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V160-S & -T

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1. 5 5 o 160 WIRING DIAGRAM 8 8 WHITE 2 BLUE 3 o DC e DC Wie e T dc BLACK BROWN BLACK HF TRANSFORMER 4 3 412 46 DC W2 23 a INVERTER BOARD 08 INPUT BOARD W05X0130 YELLOW GREEN SCHEMATIC olo SCHEMATIC GND Pe 0203 gt 5 FAN 5 2 2345678910 2 1 2 515 m o E GAS 3 5 SOLENOID 2 JP1 2365678910 112 3 1415 16 g o 26 25 24 23 22 21 20 19 18 17 16 15 14 13 12 11 1098765432 Ez DISPLAY BOARD W05X0370 SCHEMATIC 70 0 2 WELD CONTROLLER W05X0207 515 W05X0233 SCHEMATIC dc 0207 SCHEMATIC JP X0233 WARNING HIGH VOLTAGE KILL not operate with covers removed Disconnect input power by unplugging EN ES power cord before servicing not touch electrically Live parts LA S Only qualified persons should install EARTH REMOTE BOARD NN S use or service this machine 1 1 05 032727 5 SCHEMATIC X03221 RIBBON CABLE Return to Section TOC Return to Master TOC NOTE This
2. BB 3 Oo Controls and Settings 2 Step and 4 Step Tig Sequence BB 3 BB 6 O DIP Switch Functions Service Information BB 7 v 3 DIP Switch 1 Machine Type BB 7 o p Prafiaw DIRIGE A lt E CR o BB 7 2 2 DIP Switch 3 2 Step Restart Enable BB 8 DIP Switch 4 4 Step Restart Enable BB 9 BB 10 DIP Switch 5 Low OCV Enable BB 11 DIP Switch 6 European USA Machine Configuration BB 11 DIP Switch 7 amp 8 Upslope BB 12 o z Start Crater Current Adjustment aasan a aana eea BB 12 v g E o o v g E E o V160 S 8 T LINCOLN amp Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC o 5 2 3 Return to Section Return to Master TOC o 2 D 8 c x 3 2 Read and understand th
3. A 3 Ground Connettore sa riie o mi aA E i EA h tte 4 Output Connections 5 Output and Gas Connection for Tig Welding A 5 Output Connection for Stick Welding A 5 Quick Disconnect Plug 3 6 Output Connection for Tig A 6 Remote Control Connection A 6 V160 S amp T LINCOLN ais INSTALLATION ds TECHNICAL SPECIFICATION V160 S INPUT SINGLE PHASE ONLY Input Voltages 50 60 Hz Max Input Current at rated Output 115 V 20 A branch 115 V 30 A branch 230 V Return to Section TOC Return to Master TOC RATED OUTPUT Duty Cycle Output Amps Output Volts Input Circuit 60 Stick 22 4 115V 20A Branch 90 TIG 13 6 80 Stick 23 2 115V 30A Branch 110 TIG 14 4 160 Stick 26 4 230V 30A Branch 160 TIG 16 4 130 Stick 25 2 230V 30A Branch 130 TIG 15 2 OUTPUT Output Current Range Maximum Open Circuit Voltage Type of Output CUTE RECOMMENDED INPUT WIRE AND FUSE SIZES FOR MAXIMUM RATED OUTPUT INPUT VOLTAGE TYPE S
4. 7 Shielding Gas Connection AA 7 Remote Control Connection AA 7 o O v g E o v g E E V160 S amp T LINCOLN INSTALLATION TECHNICAL SPECIFICATIONS V160 T INPUT SINGLE PHASE ONLY Input Voltages 50 60 Hz Max Input Current at rated Output 115 V 20 A Plug and branch 115 V 30 A branch 230 V Return to Section TOC Return to Master TOC RATED OUTPUT Duty Cycle Output Amps Output Volts 60 Stick 22 4 115V 20A Plug and Branch 90 TIG 13 6 100 80 ae 23 2 115V 30A Branch sat _ e o 164 10095 130 Stick 25 2 230V 30A Branch 130 pm 15 2 OUTPUT o 5 97 g amp x 5 Return to Master Output Current Range Current Range Maximum Maximum Open Circuit Voltage Maximum Open Circuit Voltage Voltage Type Type of Output Type of Output 050006 RECOMMENDED INPUT WIRE AND FUSE SIZES FOR MAXIMUM RATED OUTPUT INPUT VOLTAGE TYPE S SO ST STO OR EXTRA MAXIMUM TIME DELAY CIRCUIT FREQUENCY HZ HARD USAGE INPUT CORD AWG BREAKER OR FUSE SIZE AMPS 9 PHYSICAL DIMENSIONS 2 gt Weight 818 Approx 24 2165 11 kgs
5. B 2 M 2 Rear Control Panels ssai sa sanana i a ama wa a EEE g aa ea BRE er EE a E e KOE M E EA E ca dE EE ME aE de a NRR E B 3 Controls and Settings eee B 3 B 4 DIP Switch Functions Service 1 B 5 DIP Switch 1 Machine Type B 5 DIP Switch 6 European USA Machine Configuration 6 V160 S 8 T LINCOLN Return to Section TOC Return to Master TOC Return to Section TOC O10 Fie 5 5 10 9 1 0 sie pir oO oO ayo Return to Section TOC Return to Master TOC Return to Master TOC OPERATION ps Read and understand this entire section before operating your machine SAFETY INSTRUCTIONS A WARNING e ELECTRIC SHOCK can kill Do not touch electrically live parts such as output terminals or internal wiring Insulate yourself from the work and ground Always wear dry insulating gloves FUMES AND GASES can be dangerous 3 Keep your head out of fumes Use ventilation or exhaust to remove fumes from breathing zone WELDING CUTTING and GOUGING SPARKS can cause fire or explosion 27 D Keep flammable material away Do not weld
6. 13 12VDC For Fan Pins 1 amp 2 NZ ar 4X2 15Vde 4 819 ele JE dr ia Gc 27 2R2 al m me ee E VER Solenoid Circuit present on TIG machines only EV R2 10 UE 7 NOTE This diagram is for reference only It may be accurate for all machines covered by this manual
7. EJE 2 818 cfc 513 pie olo Return to Section TOC Return to Master TOC OPERATION DIP SWITCH FUNCTIONS This section has 8 DIP switch functions of the V160 S Read and understand the functions before making any changes because abnormal operation can occur with the wrong settings The machine must be turned OFF when the DIP Switches are changed A WARNING ELECTRIC SHOCK CAN KILL Be sure that all installation operation maintenance and repair procedures are performed only by qualified indi viduals 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 Do not open the machine or change the DIP Switches with power applied to the machine Only Lincoln trained service technicians are authorized to per form these modifications The DIP switches are numbered from 1 to 8 shown in Figure B 3 Switch 1 is on the bottom and switch 8 is on the top When a switch is pushed to the right or to the back of the machine it is ON when it is pushed to the left or to the front of the machine it is OFF The standard production settings for the V160 S are shown with in bold letters ON Table B 1 If a switch set ting has bold letters ON do not make any changes abnormal operation could o
8. DRAIN PASSIVE DRAIN DRIFT REGION n lt BUFFER LAYER p INJECTING LAYER POSITIVE VOLTAGE BODY REGION DRAIN DRIFT REGION BUFFER LAYER INJECTING LAYER V160 S amp T LINCOLN TABLE OF CONTENTS INSTALLATION SECTION V160 T o o ke 5 Installati n 125222 1 9 gt g Technical Specifications 0 0 hh hh sh AA 2 o Select Suitable Location ke aed AA 3 EAC t 11o MR REPTILES 3 3 Machine Grounding and High Frequency Interference Protection 4 Input Connections hne 4 O Ground 4 5 v 3 ET a BID T ST NT TET ane a ghee ka ee pee AA 6 Output and Gas Connection for Tig AA 6 2 2 Work Cable Connection 6 Output Connection for Stick AA 6 Quick Disconnect Plug aisa a aiani
9. ae Mo RERO Saale a d NC Ga E 2 CON Me TITLE E 2 ETE 3 WAM OMS FeO ANC eat cH 4 Display 22222222 ete 2 isda b e 5 Insulated Gate Bipolar Transistor IGBT Operation E 6 Return to Master TOC FIGURE E 1 V160 S BLOCK LOGIC DIAGRAM 51 WHITE 2 22311 BLUE RED toro 1 DC DC gum 4 3 BROWN BLACK BLACI O 2 DC A DC w2 INVERTER BOARD W05X0190 SCHEMATIC X0190 115 230 1 50 60 Vac Y G INPUT BOARD GND GND W05X0250 SCHEMATIC X0203 JP1 123456789 10 v JP2 3 6 JP1 12345678910 11 1213141516 Q 2 0 i c x 5 26 25 24 23 22 21 20 19 18 17 16 15 14 13 12 11 10987654321 DISPLAY BOARD WO05X0245 SCHEMATIC X0245 WELD CONTROLLER W05X0233 SCHEMATIC X0233 WARNING HIGH VOLTAGE CAN KILL Do not operate with coers removed Disconnect input power by unplugging power cord before servicing REMOTE Do not touch electrically live parts Only qualified persons should install CONNECTOR use or service this machine Return to Master TOC V160 S amp T LINCOLN Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC ojo o E 5 5 8 R7 9 1 0 gt 6 1 8 O Ret
10. 2 2 TEMPERATURE RANGES OPERATING TEMPERATURE RANGE STORAGE TEMPERATURE RANGE 20 C to 40 50 C to 85 C ake ola lz ele tz 5 2 2 2 V160 S 8 T LINCOLN Return to Section TOC Return to Master TOC Return to Section TOC O10 Fie s 10 9 1 0 gt 6 1 8 oO oO Return to Section TOC Return to Master TOC Return to Master TOC AA 3 Read entire installation section before starting installation SAFETY PRECAUTIONS A WARNING ELECTRIC SHOCK can kill Only qualified personnel should per form this installation Disconnect input power by removing plug from receptacle before working inside V160 T Allow machine to sit for 5 minutes minimum to allow the power capacitors to discharge before working inside this equipment nsulate yourself from the work and ground Always wear dry insulating gloves Always connect the V160 T to a power supply grounded according to the National Electrical Code and local codes SELECT SUITABLE LOCATION This machine will operate in harsh environments However it is important that simple preventative mea sures are followed to assure long life and reliable oper ation Do not place or operate this machine a surface with an incline greater than 15 from horizontal This machine must be located where there is free cir culation of clean air without restrictions for air move ment to and from t
11. 4 PY Y O GH TA1 au q o 110V 100A R27 C13 EH R31 R32 R28 D17 TA2 220R 4n7F A BYT12PI a E T2A T2B 016 Lu 1W 4kV 1 5KE250 2n2F Lost 630V MONTARE 4 4 4 Oo VOLANTE D L f we 0 Dio 045 R29 dJ dq 1K om x R15 1 5KE250 D11 C8 487 o g NON MONTARE R7 1nF cio STTA1206DI 1600V Q3 Q5 Q7 D18 C11 C15 n iv HGTP12N0604A I Bn3F 4n7F 2 gt R16 R6 1600 4kV 10R c9 C10 BYV26E 487 2 3W 4n7F 4n7F 4kV 4kV R22 c E e 9 hd O 2 2 e 1mohm R18 R20 R25 SZ A1 108 108 10R R1 R23 R24 1 22 X 2 CALIBR V_FB 3 C FB GL OCV r 15 Is 5 VO 5 EL R3 iS 7 100K 15 5 1GIRO CALIBR X 10 IOUT SET 11 12 D4 TOUT 1 BYV26B 2 SOFT START 19 10 X 17 O O R5 R4 15V 18 Fle 1K ART 2 lt 0 5W 0 5W olo c5 C4 2 35190 2 1 47 F 100F T ERROR 9 a 25V 25V ON OFF 23 PWM 2 2 15 1N4148 1N4148 1N4148 25 olo D3 D2 D1 200mA 12V 50mA P s GH VY v E NON MONTARE C5 ala R R11 olo 2 7 41 d 3 470R IRFD110 o 1 4W 25V 1 4W Q2 JP1 20 TID m V FB m 1 D T1B 1 8 A 1N4749A ERROR COMPONENTI MECCANICI CONNESSI 7 R12 ON OFF 8 d 100R R13 SET ELETTRICAMENTE
12. TROUBLESHOOTING amp REPAIR Pet INPUT BOARD REMOVAL AND REPLACEMENT PROCEDURE WARNING Service and repair should be performed by only Lincoln Electric factory trained personnel Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty For your safety and to avoid electrical shock please observe all safety notes and pre cautions detailed throughout this manual Return to Section TOC Return to Master TOC If for any reason you do not understand the test procedures or are unable to per form the tests repairs safely contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed Call 1 888 935 3877 DESCRIPTION This procedure will aid the technician in the removal and replacement of the Input Board MATERIALS NEEDED Return to Section TOC Return to Master TOC Analog Volt Ohmmeter Phillips Head Screwdriver 7mm Nutdriver Wiring Diagram O10 Fie 5 5 10 9 1 0 sie oO oO Return to Section TOC Return to Master TOC V160 S amp T LINCOLN Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC Fie 5 5 10 9 1 0 gt 218 olo r amp Return to Section TOC Return to Master TOC F 28 TROUBLESHOOTING amp REPAIR INPUT BOARD REMOVAL AND REPLACEMENT PROCEDURE contin
13. rm TROUBLESHOOTING amp REPAIR FIM INPUT CAPACITOR DISCHARGE PROCEDURE continued o 8 4 Obtain a high resistance and high wattage resistor 9 ELECTRIC SHOCK can 25 1000 ohms and 25 watts minimum 5 kill This resistor is not with the machine NEVER USE pee A SHORTING STRAP FOR THIS PROCEDURE 2 Have an electrician install es S PROCEDU E E 5 Locate the eight capacitor solder pads shown in Turn the input power off at Figure F2 the fuse box before working on equipment 6 Using electrically insulated gloves and pliers hold the body of the resistor with the pliers and connect Do not touch electrically hot the resistor leads across the two capacitor solder pads Hold the resistor in place for 15 seconds Prior to performing preventative maintenance per DO NOT TOUCH CAPACITOR SOLDER PADS form the following capacitor discharge procedure to WITH YOUR BARE HANDS 9 8 avoid electric shock 7 Repeat the discharge procedure for the other capacitor o gt DISCHARGE PROCEDURE 8 Check the voltage across the terminals of all capac 2 itors with a DC voltmeter Voltage should be zero 1 Remove the input power to the machine If any voltage remains repeat the capacitor dis E z u 2 Using the phillips head screwdriver remove the Screws securing the case wraparound cover 3 Be carefu
14. After the arc is turned OFF the gas valve will remain open to continue the flow of the shielding gas to the hot electrode and work piece The duration of this postflow shielding gas is adjusted by the Postflow Parameter This operation is shown in 2 step dia gram 1 2 Step Diagram 1 1 TORCH BUTTON u EN CURRENT PRE FLOW POST FLOW 5 GAS Possible variations of this standard sequence is shown below It is possible to press and hold the TIG torch trigger a second time during downslope to restart After the trigger is pressed the output current will increase to the welding current This operation is shown in 2 step diagram 2 2 Step Diagram 2 0 2 BUTTON PRE FLOW OUTPUT CURRENT POST FLOW GAS ON GAS V160 S amp T LINCOLN BB 6 OPERATION BB 6 4 Step Sequence Possible variations of this standard sequence are Note 4 Step works with Arc Start Switch only Amptrol shown below It is possible to press and hold the TIG type devices will not work properly and should not torch trigger another time to end the downslope time be used The Arc Start Switch s actuator is also maintain the output current at the Start Finish cur referred to as the Tig torch trigger in the following When the TIG torch trigger is released the output will turn OFF and postflow will begin This operation
15. ELECTRICAL DIAGRAMS me WIRING DIAGRAM V160 S CODE 10877 2 8 c V160 S WIRING DIAGRAM 512 2 2 51 BLUE 1 pen 1 E 5 SIUE L 1 DC o l w1 ec 115 230 1 50 60 BLACK 5 0 2 DC A W2 e ac BLACK BROWN INVERTER BOARD INPUTBOARD s GREEN banD wosx0250 SCHEMATIC X0190 O ES c GREEN YELLOW SCHEMATIC X0203 i 5 9 o 2 a 2 L 2 345678 910 4 g JP2 a 3 4 1 I 128945678910 11219141516 J 26 25 24 23 22 21 20 1918 17 16 15 14131211 10987654321 5 5 29 1 DISPLAY BOARD 8 2 WO05X0245 J1 2 SCHEMATIC X0245 8 a 2 JP1 4 4 5 BT BL J WARNING HIGH VOLTAGE CAN KILL Do not operate with covers removed 2 9 Disconnect input power by unplugging r E lt po Ls power cord before servicing 1 812 Do not touch electrically live parts 312 5 Only qualified persons should install Y elg use or service this machine CW N ee eee ee ee ee 51 glg NOTE This diagram is for reference only It may not be accurate for all machines covered by this
16. A CAUTION Disconnect the power supply before every oper ation Always use gloves in compliance with the safety standards V160 S amp T LINCOLN 3 V160 S 8 T LINCOLN 3 ELECTRIC MAINTENANCE Figure DD 1 Major Component Locations 1 Front Assembly 2 Rear Assembly 3 Base Main Assembly DD 3 DOL J91Se N uunjeH DOL J91Se N 01 uunjeH DOL J91Se N 01 uunjeH DOL J91Se N 0 UuunjeH DOL uonoes DOL uonoes uumeg DOL uonoes uumeg uonoes DD 4 NOTES V160 S amp T LINCOLN E DD 4 DOL J91Se N 01 uunjeH DOL J91Se N 01 uunjeH DOL J91Se N 01 uunjeH DOL J91Se N 01 UuunjeH DOL uonoes DOL uonoes uonoes DOL uonoes TABLE OF CONTENTS THEORY OF OPERATION SECTION o O 5 Theory of Operation sederet M QUART Ne Ed add rw e s E 1 i z g General Description uus iw duces ae a ee ewe GR CR ee ACC i OR a ae EE 2 Welding Capability Sk DR aad lene Sata EE 2 Lirmitatiorns esa dat enh EE 2 MEET 3 Mwene EBO E P Ern 4 Display 2 2 4 2 2525 2 2 8 5 5 Insulated Gate Bipolar Transistor IGBT
17. Return to Section TOC Return to Master TOC 12345678910 7 12345678910 111213 14 15 16 26 25 24 23 22 21 20 19 18 17 16 15 14 13 12 11 10987654321 DISPLAY BOARD W05X0245 SCHEMATIC X0245 METER BOARD W05X0207 SCHEMATIC X0207 WELD CONTROLLER W05X0233 SCHEMATIC X0233 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 Only qualified persons should install CONNECTOR use or service this machine Return to Section TOC Return to Master TOC DISPLAY BOARD The display board receives status and analog signals from the inverter board and various sensors It is com posed of 2 parts Weld controller Interprets signals makes decisions and changes the machine mode and output to satis fy the requirements as dictated by the operator Display board Supports all the potentiometer switches and LED O10 Fie 5 5 10 9 1 0 gt 6 1 8 oO oO Meter board Displays the pre set and actual output current NOTE Unshaded areas of Block Logic Diagram are the subject of discussion Return to Section TOC Return to Master TOC V160 S amp T LINCOLN Return to Section TOC Return to Master TOC Return to Section TOC O10 Fie 5 5 10 9 1 0 gt 6 1 8 oO oO Return to Section TOC Retur
18. Return to Section TOC Return to Master TOC V160 S amp T LINCOLN Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC O10 Fie 5 5 10 9 1 0 sie oO oO Return to Section TOC Return to Master TOC pes TROUBLESHOOTING amp REPAIR ES MAIN IGBT INVERTER BOARD V160 S T WELDING LOGIC AND INVERTER SECTION TEST continued FIGURE F 12 MAIN IGBT INVERTER BOARD LOCATION CHECK THE IGBT S FOR SHORTS AN OPEN STATUS NORMALLY IS EVIDENT CHECK FOR THERMAL PROTECTION 36 OHMS CHECK THE OUTPUT DIODES FOR SHORTS CHECK FOR 1K OHMS CHECK THE DIODES FOR SHORTS TEST PROCEDURE Locate test points on inverter board See Figure F 12 N Check IGBT and diodes for shorts Check thermal protector for 36 ohms m Check lower left section as marked for 1K Ohms 160 5 amp T LINCOLN Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC olo O s 10 9 0 olz pir oO oO Return to Section TOC Return to Master TOC dian TROUBLESHOOTING amp REPAIR MAIN IGBT INVERTER BOARD 160 5 WELDING LOGIC AND INVERTER SECTION TEST continued FIGURE F 13 MAIN IGBT INVERTER BOARD LOCATION VOLTAGE CHECKS ON JP1 INVERTER BOARD JP1 9 TO JP1 2 C FB Current feedback from shunt Voltage signal between 0 10V 0 600 Exampl
19. DISPLAY BOARD m W05X0245 93 METER BOARD W05X0207 SCHEMATIC X0207 WELD CONTROLLER W05xX0233 SCHEMATIC X0233 Return to Section TOC Return to Master TOC WARNING HIGH VOLTAGE CAN KILL Do not operate with coers removed Disconnect input power by unplugging power cord before servicing REMOTE Do not touch electrically live parts Only qualified persons should install GONMECTOR use or service this machine INVERTER BOARD The inverter board includes the following circuits Inverter circuit Transforms the DC current at 80KHz and feeds the main transformer The current is regu lated via Pulse Width Modulation Main transformer It has two functions 1 gives the correct output voltage for welding 2 Insulates the operator side from the output line O10 Fie 5 5 10 9 1 0 gt 6 1 8 oO oO Output circuit The output diodes rectify the output the current from the main transformer The choke fil ters the output current The shunt provides output feedback information to the control board NOTE Unshaded areas of Block Logic Diagram are the subject of discussion Return to Section TOC Return to Master TOC 160 5 8 T LINCOLN EES THEORY OF OPERATION FIGURE EE 5 DISPLAY BOARD 51 115 230 1 50 60 INVERTER BOARD W05X0190 SCHEMATIC X0190 INPUT BOARD GND WO05X0250 SCHEMATIC X0203
