Lincoln Electric IMVERTEC IM738-A User's Manual
Contents
1. A 2 Input gell Ee A 3 Ground A 3 A 4 teret armee A 4 Output Connections LL 5 Output and Gas Connection for Tig Welding A 5 Output Connection for Stick Welding ss A 5 Work Cable Conhaection in ctetu oer E ee aL v D A 5 Quick Disconnect PIUG iei tee teet T tegere ertet ee ars A 6 Shielding Gas Connection sen A 6 Remote Control Connection sis A 6 leri e Section B Safety Instructions sense B 1 General Description sise B 1 Welding Capability eec EE B 1 a 1 Rear Conrol Panel sise B 2 Controls and Settings 2 Step 4 Step Tig Sequence B 2 thru B 5 DIP Switch Functions Service Information B 6 thru B 11 DIP Switch 1 Machine Type iii B 6 DIP Switch 2 Preflow Tmer sis B 6 DIP Switch 3 2 Step Restart Enable enne B 7 DIP Switch 4 4 Step Restart B 8 B 9 DIP Switch 5 Low Enable sisi B 10 DIP Switch 6 European USA Machine Configuration B 10 DIP Switch 7 amp 8 Upslope Timer us B 11 Start Crater Current Adjustment inerte B 11 EE Section C Optional Accessories and Compatible C 1 Fac2. eu episui paysed si sejnoed e 104 urejBeip y siy Aq JO 9721n99e eq jou U uo 104 51 SIUL 910 11890 NO88I DIAGRAMS F 2 lt CCEOXSO0M Hiya 104 1 JO asn S 110W 14 D A pjnous suosJad patjronb qug D SU aM 0212919 Jou og N LT BUDIAJSS 3404 q pJo3 Jamod B BuibGnydun Aq Jawod mu 290002810 PSAOWSJ 514103 3 DJ3d0 Jou og i TN NYJ HJIH NING EEZOX LI E JILYW3HIS EEZOXSOM OTIM cp i 0LEOX Les OLEOXSOM d 408 AYIdSIO ZCEYSILB 60 W ZL amp SL OL Lb 81 GL OZ 1 ZZ EZ 42 SZ 92 1 1915 7 94 0 068 967 0102105 SR e LH Zdf ris Ob 6 BL 9S PES Lr 7 7 L 020 e JILYWGHIS 0610X m JL VW3H3S EOZOXSOM 298 N3388 7 MOTA O6L0XSOM 0909 LAdNI on 0909 33133ANI is 6 EI J0 21 SCH YIWAOASNVAL 4H X18 W
3. 1 Keep the welder power supply lines as short as possible 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 con tent such as Lincoln Stable Arc better resist high frequency leakage than neoprene and other syn thetic rubber insulated cables 4 Keep the torch in good repair and all connections tight to reduce high frequency leakage 5 The work terminal must be connected to a ground within ten feet of the welder using 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 eff
4. D OUTPUT CURRENT POST FLOW GAS ON GAS V160 T LINCOLN P B 9 4 Step Restart Enabled DIP Switch 4 ON Same as step 1 Same as step 2 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 FIGURE B 10 2 3 TORCH 2 m BUTTON OUTPUT Leif a CURRENT POST FLOW dem GAS GAS ON This sequence has an automatic restart so welding will continue after this step If the weld is completely finished use the following sequence instead of step 3 described above 3A Quickly press and release the TIG torch trigger The machine will now decrease the output cur rent 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 As shown in figure B 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
5. 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 tions are clearly understood 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 USA Machine Configuration DIP Switch 6 ON 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 OPERATION B 10 Remote control connected The TIG slope functions are disabled for the 2 step trigger mode If slopes are needed a foot pedal remote control can be used The TIG slope functions are enabled for the 4 step trigger mode A trigger is always needed to turn ON the output of the machine V160 T LINCOLN P B 11 DIP Switch 7 amp
6. Circuit Boards on the case front OPERATION B 11 2 To adjust the start crater current 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 connected 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 damage to measuring equipment will occur Trigger Mode 4 Step 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 percenta
7. LINCOLN 8 2 INSTALLATION 2 Read entire installation section before starting installation SAFETY PRECAUTIONS WARNING 6 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 equip ment Insulate 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 measures are followed to assure long life and reliable operation 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 circulation of clean air without restrictions for air movement to and from the air vents Do not cover the machine with paper cloth or rags when switched on 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 Locate the machine away from radio controlled machinery Normal operation may adversely affect the operation of nearby radio controlled ma
8. The machine will open the gas valve to start the flow of the shielding gas After 0 5 second preflow time to purge air from the torch hose the out put of the machine is turned ON At this time the arc can be started After the arc is started the output cur rent will be at the Start Finish current This condition can be maintained as long or as short as necessary If the Start Finish current is not necessary do not hold the TIG torch trigger as described at the beginning of this step Instead quickly press and release the trig ger 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 increase to the welding current 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 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
