts marked X in the column under the heading number called for in the assembly page indicate a change in this printing First read the Part List reading instructions above then refer to the Spare Part manual supplied with the machine that contains a picture descriptive part number cross reference Electrical Schematic Refer to the Spare Part manual supplied with the machine Accessories K10513 17 4VS TIG torch with tap 4m English 6 English2. 25 120A 24 8Vdc Output Current Output Voltage 135S 100 90A 23 6Vdc 1905 30 140A 25 6Vde 100 100A 24 0Vdc 35 160A 26 4Vdc OUTPUT RANGE Welding Current Range Maximum Open Circuit Voltage 10 120A 45Vdc CE model 10 140A 10 160A 32Vdc AUSTRALIA model RECOMMENDED INPUT CABLE AND FUSE SIZES 170S Fuse delayed or Circuit Breaker D characteristic Size Type of Plug Input Power Cable Included with Machine 2 e n ALL SCHUKO 16A 250V or 1708 16A ia AUSTRALIAN 15A 250V PHYSICAL DIMENSIONS Operating Temperature Storage Temperature 10 C to 40 C 25 C to 55 C English 5 English WEEE Do not dispose of electrical equipment together with normal waste 5 In observance of European Directive 2002 96 EC on Waste Electrical and Electronic Equipment WEEE 07 06 and its implementation in accordance with national law electrical equipment that has reached the end of its life must be collected separately and returned to an environmentally compatible recycling facility As the owner of the equipment you should get information on approved collection systems from our local representative By applying this European Directive you will protect the environment and human health Spare Parts 12 05 Part List reading instructions Do not use this part list for a machine if its code number is not listed Contact the Lincoln Electric Service Department for any code number not listed
3. ambient temperature greater than 40 C Input Supply Connection Check the input voltage phase and frequency supplied to this machine before turning it on The allowable input voltage is indicated in the technical specification section of this manual and on the rating plate of the machine Be sure that the machine is grounded Make sure the power available at the input connection is adequate for normal operation of the machine The fuse rating and cable sizes are both indicated in the technical specification section of this manual Input Supply From Engine Driven Generators e 1358 AN WARNING This machine is not designed to operate on engine driven generators Operation of this machine with engine driven generators may damage the machine English e 1508 1708 The machines are designed to operate on engine driven generators as long as the auxiliary can supply adequate voltage frequency and power as indicated in the Technical Specification section of this manual The auxiliary supply of the generator must also meet the following conditions e Vac peak voltage below 410V e Vac frequency in the range of 50 and 60Hz e RMS voltage of the AC waveform 230Vac 15 It is important to check these conditions because many engine driven generators produce high voltage spikes Operation of this machine with engine driven generators not conforming to these conditions is not recommended and may damage the machine Output Connect
4. IM2013 01 2011 INVERTEC 135S 150S amp 170S OPERATOR S MANUAL ENGLISH LINCOLN LINCOLN ELECTRIC ITALIA S r l Via Fratelli Canepa 8 16010 Serr Ricc GE Italia www lincolnelectric eu LINCOLN Declaration of conformity LINCOLN ELECTRIC ITALIA S r l Declares that the welding machine INVERTEC 135S INVERTEC 150S INVERTEC 170S conforms to the following directives 2006 95 CEE 2004 108 CEE and has been designed in compliance with the following standards EN 60974 1 EN 60974 10 2009 Dario Gatti European Engineering Director Machines LINCOLN ELECTRIC ITALIA S r l Via Fratelli Canepa 8 16010 Serra Ricc GE Italia English English LINCOLN 12 05 THANKS For having choosen the QUALITY of the Lincoln Electric products e Please Examine Package and Equipment for Damage Claims for material damaged in shipment must be notified immediately to the dealer For future reference record in the table below your equipment identification information Model Name Code amp Serial Number can be found on the machine rating plate Model Name Code amp Serial number ENGLISH INDEX dll ioni 1 Installation and Operator Instructions iii 2 Electromagnetic Compatibility EMC ee 4 Technical SPEGIICANONS teleii Lie 5 EEE 6 SPAle PilSac iene 6 Electrical Schematic iii 6 ACCESSO lla ai 6 English Il Eng
5. al electrical regulations ELECTRICALLY POWERED EQUIPMENT Regularly inspect the input electrode and work clamp cables If any insulation damage exists replace the cable immediately Do not place the electrode holder directly on the welding table or any other surface in contact with the work clamp to avoid the risk of accidental arc ignition ELECTRIC AND MAGNETIC FIELDS MAY BE DANGEROUS Electric current flowing through any conductor creates electric and magnetic fields EMF EMF fields may interfere with some pacemakers and welders having a pacemaker shall consult their physician before operating this equipment CE COMPLIANCE This equipment complies with the European Community Directives ARTIFICIAL OPTICAL RADIATION According with the requirements in 2006 25 EC Directive and EN 12198 Standard the equipment is a category 2 It makes mandatory the adoption of Personal Protective Equipments PPE having filter with a protection degree up to a maximum of 15 as required by EN169 Standard FUMES AND GASES CAN BE DANGEROUS Welding may produce fumes and gases hazardous to health Avoid breathing these fumes and gases To avoid these dangers the operator must use enough ventilation or exhaust to keep fumes and gases away from the breathing zone ARC RAYS CAN BURN 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 Use suitable clothing made from durable fl