20. T2 Transformer 115 amp 230 D20 Rectifier 160 5 amp T LINCOLN Peis TROUBLESHOOTING amp REPAIR a 8 9 INPUT BOARD TEST V160 S T continued Fie 5 FIGURE 8 INPUT BOARD 518 z V160 TOP VIEW 5 2 1 2 115 230 Input Input PCB 320 VDC Input DC F2 Thermostat 320 VDC Input DC Output Same As pnmum M H3 m 1 Input 115 230 Input Input Filter PCB Not On All Models Pwm Drive PCB Inverter PCB Return to Section TOC Return to Master TOC olo O 5 5 10 9 1 0 gt pir oO oO Return to Section TOC Return to Master TOC V160 S amp T LINCOLN Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC o 5 97 2 G 3 Return to Section TOC Return to Master TOC o 2 0 8 c x 3 19 TROUBLESHOOTING amp REPAIR MAIN IGBT INVERTER BOARD V160 S T WELDING LOGIC AND INVERTER SECTION TEST A WARNING Service and repair should be performed by only Lincoln Electric factory trained personnel Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty For your safety and to avoid electrical shock please observe all safety notes and pre cautions detai
21. TIG or dam age to measuring equipment will occur To test HF on V160T attach tig torch remote amptrol and argon shielding gas V160 S amp T LINCOLN TABLE OF 5 DIAGRAM SECTION e o O 5 Electrical Diagrams qua uw ua p d aie G 1 g S Wiring Diagram V160 S Code 10877 G 2 o Wiring Diagram V160 S Code 11031 2 1 0 teen nent eens G 3 Wiring Diagram V160 T Code 10878 G 4 Wiring Diagram V160 T Code 11032 G 5 Schematic 160 5 T Page 1 G 6 Schematic 160 5 T Page2 G 7 Schematic V160 S T Input PC Board G 8 Schematic V160 S T Input PC Board Voltage Supplies G 9 Return to Master TOC NOTE Many PC Board Assemblies are now totally encapsulated surface mounted and or multi layered and are therefore considered to be unserviceable Assembly drawings of these boards are no longer provided o 2 0 i c x 3 Return to Master TOC V160 S amp T LINCOLN
22. The output current control knob on the display panel is not used TIG Welding Modes The maximum output current of the machine is set by the output current control knob The remote control then adjusts the output current from the minimum output 5A to the value set by the output current control knob For example if the output current control knob on the machine is set to 100A then the remote control will adjust the output current from a minimum of 5A to a maximum of 100A 11 Downslope Control In the TIG welding modes this control knob will adjust the downslope time from 0 5 to 20 seconds The default upslope time 15 0 5 sec onds Refer to the trigger sequence section below to understand how downslope is activated In Stick weld ing mode this function is not used 4 Mode Switch 14 Pulse Mode Switch 5 Trigger Mode Switch 15 Pulse LED 6 Power LED 16 Pulse Frequence Control 7 Thermal LED 17 Background Current Control 8 Remote LED 18 Electrode Connection Negative 9 Output LED 19 Remote Control Connector 10 Output Current Control 20 Electrode Connection Positive 11 Downslope Control 12 Postflow Control 13 Digital Display Return to Section TOC Return to Master TOC V160 S amp T LINCOLN Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC Fie 5 5 0 9 0 gt 8 oO oO Return to Section TOC Return to
23. 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 When connected to a branch circuit with lower ampacity lower welding cur rent and duty cycle must be used An output guide is provided below The values are approximate and must be adjusted downward if the fuse or circuit breaker trips off Other loads on the circuit and fuse circuit breaker characteristics will affect the available output Do not exceed these welding conditions 15A plug on a 15A branch 10 duty cycle Stick 65A TIG 95 15A plug on a 20A branch 10 duty cycle Stick 75 TIG 105A 20A plug on a 20A branch 10 duty cycle Stick 85A TIG 120A The Invertec V160 S is provided with a 115 230V cable 6 6ft 2m in length with a 15Amp 5 15P plug molded onto the cord The V160 S is supplied with an additional 20A plug that can replace the 15A plug to achieve higher output To install the supplied 20A plug Connect the white neutral wire under terminal clamp with silver screw and black hot wire under terminal clamp with brass screw Connect green wire under ter minal clamp with green screw ARFU Auto Restore Fuse The dual input voltage machine is provided with an ARFU device It only operates when the input is con nected to an 115V supply and protects from input ove
24. contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed Call 1 888 935 3877 DESCRIPTION This procedure will aid the technician in the removal and replacement of the display board Return to Section TOC Return to Master TOC MATERIALS NEEDED Analog Volt Ohmmeter Phillips Head Screwdriver 7mm Nutdriver 2 5mm Allen Wrench Wiring Diagram O10 Fie 5 5 10 9 1 0 sie oO oO Return to Section TOC Return to Master TOC V160 S amp T LINCOLN Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC o 5 97 2 G 3 Return to Section TOC Return to Master TOC o 2 D 8 c x 3 TROUBLESHOOTING amp REPAIR F 36 DISPLAY BOARD REMOVAL AND REPLACEMENT PROCEDURE continued FIGURE F 20 DISPLAY BOARD LOCATION DISPLAY BOARD CONTROL KNOB RED o 6MM NUT amp WASHER REMOVAL PROCEDURE FOUR 7MM MOUNTING SCREWS 1 Remove input power to the V160 S T 9 Using a thin knife blade or small flathead screwdriver carefully remove the red 2 Perform thd Case Cover Removal caps on the 5 control knobs located on the front of the machine See Figure F 20 3 Perform the Capacitor Discharge 10 Using a 6mm nutdriver remove the nut and associated washers located 4 Locate the Display Board Se
25. cut or gouge on containers that have held com bustibles 4 RAYS Wear eye ear and body protection Observe additional guidelines detailed in the beginning of this manual Only qualified personnel should operate this equip ment Observe all safety information throughout this manual GENERAL DESCRIPTION The Invertec V160 S is an industrial 160 amp arc weld ing power source which utilizes single phase input power to produce constant current output The weld ing response of this Invertec has been optimized for stick SMAW and Touch Start TIG GTAW The unit is ideal for industrial applications where portability is important The Invertec V160 S is recommended for stick welding with such popular electrodes as Fleetweld 35 Fleetweld 37 Fleetweld 180 and LH 78 It features adjustable arc control to adjust the arc force and start 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 3595 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 10096 duty cycle If the duty cycle is exceeded a thermal pro tector will shut off the output until the machine cools See Technical Specifications in A 1 for other rated out puts The Invertec V160 S is recommended for stick welding with such popular electro
26. 11 12 13 14 15 16 26 25 24 23 22 21 20 19 18 17 16 15 14 13 12 11 10987654321 O10 OJO DISPLAY BOARD rir WO05X0245 c SCHEMATIC 245 0 12 cx cro ag 8 8 WELDCONTROLLER W05X0233 i SCHEMATIC X0233 1 21 WARNING HIGH VOLTAGE CAN KILL Do not operate with coers removed Disconnect input power by unplugging power cord before servicing REMOTE Do not touch electrically live parts Only qualified persons should install CONNECTOR use or service this machine INVERTER BOARD The inverter board includes the following circuits Inverter circuit Transforms the DC current at 80KHz and feeds the main transformer The current is regu lated via Pulse Width Modulation Main transformer It has two functions 1 gives the correct output voltage for welding 2 Insulates the operator side from the output line o Fle 22 9 5 212 43 21 cc a Output circuit The output diodes rectify the output the current from the main transformer The choke fil ters the output current The shunt provides output feedback information to the control board NOTE Unshaded areas of Block Logic Diagram are the subject of discussion V160 S amp T LINCOLN B Return to Section TOC Return to Master TOC THEORY OF OPERATION FIGURE 5 CONTROL DISPLAY BOARD Fie 1 BLUE 5 5 WH
27. DC voltage is applied at inverter Pcb s During the precharge time the DC input voltage is applied to the filter capacitors located on the inverter Pcb through a precharge resistances located on input board that limit the charge current During precharge time an automatic system manages by reconnect board mounted on the input board sets the input board for 115V or 230V working mode volt age duplicator when 115Vac is applied After this time the start relays go closed and they by pass the precharge resistances there are two precharge relays RL1B and RL4B The input voltage is also applied to an auxiliary voltage circuit that gives the necessary low voltages 15 5V and 5 for the control display board and inverter board The fan is activated when the power is first supplied to the machine It will stay on as long as output is present The fan shuts down after 5 minutes when the output is shut off NOTE Unshaded areas of Block Logic Diagram are the subject of discussion V160 S amp T LINCOLN 8 FES THEORY OF OPERATION FIGURE 4 INVERTER BOARD 81 WHITE 2 2211 BLUE 115 230 1 50 60 we INVERTER BOARD WO05X0190 SCHEMATIC X0190 INPUT BOARD GND W05X0250 SCHEMATIC 203 Return to Section TOC Return to Master TOC 123456789 10 JP1 1234567891011 12 13 14 15 16 26 25 24 23 22 21 20 19 18 17 16 15 14 13 12 11 10987654321
28. Operation EE 6 Return to Master TOC FIGURE E 1 BLOCK LOGIC DIAGRAM 51 115 230 1 50 60 INVERTER BOARD WO05X0190 SCHEMATIC X0190 INPUT BOARD GND WO05X0250 SCHEMATIC X0203 12345678910 JP1 12345678910 11 1213141516 Q 2 0 i c x 3 10987654321 26 25 24 23 22 21 20 19 18 17 16 15 14 13 12 11 DISPLAY BOARD WO05X0245 245 METER BOARD W05X0207 SCHEMATIC X0207 WELD CONTROLLER W05X0233 SCHEMATIC X0233 WARNING HIGH VOLTAGE CAN KILL Do not operate with coers removed Disconnect input power by unplugging 20 Do not touch electrically live parts Only qualified persons should install CONNECTOR use or service this machine Return to Master TOC V160 S amp T LINCOLN Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC Fie s 10 9 1 0 gt oO oO Return to Section TOC Return to Master TOC EE 2 THEORY OF OPERATION EE 2 FIGURE EE 2 GENERAL DESCRIPTION WELDING CAPABILITY amp LIMITATIONS 81 WHITE 2 ol BLUE 115 230 1 50 60 INPUT BOARD GND WO5X0250 SCHEMATIC X0203 C INVERTER BOARD 05 019 iu SCHEMATIC X0190 JP1 12345878910 DISPL
29. S 0 0 0 0 Section D Maintenance V160 T Section DD Theory of Operation V160 S Section E Theory of Operation V160 T Section EE Troubleshooting and Repair 160 5 1 Section F Electrical Diagrams V160 S T Lilliiill el llle Section G Parts Manual 160 5 T ve Dl Ever xD Edu a En P 403 V160 S amp T LINCOLN Return to Master TOC Return to Master TOC o 2 0 i c x 3 Return to Master TOC A 1 TABLE OF CONTENTS INSTALLATION SECTION V160 S 1 Installation mE m mr TTTT A 1 Technical Specifications A 2 Safety Precautions sso iaia ceainaria a 3 Select Suitable Location liliis hrs rn A 3 SLACKING ss 3 ac erat 25 dco ote aerate 3 Input Connections
30. SO ST STO OR EXTRA MAXIMUM TIME DELAY CIRCUIT FREQUENCY HZ HARD USAGE INPUT CORD AWG BREAKER OR FUSE SIZE AMPS PHYSICAL DIMENSIONS Weight Approx 24 2lbs 11 kgs TEMPERATURE RANGES OPERATING TEMPERATURE RANGE STORAGE TEMPERATURE RANGE 20 C to 40 C 50 C to 85 C Return to Section TOC Return to Master TOC olo Fle f i 813 515 oO oO a Return to Section TOC Return to Master TOC V160 S amp T LINCOLN Return to Section TOC Return to Master TOC Return to Section TOC olo o Fle f 9 1 813 cfc 515 pie oO oO Return to Section TOC Return to Master TOC Return to Master TOC AS INSTALLATION Read entire installation section before starting installation SAFETY PRECAUTIONS A WARNING ELECTRIC SHOCK can kill Only qualified personnel should per form this installation Disconnect input power by removing plug from receptacle before working inside V160 S Allow machine to sit for 5 minutes minimum to allow the power capacitors to discharge before working inside this equipment Insulate yourself from the work and ground Always wear dry insulating gloves Always connect the V160 S to a power supply grounded according to the National Electrical Code and local codes SELECT SUITABLE LOCATION This machine will operate in harsh environments However it is important that simple preventat
31. See figure F 4 2 Check capacitors input bridge for open or shorts See input board schematic 3 Check Fuse F1 4 Check start resistor for 20 ohms V160 S amp T LINCOLN Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC O10 Fie 5 5 10 9 1 0 gt 1 8 oO oO Return to Section TOC Return to Master TOC PIS TROUBLESHOOTING amp REPAIR Us INPUT BOARD TEST V160 S T continued FIGURE F 5 INPUT BOARD Voltage check on JP1 input board CONNECTOR JP1 Refer PIN 11 as ground Pin 5 5Vdc Pin 7 15Vdc Pin 9 5Vdc TEST PROCEDURE 1 Locate connector JP1 See figure F5 2 Check pin 5 to pin 11 for 5vdc 3 Check pin 7 to pin 11 for 15vdc 4 Check pin 9 to pin 11 for 5vdc V160 S amp T LINCOLN B Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC ojo Fie E s 3 512 nl 5 2 c oO oO Return to Section TOC Return to Master TOC TROUBLESHOOTING amp REPAIR Pia INPUT BOARD TEST V160 S T continued FIGURE F 6 INPUT BOARD 320 Vdc 115V or 230Vac DC DC AC1 AC2 TEST PROCEDURE 1 Locate test points See Figure F 6 2 Check AC1 AC2 for 115 VAC or 230 VAC depending on input voltage 3 Check DC to DC for 320Vdc V160 S amp T mE Return to Section TOC Return to Master TOC Return to Section TOC Ret
32. TIG torch and cables insulation in good condition and in place OUTPUT AND GAS CONNECTION FOR TIG WELDING FIGURE AA 1 FIGURE AA 1 GAS HOSE NOZZLE TENY TIG TORCH WORK CABLE WORK CLAMP This unit does not include a TIG torch but one may be purchased separately The Lincoln PTA 9 K1781 1 or K1781 3 only with no gas valve or PTA 17 K1782 1 or K1782 3 are recommended for use with this machine for this purpose however any similar TIG torch can be used To attach the Twist Mate Plug to a Lincoln Torch slide the rubber boot onto the torch cable enlarge the boot opening if necessary screw the fitting on the torch cable into the brass connector snugly and slide the boot back over the brass connec tor ADAPTEUR DE TIG INITIALISATION DE PASSE IL LE TIG INCENDIENT LE CABLE ELECTRIQUE AV TE COMPOS DE RETENUE INSTALLATION AA 6 The ground lead and TIG Torch Twist Mate Connector are supplied with the welder To connect the cables turnthe PowerSwitch OFF Connect the torch Twist Mate plug into the DC Electrode Gas Output Receptacle on the front of the welder and turn it clock wise until tight WORK CABLE CONNECTION Next connect the work cable to the output terminal in the same way To minimize high frequency interference refer to Machine Grounding and High Frequency Interference Protection section of this manual for the prope
33. are supplied with the welder To connect the cables turnthe PowerSwitch OFF OUTPUT AND GAS CONNECTION FOR TIG WELDING FIGURE A 1 FIGURE A 1 GAS HOSE NOZZLE WORK CABLE WORK CLAMP This unit does not include a TIG torch but one may be purchased separately The Lincoln K1781 7 PTA 9FV K1782 11 PTA 17FV and K1782 6 K1782 8 PTA 17V are recommended for use with this machine for this purpose however any similar TIG torch can be used To attach the Twist Mate Plug to a Lincoln Torch slide the rubber boot onto the torch cable enlarge the boot opening if necessary screw the fitting on the torch cable into the brass connector snugly and slide the boot back over the brass connector OUTPUT CONNECTION FOR STICK WELDING FIGURE A 2 FIGURE A 2 WORK CLAMP Mine 2 2 FG ELECTRODE 2 Po Z HOLDER 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 corresponding to this polarity For instance for DC welding connect the electrode cable which is connected to the electrode holder to the output terminal and the work cable which is connected to the work clamp to the output terminal Insert the connector with the key lining up with the key way and rotate approximately 1 4 turn clockwise until the connection is snug Do n
34. damaged Keep cylinder upright and chained to a support cylinder away from areas where it could be damaged Never allow the torch to touch the cylinder Keep cylinder away from live electrical cir cuits 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 Refer to the Optional Accessories section of this manual for available remote controls The following items can be connected to the 6 pin socket on the front panel Remote control potentiometer K857 for Stick weld ing Remote Foot Amptrol K870 Hand Amptrol K963 3 Arc Start Switch K814 V160 S amp T LINCOLN 8 5 V160 S 8 T LINCOLN E AA 8 DOL J91Se N 01 uunjeH NOL J91Se N 01 uunjeH DOL J91Se N 01 uunjeH DOL J91Se N 01 UuunjeH DOL uonoes uumeg DOL uonoes uonoes DOL uonoes 881 TABLE OF CONTENTS OPERATION SECTION PP o O 5 Operation Mec 1 g S Safety CUNNING 2 ECC wo e d ROS S28 D nA BB 2 o General Description qs oca 2 Welding Capability BB 2 E ucus E ETT BB 2 Rear Control Panel
35. 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 LINCOLN amp V160 S T ELECTRICAL DIAGRAMS G6 SCHEMATIC V160 S amp T PAGE 1 1N4148 88 FEE ojg DCraO 320v T 1 D c Q N R14 ce o gt c12 10R 2n2F dnF 3w 630V 2 Q8 Q6 Q4 1600V 19 12 0604 Ld ac A STTA1206D 11 c i R30 513 10R D12 2 ph tc m pu MEM D9 R26 R21 R19 C14 MONTARE 10R 10R 10R 10 10 voran K D 110V 160A vo 1600V 1600V D14 L1 1
36. framework or other locations away from the welding area increase the possibility of the welding current passing through lifting chains crane cables or other alternate circuits This can create fire hazards or overheat lifting chains or cables until they fail 6 h Also see item 1 c LINCOLN 7 a 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 All hoses fittings etc should be suitable for the application and maintained in good condition Always keep cylinders in an upright position securely chained to an undercarriage or fixed support Cylinders should be located Away from areas where they may be struck or subjected to physical damage safe distance from arc welding or cutting operations and any other source of heat sparks or flame Never allow the electrode electrode holder or any other electrically hot parts to touch a cylinder Keep your head and face away from the cylinder valve outlet when opening the cylinder valve Valve protection caps should always be in place and hand tight except when the cylinder is in use or connected for use Read and follow the instructions compressed gas cylinders associated equipment and CGA publication P I Precautions for Safe Handling of Compressed Gases in Cylinders available from the Compressed Gas Association
37. need to have a plug attached 1 Cut off welding cable lug if present 2 Remove 75 in 19mm of welding cable insulation 3 Slide rubber boot onto cable end The boot end may be trimmed to match the cable diameter Use soap or other nonpetroleum based lubricant to help slide the boot over the cable if needed BOOT WELDING CABLE 75 19 mm TRIM IF REQ D TO FIT OVER CABLE 4 Cut 45 5096 of the copper strands back 1 4 6 mm WELDING CABLE 25 in 6mm 5 Fold copper strands over cut strands and insert into ferrule l FERRULE 50 in max 12 mm max WELDING CABLE 6 Slide the copper ferrule into the brass plug 7 Tighten set screw to collapse copper tube Screw must apply pressure against welding cable The top of the set screw will be well below the surface of the brass plug after tightening P aud SCREW BRASS PLUG COPPER TUBE 8 Slide rubber boot over brass plug The rubber boot must be positioned to completely cover all electrical surfaces after the plug is locked into the receptacle INSTALLATION AA 7 SHIELDING GAS CONNECTION Obtain the necessary inert shielding gas Connect the cylinder of gas with a pressure regulator and flow gage Install a gas hose between the regulator and gas inlet located on the rear of the welder The gas inlet has a 5 16 18 right hand female thread CGA 032 A WARNING CYLINDER could explode if