9. 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 SAFETY KE WELDING and CUTTING 7 77 SPARKS can 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 extinguisher readily available 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 s
10. be dangerous 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 pacemaker should consult their physician before welding 1 d Keep all equipment safety guards covers and devices in position 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 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 In some cases it may be necessary to remove safety diebus due minimize exposure to EMF fields from the welding circuit 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 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 1 f Do not put your hands near the engine fan Do not attempt to override the governor or idler by pushing on the throttle control rods while the engine is running 2 4 3 Do not place your body between the ele
11. by an Arc Start Switch or Hand Foot Amptrol attached to the Remote Control Connector See 4 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 func tion 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 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 2 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 is 0 5 sec onds Refer to the trigger sequence section below to understand how downslope is activated In Stick welding mode this function is not used 4 Mode Switch 14 Pulse Mode Switch 5 Trigger Mode Switch 15 Pulse LED 6 Powe
12. 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 Eloigner les mat riaux inflammables ou les recouvrir afin de pr venir tout risque d incendie d 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 lev age 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 ag
13. func tion is ON this control knob will adjust the pulsing frequency 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 puls ing background current This is the 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 start ed After the arc is started the output current will be increased to the welding current The time for this increase or upslope is presettable Th
14. on the edges 2 Dirt on the filler material 3 Excessive travel speed If al ded ibl f 4 Current intensity too low pesti areas misadjustment have been checked Hot cracking 1 Unsuitable filler material and the problem persists Contact 2 High heat supply your local Lincoln Authorized 3 Dirty materials Field Service Facility V160 T LINCOLN 8 E 4 TROUBLESHOOTING E 4 Observe all Safety Guidelines detailed throughout this manual Machine fails to come on No Input Voltage Power LED off Faulty supply plug or cable Internal fuse blown Power Input incorrect Input voltage out of range less Input over current than 95 or greater than 265VAC Power LED Flashing Input current too high due to oper ating beyond rated duty cycle If all recommended possible areas of misadjustment have been checked and the problem persists Contact your local Lincoln Authorized Field Service Facility No output current While in TIG mode Trigger circuit Power LED on not mode at 6 pin amphenol Output LED off Thermal overload Unit has been operated beyond its Thermal LED on capacity rating Airflow through machine is restrict ed or fan has failed V160 T LINCOLN 8 DIAGRAMS F 1 F 1 epoo jueuudinbe y e JO eorues eu elaiBalll s j sjaued einsoj oue Jo e
15. themselves to the arc rays or to hot spatter or metal 4 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 within applicable OSHA PEL and ACGIH TLV limits using local exhaust or mechanical ven tilation In confined spaces or in some circumstances outdoors a respirator may be required Additional pre cautions 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 application 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 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
16. 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 WARNING ELECTRIC SHOCK can kill e Keep the electrode holder TIG torch and cables insulation in good condition and in place e 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 AND GAS CONNECTION FOR TIG WELDING FIGURE A 1 FIGURE A 1 a oN a f I TIG TORCH 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 See Figure A 1a INSTALLATION A 5 FIGURE A 1a STRAIN RELIEF BOOT TIG TORCH POWER CABLE W
17. 8 A 6 QUICK DISCONNECT PLUG FOR STICK ELEC TRODE CABLE 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 75in 19 mm TRIM IF REQ D TO FIT OVER CABLE 4 Cut 45 50 of the copper strands back 1 4 6 mm WELDING CABLE 25 6mm 5 Fold copper strands over cut strands and insert into ferrule COPPER FERRULE WELDING CABLE lt ee 50 in 12 mm max 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 SCREW BRASS PLUG COPPER TUBE 8 Slide rubber boot over brass plug The rubber boot must be positioned to completely cover all electri cal surfaces after the plug is locked into the recep tacle INSTALLATION SHIELDING GAS CONNECTION Obtain the necessary inert shielding gas Connect the cylinder of gas with a pressure regulator and flow gage Install a ga