6. ame resistant material to protect you skin and that of your helpers Protect other nearby personnel with suitable non flammable screening and warn them not to watch the arc nor expose themselves to the arc WELDING SPARKS CAN CAUSE FIRE OR EXPLOSION Remove fire hazards from the welding area and have a fire extinguisher readily available Welding sparks and hot materials from the welding process can easily go through small cracks and openings to adjacent areas Do not weld on any tanks drums containers or material until the proper steps have been taken to insure that no flammable or toxic vapors will be present Never operate this equipment when flammable gases vapors or liquid combustibles are present WELDED MATERIALS CAN BURN Welding generates a large amount of heat Hot surfaces and materials in work area can cause serious burns Use gloves and pliers when touching or moving materials in the work area English 1 English SAFETY MARK This equipment is suitable for supplying power for welding operations carried out in an environment with increased hazard of electric shock CYLINDER MAY EXPLODE IF DAMAGED Use only compressed gas cylinders containing the correct shielding gas for the process used and properly operating regulators designed for the gas and pressure used Always keep cylinders in an upright position securely chained to a fixed support Do not move or transport gas cylinders with the protection cap removed Do not allow the e
7. c disturbance generated by this machine This machine has been designed to operate in an industrial area The operator must install and operate this equipment as described in this manual If any electromagnetic disturbances are detected the operator must put in place corrective actions to eliminate these disturbances with if necessary assistance from Lincoln Electric The Class A equipment is not intended for use in residential locations where the electrical power is provided by the public low voltage supply system There may be potential difficulties in ensuring electromagnetic compatibility in those locations due to conducted as well as radiated disturbances This equipment does not comply with IEC 61000 3 12 If it is connected to a public low voltage system it is responsibility of the installer or user of the equipment to ensure by consultation with the distribution network operator if necessary that the equipment may be connected English English Before installing the machine the operator must check the work area for any devices that may malfunction because of electromagnetic disturbances Consider the following e Input and output cables control cables and telephone cables that are in or adjacent to the work area and the machine Radio and or television transmitters and receivers Computers or computer controlled equipment Safety and control equipment for industrial processes Equipment for calibration and measurement Persona
8. ectrode on the work piece in order to create a low current short circuit Then the electrode is lifted from the work piece to start the TIG arc Meter The meter displays the preset welding current before welding and the 170S only actual welding current during welding Error condition list If occurs try to turn Off the machine wait for a few seconds then turn ON again If the error remains a maintenance is required Please contact the nearest technical service center or Lincoln Electric and report the LED Status found on the machine Front Panel Blink Blink 150S ir 170S This occurs when an Internal auxiliary onl undervoltage condition is detected y Volt To restore the machine orage e Turn OFF then ON the Mains Switch to Lockout restart the machine A Power Switch It turns ON A OFF the input power to the machine B Input cable This machine is provided with a plugged input C cord Connect it to the mains Lb C Fan e 135S The fan is turned ON OFF by the machine Power Switch e 150S 170S This machine has a F A N Fan As Needed circuitry inside The machine automatically reduces the speed of the fan or turns it OFF This feature reduces the amount of dirt which can be drawn inside the machine and reduces power consumption When the machine is turned ON the fan will turn ON The fan will continue to run whenever the machine is welding The F A N feature is ac