38. or delay type circuit breakers Using fuses or circuit breakers smaller than recommended may result in nuisance shut offs from welder inrush currents even if not welding at high currents 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 T is recommended for use on an individual branch circuit 115V INPUT The rated output of the V160 T is available when con nected to a 30A branch circuit When connected to a branch circuit with lower ampacity lower welding cur rent and duty cycle must be used An output guide is provided below The values are approximate and must be adjusted downward if the fuse or circuit breaker trips off Other loads on the circuit and fuse circuit breaker characteristics will affect the available output Do not exceed these welding conditions 15A plug on a 15A branch 10 duty cycle Stick 65A TIG 95 15A plug on a 20A branch 10 duty cycle Stick 75A TIG 105A 20A plug on a 20A branch 10 duty cycle Stick 85 TIG 120A The Invertec V160 T is provided with a 115 230V cable 6 6ft 2m in length with a 15Amp 5 15P plug molded onto the cord The V160 T is supplied with an additional 20A plug that can replace the 15A plug to achieve higher output To install the supplied 20A plug Connect the white neutral wire under ter
39. 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 FIGURE BB 2 OPERATION BB 4 8 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 control refer to the output current control section below Note When K814 Arc Start Switch is connected to remote connector remote LED will remain OFF 9 Output LED This indicator turns on when the output of the machine is on In the stick welding mode the output of the machine is automatically turned ON For both of the TIG welding modes the output of the machine is turned ON and OFF by an Arc Start Switch or Hand Foot Amptrol attached to the Remote Control Connector See 44 Mode Switch above for details on output triggering for TIG arc starting 10 Output Current Control This controls the output or welding current of the machine The function of this control knob is changed if a remote control is connected If the Remote LED is ON this indi cates that a remote control is connected and the function of the output current control will be Stick Welding Mode The remote control will adjust the output current of the machine from 5 to 160A
40. source must have a pressure regulator and flow gage installed See Figure BB 1 CONTROLS AND SETTINGS See Figure BB 2 4 Mode Switch This switch changes the welding modes of the machine The V160 T has three weld ing modes Stick SMAW Lift TIG GTAW and HF TIG GTAW When the mode switch is in the Stick position the fol lowing welding features are enabled OPERATION BB 3 Hot Start This is a temporary increase in the output current during the start of the stick welding process This helps ignite the arc quickly and reliably Arc Force This is a temporary increase in the out put current during normal stick welding This tempo rary increase in output current is used to clear inter mittent connections between the electrode and the weld puddle that occur during normal stick welding Anti Sticking This is a function which decreases the output current of the machine to a low level when the operator makes an error and sticks the elec trode to the work piece This decrease in current allows the operator to remove the electrode from the electrode holder without creating large sparks which can damage the electrode holder FIGURE BB 1 1 Power Switch 2 Fan 3 Gas Inlet V160 S amp T LINCOLN Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC elo ci gt cfc 515 pie oO oO ayo BB 4 When the mode switch is in the Lif
41. the Magnum PTA 9 torch If you do not care to interchange this part between torch es one is required to connect Magnum PTA 9 or PTA 17 TIG torches with one piece cable to the V160 T you may order an additional adapters The quick connect plug provides connection for both gas and welding cur rent TIG Torch Parts Kits Parts kits are available for the PTA 9 and PTA 17 TIG torches These kits include back cap collets collect bodies nozzles and tungsten Order KP507 for PTA 9 torches Order KP508 for PTA 17 torches See publication E12 150 for parts kits breakdown Cut Length Consumables TIG welding filler metals are available for welding stainless steel mild steel alu minum and copper alloys See publication C9 10 V160 S amp T LINCOLN 204 TABLE CONTENTS MAINTENANCE SECTION PP ee acu x 8 474 8 808 4 8 4 8 404478 dong Ros moe Erw mea Wow n Rus EUR RU RU Rode x RE Nr end DD 1 Safety Precautions orike rex da xS pada whee KAUF RE UE Ree d DD 2 Return to Master TOC Input Filter Capacitor Discharge Procedure DD 2 Routine Maintenance ssi eoe nose bau do dece dee Poa bea Pease sic pee DD 2 Major Component Location for 1605 8 8 DD 3 Return to Master TOC o 2 0 i c x 3 Return to Master
42. to the selected welding mode Lift TIG or HF TIG After the arc is started the output current will be at the Start Crater current This condition can be maintained as long or as short as necessary FIGURE BB 7 1 2 3 4 BUTTON OUTPUT CURRENT c POST FLOW POST FLOW GAS ON l GAS If the Start Crater current is not necessary do not hold the TIG torch trigger as described at the beginning of this step Instead quickly press and release it In this condition the machine will automatically pass from Step 1 to Step 2 when the arc is started 2 Release the TIG torch trigger to start the main part of the weld The output current will be increased upslope to the welding current 3 Press and hold the TIG torch trigger when the main part of the weld is complete The machine will now decrease the output current at a controlled rate downslope until the Start Crater current is reached This Start Crater current can be main tained as long or as short as necessary 3A If it is not necessary to maintain the Start Crater current the TIG torch trigger can be pressed and released instead of holding it In this case step 4 will automatically follow OPERATION BB 9 4 Release the TIG torch trigger The output current of the machine will turn OFF and the gas valve will remain open for the duration of the postflow time As shown in figure BB 8 after the TIG torch trigger is quickly presse
43. 0 amps 25 2 volts at a 10096 duty cycle If the duty cycle is exceeded a thermal protector will shut off the output until the machine cools See Technical Specifications in A 2 for other related out puts LIMITATIONS The V160 S is not recommended for pipe thawing NOTE Unshaded areas of Block Logic Diagram are the subject of discussion V160 S amp T LINCOLN Return to Master TOC Return to Master TOC o O 0 v gt o E x E 43 Return to Master TOC EM THEORY OF OPERATION nis FIGURE E 3 INPUT BOARD 51 WHITE 2 PAL BLUE 115 230 1 50 60 INPUT BOARD GND WO05X0250 SCHEMATIC X0203 12345678910 11 12 13 14 15 16 The input board includes the following circuits INPUT LINE VOLTAGE FAN CIR CUIT AUXILIARY VOLTAGE AND PRECHARGE The Invertec V160 S can be connected to a 115V or 230V single phase input voltage This unit can also connect to engine driven genera tors but it must follow the below conditions e Vac peak voltage below 250V for 115Vac input or 410V for 230Vac input e Vac frequency in the range of 50 and 60 Hertz e RMS voltage of the AC waveform V160 S 115Vac or 230Vac 1096 The initial power is applied to the Invertec V160 S directly on the input board A line switch located on the back of the machine supplies the logic part that manages machine functions The voltage is after rectified by the in
44. 1 Press and hold the Arc Start Switch to start the a step sequence The machine will open the gas valve to start 4 Step Diagram 2 the flow of the shielding gas After 0 5 second preflow time to purge air from the torch hose the output of the 3 4 machine is turned ON At this time the arc can be start TORCH A ed After the arc is started the output current will be at BUTTON the Start Finish current This condition can be main tained as long or as short as necessary Return to Section TOC Return to Master TOC If the Start Finish current is not necessary do not hold the TIG torch trigger as described at the beginning of OUTPUT 5 8 this step Instead quickly press and release the trigger CURRENT Fie In this condition the machine will automatically pass sls from Step 1 to Step 2 when the arc is started 5170 POST FLOW AE oa 9 gt 2 Release the TIG torch trigger to start the main part of GAS ON olo the weld 4 tz en 3 5 The output current will increase to the welding current 2 2 The time for this increase or upslope is presettable The default is 0 5 seconds 3 Press and hold the TIG torch trigger when the main part of the weld is complete The machine will now decrease the output current at a controlled rate or downslope time until the Start Finish current is reached The downslope time is adjusted by the Downslope Parameter This Start Finish current can
45. 1235 Jefferson Davis Highway Arlington VA 22202 FOR ELECTRICALLY powered equipment 8 a Turn off input power using the disconnect Switch at the fuse box before working on the equipment Install equipment in accordance with the U S National Electrical Code all local codes and the manufacturer s recommendations Ground the equipment in accordance with the U S National Electrical Code and the manufacturer s recommendations Mar 95 Return to Master Return to Master TOC o 2 0 lt c x 3 Return to Master PR CAUTIONS DE S RET Pour votre propre protection lire et observer toutes les instructions et les pr cautions de s ret specifiques qui parraissent dans ce manuel aussi bien que les pr cautions de s ret g n rales suiv antes S ret Pour Soudage A L Arc 1 Protegez vous contre la secousse lectrique a Les circuits l lectrode et la pi ce sont sous tension quand la machine souder est en marche Eviter toujours tout contact entre les parties sous tension et la peau nue ou les v tements mouill s Porter des gants secs et sans trous pour isoler les mains Faire tr s attention de bien s isoler de la masse quand on soude dans des endroits humides ou sur un plancher met allique ou des grilles metalliques principalement dans les positions assis ou couch pour lesquelles une grande partie du corps peut tre en con
46. 4148 o a N M N M 10 F RI 63V 470R ai olo By o w4300510 5 m 220nF 1 Ey CNY17 3 50v 9 lt REF 1 4 oc 1 LMC7660 10K o gt u3 R8 81 uo 5 BVdc lt TA 14W vouT Pesvdo S o 1K 43 RI 3 osc 2 4 CAP 9 E 10 F CAP 5 15 WZ 63V D 1N4148 D7 ojo IHF JP1 FAN gv 1 2 IHF A sov 5 W58X0191 58 0200 R15 14 D19 3 16 5Vdc 8 21 24 Y Y 4 IE 1 15Vde 8 220R BYV26E 150 9 3w 216509 1200 saa 10 015 C22 014 D10 1 20 26 470nF BYV26E RL3B 17 100nF 32V i 50V W4001003 DC 2 MONTARE VOLANTE sTo m E o NON MONTARE C24 E D18 u C23 C24 TOP223Y amp v X0203rev01 gt 600V olo O O 5 5 xlv PEN gt 8 8 4353 o o 1 NOTE This diagram is for reference only It may not be accurate for all machines covered by this manual LINCOLN E ELECTRIC V160 S T G 8 SCHEMATIC INPUT PC BOARD ELECTRICAL DIAGRAMS G 8 2 1570 A7 15Vdc 2M PY 4 R12 en 400V 220R 220pF x 8369 04 320VDC Input Return to Section TOC Return to Master TOC 05 1 5KE200V 100nF W59X0173 2 630 v IN gout 03 Na148 57 CNY17 3 ut z 17805 3 Ms 5VDQ PMW C
47. 60T only voltage it must be 12vdc when The control board may be faulty the trigger is pressed Replace the gas solenoid The power LED on the front panel is Check the input voltage Connect the machine to the cor Check for high input current due race vollaga to exceeding duty cycle rating Perform the Input Board Test Bad welding in stick mode Check the input voltage must 1 Maybe the arc force does not match the rating plate work Replace the weld con troller board or the display Check the mode switch board The thermal light remains lit The machine has output current but it is not adjustable A CAUTION If for any reason you do not understand the test procedures or are unable to perform the tests repairs safely contact the Lincoln Electric Service Department for technical troubleshooting assistance before you proceed Call 1 888 935 3877 V160 S amp T LINCOLN 5 V160 S 8 T LINCOLN E DOL J91Se N 01 uunjeH DOL J91Se N 01 uunjeH DOL J91Se N 01 UuunjeH DOL J91Se N 01 UuunjeH DOL uonoes DOL uonoes DOL uonoes DOL uonoes dd TROUBLESHOOTING amp REPAIR Jud CASE COVER REMOVAL AND REPLACEMENT PROCEDURE WARNING Service and repair should be performed by only Lincoln Electric factory trained personnel Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will i
48. AY BOARD SCHEMATIC X0245 WELD CONTROLLER 05X023 SCHEMATIC X0233 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 Only qualified persons should install use or service this machine GENERAL DESCRIPTION The V160 T is an industrial 160 amp arc welding power source which utilizes single phase input power to pro duce constant current output The welding response of this Invertec has been optimized for stick SMAW and Touch Start TIG GTAW The unit is ideal for industrial applications were portability is important The Invertec V160 T performs DC TIG with high fre quency or Touch Start Tig Starting with excellent results 1 1 METERBOARD 05X0207 SCHEMATIC 207 WELDING CAPABILITY The Invertec V 160 T is rated at 160 amps 26 4 volts at 3596 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 a 10096 duty cycle If the duty cycle is exceeded a thermal protector will shut off the output until the machine cools See Technical Specifications in AA 2 for other related outputs The Invertec V160 T is recommended for stick welding with such popular electrodes as Fleetweld 35 Fleetweld 37 Fleetweld 180 and Jet LH 78 MR It fea tures adjustable arc control to adj
49. B 1 1 Power Switch 2 Fan V160 S amp T LINCOLN Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC EJE i 8 gt 2 cfc 515 pie olo Return to Section TOC Return to Master TOC B 4 OPERATION BA 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 control refer to the output current control section below 8 Output LED This indicator turns on when the output of the machine is on In stick welding mode the output of the machine is automatically turned ON In Lift TIG welding mode without a remote control the output of the machine is automatically turned ON In this condition a triggering device is not need ed In Lift TIG welding mode with a remote control the output of the machine is turned ON and OFF by the remote device i e hand or foot amptrol connected to the remote connector on the front of the machine Output must be triggered ON output LED lit to enable Lift TIG starting After machine output is trig gered ON the arc must be started within 6 5 sec onds or output will turn OFF and trigger sequence must be restarted Note Any remote control device with trigger only circuit such as the K814 Arc Start Switch will not be sensed by the V160 S remote control
50. Cable Assembly Work Cable and Clamp Strap Packet Instruction Manual Field Installed K870 Foot Amptrol for TIG welding When the V160 S s Output Control is in the REMOTE position the foot Amptrol energizes the output and controls the output remotely The Foot Amptrol connects directly to the 6 pin Amphenol K963 3 Hand Amptrol for TIG welding When the V160 S s Output Control is in the Remote position the hand Amptrol energizes the output and controls the output remotely The Hand Amptrol connects directly to the 6 pin Amphenol PTA 17V TIG Torch 150 Amp air cooled compact and durable Tig Torch with integral gas valve for gas control at the torch The following 1 piece cable torches can be used with a K960 1 adapter K1782 6 12 50 Ft 1 Piece Cable K1782 8 25 0 Ft 1 Piece Cable PTA 9FV TIG Torch Gas Valve flexible head torch K1781 7 25 0 Ft 1 Piece Cable PTA 17FV TIG Torch Gas Valve flexible head torch K1782 11 25 0 Ft 1 Piece Cable K960 1 TIG Torch Adapter for connection of PTA 17V torches 1 piece cable to power sources without gas passing through the Twist Mate connection NOTE Any remote control with trigger only circuit such as the K814 Arc Start Switch will not be sensed by the V160 S remote control connection and there fore will not allow control of the output CABLE PLUGS K852 50 Cable Plug Kit for 41 72 cable Attaches to welding cable to provide quick disconnec
51. ITE 2 orol gt b 115 230 1 50 60 3 BROWN 2 DC A DC w 4 9 o 2 INVERTER BOARD WO05X0190 5 g SCHEMATIC X0190 Y G cic INPUT BOARD GND rf 5 GND WO5X0250 aZ D SCHEMATIC X0203 JP1 2 2 i 12348678910 JP2 3 6 JPA 26 25 24 03 22 21 20 19 18 17 16 15 14 13 12 11 10987654321 DISPLAY BOARD ji ojo 05 0245 SCHEMATIC 245 22 53 9 oO eS aS SSeS SSS 1 o gt WELDCONTROLLER i WO5X0233 o 2 SCHEMATIC X0233 i 4 i i L1 JP1 tz llb IMMER 5 1 2 3 4 5 6 7 8 WARNING HIGH VOLTAGE KILL Do not operate with coers removed tt Disconnect input power unplugging D E C B A power cord before servicing REMOTE Do not touch electrically live parts Only qualified persons should install CONNECTOR use or service this machine o cw DISPLAY BOARD The display board receives status and analog signals from the inverter board and various sensors It is com posed of 2 parts Weld controller Interprets signals makes decisions and changes the machine mode and output to satis fy the requirements dictated by the operator Display board Supports all the potentiometer switches and LED O10 e jE 10 9 1 0 lz 6 1 8 pir oO oO NOTE Unshaded areas of Block Logic Diagram are the subject of discussion Ret
52. J91Se N 01 uunjeH DOL J91Se N 01 uunjeH DOL J91Se N 01 uunjeH DOL J91Se N 0 uunjeH DOL uonoes DOL uonoes DOL uonoes DOL uonoes TROUBLESHOOTING amp REPAIR dud MAIN IGBT INVERTER BOARD REMOVAL AND REPLACEMENT PROCEDURE WARNING Service and repair should be performed by only Lincoln Electric factory trained personnel Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty For your safety and to avoid electrical shock please observe all safety notes and pre cautions detailed throughout this manual Return to Section TOC Return to Master TOC If for any reason you do not understand the test procedures or are unable to per form the test repairs safely contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed Call 1 888 935 3877 DESCRIPTION This procedure will aid the technician in the removal and replacement of the Main IGBT Inverter Board MATERIALS NEEDED Return to Section TOC Return to Master TOC Volt Ohmmeter Philips Head Screwdriver 7mm _ Nutdriver 10mm _ Nutdriver Wiring Diagram Oscilloscope O10 Fie 5 5 10 9 1 0 sie oO oO Return to Section TOC Return to Master TOC V160 S amp T LINCOLN Return to Section Return to Master TOC Return to Se