18. 8 Upslope Timer These control the upslope timer for TIG welding used only type machines The following table shows the DIP Switch settings and selected upslope time DIP Switch 7 DIP Switch 8 ON ON 0 1 Seance 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 16A 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 Welding equipment generates high voltages not touch the live parts of the machine the electrode the work clamp or connected work pieces when this equipment is on e Insulate yourself from live electrical connec tions the electrode the work clamp and the connected work pieces X e 1 Remove the cover of the machine to access the control Printed
19. ARNING 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 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 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 driv en 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 V160 T LINCOLN 8 A 5 The following Lincoln engine drives meet these tions when run in the high idle mode Ranger 250
20. COLN 8 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 Autant que possible l installation et l entretien du poste seront effectu s par un lectricien qualifi Avant de faires des travaux l interieur de poste la debranch er l interrupteur la boite de fusibles Garder tous les couvercles et dispositifs de s ret leur place V V for selecting a QUALITY product We want you to take pride in operating this product as much pride as we have in bringing this product to you CUSTOMER ASSISTANCE POLICY The business of The Lincoln Electric Company is manufacturing and selling high quality welding equipment consumables and cutting equip ment Our challenge is to meet the needs of our customers and to exceed their expectations On occasion purchasers may ask Lincoln Electric for advice or information about their use of our products We respond to our customers based on the best information in our posses sion at that time Lincoln Electric is not in a position to warrant or guarantee such advice and assumes no liability with respect to such infor mation or advice We expressly disclaim any warranty of any kind including any warranty of fitness for any customer s particular purpose with respect to such information or advice A
21. INVERTEC V160 T For use with machines having Code Numbers 10878 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 thoughtful operation on your part DO NOT INSTALL OPERATE OR REPAIR THIS EQUIPMENT WITHOUT READ ING THIS MANUAL AND THE SAFETY PRECAUTIONS CON TAINED THROUGHOUT And most importantly think before you act and be careful OPERATOR S MANUAL i565 e 4 GS EX Le Desigi a Q ne LINCOLN 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 ABS Quality Eval to ISO 9001 is CERTIFICATE NUMBER 30273 SAFETY WARNING CALIFORNIA PROPOSITION 65 WARNINGS A Diesel engine exhaust and some of its constituents The engine exhaust from this product contains are known to the State of California to cause can chemicals known to the State of California to cause cer birth defects and other reproductive harm cancer birth defects or other reproductive harm The Above For Diesel Engines The Above For Gasoline Engines ARC WELDING CAN BE HAZARDOUS PROTECT YOURSELF AND OTHERS FROM POSSIBLE SERI
22. ITH GAS FITTING TIG ADAPTER 0000 RETAINING COMPOUND The ground lead and TIG Torch Twist Mate Connector are supplied with the welder To connect the cables turn the Power Switch OFF Connect the torch Twist Mate plug into the DC Electrode Gas Output Receptacle on the front of the welder and turn it clockwise 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 proper procedure on grounding the work clamp and work piece OUTPUT CONNECTION FOR STICK WELDING FIGURE 2 FIGUREA2 WORK CLAMP dp KU H N KC A amp 4 WORK CABLE m MM L ro Cc Ae 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 termi nal Insert the connector with the key lining up with the keyway and rotate approximately 1 4 turn clock wise until the connection is snug Do not over tighten V160 T LINCOLN
23. N 8 1 TROUBLESHOOTING 1 HOW TO USE TROUBLESHOOTING GUIDE A 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 SYMP TOMS This column describes possible symptoms that the machine may exhibit Find the listing that best describes the symptom that the machine is exhibiting Step 2 POSSIBLE CAUSE The second column labeled POSSIBLE CAUSE lists the obvious external possibilities that may contribute to the machine symptom Step 3 RECOMMENDED COURSE OF ACTION This column provides a course of action for the Possible Cause generally it states to contact your local Lincoln Authorized Field Service Facility If you do not understand or are unable to perform the Recommended Course of Action safely contact your local Lincoln Authorized Field Service Facility CAUTION If for any reason you do not understand the test procedures or are unable to perform the tests repairs