9. formation the operator to remove the electrode from the Most TIG welding is done with DC polarity shown electrode holder without creating large sparks that here If DC polarity is necessary switch the cable can damage the electrode holder connections at the machine Refer to the section below for more details Controls and Operational Features be Machine Start Up When the machine is turned ON an auto test is executed 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 e 135S The Machine is ready to operate when on the Front Control Panel lights up the Power ON p 7i LED Connect the torch cable to the terminal of the e 150S 170S The Machine is ready to operate machine and the work clamp ifs terminal Insert when on the Front Control Panel lights up the Power the connector with the key lining up with the keyway and ON LED with one of the three LED of the Welding rotate approximately turn clockwise Do not over mode command tighten Finally connect the gas hose to the gas regulator on the cylinder of gas to be used Front Panel Controls Output Current Knob Potentiometer used Allowable TIG processes to set the output current used during e 135S Scratch TIG welding e 1508 1708 Lift TIG Power ON OFF LED This LED lights up Arc Force when the machine is ON Auto Adaptive Arc Force with MMA welding 150S 170S If blin
10. ions A quick disconnect system using Twist Mate cable plugs is used for the welding cable connections Refer to the following sections for more information on connecting the machine for operation of stick welding MMA or TIG welding e Positive Quick Disconnect Positive output connector for the welding circuit e Negative Quick Disconnect Negative output connector for the welding circuit Stick Welding MMA First determine the proper electrode polarity for the electrode to be used Consult the electrode data for this information Then connect the output cables to the output terminals of the machine for the selected polarity Shown here is the connection method for DC welding Connect the electrode cable to the terminal and the work clamp to the terminal Insert the connector with the key lining up with the keyway and rotate approximately 1 4 turn clockwise Do not over tighten For DC welding switch the cable connections at the machine so that the electrode cable is connected to English and the work clamp is connected to e Anti Sticking This is a function that decreases the TIG Welding output current of the machine to a low level when This machine does not include a TIG torch necessary for the operator makes an error and sticks the electrode TIG welding but one may be purchased separately to the work piece This decrease in current allows Refer to the accessories section for more in
11. king this LED indicates 150S 170S only fi that an Input Voltage Overrange protection During MMA welding is activated the function Auto is active the Machine restarts automatically Adaptive Arc Force that increases temporary the output when the Input Voltage returns in the correct current used to clear intermittent connections between range the electrode and the weld puddle that occur during stick i Thermal LED This indicator will turn on welding sas ia when the machine is overheated and the output has been disabled This normally occurs when the duty cycle of the machine has been exceeded Leave the machine on to allow the internal components to cool When the indicator turns off normal operation is again possible VRD LED s enabled on Australian This is an active control feature that guarantees the best arrangement between the arc stability and spatter presence The feature Auto Adaptive Arc Force has instead of a fixed or manual regulation an automatic and multilevel setting its intensity depends by the output voltage and it is calculated in real time by the microprocessor where are also mapped the Arc Force Machines only This machine is provided levels The control measure in each instant the output by VRD Voltage Reduction Device voltage and it determines the amount of the peak of current to apply that value is enough to breaks the metal drop that is being transferred from the electrode to the workpiece as t
12. l medical devices like pacemakers and hearing aids Check the electromagnetic immunity for equipment operating in or near the work area The operator must be sure that all equipment in the area is compatible This may require additional protection measures e The dimensions of the work area to consider will depend on the construction of the area and other activities that are taking place Consider the following guidelines to reduce electromagnetic emissions from the machine e Connect the machine to the input supply according to this manual If disturbances occur if may be necessary to take additional precautions such as filtering the input supply e The output cables should be kept as short as possible and should be positioned together If possible connect the work piece to ground in order to reduce the electromagnetic emissions The operator must check that connecting the work piece to ground does not cause problems or unsafe operating conditions for personnel and equipment e Shielding of cables in the work area can reduce electromagnetic emissions This may be necessary for special applications Technical Specifications Input Power at Rated Output EMC Class 2 0kW 100 Duty Cycle Input Voltage 3 5kW 25 Duty Cycle 230V 15 2 5kW 100 Duty Cycle Single Phase 4 2kW 30 Duty Cycle 2 9kW 100 Duty Cycle 5 1kKW 35 Duty Cycle RATED OUTPUT AT 40 C Frequency 50 60Hz Duty Cycle Based on a 10 min period 100 TOA 22 8Vdc