53. Jd 419 ATOR OCV E D6 15 4 D H PWM 3 HS2 Ld 2 414148 C3 1 GL 100 25V D L R8 V HS1 470R IRFD110 Ej at O10 1 Ke X0190rev02 TC D7 Kp 1N4749A 2 R9 SiT HS3 100R R10 R17 470R lt oz PTC uj EL 5 818 o o NOTE This diagram is for reference only It may not be accurate for all machines covered by this manual LINCOLN amp V160 S T ELECTRICAL DIAGRAMS 160 5 amp 2 x W58X0220 5 T 7165610 WT162430 L1 MONTARE VOLANTE RL2B RL1B 1 4 8 0 AC2 Q Ac2 x 21 54 ce R5 RLIC 2 c12 1615 R14 DC a o 2 L 8 15 1500 F 1500 F 15K 40v O olo 2 250V 250V 3w 30A 115V 20R 10w 9 2 25 77 n iem E DC
54. Master TOC BB 5 12 Postflow Control In the TIG welding modes this control knob will adjust the shielding gas postflow time from 0 5 to 30 seconds The preflow time is always 0 5 seconds In Stick welding mode this function is not used 13 Digital Display This meter displays the preset weld ing current before welding and the actual welding cur rent during welding Like the output current control the function of the meter is changed if a remote con trol is connected 14 Pulsing Mode Switch In the TIG welding modes this switch turns the pulsing function ON and controls the pulsing frequency range 20Hz or 300Hz In Stick welding mode this function is not used 15 Pulsing LED This indicator shows the pulsing fre quency when pulsing is turned ON With this indica tion the operator can adjust the frequency to the desired value before welding Note At higher fre quencies the LED blinks very fast and seems to be continuously ON however it is pulsing If pulsing is turned OFF or if the machine is in Stick welding mode the indicator will be OFF 16 Pulsing Frequency Control When the pulsing func tion is ON this control knob will adjust the pulsing fre quency The pulsing frequency adjustment range is 0 2 20Hz or 3 300Hz depending on the Pulsing Mode Switch position 17 Background Current Control When the pulsing function is ON this control knob will adjust the pulsing background current This is the
55. Return to Master TOC TROUBLESHOOTING amp REPAIR 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 This Troubleshooting Guide is provided to help you locate and repair possible machine malfunctions Simply follow the three step procedure listed below Step 1 LOCATE PROBLEM SYMPTOM Look under the column labeled PROBLEM SYMPTOMS This column describes pos sible symptoms that the machine may exhib it Find the listing that best describes the symptom that the machine is exhibiting Symptoms are grouped into the following categories output problems function prob lems wire feeding problems and welding problems Step 2 PERFORM EXTERNAL TESTS The second column labeled POSSIBLE AREAS OF MISADJUSTMENT S lists the obvious external possibilities that may con tribute to the machine symptom Perform these tests checks in the order listed In general these tests can be conducted with out removing the case wrap around cover Step 3 RECOMMENDED COURSE OF ACTION The last column labeled Recommended Course of Action lists the most likely com ponents th
56. Return to Master TOC Return to Master TOC O O E 42 o 0 gt c 3 5 Return to Master TOC View Safety Info View Safety Info 2 gt 2 2 o gt View Safety Info VIGO S amp T For use with machines having Code Numbers 10877 10878 11031 11032 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 jg SERVICE MANUAL LI NCOLN Copyright 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 Return to Master TOC Return to Master TOC o 2 0 2 c x E Return to Master TOC SAFETY A WARNING Diesel engine exhaust and some of its constituents are known to the State of California to cause can cer birth defects and other reproductive harm A CALIFORNIA PROPOSITION 65 WARNINGS A The engine exhaust from this product conta
57. TOC V160 S amp T LINCOLN Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC O10 Fie 5 5 1 9 1 0 gt 6 1 8 oO Return to Section TOC Return to Master TOC DD 2 SAFETY PRECAUTIONS WARNING ELECTRIC SHOCK can kill Have an electrician install and ser vice 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 Do not touch electrically live parts INPUT FILTER CAPACITOR DISCHARGE PROCEDURE WARNING The machine has internal capacitors which are charged to a high voltage during power on conditions This voltage is dangerous and must be discharged before the machine can be serviced Discharging is done automatically by the machine each time the power is switched off However you must allow the machine to sit for at least 5 minutes to allow time for the process to take place ROUTINE MAINTENANCE Prevent metal powder from accumulating near the Heat Sink fins A WARNING Disconnect the power supply before every opera tion Carry out the following periodic controls on the power Source Clean the power source inside by means of low pressure compressed air e Check the electric connections and all the connec tion cables MAINTENANCE DD 2
58. V160 S amp T LINCOLN Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC o 5 97 2 G 3 Return to Section TOC Return to Master TOC o 2 0 8 c x 3 TROUBLESHOOTING amp REPAIR F 9 INPUT FILTER CAPACITOR DISCHARGE PROCEDURE WARNING Service and repair should be performed by only Lincoln Electric factory trained personnel Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty For your safety and to avoid electrical shock please observe all safety notes and pre cautions detailed throughout this manual If for any reason you do not understand the test procedures or are unable to per form the test repairs safely contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed Call 1 888 935 3877 DESCRIPTION This procedure will drain off any charge stored in the capacitor that is part of the input board assembly The procedure MUST be performed as a safety precaution before conducting any test or repair procedure that requires you to touch internal components of the machine MATERIALS NEEDED Phillips Screwdriver Insulated Pliers Insulated Gloves High Wattage Resistor 25 1000 ohms and 25 watts minimum Volt Meter V160 S amp T LINCOLN
59. a x HS 019 018 R23 La D6 1500 F 7 1500 F 15K D D act OAC Lf A 1 100v 250V 250V 3w DC 1 7 W58X0179 1 1 1 o 1 3 D9 D12 x 1 1 4148 1 4148 i GND p RL2A exa Ls 9 vec 5 41 6 17 PRI amp 5V 8 RL4C 22 a D44H8 he D44H8 5 1 21 24 2 200v HS 4HS 10 1 5A D21 gt 2 10 RL4B 12 230v D20 HS 2V4 D22 1 n 11 14 1 u6 2V4 1 17805 1 11 3 115V 16V 14 11 our HL PRI 5V 45 x E x 16 x 17 O R17 R16 4 0 47162430 ov de C20 18 25 188 6R8 Fle a 1500 F 220 F ERR 20 F1 W59X0225 35V e 2 1 1 PRI GND w47x0206 2 010 X x R19 R20 7 4 Vref gt 9 E 270K 270K D11 1 AW R21 C21 OI 1000V 18K T ADF 15 14 25V 4 2 a 45Vdc o 9 i m D2 114007 2208 R12 C11 220 1w esov wa300510 T C R3 400V W59X0173 D4 470R Q2 t pl D 15Vde FAN 5 y w4028200 2 D8 R13 R4 FAN BYV26C 220R 10K 3w _ 05 R6 R7 15Vdc 2 TIA ES 1K 4 99 2 5 5 1000 F 1000 F 470nF 3 25V 25V 63v 630V 1 5KE200V 100pF 18Vdc J t j gt gt GND W3043470 ui 100nF a R10 18V 1 3 4HS olo oon UIA w4607805 1 05 1 3 5Vdc 01 223 R9 ca IN OUT 1 1 i gt 5Vde 1 4007 4HS CTR d 4 2 L4 8 e e 1N
60. and the rays of the arc when welding or observing open arc welding Headshield and filter lens should conform to ANSI 287 standards Use suitable clothing made from durable flame resistant material to protect your skin and that of your helpers from the arc rays Protect other nearby personnel with suitable non flammable screening and or warn them not to watch the arc nor expose themselves to the arc rays or to hot spatter or metal FUMES AND GASES can be dangerous 5 a Welding may produce fumes and gases hazardous to health Avoid breathing these fumes and gases When welding keep your head out of the fume Use enough ventilation and or exhaust at the arc to keep fumes and gases away from the breathing zone When welding with electrodes which require special ventilation such as stainless or hard facing see instructions on container or MSDS or on lead or cadmium plated steel and other metals or coatings which produce highly toxic fumes keep exposure as low as possible and below Threshold Limit Values TLV using local exhaust or mechanical ventilation In confined spaces or in some circumstances outdoors a respirator may be required Additional precautions are also required when welding on galvanized steel The operation of welding fume control equipment is affected by various factors including proper use and positioning of the equipment maintenance of the equipment and the specific welding procedure and applicat
61. ased the output will turn OFF and the postflow time will start FIGURE BB 5 51014 TORCH BUTTON E OUTPUT CURRENT PRE FLOW POST FLOW GAS ON GAS OPERATION BB 8 2 Step Restart Enabled DIP Switch 3 ON Same as step 1 Same as step 2 As shown in figure BB 6 it is possible to press and hold the TIG torch trigger a second time during downs lope to restart After the trigger is pressed the output current will increase to the welding current like in step 1 When the main part of the weld is complete go to the beginning of step 2 FIGURE BB 6 TORCH BUTTON OUTPUT CURRENT PRE FLOW POST FLOW GAS ON GAS V160 S amp T LINCOLN Return to Section TOC Return to Master TOC Return to Section TOC O s 10 9 1 0 gt oO oO Return to Section TOC Return to Master TOC Return to Master TOC BB 9 DIP Switch 4 4 Step Restart Enable This controls the 4 Step Restart function When the Switch is ON the 4 Step Restart function is enabled Foot pedal remote controls should never be used with the 4 step sequences 4 Step Restart Disabled DIP Switch 4 2 OFF 1 Press and hold the TIG torch trigger to start the sequence The machine will open the gas valve to start the flow of the shielding gas After the preflow time the output of the machine is turned ON At this time the arc is started according
62. at may have failed in your machine It also specifies the appropriate test procedure to verify that the subject com ponent is either good or bad If there are a number of possible components check the components in the order listed to eliminate one possibility at a time until you locate the cause of your problem All of the referenced test procedures referred to in the Troubleshooting Guide are described in detail at the end of this chapter Refer to the Troubleshooting and Repair Table of Contents to locate each specific Test Procedure All of the specified test points components terminal strips etc can be found on the referenced electrical wiring diagrams and schematic Refer to the Electrical Diagrams Section Table of Contents to locate the appropriate diagram A CAUTION If for any reason you do not understand the test procedures or are unable to perform the tests repairs safely contact the Lincoln Electric Service Department for technical troubleshooting assistance before you proceed Call 1 888 935 3877 V160 S amp T LINCOLN Return to Section TOC Return to Master TOC Return to Section TOC O10 Fie 5 5 9 1 0 gt 6 1 8 oO Return to Section TOC Return to Master TOC Return to Master TOC TROUBLESHOOTING amp REPAIR p PC BOARD TROUBLESHOOTING PROCEDURES A WARNING S ELECTRIC SHOCK 9 can kill Have an electrician install and service this equip
63. be maintained as long or as short as necessary 4 Release the TIG torch trigger The output current of the machine will turn OFF and the gas valve will remain open to continue the flow of the shielding gas The duration of this postflow time is adjusted by the Postflow control knob This operation is shown in 4 step diagram 1 O10 F 5 5 190 9 0 gt 6 1 8 O 4 Step Diagram 1 2 3 4 rors A 1 o O 8 Fie CURRENT 241 2 PRE FLOW POST FLOW o z GAS ON GAS 8 E E alz V160 S 8 T LINCOLN B Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC LE E S o 8 c 3 Return to Section TOC Return to Master TOC 2 0 8 c x 3 7 DIP SWITCH FUNCTIONS The following sections explain the 8 DIP switch func tions of the V160 Read and understand the functions before making any changes because abnormal opera tion can occur with the wrong settings The machine must be turned OFF when the DIP Switches are changed A WARNING ELECTRIC SHOCK CAN KILL Be sure that all installation operation maintenance and repair procedures are performed only by qualified indi viduals Lincoln Electric is not responsible for damages caused by improper installation improper care or abnormal operation Before openi
64. ccur TABLE 1 1 2 3 4 5 6 7 8 DIP Switch 1 Machine Type This controls the output of the V160 S and some weld ing waveform functions It configures the V160 S to automatically turn ON depending on the position of the Welding Mode switch Refer to DIP Switch 6 for more information DIP Switch 2 thru 5 non functional for the V160 S FIGURE B 3 Front of machine Switch 1 V160 S amp T LINCOLN 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 Return to Section TOC Return to Master TOC 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 clearly understood DIP Switch 1 ON In TIG welding mode the following conditions can exist TIG slopes are available If slopes are needed foot pedal remote control can be used No remote control connected With no remote con trol connected the output is ON and a trigger is not needed Simple Lift TIG welding is possible Return to Section TOC Return to Master TOC e Remote control connected With a remote control connected the output i
65. chine is ready for Lift TIG welding Lift TIG is a method of start ing a TIG weld by first pressing the TIG torch electrode 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 4 Arc Control The Arc Control simultaneously adjust the level at Hot Start and Arc Force Increasing the Arc Control setting increases both Hot Start and Arc Force Hot Start This is a temporary increase in the output current during the start of the stick welding process This helps ignite the arc quickly and reliably Arc Force This is a temporary increase in the output current during normal stick welding This temporary increase in output current is used to clear intermit tent shorts between the electrode and the weld pud dle that occur during normal stick welding 5 Power LED This indicator will blink on and off when the machine is first turned on After approximately 2 seconds it will stop blinking and remain on to signal that the machine is ready The indicator will also blink during over current conditions when operating on 115V input 6 Thermal LED This indicator will turn on when the machine is overheated and the output has been dis abled 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 indi cator turns off normal operation is again possible FIGURE
66. connection and therefore will not allow con trol of the output FIGURE B 2 e 94 Sago A 4 Na 9 Output Current Control This controls the output or welding current of the machine The function of this control knob is changed if a remote control is connected If the Remote LED is ON this indicates that a remote control is connected and the function of the output current control will be Stick Welding Mode The remote control will adjust the output current of the machine from 5 to 160A The output current control knob on the display panel is not used TIG Welding Modes The maximum output current of the machine is set by the output current control knob The remote control then adjusts the output current from the minimum output 5A to the value set by the output current control knob For example if the out put current control knob on the machine is set to 100A then the remote control will adjust the output current from a minimum of 5A to a maximum of 100A 10 Twist Mate Connection Negative 11 Remote Control Connector 12 Twist Mate Connection Positive 3 Mode Switch 4 Arc Control 5 Power LED 6 Thermal LED 7 Remote LED 8 Output LED 9 Output Current Control 10 Electrode Connection Negative 11 Remote Control Connector 12 Electrode Connection Positive V160 S amp T LINCOLN Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC
67. ct ground lead to new P C Board Position new P C Board in its proper loca tion Replace 2 10 mm bolts previously removed Connect leads DC DC and plugs to there proper position Replace the previously removed 7mm P C Board mounting screws Replace the case cover FIGURE F 18 MAIN IGBT INVERTER BOARD PLUG LOCATIONS DC DC JP1 Ground V160 S amp T LINCOLN Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC O10 Fie s 0 9 1 0 sie oO oO Return to Section TOC Return to Master TOC F 34 TROUBLESHOOTING amp REPAIR MAIN IGBT INVERTER BOARD REMOVAL AND REPLACEMENT PROCEDURE continued FIGURE F 19 MAIN IGBT INVERTER BOARD MOUNTING BOLTS 7 SCREWS V160 S amp T LINCOLN F 34 peas TROUBLESHOOTING amp REPAIR DISPLAY BOARD REMOVAL AND REPLACEMENT PROCEDURE WARNING Service and repair should be performed by only Lincoln Electric factory trained personnel Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty For your safety and to avoid electrical shock please observe all safety notes and pre cautions detailed throughout this manual Return to Section TOC Return to Master TOC If for any reason you do not understand the test procedures or are unable to per form the test repairs safely
68. ction TOC Return to Master TOC 5 5 10 9 1 0 5 9 oO oO Return to Section TOC Return to Master TOC F 32 TROUBLESHOOTING amp REPAIR F 32 MAIN IGBT INVERTER BOARD REMOVAL AND REPLACEMENT PROCEDURE continued REMOVAL PROCEDURE 1 Remove input power to the V160 S T 7 Using a 10mm nutdriver remove the two bolts connecting the P C Board to heavy 2 Perform the Case Cover Removal leads See Figure 19 Procedure Procedure 8 The Board may now be tilted forward to 8 Perform the Capacitor Discharge gain access to the ground lead 8 Label ground lead position and disconnect F 17 4 Locate the Inverter Board See Figure 10 Remove and replace Main Input P C Board 5 Using a 7mm nutdriver r Board mounting screws move ine See Figure 19 6 Label and disconnect leads DC DC and plug JP1 from the top of the Inverter Board See Figure F 18 FIGURE F 17 MAIN IGBT INVERTER BOARD LOCATION Inverter Board V160 S amp T LINCOLN Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC O10 Fie 5 5 10 9 1 0 gt fom 1 8 oO oO a Return to Section TOC Return to Master TOC F 33 TROUBLESHOOTING amp REPAIR F 33 MAIN IGBT INVERTER BOARD REMOVAL AND REPLACEMENT PROCEDURE continued r ae PROCEDURE 2 Conne
69. current during the low portion of the pulse waveform it can be adjusted from 1096 to 9096 of the welding current TRIGGER MODE SEQUENCES For the V160 T TIG welding can be done in either the 2 step or 4 step mode which is selected with the Trigger Mode Switch DIP Switch functions are set by the factory For adjustments on DIP Switch settings and functions see DIP SWITCH FUNCTIONS in this Operations Section 2 Step Sequence Note 2 Step works with either an Arc Start Switch for output triggering only current control is at machine or with a Foot or Hand Amptrol for both remote output triggering and current control 2 Step used with Arc Start Switch is referenced in following sequence 1 Press and hold the Arc Start Switch to start the sequence The machine will open the gas valve to start the flow of the shielding gas After a 0 5 second preflow time to purge air from the torch hose the output of the machine is turned ON At this time the arc can be started OPERATION BB 5 After the arc is started the output current will be increased to the welding current The time for this increase or upslope is presettable The default is 0 5 seconds 2 Release the Arc Start Switch to stop welding The machine will now decrease the output current at a controled rate or downslope time until the Start Crater current is reached and the output of the machine is turned OFF The downslope time is adjusted by the Downslope Parameter