24. OUS INJURY OR DEATH KEEP CHILDREN AWAY PACEMAKER WEARERS SHOULD CONSULT WITH THEIR DOCTOR BEFORE OPERATING 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 249 1 from the American Welding Society 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 PERFORMED ONLY BY QUALIFIED INDIVIDUALS N FOR ENGINE 5 r 1 h nd scalding Ao niot ene the powered equipment ob zer pus or pressure cap when the engine is 1 a Turn the engine off before troubleshooting and maintenance work unless the maintenance work requires it to be running 1 b Operate engines in open well ventilated areas or vent the engine exhaust fumes e outdoors 1 c Do not add the fuel near an open flame welding arc or when the engine is running Stop the engine and allow it to cool before refueling to prevent spilled fuel from vaporiz ing 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 ELECTRIC AND SR MAGNETIC FIELDS 359 may
25. 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 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 min utes 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 information about conditions when the output of the machine is ON 3 Gas Inlet Connector for the TIG shielding gas The gas source must have a pressure regulator and flow gage installed See Figure B 1 CONTROLS AND SETTINGS See Figure B 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 Hot Start This is a temporary increase in the output B 2 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 tem porary increase in output current is used to clear intermittent connections between the electro
26. ang ypyg 09 0S L 0 2 SU e e Ie e 0 UN e z ma EIN WVYOVIC BNISIM L OSLA c 0LL 3002 INVH9VIG SNIBIM V160 T LINCOLN E NOTES V160 T LINCOLN 8 Spanish AVISO DE PRECAUCION French ATTENTION German WARNUNG ATEN AO ZS FA Chinese Do not touch electrically live parts or electrode with skin or wet clothing Insulate yourself from work and ground No toque las partes o los electrodos bajo carga con la piel da Aislese del trabajo y de la tierra Nelaissez ni la peau ni des v te ments mouill s entrer en contact avec des pi ces sous tension solez vous du travail et de la terre Ber hren Sie keine stromf hrenden Teile oder Elektroden mit Ihrem K rper oder feuchter Kleidung solieren Sie sich von den Elektroden und dem Erdboden N o toque partes el tricas e electro dos com a pele ou roupa molhada sole se da pe a e terra CMRPORABA 7 v 56nfdcmWn amp toc t e RI4soT 2Am P55 801g ATUSHELT FSU Keep flammable materials away el material combustible fuera del rea de trabajo Gardez l cart de tout mat riel inflammable Entfernen Sie brennbarres Material Mantenha inflam veis bem guarda dos efmiet os60o00PcomitEs LC AR 4A Wear eye ear and body protection Prot jase los ojos los o dos y e
27. chinery 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 C the output duty cycle may be reduced 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 interference 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 T LINCOLN 8 3 INSTALLATION A 3 Keeping these contributing factors in mind installing equipment per the following instructions should mini mize problems
28. ctrode and work cables If the electrode cable is on your right side the work cable should also be on your right side AR A Connect the work cable to the workpiece as close as possible to the area being welded 1 g 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 LINCOLN je Do not work next to welding power source SAFETY ELECTRIC SHOCK can kill 3 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 wearing 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 Contr
29. 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 welding When the main part of the weld is complete go to step 3 V160 T OPERATION B 9 FIGURE B 11 OUTPUT CURRENT Y A RN GAS ON GAS As shown in figure B 12 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 B 12 TORCH Au n BUTTON RE E OUTPUT CURRENT POST FLOW GAS ON GAS LINCOLN P B 10 DIP Switch 5 Low OCV Enable This controls the OCV of the machine When the DIP switch is OFF the is set to the normal level as stated in the manuals for the machines When the DIP switch is ON the is reduced to 20 This low OCV mode was created for the Australian markets 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 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 slope timers
30. d 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 B 4 1 2 TORCH BUTTON OUTPUT CURRENT T A PRE FLOW POST FLOW GAS ON GAS As shown in figure B 5 it is also possible to press and hold the TIG torch trigger a second time during downslope to end the downslope time and maintain the output current at the Start Crater current When the TIG torch trigger is released the output will turn OFF and the postflow time will start FIGURE B 5 h 4 015 TORCH BUTTON OUTPUT CURRENT PRE FLOW POST FLOW GAS ON GAS 2 Step Restart Enabled DIP Switch 3 ON Same as step 1 Same as step 2 As shown in figure B 6 it is possible to press and hold the TIG torch trigger a second time during downslope to restart After the trigger
31. de 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 electrode to the work piece This decrease in cur rent allows the operator to remove the electrode from the electrode holder without creating large sparks which can damage the electrode holder FIGURE B 1 1 Power Switch 2 Fan 3 Gas Inlet V160 T LINCOLN P B 3 OPERATION B 3 When the mode switch is in the Lift TIG position the stick welding functions are disabled and the machine is ready for Lift TIG welding Lift TIG is a method of 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 After machine output is triggered ON with an Arc Start Switch or Foot Amptrol the arc must be started within 6 5 seconds or output will turn OFF and trigger 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 g