13. lectrode electrode holder work clamp or any other electrically live part to touch a gas cylinder Gas cylinders must be located away from areas where they may be subjected to physical damage or the welding process including sparks and heat sources Installation and Operator Instructions Read this entire section before installation or operation of the machine Location and Environment This machine can operate in harsh environments However it is important that simple preventative measures are followed to assure long life and reliable operation e Do not place or operate this machine on a surface with an incline greater than 15 from horizontal e Do not use this machine for pipe thawing e This machine must be located where there is free circulation of clean air without restrictions for air movement to and from the air vents Do not cover the machine with paper cloth or rags when switched on e Dirt and dust that can be drawn into the machine should be kept to a minimum e This machine has a protection rating of e 1358S IP21 e 150S IP23 e 170S IP23 Keep it dry when possible and do not place it on wet ground or in puddles e Locate the machine away from radio controlled machinery Normal operation may adversely affect the operation of nearby radio controlled machinery which may result in injury or equipment damage Read the section on electromagnetic compatibility in this manual e Do not operate in areas with an
14. lish Safety 01 11 AN WARNING This equipment must be used by qualified personnel Be sure that all installation operation maintenance and repair procedures are performed only by qualified person Read and understand this manual before operating this equipment Failure to follow the instructions in this manual could cause serious personal injury loss of life or damage to this equipment Read and understand the following explanations of the warning symbols Lincoln Electric is not responsible for damages caused by improper installation improper care or abnormal operation WARNING This symbol indicates that instructions must be followed to avoid serious personal injury loss of life or damage to this equipment Protect yourself and others from possible serious injury or death READ AND UNDERSTAND INSTRUCTIONS Read and understand this manual before operating this equipment Arc welding can be hazardous Failure to follow the instructions in this manual could cause serious personal injury loss of life or damage to this equipment ELECTRIC SHOCK CAN KILL Welding equipment generates high voltages Do not touch the electrode work clamp or connected work pieces when this equipment is on Insulate yourself from the electrode work clamp and connected work pieces ELECTRICALLY POWERED EQUIPMENT Turn off input power using the disconnect switch at the fuse box before working on this equipment Ground this equipment in accordance with loc
15. o guarantee the arc stability but not too The VRD function is enabled by factory high to avoid spatters around the welding puddle That default only on machines that meet the means e l AS 1674 2 Australian Standards C Tick e Electrode workpiece sticking prevention also with logo on near the Rating Plate applied low current values on the machine e Spatters reduction function this reduces the voltage at the output leads The VRD LED is ON when the Output The welding operations are simplified and the welded Voltage is below 32V with the Machine at joins looks better also if not brushed after the welding idle no welding time With the MMA welding are also enabled the following For others machines this function is features disabled the LED is always OFF e Hot Start This is a temporary increase in the initial welding current This helps ignite the arc quickly and reliably English 3 English Welding Mode Switch With three positions controls the welding mode of the machine two for Stick welding Soft and Crisp and one for Lift TIG welding Soft Stick For a welding with a low spatter presence e Crisp Stick For an aggressive welding with an increased Arc stability e Lift TIG When the mode switch is in the Lift TIG position the stick welding functions are disabled and the machine is ready for Lift TIG welding Lift TIG is a method of starting a TIG weld by first pressing the TIG torch el
16. tive after that the machine doesn t weld for more than 10 minutes the fan speed will return to the maximum speed if a welding operation restarts Maintenance AN WARNING For any maintenance or repair operations it is recommended to contact the nearest technical service center or Lincoln Electric Maintenance or repairs performed by unauthorized service centers or personnel will null and void the manufacturers warranty The frequency of the maintenance operations may vary in accordance with the working environment Any noticeable damage should be reported immediately e Check cables and connections integrity Replace if necessary e Keep clean the machine Use a soft dry cloth to clean the external case especially the airflow inlet outlet louvers AN WARNING Do not open this machine and do not introduce anything into its openings Power supply must be disconnected from the machine before each maintenance and service After each repair perform proper tests to ensure safety Electromagnetic Compatibility EMC 01 11 This machine has been designed in accordance with all relevant directives and standards However it may still generate electromagnetic disturbances that can affect other systems like telecommunications telephone radio and television or other safety systems These disturbances can cause safety problems in the affected systems Read and understand this section to eliminate or reduce the amount of electromagneti
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