70. d and released from step it is possible to press and hold the TIG torch trigger another time to end the downslope time and main tain the output current at the Start Crater current When the TIG torch trigger is released the output will turn OFF and postflow will begin FIGURE BB 8 8A 4 TORCH uA A BUTTON D OUTPUT CURRENT POST FLOW GAS 0N GAS As shown in figure BB 9 again after the TIG torch trigger is quickly pressed and released from step 3A it is possible to quickly press and release the TIG torch trigger a second time to end the downs lope time and stop welding FIGURE BB 9 s 080 BUTTON a x 4 OUTPUT CURRENT POST FLOW GAS ON GAS V160 S amp T LINCOLN 10 OPERATION 10 4 Step Restart Enabled DIP Switch 4 ON FIGURE BB 11 Same as step 1 aor 3 4 BUTTON Wy 4 Same as step 2 3 Press and hold the TIG torch trigger when the main J part of the weld is complete The machine will now decrease the output current at a controlled rate OUTPUT downslope until the Start Crater current is CURRENT reached This Start Crater current can be main tained as long or as short as necessary Return to Section TOC Return to Master TOC FIGURE BB 10 1 GAS As shown in figure BB 12 again after the TIG torch WS 8 3 4 3A trigger is quickly pressed and released from step 3A BUTTON i i i
71. des as Fleetweld 35 Fleetweld 37 Fleetweld 180 and Jet LH 78 It fea tures adjustable arc control to adjust the arc force and start LIMITATIONS The V160 S is not recommended for pipe thawing When connected to 230VAC inputs V160 S amp T LINCOLN Return to Section TOC Return to Master TOC Return to Section TOC f i z cfc 513 pie oO oO ayo Return to Section TOC Return to Master TOC Return to Master TOC B OPERATION E 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 If the output of the machine is OFF for more than five minutes the fan will turn OFF This reduces the amount of dirt that is deposited inside the machine and reduces power consumption See Figure B 1 Refer to the Output LED section below for more infor mation about conditions when the output of the machine is ON See Figure B 1 CONTROLS AND SETTINGS See Figure B 2 3 Mode Switch This switch changes the welding modes of the machine The V160 S has two welding modes Stick SMAW and Lift TIG GTAW When the mode switch is in the Lift TIG position the stick welding functions are disabled and the ma
72. e 100A 1 66V REFER PIN 2 AS GROUND JP1 10 to JP1 2 V FB Voltage feedback Voltage signal bewteen 0 10V 0 60 Example 7 1V 42v PIN 3 15 VDC PIN 7 O VDC INVERTER ON PIN 7 15 VDC INVERTER OFF PIN 3 ET wi m T cmi AS REVISION NUMBER PIN 7 D11 CHECK FOR SHOR CHECK BETWEEN POINTS 1 amp 2 FOR SHORTS PIN 2 OUTPUT DIODES 1 BOTH WAYS CAN BE CHECKED AT OUTPUT STUDS D17 ALSO CHECK FOR SHORT 27 Ohms NORMAL D19 CHECK FOR SHORT 27 Ohms NORMAL INVERTER PCB V160 S amp T LINCOLN Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC O e cy 82 g 2 cfc 515 pie oO oO ayo Return to Section TOC Return to Master TOC TROUBLESHOOTING 8 REPAIR pes MAIN IGBT INVERTER BOARD V160 S T WELDING LOGIC AND INVERTER SECTION TEST continued FIGURE F 14 MAIN IGBT INVERTER BOARD LOCATION GATE DRIVE N N a x 1 gt gt koa 1 gt S RECTIFIER he ne lt INSIDE INVERTER PCB 160 5 amp T LINCOLN P 26 5 V160 S 8 T LINCOLN E F 26 DOL J91Se N 01 uunjeH DOL J91Se N 01 uunjeH DOL J91Se N 01 uunjeH DOL J91Se N 0 uunjeH DOL uonoes DOL uonoes DOL uonoes DOL uonoes
73. e Figure beneath the previously removed red F 20 caps on the control knobs See Figure F 20 5 Gently place machine on its side 11 Remove control knobs 6 Using a 7mm nutdriver remove the three casefront mounting screws located 12 Using a 2 5mm allen wrench remove the bottom of the machine See Figure the four display board mounting bolts located at corners of board Note washer position for replacement See 7 Using a 7mm nutdriver remove the two Figure F 20 casefront mounting screws four total on either side of the machine See Figure 13 Disconnect plugs J1 and JP1 from the F 20 display board 8 The casefront may now be gently pulled 14 Remove and replace display board forward to gain access to display board mounting bolts V160 S amp T LINCOLN Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC O10 Fie 5 5 10 9 1 0 gt 6 1 8 oO oO Return to Section TOC Return to Master TOC pur TROUBLESHOOTING amp REPAIR Par DISPLAY BOARD REMOVAL AND REPLACEMENT PROCEDURE continued FIGURE F 21 BOTTOM OF MACHINE 7 MM CASEFRONT MOUNTING SCREWS 000000000000000000000 o 0000000000000000 00000000000 0000000000 0000000000000000000 00000000000000000000000000 REPLACEMENT PROCEDURE 6 Replace the 4 mounting screws on either 1 Connect plugs J1 and JP1 to new dis side of the machine play board 2 Re
74. eakage 5 The work terminal must be connected to a ground within ten feet of the welder using one of the follow ing methods a Ametal underground water pipe in direct con tact with the earth for ten feet or more b A 3 4 19mm galvanized pipe or a 5 8 16mm solid galvanized iron steel or copper rod driven at least eight feet into the ground The ground should be securely made and the grounding cable should be as short as possible using cable of the same size as the work cable or larger Grounding to the building frame electrical conduit or a long pipe system can result in re radi ation effectively making these members radiating antennas 6 Keep all panels securely in place 7 All electrical conductors within 50 ft 15 2m of the welder should be enclosed in grounded rigid metal lic conduit or equivalent shielding Flexible metallic conduit is generally not suitable 8 When the welder is enclosed in a metal building several earth driven electrical grounds connected as in 5 b above around the periphery of the build ing are recommended Failure to observe these recommended installation procedures can cause radio or TV interference prob lems INSTALLATION INPUT CONNECTIONS A WARNING ELECTRIC SHOCK can kill Have a qualified electrician install and service this equipment Disconnect input power by removing plug from receptacle before working inside V160 T Allow machine to sit for 5 min
75. ecommended for use with the V160 S A K960 1 Tig Torch adapter is required Accessories Section 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 automatically sense if a remote control connection is made In Lift TIG mode GTAW WITHOUT remote control device connected to the V160 S the output will come on auto matically WITH a remote control device connected to the unit the output will need to be triggered i e a Foot Amptrol Refer to the Optional Accessories section of this manual for available remote controls The following items can be connected to the 6 pin socket on the front panel Remote control potentiometer K857 for Stick weld ing Remote Foot Amptrol K870 Hand Amptrol K963 3 V160 S amp T LINCOLN Return to Master TOC Return to Master TOC o 2 0 i c x 3 Return to Master TOC B TABLE OF CONTENTS OPERATION SECTION B EM mE B 1 Safety Precautions B 2 General Description B 2 Welding Capability
76. elding When the main part of the weld is complete go to step 3 Return to Section TOC Return to Master TOC V160 S amp T LINCOLN BB 11 OPERATION BB 11 DIP Switch 5 Low OCV Enable Remote control connected The TIG slope functions are disabled for the 2 step trigger mode If slopes This controls the OCV of the machine When the DIP are needed a foot pedal remote control can be used Switch is OFF the OCV is set to the normal level as The TIG slope functions are enabled for the 4 step stated in the manuals for the machines When the trigger mode DIP switch is ON the OCV is reduced to 20V This low OCV mode was created for the Australian mar kets and should only be used as required by these Australian specifications The low OCV will somewhat reduce the starting performance of the machine when dirt rust and or slag is present on the work piece A trigger is always needed to turn ON the output of the machine Return to Section TOC Return to Master TOC DIP Switch 6 European USA Machine Configuration This configures several functions of the V160 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 func
77. erence radiated from the welder 2 Direct interference radiated from the welding leads 3 Direct interference radiated from feedback into the power lines 4 Interference from re radiation of pickup by ungrounded metallic objects V160 S amp T LINCOLN Return to Section TOC Return to Master TOC Return to Section TOC O10 Fie 5 5 10 9 1 0 gt 6 1 8 oO oO Return to Section TOC Return to Master TOC Return to Master TOC 4 Keeping these contributing factors in mind installing equipment per the following instructions should mini mize problems 1 Keep the welder power supply lines as short as pos sible and enclose as much of them as possible in rigid metallic conduit or equivalent shielding for a distance of 50ft 15 2m Both ends of the conduit should be connected to a driven ground and the entire length should be continuous 2 Keep the work and electrode leads as short as pos sible and as close together as possible Lengths should not exceed 25ft 7 6m Tape the leads together when practical 3 Be sure the torch and work cable rubber coverings are free of cuts and cracks that allow high frequen cy leakage Cables with high natural rubber content such as Lincoln Stable Arc better resist high fre quency leakage than neoprene and other synthetic rubber insulated cables 4 Keep the torch in good repair and all connections tight to reduce high frequency l
78. eturn to Master TOC Return to Section TOC O e 5 5 0 9 1 0 gt oO oO a Return to Section TOC Return to Master TOC Return to Master TOC BB 8 DIP Switch 3 2 Step Restart Enable This controls the 2 Step Restart function When the Switch is ON the 2 Step Restart function is enabled 2 Step Restart Disabled DIP Switch 3 2 OFF 1 Press and hold the TIG torch trigger to start the sequence The machine will open the gas valve to start the flow of the shielding gas After the preflow time the output of the machine is turned ON At this time the arc is started according to the selected welding mode Lift TIG or HF TIG After the arc is started the output current will be increased ups lope to the welding current 2 Release the TIG torch trigger to stop welding The machine will now decrease the output current at a controlled rate downslope until the Start Crater current is reached and the output of the machine is turned OFF After the arc is turned OFF the gas valve will remain open for the duration of the post flow time FIGURE BB 4 1 2 TORCH BUTTON OUTPUT CURRENT lt PRE FLOW POST FLOW GAS ON GAS As shown in figure BB 5 itis also possible to press and hold the TIG torch trigger a second time during downs lope to end the downslope time and maintain the out put current at the Start Crater current When the TIG torch trigger is rele
79. he air vents Do not cover the machine with paper cloth or rags when switched on Dirt and dust that can be drawn into the machine should be kept to a minimum Keep the machine dry 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 Machine Grounding and High Frequency Interference Protection in this manual When operated in ambient temperatures greater than 40 the output duty cycle may be reduced INSTALLATION AA 3 Do not mount over combustible surfaces STACKING The Invertec V160 T cannot be stacked TILTING Place the machine directly on a secure level surface The machine may topple over if this procedure is not followed MACHINE GROUNDING AND HIGH FRE QUENCY INTERFERENCE PROTECTION The Capacitor Discharge Circuit used in the high fre quency generator can be blamed for many radio TV and electronic equipment interference problems These problems may be the result of radiated interfer ence Proper grounding methods can reduce or elimi nate radiated interference The Invertec V160 T has been field tested under rec ommended installation conditions It complies with FCC allowable limits for radiation Radiated interference can develop in the following four ways 1 Direct interf
80. ins chemicals known to the State of California to cause cancer birth defects or other reproductive harm The Above For Diesel Engines PERFORMED ONLY BY QUALIFIED INDIVIDUALS FOR ENGINE powered equipment 1 a Turn the engine off before troubleshooting and maintenance work unless the maintenance work requires it to be running X 1 b Operate engines in open well ventilated areas or vent the engine exhaust fumes outdoors 1 c Do not add the fuel near an open flame weld ing arc or when the engine is running Stop the engine and allow it to cool before refuel ing to prevent spilled fuel from vaporizing on contact with hot engine parts and igniting Do not spill fuel when filling tank If fuel is spilled wipe it up and do not start engine until fumes have been eliminated 1 d Keep all equipment safety guards covers and devices in posi tion and in good repair Keep hands hair clothing and tools away from V belts gears fans and all other moving parts when starting operating or repairing equipment 1 6 In some cases it may be necessary to remove safety guards to perform required maintenance Remove guards only when necessary and replace them when the maintenance requiring their removal is complete Always use the greatest care when working near moving parts 1 f Do not put your hands near the engine fan Do not attempt to override the governor or idle
81. ion involved Worker expo sure level should be checked upon installation and periodi cally thereafter to be certain it is within applicable OSHA PEL and ACGIH TLV limits Do not weld in locations near chlorinated hydrocarbon vapors coming from degreasing cleaning or spraying operations The heat and rays of the arc can react with solvent vapors to form phosgene a highly toxic gas and other irritating prod ucts Shielding gases used for arc welding can displace air and cause injury or death Always use enough ventilation especially in confined areas to insure breathing air is safe Read and understand the manufacturer s instructions for this equipment and the consumables to be used including the material safety data sheet MSDS and follow your employer s safety practices MSDS forms are available from your welding distributor or from the manufacturer Also see item 1 b Aug 06 Return to Master TOC Return to Master TOC o ke 2 D 2 c x 5 Return to Master TOC SAFETY WELDING SPARKS 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 Avoid welding near hydraulic lines Have a fire extingu
82. is entire section before operating your machine SAFETY INSTRUCTIONS A WARNING ELECTRIC SHOCK can kill e Do not touch electrically live parts such as output terminals or internal wiring e Insulate yourself from the work and ground Always wear dry insulating gloves FUMES AND GASES can be dangerous Keep your head out of fumes Use ventilation or exhaust to remove fumes from breathing zone E WELDING CUTTING and GOUGING SPARKS can cause fire or explosion Keep flammable material away Do not weld cut or gouge on containers that have held com bustibles 4 RAYS 2 Wear eye ear and body protection Only qualified personnel should operate this equip ment Observe all safety information throughout this manual OPERATION BB 2 GENERAL DESCRIPTION The Invertec V160 T is an industrial 160 amp arc weld ing power source which utilizes single phase input power to produce constant current output The welding response of this Invertec has been optimized for stick SMAW and TIG GTAW The unit is ideal for indus trial applications where portability is important The Invertec V160 T performs DC TIG with high fre quency or Touch Start Tig Starting with excellent results WELDING CAPABILITY The Invertec V160 T 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 outp
83. isher readily available 6 b Where compressed gases are to be used at the job site special precautions should be used to prevent hazardous situations Refer to Safety in Welding and Cutting ANSI Standard Z49 1 and the operating information for the equipment being used When not welding make certain no part of the electrode circuit is touching the work or ground Accidental contact can cause overheating and create a fire hazard Do not heat cut or weld tanks drums or containers until the proper steps have been taken to insure that such procedures will not cause flammable or toxic vapors from substances inside They can cause an explosion even though they have been cleaned For information purchase Recommended Safe Practices for the Preparation for Welding and Cutting of Containers and Piping That Have Held Hazardous Substances AWS F4 1 from the American Welding Society see address above Vent hollow castings or containers before heating cutting or welding They may explode Sparks and spatter are thrown from the welding arc Wear oil free protective garments such as leather gloves heavy shirt cuffless trousers high shoes and a cap over your hair Wear ear plugs when welding out of position or in confined places Always wear safety glasses with side shields when in a welding area Connect the work cable to the work as close to the welding area as practical Work cables connected to the building
84. ive mea sures are followed to assure long life and reliable oper ation Do not place or operate this machine on a surface with an incline greater than 15 from horizontal This machine must be located where there is free cir culation of clean air without restrictions for air move ment to and from the air vents Do not cover the machine with paper cloth or rags when switched on Dirt and dust that can be drawn into the machine should be kept to a minimum Keep the machine dry and do not place it on wet ground or in puddles When operated in ambient temperatures greater than 40 the output duty cycle may be reduced Do not mount over combustible surfaces STACKING The Invertec V160 S cannot be stacked TILTING Place the machine directly on a secure level surface The machine may topple over if this procedure is not followed INPUT CONNECTIONS A WARNING ELECTRIC SHOCK can kill e Have a qualified electrician install and service this equipment Disconnect input power by removing plug from receptacle before working inside V160 S Allow machine to sit for 5 minutes minimum to allow the power capacitors to discharge before working inside this equipment Do not touch electrically live parts GROUND CONNECTION The frame of the welder must be grounded A ground terminal marked with the symbol is located on the under panel for this pur pose See your local and national elec trical code