32. e default is 0 5 seconds 2 Release the Arc Start Switch to stop welding The machine will now decrease the output current at a controlled 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 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 2 TORCH BUTTON OUTPUT PRE FLOW POST FLOW GAS ON GAS Possible variations of this standard sequence is shown below It is possible to press hold the 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 1 2 2 TORCH BUTTON CURRENT PRE FLOW POST FLOW GAS ON GAS V160 T LINCOLN P B 5 OPERATION B 5 4 Step Sequence Note 4 Step works with Arc Start Switch only Amptrol type devices will not work properly and should not be used The Arc Start Switch s actuator is also referred to as the Tig torch trigger in the following sequence 1 Press and hold the Arc Start Switch to start the sequence
33. e or explosion Keep flammable material away Do not weld cut or gouge on containers that have held com bustibles ARC RAYS can burn L Wear eye ear and body protection Only qualified personnel should operate this equip ment Observe all safety information throughout this manual GENERAL DESCRIPTION The Invertec V160 T 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 TIG GTAW The unit is ideal for industrial applications where portability is impor tant 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 output 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 weld ing 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 T LINCOLN 8 B 2 REAR CONTROL
34. ectively 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 building are recommended Failure to observe these recommended installation procedures can cause radio or TV interference prob lems 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 minutes minimum to allow the power capacitors to discharge before working inside this equip ment 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 CAUTION The grounding is supplied in the input cord it is important that the Supply Ground con nection is connected A WARNING This installation should be performed by a quali fied electrician to ensure correct connection
35. ectrical 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 Refer to http www lincolnelectric com safety for additional safety information SAFETY PR CAUTIONS DE SURETE 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 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 metallique ou des grilles metalliques principalement dans les positions assis ou couch pour lesquelles une grande partie du corps peut tre en contact 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 defonctionnement 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
36. er 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 during over current conditions when operating on 115V input Thermal LED This indicator will turn on when the machine is overheated and the output has been disabled This normally occurs when the duty cycle of the machine has been exceeded FIGURE B 2 Leave the machine on to allow the internal components to cool When the indicator turns off normal operation is again possible 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 Output LED This indicator turns 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
37. ge of this 160A setting Use the following equation for determining the desired start 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 T LINCOLN P C1 ACCESSORIES 1 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 Amptrol 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 cur rent set by the Current C
38. he 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 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 B 8 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 turn OFF and postflow will begin FIGURE B 8 3A 4 TORCH M A BUTTON OUTPUT CURRENT H POST FLOW GAS ON GAS As shown in figure B 9 again after the TIG torch trigger is quickly pressed and released from step 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 9 TORCH BUTTON 1 x
39. ing LINCOLN 8 CYLINDER may explode if damaged 7a 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 A 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 on 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 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 El
40. ir avec les vapeurs du solvant pour produire 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 2 Dans le cas de travail au dessus du niveau du sol se prot ger PR CAUTIONS DE S RET POU R contre les chutes dans le cas ou on recoit un choc Ne jamais enrouler le c ble lectrode autour de n importe quelle partie LES MACHINES SOUDER ES TRANSFORMATEUR ET Un coup d arc peut tre plus s v re qu un coup de soliel REDRESSEUR donc a Utiliser un bon masque avec un verre filtrant appropri 1 ainsi qu un verre blanc afin de se prot ger les yeux du ray onnement de l arc et des projections quand on soude ou quand on regarde l arc Porter des v tements convenables afin de prot ger la peau de soudeur et des aides contre le rayonnement de l arc 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 protection 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 o l on pique le laitier LIN