85. l The wiring diagram specific to your code is pasted inside one of the enclosure panels of your machine LINCOLN Q V160 S Return to Section TOC Return to Master TOC e ELECTRICAL DIAGRAMS WIRING DIAGRAM V160 T CODE 10878 V160 T WIRING 51 WHITE T BLUE Return to Section TOC Return to Master TOC 115 230 1 50 60 TRANSFORMER Vac W2 WEZ INVERTER BOARD INPUT BOARD W05X0190 GN 05 0203 SCHEMATIC X0190 SCHEMATIC 0203 Return to Section TOC Return to Master TOC DISPLAY BOARD Meca METER BOARD 050207 w05x0233 s 1 SCHEMATIC X0207 ojo o 2 gt 818 cic 515 ply o ajo L zl SCHEMATIC 0233 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 Only qualified persons should install use or service this machine Return to Section TOC Return to Master TOC 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 LINCOLN amp V160 S T Gs ELECTRICAL DIAGRAMS oe WIRING DIAGRAM V160 T CODE 11032
86. l not to make contact with the capacitor solder pads located on the input board See Figure F2 FIGURE 2 LOCATION OF INPUT FILTER CAPACITOR TERMINALS ON THE INPUT BOARD INSULATED PLIERS O10 515 10 5 9 2 o 1 INSULATED GLOVES Return to Section TOC Return to Master TOC V160 S amp T LINCOLN Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC o 5 97 2 G 3 Return to Section TOC Return to Master TOC o 2 0 8 c x 3 11 TROUBLESHOOTING amp REPAIR INPUT BOARD TEST V160 S T WARNING Service and repair should be performed by only Lincoln Electric factory trained personnel Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty For your safety and to avoid electrical shock please observe all safety notes and pre cautions detailed throughout this manual If for any reason you do not understand the test procedures or are unable to per form the test repairs safely contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed Call 1 888 935 3877 TEST DESCRIPTION This test will help determine if the Input Board is functioning properly Note There have been some revisions
87. led throughout this manual If for any reason you do not understand the test procedures or are unable to per form the test repairs safely contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed Call 1 888 935 3877 TEST DESCRIPTION This test will help determine if all of the Welding Logic Circuit and Inverter are functioning properly Note There have been some revisions to the inverter boards The older boards are identified with line art drawings The later boards are presented as digital pho tographs Perform correct test procedures for suspect boards MATERIALS NEEDED Volt Ohmmeter Phillips Head Screwdriver Wiring Diagram V160 S amp T LINCOLN F 19 TROUBLESHOOTING amp REPAIR iss MAIN IGBT INVERTER BOARD V160 S T WELDING LOGIC AND INVERTER SECTION TEST continued TEST PROCEDURE 1 Remove input power to the V160S T machine 2 Perform Case Cover Removal 3 Perform the Capacitor Discharge detailed earlier in this section Return to Section TOC Return to Master TOC 4 Locate the inverter section of the Main inverter board FIGURE F 9 MAIN IGBT INVERTER BOARD LOCATION Return to Section TOC Return to Master TOC Fie 5 5 10 9 1 0 oO oO Inverter Board Return to Section TOC Return to Master TOC V160 S amp T LINCOLN B Return t
88. llowing table shows the DIP Switch settings and selected upslope time DIP Switch 7 DIP Switch 8 ON ON ON ON 0 1 seconds 0 5 seconds 1 second Start Crater Current Adjustment The start crater current of a T type machine can be changed if necessary The values are set from the fac tory European Machines 20 160A welding current 32A start crater current USA Machines 10 160A welding current 16 start crater current A WARNING Be sure that all installation operation mainte nance and repair procedures are performed only by qualified individuals Lincoln Electric is not responsible for damages caused by improper installation improper care or abnormal operation This adjustment procedure must be performed only by Lincoln trained service technicians The machine will be operating with the cover removed where it is possible to come in contact with high voltages Read all the following instructions before starting the procedure ELECTRIC SHOCK CAN KILL e Welding equipment generates high voltages Do not touch the live parts of the machine the electrode the work clamp or connected work pieces when this equipment is on Insulate yourself from live electrical connec tions the electrode the work clamp and the connected work pieces OPERATION BB 12 1 Remove the cover of the machine to access the control Printed Circuit Boards on the case front 2 To adjust the start crater c
89. manual The wiring diagram specific to your code is pasted inside one of the enclosure panels of your machine LINCOLN amp V160 S T G 3 ELECTRICAL DIAGRAMS 0 3 WIRING DIAGRAM V160 S CODE 11031 NOTE INPUT FILTER NOT ON ALL MODELS T 7 BLUE RED 1 5 4 FILTER AC 4 0 wi e WOSX0431 GND Return to Section TOC Return to Master TOC SCHEMATIC X0431 777 SCHEMATIC 203 BROWN T Y G INVERTER BOARD n INPUT BOARD W05X0190 05 0250 YI SCHEMATIC X0190 o o 8 3 Return to Master TOC NOTE DISPLAY NOT ON ALL MODELS N eB 5 E DISPLAY BOARD 26 25 24 23 22 21 20 19 18 17 16 15 14 3121 10987654321 mee gig E WOSX0747 WELD CONTROLLER 3 8 W05X033 E WARNING HIGH VOLTAGE KILL not operate with covers removed ___ _ _ _ E ed s Disconnect input power by unplugging 2 power cord before servicing Do not touch electrically live parts E Only qualified persons should install REMOTE BOARD 2 use or service this machine W05X0322 5 Los S 4 RIBBON CABLE lt lt NOTE REMOTE PCB NOT ON ALL MODELS NOTE This diagram is for reference only It may not be accurate for all machines covered by this manua
90. ment Turn the input power OFF at the fuse box before working on equipment Do not touch electrically hot parts CAUTION Sometimes machine failures appear to be due to PC board failures These problems can sometimes be traced to poor electrical connections To avoid prob lems when troubleshooting and replacing PC boards please use the following procedure 1 Determine to the best of your technical ability that the PC board is the most likely component causing the failure symptom 2 Check for loose connections at the PC board to assure that the PC board is properly connected 3 If the problem persists replace the suspect PC board using standard practices to avoid static electrical damage and electrical shock Read the warning inside the static resistant bag and perform the following procedures PC board can be damaged by static electricity Remove your body s static charge before opening the static shielding bag Wear an anti static wrist strap For safety use a 1 Meg ohm resistive cord connected to a grounded part of the equipment frame ATTENTION Static Sensitive Devices Handle only at Static Safe Workstations If you don t have a wrist strap touch an un painted grounded part of the equipment frame Keep touching the frame to prevent static build up Be sure not to touch any electrically live parts at the same time Tools which come in contact with the PC board must be either conductive anti
91. minal clamp with silver screw and black hot wire under terminal clamp with brass screw Connect green wire under ter minal clamp with green screw ARFU Auto Restore Fuse The dual input voltage machine is provided with an ARFU device It only operates when the input is con nected to an 115V supply and protects from input over current conditions INSTALLATION AA 5 When the ARFU has been activated due to an input over current condition the output will be turned off and the green Power LED will blink indicating an over cur rent condition This condition usually occurs when the unit is operated beyond its rated duty cycle The unit will self restore after a short time and will be ready for normal operation once the green Power LED stops blinking and remains on NOTE The ARFU replaces a fuse F2 that was used in older V160 s A WARNING Failure to wire as instructed may cause personal injury or damage to equipment To be installed or checked by an electrician or qualified person only 230V INPUT To achieve the full output capacity of the V160 T 230VAC inputs should be used The change over is accomplished by replacing the 115VAC plug with a 30 Amp 230VAC plug NEMA 6 30P ATTACHMENT PLUG In all cases the green or green yellow grounding wire must be connected to the grounding pin of the plug usu ally identified by a green screw All attachment plugs must comply with the Standard for Attachment Pl
92. mptrol for TIG welding When the V160 T s Output Control is in the REMOTE position the foot Amptrol energizes the output and controls the output remotely The Foot Amptrol connects directly to the 6 pin Amphenol K963 3 Hand Amptrol for TIG welding When the V160 T s Output Control is in the Remote position the hand Amptrol energizes the output and controls the output remotely The Hand Amptrol connects directly to the 6 pin Amphenol K814 Arc Start Switch Energizes the output for TIG welding if remote output control of the amperage is not desired It allows on off TIG welding at the current set by the Current Control on the control panel When using the Arc Start Switch set the Output Control to the LOCAL position Magnum PTA 9 and PTA 17 TIG Torches The fol lowing standard Magnum TIG torches with one piece cable may be used with the Invertec V160 T K1781 1 PTA 9 1254 medium back cap K1781 3 9 254 medium back cap K1782 1 PTA 17 12 5ft long back cap K1782 3 17 254 long back cap NOTE Each torch requires a Twist Mate adapter one is included with the machine Collects collect bodies and nozzles are not included and must be ordered separately ACCESSORIES 2 CABLE PLUGS K852 50 Cable Plug Kit for 1 0 2 0 cable Attaches to welding cable to provide quick disconnect from machine Twist Mate Torch Adapter K1622 1 One is shipped with the welder to connect
93. n to Master TOC Return to Master TOC EE 6 INSULATED GATE BIPOLAR TRAN SISTOR IGBT OPERATION An IGBT is a type of transistor IGBT are semiconduc tors well suited for high frequency switching and high current applications Example A in figure EE 6 shows an IGBT in passive mode There is no gate signal zero volts relative to the source and therefore no current flow The drain ter minal of the IGBT may be connected to a voltage sup ply but since there is no conduction the circuit will not supply current to the components connected to the Source The circuit is turned OFF like a light switch Example B shows the IGBT in an active mode When the gate signal a positive DC voltage relative to the THEORY OF OPERATION EE 6 source is applied to the gate terminal of the IGBT it is capable of conducting current A voltage supply con nected to the drain terminal will allow the IGBT to con duct and supply current to the circuit components coupled to the source Current will flow through the conducting IGBT to downstream components as long as the positive gate signal is present This is similar to turning ON a light switch FIGURE EE 6 IGBT DRAIN DRIFT REGION BUFFER LAYER INJECTING LAYER POSITIVE VOLTAGE BODY REGION DRAIN DRIFT REGION V160 S amp T LINCOLN Return to Master TOC Return to Master TOC o 2 0 i c
94. ng the machine to make changes to the DIP Switches it must first be turned OFF and disconnected from the input source Do not open the machine or change the DIP Switches with power applied to the machine Only Lincoln trained service technicians are authorized to per form these modifications The DIP switches are numbered from 1 to 8 shown in Figure BB 3 Switch 1 is on the bottom and switch 8 is on the top When a switch is pushed to the right or to the back of the machine it is ON when it is pushed to the left or to the front of the machine it is OFF The standard production settings for the V160 T are shown with in bold letters OFF Table BB 1 If a switch setting has bold letters OFF do not make any changes abnormal operation could occur TABLE BB 1 DIP V160 T V160 T Pulse V160 T Switch CE CE USA 1 2 3 4 5 6 7 8 OPERATION BB 7 DIP Switch 1 Machine Type This controls the output of the V160 T and some weld ing waveform functions It configures the V160 T to automatically turn OFF depending on the position of the Welding Mode switch Refer to DIP Switch 6 for more information DIP Switch 2 Preflow Timer This controls the preflow timer for TIG welding used only on T type machines When the DIP switch is OFF the preflow time is 0 5 seconds When it is ON the preflow time is 0 1 seconds FIGURE BB 3 Front of machine Switch 1 V160 S amp T LINCOLN Return to Section TOC R
95. nvalidate your factory warranty For your safety and to avoid electrical shock please observe all safety notes and precautions detailed throughout this manual Return to Section TOC Return to Master TOC If for any reason you do not understand the test procedures or are unable to perform the test repairs safely contact the Lincoln Electric Service Department for electrical trou bleshooting assistance before you proceed Call 1 888 935 3877 TEST DESCRIPTION This procedure will aid the technician in the removal and replacement of the case cover MATERIALS NEEDED Phillips Head Screwdriver Return to Section TOC Return to Master TOC O10 Fie 5 5 10 9 1 0 sie oO oO Return to Section TOC Return to Master TOC V160 S amp T LINCOLN TROUBLESHOOTING amp REPAIR CASE COVER REMOVAL AND REPLACEMENT PROCEDURE CONTINUED FIGURE F 1 CASE REAR SCREWS REMOVAL Return to Section TOC Return to Master TOC Four Screws Return to Section TOC Return to Master TOC PROCEDURE 1 Remove input power to the V160S T 2 Using a phillips head screwdriver remove the four screws on the back See Figure 1 O10 Fie s 10 9 1 0 lz 8158 lo x amp 3 Pull out the rear panel take off the handle then remove the cover 4 Perform the Input Filter Capacitor Discharge Procedure detailed in this section Return to Section TOC Return to Master TOC
96. o Section TOC Return to Master TOC Return to Section TOC Return to Master TOC O10 Fie 5 5 10 9 0 lz 6 1 8 oO oO Return to Section TOC Return to Master TOC FI TROUBLESHOOTING amp REPAIR Pal MAIN IGBT INVERTER BOARD V160 S T WELDING LOGIC AND INVERTER SECTION TEST continued FIGURE F 10 MAIN IGBT INVERTER BOARD LOCATION 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 T PIN 7 0 VDC INVERTER ON O PIN 3 P e e e e PIN 2 V160 S amp T LINCOLN Fa TROUBLESHOOTING amp REPAIR nee MAIN IGBT INVERTER BOARD V160 S T WELDING LOGIC AND INVERTER SECTION TEST continued FIGURE F 11 MAIN IGBT INVERTER BOARD LOCATION Return to Section TOC Return to Master TOC WAVEFORM ON EACH GATE o 2 amp x 3 Return to Master TOC 5us div 10V div olo ake O12 Take note that you need an oscilloscope insulated from 9 the supply line to do this measure 13579 NUMBERING 312 2 2 TEST PROCEDURE 4 6 8 10 1 Locate 6 gate points indicated on Figure GROUND 1 2 Connect scope probe set at 5us div 10V div and check waveform on each gate with ground probe to pin 2 in molex 1
97. on libres de l huile tels que les gants en cuir chemise paisse pan talons sans revers et chaussures montantes Toujours porter des lunettes de s curit dans la zone de soudage Utiliser des lunettes avec crans lateraux dans les zones l on pique le laitier i SAFETY i 6 Eloigner les mat riaux inflammables ou les recouvrir afin de pr venir tout risque d incendie aux tincelles Quand on ne soude pas poser la pince une endroit isol de la masse Un court circuit accidental peut provoquer un chauffement et un risque d incendie S assurer que la masse est connect e le plus pr s possible de la zone de travail qu il est pratique de le faire Si on place la masse sur la charpente de la construction ou d autres endroits loign s de la zone de travail on augmente le risque de voir passer le courant de soudage par les chaines de levage c bles de grue ou autres circuits Cela peut provoquer des risques d incendie ou d echauffement des chaines et des c bles jusqu ce qu ils se rompent Assurer une ventilation suffisante dans la zone de soudage Ceci est particuli rement important pour le soudage de t les galvanis es plomb es ou cadmi es ou tout autre m tal qui produit des fume s toxiques Ne pas souder en pr sence de vapeurs de chlore provenant d op rations de d graissage nettoyage ou pistolage La chaleur ou les rayons de l arc peuvent r agir avec les vapeurs du solvant pour prod
98. ontrolled u ojo dii 100KZ to Maintain Tr i 2 U4B Proper suppl x 17 3 olo 3R8 7 1 5VDG s 2 gt alr ay c gt E E A 4 9 ply oO 15 4 m c3 100 7T 07 1 4148 50V 025 BYV26E HEY ojo WSBX0191 019 26 C16 1200Vde 5 150nF ois o 20mA BYV26E 2 5 oO ajo D24 R28 5404 ih Ore 00R HS wa08162 24 10K 016 DIT 600V 180 160V a 07 1 TOP223Y con HS G25 33nF C26 amp nBF 100V 1KV HIGH FREQ CIRCUIT ONLY ON TIG VERSION NOT ON STICK VERSION NOTE This diagram is for reference only It may not be accurate for all machines covered by this manual Return to Section TOC Return to Master TOC LINCOLN 8 V160 S T oe ELECTRICAL DIAGRAMS mo SCHEMATIC INPUT PC BOARD VOLTAGE SUPPLIES cis 415Vdc ES 2 P 313 volts Fan 12VDC Fan Signal From Control PCB 3 E R29 EV E 3 dis Gone Supplies 5 lt erai eN 73 Input Board lt Qo volts Fan Off 56 12VDC Fan On If F2 Thermostat Opens U8B Opens 100nF 2 BS Imax set 3 3 470R 57 FE Signal Sept to Control Board When using 115V Input 215 R4 FAN JP1 To Control PCB e 10K a
99. ot over tighten V160 S amp T LINCOLN Return to Section TOC Return to Master TOC Return to Section TOC O10 Fie 5 5 10 9 1 0 lz 6 1 8 pir oO oO Return to Section TOC Return to Master TOC Return to Master TOC iis INSTALLATION QUICK DISCONNECT PLUG FOR STICK ELEC TRODE CABLE A quick disconnect system is used for the welding cable connections The stick electrode cable will need to have a plug attached 1 Cut off welding cable lug if present 2 Remove 75 in 19mm of welding cable insulation 3 Slide rubber boot onto cable end The boot end may be trimmed to match the cable diameter Use soap or other nonpetroleum based lubricant to help slide the boot over the cable if needed BOOT WELDING CABLE 75 19 TRIM IF REQ D TO FIT OVER CABLE 4 Cut 45 5096 of the copper strands back 1 4 6 mm WELDING CABLE in 6mm 5 Fold copper strands over cut strands and insert into ferrule COPPER FERRULE WELDING CABLE 50 in max 12 mm max SCREW PLUG COPPER TUBE 6 Slide the copper ferrule into the brass plug 7 Tighten set screw to collapse copper tube Screw must apply pressure against welding cable The top of the set screw will be well below the surface of the brass plug after tightening OUTPUT CONNECTION FOR TIG WELDING A one piece Gas Valve Tig Torch is r
100. pacemaker should consult their physician before welding Exposure to EMF fields in welding may have other health effects which are now not known All welders should use the following procedures in order to minimize exposure to EMF fields from the welding circuit 2 d 1 Route the electrode and work cables together Secure them with tape when possible 2 d 2 Never coil the electrode lead around your body 2 d 3 Do not place your body between the electrode and work cables If the electrode cable is on your right side the work cable should also be on your right side Connect the work cable to the workpiece as close as possible to the area being welded Do not work next to welding power source Mar 95 LINCOLN Return to Master TOC Return to Master TOC o 2 0 lt c x 3 Return to Master SAFETY ii 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 3 b Insulate yourself from work and ground using dry insulation Make certain the insulation is large enough to cover your full area of physical contact with work and ground In addition to the normal safety precautions if welding must be performed under electrically hazardous conditions in damp locations or while wea