41. is pressed the output cur rent 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 B 6 yf OUTPUT CURRENT PRE FLOW POST FLOW GAS ON V160 T LINCOLN P B 8 OPERATION B 8 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 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 at the Start Crater current This condition can be maintained as long or as short as necessary FIGURE B 7 1 2 3 TORCH BUTTON OUTPUT CURRENT e Wi 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 t
42. is shown in 4 step diagram 1 4 Step Diagram 1 1 2 3 4 E p 34 4 PRE FLOW POST FLOW OUTPUT CURRENT GAS ON GAS Possible variations of this standard sequence are shown below It is possible to press and hold the torch trigger another time to end the downslope time and maintain the output current at the Start Finish cur rent When the TIG torch trigger is released the output will turn OFF and postflow will begin This operation shown in 4 step diagram 2 4 Step Diagram 2 3A 4 TORCH BUTTON OUTPUT CURRENT Larl POST FLOW GAS ON GAS V160 T LINCOLN P B 6 OPERATION B 6 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 WARNING ELECTRIC SHOCK CAN KILL Be sure that all installation opera tion maintenance and repair proce dures are performed only by qualified individuals Lincoln Electric is not responsible for damages caused by 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
43. l cuerpo Prot gez vos yeux vos oreilles et votre corps Tragen Sie Augen Ohren und K r perschutz Use prote o para a vista ouvido e corpo HAUSHERMRELTF e f HSRMABR IMM RMR SESHSEGSEmA e KRAKA 8 B RbAAT Sag AIX ex at HEHA ez SE au Fe FS su ya qye e ij AAS ASAl niMAlg Jui W og nes uil pia gun ye ALS ah gl dui doe de L cll slay AN gl pu oec SS aal DS Ye po READ AND UNDERSTAND THE MANUFACTURER S INSTRUCTION FOR THIS EQUIPMENT AND THE CONSUMABLES TO BE USED AND FOLLOW YOUR EMPLOYER S SAFETY PRACTICES SE RECOMIENDA LEER Y ENTENDER LAS INSTRUCCIONES DEL FABRICANTE PARA EL USO DE ESTE EQUIPO Y LOS CONSUMIBLES QUE VA A UTILIZAR SIGA LAS MEDIDAS DE SEGURIDAD DE SU SUPERVISOR LISEZ ET COMPRENEZ LES INSTRUCTIONS DU FABRICANT EN CE QUI REGARDE CET EQUIPMENT ET LES PRODUITS A ETRE EMPLOYES ET SUIVEZ LES PROCEDURES DE SECURITE DE VOTRE EMPLOYEUR LESEN SIE UND BEFOLGEN SIE DIE BETRIEBSANLEITUNG DER ANLAGE UND DEN ELEKTRO DENEINSATZ DES HERSTELLERS DIE UNFALLVERHUTUNGSVORSCHRIFTEN DES ARBEITGEBERS SIND EBENFALLS ZU BEACHTEN Keep your head out of fumes Use ventilation or exhaust to remove fumes from breathing zone Los humos fuera de la zona de res Mantenga la cabeza f
44. ld steel aluminum and copper alloys See publication C9 10 V160 T LINCOLN 8 D 1 MAINTENANCE D 1 SAFETY PRECAUTIONS WARNING ELECTRIC SHOCK can kill O Have an electrician install and serv ice 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 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 Check the electric connections and all the connec tion cables CAUTION the power supply before every oper ation Always use gloves in compliance with the safety standards V160 T LINCOL
45. ly the information you have recorded above The code number is especially important when identifying the correct replacement parts On Line Product Registration Register your machine with Lincoln Electric either via fax or over the Internet For faxing Complete the form on the back of the warranty statement included in the literature packet accompanying this machine and fax the form per the instructions printed on it For On Line Registration Go to our WEB SITE at www lincolnelectric com Choose Quick Links and then Product Registration Please complete the form and submit your registration Read this Operators Manual completely before attempting to use this equipment Save this manual and keep it handy for quick reference Pay particular attention to the safety instructions we have provided for your protection The level of seriousness to be applied to each is explained below A WARNING This statement appears where the information must be followed exactly to avoid serious personal injury or loss of life CAUTION This statement appears where the information must be followed to avoid minor personal injury damage to this equipment TABLE OF CONTENTS Page UNC EE Section A Technical Specifications ceat tuse dre ane aa dant dre eure re nef iue A 1 Select Suitable Location RT A 2 SACKING GE A 2 TID ER 2 Machine Grounding and High Frequency Interference Protection
46. ol 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 5 ARC RAYS can burn 4 a Use a shield with the proper filter and cover plates to protect your eyes from sparks and the rays of the arc when welding or observing open arc welding Headshield and filter lens should conform to ANSI Z87 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