101. place the four display board mounting 7 Replace the three mounting screws on bolts the bottom of the machine 3 Replace control knobs 8 Replace the case cover 4 Replace nuts and associated washers securing control knobs 5 Replace previously removed red caps V160 S amp T LINCOLN Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC O10 Fie s 10 9 0 gt 6 1 8 oO oO Return to Section TOC Return to Master TOC ian TROUBLESHOOTING amp REPAIR has RETEST AFTER REPAIR If a failed test indicates that any mechanical part that could affect the machine s electri cal characteristics must be replaced or if any electrical components are repaired or replaced the machine must be retested and meet the following standards INPUT SINGLE PHASE ONLY Input Voltages 50 60 Hz Max Input Current at rated Output 115 V 20 A Plug and branch 20A 115 V 30A branch 25A 230 V 34 RATED OUTPUT Duty Cycle Output Amps Output Volts Input Circuit 60 Stick 22 4 115V 20A Plug and Branch 90 TIG 13 6 10096 80 Stick 23 2 115V 30A Branch 110 TIG 14 4 35 160 Stick 26 4 230V 30A Branch 160 TIG 16 4 100 130 Stick 25 2 230V 30A Branch 130 TIG 15 2 OUTPUT Output Current Range Maximum Open Circuit Voltage Type of Output 5 160 Amps 48 Volts Max DC To test 160 TIG mode set mode switch to LIFT do not use
102. put on the input rectifier on the input board and the resultant DC voltage is applied at inverter Pcb s During the precharge time the DC input voltage is applied to the filter capacitors located on the inverter Pcb through a precharge resistances located on input board that limit the charge current During precharge time an automatic system manages by reconnect board mounted the input board sets the input board for 115V or 230V working mode volt age duplicator when 115Vac is applied After this time the start relays go closed and they by pass the precharge resistances there are two precharge relays RL1B and RL4B The input voltage is also applied to an auxiliary voltage circuit that gives the necessary low voltages 15V 5V and 5 for the control display board and inverter board The fan is activated when the power is first supplied to the machine It will stay on as long as output is present The fan shuts down after 5 minutes when the output is shut off NOTE Unshaded areas of Block Logic Diagram are the subject of discussion V160 S amp T LINCOLN 8 Ea THEORY OF OPERATION E FIGURE E 4 INVERTER BOARD 1 01 BLUE o AC1 wi 1 la 3 BROWN BLACK 2 DC A DC we Return to Section TOC Return to Master TOC 115 230 1 50 60 INVERTER BOARD W05X0190 SCHEMATIC X0190 Y G INPUT BOARD GND GND W05X0250 SCHEMATIC 203 JP1 JP1 12345678910
103. r current conditions When the ARFU has been activated due to an input over current condition the output will be turned off and the green Power LED will blink indicating an over cur rent condition This condition usually occurs when the unit is operated beyond its rated duty cycle The unit will self restore after a short time and will be ready for normal operation once the green Power LED stops blinking and remains on NOTE The ARFU replaces a fuse F2 that was used in older V160 s WARNING Failure to wire as instructed may cause personal injury or damage to equipment To be installed or checked by an electrician or qualified person only 230V INPUT To achieve the full output capacity of the V160 S 230VAC inputs should be used The change over is accomplished by replacing the 115VAC plug with a 30 Amp 230VAC plug NEMA 6 30P ATTACHMENT PLUG In all cases the green or green yellow grounding wire must be connected to the grounding pin of the plug usu ally identified by a green screw All attachment plugs must comply with the Standard for Attachment Plugs and Receptacles UL498 The product is considered acceptable for use only when an attachment plug as specified is properly attached to the supply cord The Invertec V160 S will auto reconnect to either 115V or 230V supplies ENGINE DRIVEN GENERATOR For use on engine drives keep in mind the above input draw restrictions and the following preca
104. r by pushing on the throttle control rods while the engine is running 1 4 To prevent accidentally starting gasoline engines while turning the engine or welding generator during maintenance work disconnect the spark plug wires distributor cap or magneto wire as appropriate ARC WELDING CAN BE HAZARDOUS PROTECT YOURSELF AND OTHERS FROM POSSIBLE SERIOUS INJURY OR DEATH KEEP CHILDREN AWAY PACEMAKER WEARERS SHOULD CONSULT WITH THEIR DOCTOR BEFORE Read and understand the following safety highlights For additional safety information it is strongly recommended that you purchase a copy of Safety in Welding amp Cutting ANSI Standard Z49 1 from the American Welding Society P O Box 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 The Above For Gasoline Engines 1 h To avoid scalding do not remove the radiator pressure cap when the engine is hot 23 ELECTRIC AND ET MAGNETIC FIELDS may be dangerous m 2 a Electric current flowing through any conductor causes localized Electric and Magnetic Fields EMF Welding current creates EMF fields around welding cables and welding machines EMF fields may interfere with some pacemakers and welders having a
105. r procedure on grounding the work clamp and work piece Do not touch electrically live parts or electrode with skin or wet clothing e Insulate yourself from work and ground e Turn the input line Switch on the Invertec V160 T off before connecting or disconnecting out put cables or other equipment OUTPUT CONNECTION FOR STICK WELDING FIGURE AA 2 FIGURE AA 2 FRO 1 WORK CLAMP a WORK CABLE pr oO lt ELECTRODE Ce HOLDER 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 corresponding to this polarity For instance for DC welding connect the electrode cable which is connected to the electrode holder to the output terminal and the work cable which is connected to the work clamp to the output terminal Insert the connector with the key lining up with the key way and rotate approximately 1 4 turn clockwise until the connection is snug Do not over tighten V160 S amp T LINCOLN Return to Section TOC Return to Master TOC Return to Section TOC O10 Fie 5 5 10 9 1 0 gt 813 oO oO a Return to Section TOC Return to Master TOC Return to Master TOC AA 7 QUICK DISCONNECT PLUG FOR STICK ELEC TRODE CABLE A quick disconnect system is used for the welding cable connections The stick electrode cable will
106. ring wet clothing on metal structures such as floors gratings or scaffolds when in cramped positions such as sitting kneeling or lying if there is a high risk of unavoidable or accidental contact with the workpiece or ground use the following equipment Semiautomatic DC Constant Voltage Wire Welder DC Manual Stick Welder AC Welder with Reduced Voltage Control In semiautomatic or automatic wire welding the electrode electrode reel welding head nozzle or semiautomatic welding gun are also electrically hot Always be sure the work cable makes a good electrical connection with the metal being welded The connection should be as close as possible to the area being welded Ground the work or metal to be welded to a good electrical earth ground Maintain the electrode holder work clamp welding cable and welding machine in good safe operating condition Replace damaged insulation Never dip the electrode in water for cooling Never simultaneously touch electrically hot parts of electrode holders connected to two welders because voltage between the two can be the total of the open circuit voltage of both welders When working above floor level use a safety belt to protect yourself from a fall should you get a shock Also see Items 6 c and 8 LINCOLN B 54 5 4 a Use shield with the proper filter and cover plates to protect your eyes from sparks
107. rocedure was followed when warranty reports are to be submitted NOTE Following this procedure and writing on the warranty report INSTALLED AND SWITCHED PC BOARDS TO VERIFY PROBLEM will help avoid denial of legitimate PC board warranty claims V160 S amp T LINCOLN Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC Q 5 2 G 3 Return to Section TOC Return to Master TOC o p 0 8 c x 3 E THEORY OF OPERATION p Observe Safety Guidelines detailed in the beginning of this manual PROBLEMS POSSIBLE AREAS OF RECOMMENDED SYMPTOMS MISADJUSTMENT S COURSE OF ACTION GENERAL PROBLEMS The machine is dead Make sure that the input volt 1 Connect correct input voltage No LED age is present No Fan Check the input switch 2 Replace if necessary Check the fuse F1 F2 Auto 3 Replace necessary fuse s if depending upon input board they fail again perform the installed Input Board Test The machine has only the fan run Check the auxiliary voltages 1 Perform the Input Board Test ning no display the JP1 to the input board 2 Replace the display board if the auxiliary voltages are present The machine powers up correctly Check the output LED 1 If the output LED is on perform but there is no output 2 Check the torch trigger thel IGBT Inverter Board Test Inverter Board Te
108. s OFF and a trigger is need ed Simple Lift TIG welding is possible using a 2 step trigger sequence DIP Switch 7 thru 8 non functional for the V160 S START CRATER CURRENT ADJUSTMENT It is not possible to change the start crater current of a S type machine The values set from the factory are European Machines 2096 160A welding current 32A start crater current O10 Fie 5 5 10 9 1 0 lz 6 1 8 pir olo USA Machines 1096 160A welding current 16A start crater current Return to Section TOC Return to Master TOC V160 S amp T LINCOLN et TABLE OF CONTENTS ACCESSORIES SECTION Accessories uii lewowxk sug ave te wet eka dead au Ea E xor RE eed d c n d C 1 Optional Accessories and Compatible C 2 Return to Master TOC Factory Field Installed illii hr C 2 Return to Master TOC o 2 0 i c x 3 Return to Master TOC V160 S amp T LINCOLN Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC o bm 5 97 8 G 3 Return to Section TOC Return to Master TOC o Hr 2 D 8 c x 3 ACCESSORIES udis OPTIONAL ACCESSORIES AND COMPATIBLE EQUIPMENT Factory Installed Electrical Holder and
109. s and allow machine to sit for five minutes minimum to allow the power capaci tors to discharge before working inside this equipment Do not touch electrically hot parts INPUT FILTER CAPACITOR DISCHARGE PROCEDURE 71 11 1 The machine has internal capacitors which are charged to a high voltage during power on conditions This voltage is dangerous and must be discharged before the machine can be serviced Discharging is done automatically by the machine each time the power is switched off However you must allow the machine to sit for at least 5 minutes to allow time for the process to take place ROUTINE MAINTENANCE Prevent metal powder from accumulating near the Heat Sink fins 01116 Disconnect the power supply before every opera tion Carry out the following periodic controls on the power Source Clean the power source inside by means of low pressure compressed air e Check the electric connections and all the connec tion cables A CAUTION e Disconnect the power supply before every oper ation Always use gloves in compliance with the safety standards V160 S amp T LINCOLN E TABLE OF CONTENTS THEORY OF OPERATION SECTION o O 5 Theory of Operation 1 i z g General Description kn ene ae dd oe ale eee we eee E 2 Welding
110. s for proper grounding meth ods A CAUTION A grounding conductor is supplied in the input cord it is important that the supply receptacle ground is connected A WARNING This installation should be performed by a quali fied electrician to ensure correct connections of the leads to the plug spades The electrical system must be made by skilled technicians with the specific professional and technical qualifications and in compliance with the regulations in force in the country where the equipment is installed The welding power source supply cable is pro vided with a green or yellow green wire that must ALWAYS be earthed This green or yellow green wire must NEVER be used with other voltage con ductors Install only plugs that confirm with safety regula tions V160 S amp T LINCOLN Return to Section TOC Return to Master TOC Return to Section TOC ojo o Fie 5 5 R7 9 1 0 gt 6 1 8 oO Return to Section TOC Return to Master TOC Return to Master TOC INSTALLATION Fuse the input circuit with time delay fuses marked D or delay type circuit breakers Using fuses or circuit breakers smaller than recommended may result in nuisance shut offs from welder inrush currents even if not welding at high currents Also called inverse time or thermal magnetic circuit breakers These circuit breakers have a delay in tripping action that decreases
111. st 3 Check the welding cable 2 The control board may be faulty A CAUTION If for any reason you do not understand the test procedures or are unable to perform the tests repairs safely contact the Lincoln Electric Service Department for technical troubleshooting assistance before you proceed Call 1 888 935 3877 V160 S amp T LINCOLN Return to Section TOC Return to Master TOC Return to Section TOC o O10 Fie 5 5 10 9 0 gt 6 1 8 oO oO Return to Section TOC Return to Master TOC Return to Master TOC pu THEORY OF OPERATION ET Observe Safety Guidelines detailed in the beginning of this manual PROBLEMS POSSIBLE AREAS OF RECOMMENDED SYMPTOMS MISADJUSTMENT S COURSE OF ACTION GENERAL PROBLEMS The machine powers up correctly 1 Make sure that the tig torch is 1 The control board may be faulty but working only in stick mode good V160T pulse The machine has only touch start 1 Check the HF transformer for 1 Perform the Input Board Test and no HF V160T pulse only loose or faulty connection in HF area The fan does not operate Check if the machine is in Replace the fan stand by condition after 5 min utes of inactivity in tig mode the fan stops 3 The control board may be faulty 2 Perform the Input Board Test Check the fan supply voltage must be 12vdc The gas solenoid does not work 1 Check the gas solenoid supply 1 Perform the Input Board Test V1
112. static or static dissipative Remove the PC board from the static shielding bag and place it directly into the equipment Don t set the PC board on or near paper plastic or cloth which could have a static charge If the PC board can t be installed immediately put it back in the static shield ing bag If the PC board uses protective shorting jumpers don t remove them until installation is complete If you return a PC board to The Lincoln Electric Company for credit it must be in the static shielding bag This will prevent further damage and allow prop er failure analysis 4 Test the machine to determine if the failure symptom has been corrected by the replacement PC board NOTE It is desirable to have a spare known good PC board available for PC board troubleshooting NOTE Allow the machine to heat up so that all electrical components can reach their operating temperature 5 Remove the replacement PC board and substitute it with the original PC board to recreate the original problem a If the original problem does not reappear by substituting the original board then the PC board was not the problem Continue to look for bad connections in the control wiring harness junction blocks and terminal strips b If the original problem is recreated by the substitution of the original board then the PC board was the problem Reinstall the replacement PC board and test the machine 6 Always indicate that this p
113. t 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 electrode 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 After machine output is triggered ON the arc must be started within 6 5 seconds or output will turn OFF and trig ger sequence must be restarted When the mode switch is in the HF TIG position the stick welding functions are disabled and the machine is ready for HF TIG welding During the HF TIG mode the TIG arc is started by HF without pressing the electrode on the work piece After triggering output ON the HF and out put used for starting the TIG arc will remain ON for 6 5 seconds If the arc is not started in this time limit the trig ger sequence must be restarted 5 Trigger Mode Switch This switch changes between 2 step and 4 step trigger sequences For an explanation of these trigger sequences refer to the Trigger Mode Sequences following Controls and Settings 6 Power LED This indicator will blink on and off when the machine is first turned on After approximately 2 seconds it will stop blinking and remain on to signal that the machine is ready The indicator will also blink dur ing over current conditions when operating on 115V input 7 Thermal LED This indicator will turn on when the machine is
114. t crater current calibra tion Desired start crater current percentage multiplied by 160 calibration current For example to calibrate the machine for 1596 start crater current multiply this by 160 to get the calibration current 0 15 x 160 24 7 Release the trigger to turn off the output of the machine Turn OFF the machine and disconnect it from the input source Reassemble the machine making sure the ground wire to the cover is con nected V160 S amp T LINCOLN cot TABLE OF CONTENTS ACCESSORIES SECTION _ Accessories i 2 dora dr xd wo pac eee Ned wa e rug Nu Ed ue Rn CC 1 Optional Accessories and Compatible Equipment CC 2 Return to Master TOC Factory Field Installed 22i hr CC 2 Return to Master TOC o 2 0 i c x 3 Return to Master TOC V160 S amp T LINCOLN Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC o 5 97 8 G 3 Return to Section TOC Return to Master TOC o 2 D 8 c x 3 CC 2 OPTIONAL ACCESSORIES AND COMPATIBLE EQUIPMENT Factory Installed 1 Twist Mate Torch Connector W Gas Pass Through 1 Ground Lead and Plug Assembly Strap Packet Instruction Manual Field Installed K870 Foot A
115. t from machine TIG Torch Parts Kits Parts kits are available for the PTA 17 TIG torch This kit includes back cap collets collect bodies nozzles and tungsten Order KP508 for PTA 17 torches See publication E12 150 for parts kits breakdown Cut Length Consumables TIG welding filler metals are available for welding stainless steel mild steel alu minum and copper alloys See publication C9 10 V160 S amp T LINCOLN TABLE OF 5 MAINTENANCE SECTION 28 Maintenance asi si Rok x a cereale eee aed cR 1 Safety Precautions tte eee 2 Return to Master TOC Input Filter Capacitor Discharge D 2 Routine Maintenance ee eee ns D 2 Return to Master TOC o 2 0 i c x 3 Return to Master TOC V160 S amp T LINCOLN Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC olo o Fle f i 9 1 813 cfc 515 pir oO oO Return to Section TOC Return to Master TOC MAINTENANCE pe SAFETY PRECAUTIONS WARNING ELECTRIC SHOCK can kill Have an electrician install and ser vice this equipment 9 Turn the input power off at the fuse box disconnect supply line
116. t is possible to quickly press and release the TIG E torch trigger a second time to end the downslope 2 time and stop welding sis OUTPUT z m FIGURE 12 o POST FLOW POST FLOW 3 elg cas 4 2 L TORCH n BUTTON 44 Ble amp c This sequence has an automatic restart so welding will continue after this step If the weld is complete OUTPUT ly finished use the following sequence instead of CURRENT step 3 described above 3A Quickly press and release the TIG torch trigger GAS ON The machine will now decrease the output current GAS at a controlled rate downslope until the Start Crater current is reached and the output of the machine is turned OFF After the arc is turned OFF the postflow time will start 4 Release the TIG torch trigger The output current will again increase upslope to the welding current like in step 2 to continue welding When the main part of the weld is complete go to step 3 O 5 5 10 9 1 0 oO oO As shown in figure 11 after the TIG torch trigger is quickly pressed and released from step it is possible to press and hold the TIG torch trigger another time to end the downslope time and main tain the output current at the Start Crater current When the TIG torch trigger is released the output will again increase upslope to the welding current like in step 4 to continue w
117. tact avec la masse Maintenir le porte lectrode la pince de masse le c ble de soudage et la machine souder en bon et s r tat defonc tionnement d Ne jamais plonger le porte lectrode dans l eau pour le refroidir Ne jamais toucher simultan ment les parties sous tension des porte lectrodes connect s deux machines souder parce que la tension entre les deux pinces peut tre le total de la tension vide des deux machines Si on utilise la machine souder comme une source de courant pour soudage semi automatique ces precautions pour le porte lectrode s applicuent aussi au pistolet de soudage 2 Dans le cas de travail au dessus du niveau du sol se prot ger contre les chutes dans le cas ou on recoit un choc Ne jamais enrouler le c ble lectrode autour de n importe quelle partie du corps Un coup d arc peut tre plus s v re qu un coup de soliel donc a Utiliser un bon masque avec un verre filtrant appropri ainsi qu un verre blanc afin de se prot ger les yeux du rayon nement de l arc et des projections quand on soude ou quand on regarde l arc b Porter des v tements convenables afin de prot ger la peau de soudeur et des aides contre le rayonnement de l arc c Prot ger l autre personnel travaillant proximit au soudage l aide d crans appropri s et non inflammables Des gouttes de laitier en fusion sont mises de l arc de soudage Se prot ger avec des v tements de protecti
118. tions are clearly understood Return to Section TOC Return to Master TOC DIP Switch 1 OFF In TIG welding mode the following conditions can exist European Machine Configuration DIP Switch 6 OFF The TIG slope functions are always enabled After the arc is started the output current will be increased upslope to the welding current At the end of the weld the current will be decreased with the downs lope function Using a foot pedal remote control is not recommended with this setup A trigger is always needed to turn ON the output of the machine 5 5 10 9 1 0 gt oO oO USA Machine Configuration DIP Switch 6 The TIG slope functions depends on the possible connection of a remote control No remote control connected The TIG slope func tions are enabled After the arc is started the output current will be increased upslope to the welding current At the end of the weld the current will be decreased with the downslope function Return to Section TOC Return to Master TOC V160 S amp T LINCOLN Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC Fie 5 5 10 9 1 0 gt g e oO oO r t Return to Section TOC Return to Master TOC BB 12 DIP Switch 7 amp 8 Upslope Timer These control the upslope timer for TIG welding used only on T type machines The fo
119. to the input boards The older boards are iden tified with line art drawings The later boards are presented as digital pho tographs Perform correct test procedures for suspect boards MATERIALS NEEDED Analog Volt Ohmmeter Phillips Head Screwdriver Wiring Diagram V160 S amp T LINCOLN F 11 12 t a Cs g 4 O 5 Z2 gr oz l ajo ek 5 S S o 07 ols o I gt E 2 Je Q m c m L O 2151 2 w 5 jS jas oc ce ER a oO o 26 4 5 O E Els ESI o O 55 Oa 0 0 0 E N 4 Lu 12 DOL J91Se N 01 uunjeH DOL 1 01 uunjeH DOL J91Se N 01 uunjeH DOL J91Se N 01 uunjeH DOL uonoes DOL uonoes DOL uonoes DOL uonoes Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC O10 Fie s 0 9 1 0 lz 1 8 oO oO Return to Section TOC Return to Master TOC 18 TROUBLESHOOTING amp REPAIR 13 INPUT BOARD TEST V160 S T continued FIGURE F 4 INPUT BOARD Check Check the capacitors for Fuse F1 shorts Check the start resistor 20 Ohms Check the input bridge for shorts or open TEST PROCEDURE 1 Locate test points
120. ued FIGURE F 15 INPUT BOARD Input Board REMOVAL PROCEDURE 1 Remove input power to the V160 S T 2 Perform the Case Cover Removal 3 Perform the Capacitor Discharge 4 Locate the Input Board See Figure F 15 5 Label and remove plugs JP1 JP2 and JP3 6 Label and remove leads DC DC AC2 and ground 7 Using a 7mm nutdriver remove the four P C Board mounting screws 8 The Board may now be tilted forward to gain access to leads HF1 and HF2 Label and disconnect these leads Figure F 16 9 Disconnect ground lead 6 10 Carefully remove and replace Input Board V160 S amp T LINCOLN F 28 pes TROUBLESHOOTING amp REPAIR Eus INPUT BOARD REMOVAL AND REPLACEMENT PROCEDURE continued FIGURE F 16 INPUT BOARD AC1 AC2 Return to Section TOC Return to Master TOC Ground JP1 olo S 3 7mm 212 Mounting E 1 Bolts 5 2 2 REPLACEMENT PROCEDURE 1 Connect leads HF1 and HF2 to the new P C Board 2 Replace 7mm P C Board mounting screws ojo Fie 5 5 9 1 0 818 cfc 5 2 oO oO 3 Connect leads DC DC AC1 AC2 and ground to P C Board 4 Connect plugs JP1 JP2 JP3 amp Ground lead 5 Install case cover Return to Section TOC Return to Master TOC V160 S amp T LINCOLN 30 5 V160 S 8 T LINCOLN E F 30 DOL
121. ugs and Receptacles UL498 The product is considered acceptable for use only when an attachment plug as specified is properly attached to the supply cord The Invertec V160 T will auto reconnect to either 115V or 230V supplies ENGINE DRIVEN GENERATOR For use on engine drives keep in mind the above input draw restrictions and the following precaution The Invertec V160 T can be operated on engine driven generators as long as the 230 volt auxiliary meets the following conditions The AC waveform peak voltage is below 400 volts e The AC waveform frequency is between 45 and 65Hz e The RMS voltage of the AC waveform is always greater than 208VAC 115 VAC input divide these values in half The following Lincoln engine drives meet these condi tions when run in the high idle mode V160 S amp T LINCOLN Return to Section TOC Return to Master TOC Return to Section TOC O10 Fie 5 5 10 9 1 0 gt 6 1 8 oO oO Return to Section TOC Return to Master TOC Return to Master TOC AA 6 Ranger 250 305 Commander 300 400 amp 500 Many engine drives do not meet these conditions eg Miller Bobcats etc Operation of the Invertec V160 T is not recommended on engine drives not conforming to these conditions Such combinations may overvolt age the Invertec V160 T power source OUTPUT CONNECTIONS A WARNING 9 ELECTRIC SHOCK can kill e Keep the electrode holder
122. uire du phosg ne gas fortement toxique ou autres produits irritants 11 Pour obtenir de plus amples renseignements sur la s ret voir le code Code for safety in welding and cutting CSA Standard W 117 2 1974 PR CAUTIONS DE S RET POUR LES MACHINES SOUDER TRANSFORMATEUR ET REDRESSEUR 1 Relier la terre le chassis du poste conformement au code de l lectricit et aux recommendations du fabricant Le dispositif de montage ou la piece souder doit tre branch une bonne mise la terre 2 Autant que possible l installation et l entretien du poste seront effectu s par un lectricien qualifi 3 Avant de faires des travaux l interieur de poste la debranch er l interrupteur la boite de fusibles 4 Garder tous les couvercles et dispositifs de s ret leur place Mar 93 LINCOLN MASTER TABLE OF 5 FOR ALL SECTIONS Page EIECTUS i iv Installation V160 S Section A Installation V160 T sr cL ex Er xU x XR CR t qma e eee ee Section AA Operation V160 S Section B Operation V160 T 2 a eu SEE Ra LX eU E p auia Mt D eh Section BB Accessories 160 5 cubes ior caa kk auda eel aw De La Section C Accessories V160 T 0 00 eee eee eee eee eee Section CC Maintenance V160
123. urn to Master TOC olo 010 s 10 9 1 0 olz oe oO oO r amp Return to Section TOC Return to Master TOC F to TROUBLESHOOTING amp REPAIR INPUT BOARD TEST V160 S T continued FIGURE F 6A INPUT BOARD CONNECTOR JP1 F1 Fuse Check Capacitors For Shorts 1247 07 01450 e 73 Start Resistor 20 Ohms 1 TEST PROCEDURE 1 Locate Connector JP1 See figure F5 2 Check pin 5 to pin 11 for 5Vdc 3 Check pin 7 to pin 11 for 15Vdc 4 Check pin 9 to pin 11 for 5Vdc D11 Rectifier 115VDC D20 Rectifier 16VDC INPUT PCB BACKSIDE TEST PROCEDURE NEW MODELS 1 Locate connector JP1 See Figure F 6A 2 Check pin 5 to pin 11 for 5vdc 3 Check pin 7 to pin 11 for 15vdc 4 Check pin 9 to pin 11 for 5vdc V160 S amp T LINCOLN Return to Section Return to Master TOC Return to Section TOC Return to Master TOC olo O 5 5 10 9 1 0 olz 2 olo Return to Section TOC Return to Master TOC and TROUBLESHOOTING amp REPAIR EH INPUT BOARD TEST V160 S T continued FIGURE 7 INPUT BOARD V160 INPUT PCB INSIDE F1 Fuse Protects Reconnect Transformer F2 Thermostat Revision Number 5 VDC Supply 5 VDC Supply 15 VDC Supply Start Resistor Reconnect Relay Start Relay D11 Rectifier Reconnect PCB Transformer Relay
124. urn to Section TOC Return to Master TOC ES THEORY OF OPERATION ai FIGURE E 2 GENERAL DESCRIPTION 51 115 230 1 50 60 INPUT BOARD GND WO5X0250 SCHEMATIC X0203 INVERTER BOARD 05 019 SCHEMATIC X0190 JP1 12345678910 DISPLAY BOARD 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 Only qualified persons should install use or service this machine CONNECTOR GENERAL DESCRIPTION The V160 S is an industrial 160 amp arc welding power source which utilizes single phase input power to produce constant current output The welding response of this Invertec has been optimized for stick SMAW and Touch Start TIG GTAW The unit is ideal for industrial applications were portability is important The Invertec V160 S is recommended for stick welding with such popular electrodes as Fleetweld 35 Fleetweld 37 Fleetweld 180 and LH 78 It features adjustable arc control to adjust the arc force and start The Invertec V160 S performs DC Touch Start Tig Starting with excellent results WELDING CAPABILITY The Invertec V 160 S is rated at 160 amps 26 4 volts at 3596 duty cycle on a ten minute basis It is capable of higher duty cycles at lower output currents It is capable of 13
125. urn to Section TOC Return to Master TOC V160 S amp T LINCOLN Return to Section TOC Return to Master TOC Return to Section TOC elo o Fle f i 9 1 813 cfc 513 pir oO oO Return to Section TOC Return to Master TOC Return to Master TOC ES THEORY OF OPERATION ES INSULATED GATE BIPOLAR TRAN SISTOR IGBT OPERATION An IGBT is a type of transistor IGBT are semiconduc tors well suited for high frequency switching and high current applications Example A in figure E 6 shows an IGBT in passive mode There is no gate signal zero volts relative to the source and therefore no current flow The drain ter minal of the IGBT may be connected to a voltage sup ply but since there is no conduction the circuit will not supply current to the components connected to the source The circuit is turned OFF like a light switch Example B shows the IGBT in an active mode When the gate signal a positive DC voltage relative to the source is applied to the gate terminal of the IGBT it is capable of conducting current A voltage supply con nected to the drain terminal will allow the IGBT to con duct and supply current to the circuit components coupled to the source Current will flow through the conducting IGBT to downstream components as long as the positive gate signal is present This is similar to turning ON a light switch FIGURE E 6 IGBT GATE SOURCE lt BODY REGION
126. urrent output current from the machine must flow through a load bank or a TIG arc Connect the necessary equipment In both cases load bank or TIG arc a trigger must be con nected to the machine If a load bank is used it must be setup for 160A and approximately 25V 3 Make sure all electrical connections are free from contact with other parts of the machine Reconnect the case back if necessary Turn ON the machine 4 On the control panel of the machine select the fol lowing e Mode Switch LIFT TIG Do not use HF TIG or dam age to measuring equipment will occur Trigger Mode 4 Step e Pulsing OFF Output Current Maximum 160A 5 Activate the trigger of the machine to achieve the start or crater current portion of the welding sequence Refer to the trigger sequences explained above if more information is needed 6 In this condition measure the output current of the machine and adjust the start crater current as nec essary The calibration trimmer for the start crater current is located on the left side of the machine as viewed from the front on the display board The access hole for this trimmer is the higher one on the display board Do not adjust the lower trimmer on the display board this is the output current calibra tion The output current is set to 160A therefore the start crater current calibration will be a percentage of this 160A setting Use the following equation for determining the desired star
127. ust the arc force and start LIMITATIONS The V160 S is not recommended for pipe thawing NOTE Unshaded areas of Block Logic Diagram are the subject of discussion V160 S amp T LINCOLN Return to Master TOC Return to Master TOC o HF o v gt o E x 2 43 Return to Master TOC FIGURE EE 3 INPUT BOARD 81 WHITE 2 2211 BLUE 115 230 1 50 60 BOARD L 4 GND WO05X0250 SCHEMATIC X0203 12345678910111213 14 15 16 INPUT BOARD The input board includes the following circuits High Frequency circuit It generates the high volt age to start the welding arc INPUT LINE VOLTAGE FAN CIR CUIT AUXILIARY VOLTAGE AND PRECHARGE The Invertec V160 T can be connected to a 115V or 230V single phase input voltage This unit can also connect to engine driven genera tors but it must follow the below conditions Vac peak voltage below 250V for 115Vac input or 410V for 230Vac input Vac frequency in the range of 50 and 60 Hertz e RMS voltage of the AC waveform V160 T 115Vac or 230Vac 10 The initial power is applied to the Invertec V160 T directly on the input board A line switch located on the back of the machine supplies the logic part that manages machine functions The voltage is after rec tified by the input on the input rectifier on the input board and the resultant
128. ut currents It is capable of 130 amps 25 2 volts at 100 duty cycle If the duty cycle is exceeded a thermal protector will shut off the output until the machine cools See Technical Specifications in A 1 for other rated outputs The Invertec V160 T is recommended for stick welding with such popular electrodes as Fleetweld 35 Fleetweld 37 Fleetweld 180 and Jet LH 78 MR LIMITATIONS The V160 T is not recommended for pipe thawing 1 When connected to 230VAC inputs V160 S amp T LINCOLN Return to Section TOC Return to Master TOC Return to Section TOC O 5 5 10 9 1 0 gt 4 52 oO oO Return to Section TOC Return to Master TOC Return to Master TOC BB 3 REAR CONTROL PANEL 1 3 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 BB 1 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 If the output of the machine is OFF for more than five minutes the fan will turn OFF This reduces the amount of dirt that is deposited inside the machine and reduces power consumption See Figure BB 1 Refer to the Output LED section below for more infor mation about conditions when the output of the machine is ON Gas Inlet Connector for the TIG shielding gas The gas
129. utes minimum to allow the power capacitors to discharge before working inside this equip ment 0 Do not touch electrically hot parts GROUND CONNECTION The frame of the welder must be grounded A ground terminal marked with the symbol is located on the under panel for this purpose See your local and national electrical codes for proper grounding methods A CAUTION The grounding is supplied in the input cord it is important that the Supply Receptacle Ground con nection is connected A WARNING This installation should be performed by a quali fied electrician to ensure correct connections of the leads to the plug spades The electrical system must be made by skilled technicians with the specific professional and technical qualifications and in compliance with the regulations in force in the country where the equipment is installed The welding power source supply cable is pro vided with a green or yellow green wire that must ALWAYS be earthed This green or yellow green wire must NEVER be used with other voltage con ductors Install only plugs that are corresponding to safe ty regulations V160 S amp T LINCOLN Return to Section TOC Return to Master TOC Return to Section TOC s 10 9 1 0 lz oO Return to Section TOC Return to Master TOC Return to Master TOC AA 5 Fuse the input circuit with time delay fuses marked D
130. ution The Invertec V160 S can be operated on engine driven generators as long as the 230 volt auxiliary meets the following conditions The AC waveform peak voltage is below 400 volts The AC waveform frequency is between 45 and 65Hz The RMS voltage of the AC waveform is always greater than 208VAC for 115 VAC input divide these values in half The following Lincoln engine drives meet these condi tions when run in the high idle mode 160 5 amp T LINCOLN Return to Section TOC Return to Master TOC Return to Section TOC olo o ci 9 1 lz 813 513 pir oO oO ayo Return to Section TOC Return to Master TOC Return to Master TOC AS INSTALLATION ii Ranger 250 305 Commander 300 400 amp 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 OUTPUT CONNECTIONS A WARNING ELECTRIC SHOCK can kill e Keep the electrode holder and cable insulation in good condition Do not touch electrically live parts or electrode with skin or wet clothing Insulate yourself from work and ground Turn the input line Switch on the Invertec V160 S off before connecting or disconnecting out put cables or other equipment The Work Cable and Electrode Cable
131. x 3 Return to Master TOC F1 TABLE OF CONTENTS TROUBLESHOOTING amp REPAIR Troubleshooting and Repair F 1 How to Use Troubleshooting Guide F 2 PC Board Troubleshooting Procedures and Replacement F 3 Troubleshooting Guide 4 Case Removal nh nh nes F 7 Test Procedures Input Board Capacitor Discharge Procedure F 9 Boardi RR Tm F 11 Main IGBT Inverter Board V160 T Welding Logic and Inverter Section Test F 19 Replacement Procedures Input Board Removal and Replacement Procedure F 27 Main IGBT Inverter Board Removal and Replacement Procedure F 31 Display Board Removal and Replacement F 35 Retest Alter eee UR E F 38 V160 S amp T LINCOLN Return to Section TOC Return to Master TOC Return to Section TOC O10 F 5 5 190 9 1 0 gt 6 1 8 O Return to Section TOC Return to Master TOC

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