47. ontrol 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 12 5ft medium back cap K1781 3 PTA 9 25ft medium back cap K1782 1 PTA 17 12 5ft long back cap K1782 3 PTA 17 25 long back cap NOTE Each torch requires a Twist Mate adapter one is included with the machine Collets collet bodies and nozzles are not included and must be ordered separately 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 the Magnum 9 torch If you do not care to interchange this part between torches 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 con nect plug provides connection for both gas and weld ing current TIG Torch Parts Kits Parts kits are available for the PTA 9 and PTA 17 TIG torches These kits include back cap collets collet bodies nozzles and tung stens 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 mi
48. r 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 Postitive 11 Downslope Control 12 Postflow Control 13 Digital Display V160 T LINCOLN P B 4 OPERATION B 4 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 current during welding Like the output current con trol the function of the meter is changed if a remote control 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
49. s a matter of practical consideration we also cannot assume any responsibility for updating or correcting any such information or advice once it has been given nor does the provision of information or advice create expand or alter any warranty with respect to the sale of our products Lincoln Electric is a responsive manufacturer but the selection and use of specific products sold by Lincoln Electric is solely within the control of and remains the sole responsibility of the customer Many variables beyond the control of Lincoln Electric affect the results obtained in applying these types of fabrication methods and service requirements Subject to Change This information is accurate to the best of our knowledge at the time of printing Please refer to www lincolnelectric com for any updated information Please Examine Carton and Equipment For Damage Immediately When this equipment is shipped title passes to the purchaser upon receipt by the carrier Consequently Claims for material damaged in shipment must be made by the purchaser against the transportation company at the time the shipment is received Please record your equipment identification information below for future reference This information can be found on your machine nameplate Product Model Number Code Number or Date Code Serial Number Date Purchased Where Purchased Whenever you request replacement parts or information on this equipment always supp
50. s hose between the regulator and gas inlet located on the rear of the welder The gas inlet has 5 16 18 right hand female thread CGA 032 A WARNING CYLINDER could explode if damaged Keep cylinder upright and chained to a support Keep 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 welding Remote Foot Amptrol K870 Hand Amptrol K963 3 Arc Start Switch K814 V160 T LINCOLN 8 1 OPERATION B 1 Read and understand this entire section before operating your machine SAFETY INSTRUCTIONS WARNING ELECTRIC SHOCK can kill e 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 di E Keep your head out of fumes Use ventilation or exhaust to remove fumes from breathing zone NE WELDING CUTTING and TE GOUGING SPARKS can cause fir
51. s 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 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 conductors Install only plugs that are corresponding to safe ty regulations V160 T LINCOLN 8 4 INSTALLATION 4 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 breakers action that increases inverse time or thermal magnetic 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
52. safely contact your Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed V160 T LINCOLN 8 E 2 TROUBLESHOOTING E 2 Observe all Safety Guidelines detailed throughout this manual PROBLEMS POSSIBLE RECOMMENDED SYMPTOMS CAUSE COURSE OF ACTION PROBLEMS IN STICK WELDING Excessive spatter 1 Long arc 2 High current Craters 1 Fast movement of the electrode away from piece Inclusions 1 Poor cleanliness or distribution of the Welding passes 2 Improper movement of the elec trode Insufficient penetration 1 High progression speed 2 Welding current too low Narrow chamfering If all recommended possible areas of Sticking 1 Arc too short misadjustment have been checked 2 Current too low and the problem persists Contact Wm your local Lincoln Authorized Field Porosity 1 Humidity in electrode ili Service Facility 2 Long arc Cracks 1 Current too high 2 Dirty materials 3 Hydrogen in weld present on electrode coating V160 T LINCOLN 8 E 3 TROUBLESHOOTING E 3 Observe all Safety Guidelines detailed throughout this manual PROBLEMS POSSIBLE RECOMMENDED SYMPTOMS CAUSE COURSE OF ACTION PROBLEMS IN TIG WELDING Oxidation 1 Insufficient gas 2 No protection on the back side Tungsten inclusions 1 Incorrect electrode sharpening 2 Electrode too small 3 Operating failure contact of the tip with the workpiece 1 Dirt
53. schutzverkleidung in Betrieb setzen Mantenha se afastado das partes moventes N o opere com os paineis abertos ou guardas removidas LE UT amp L ORERTMNLARS ARK E e gdo SE As Sa appe Vae cus 13 al a Jail o AE Viel Ai dl CIR Spanish AVISO DE PRECAUCION French ATTENTION German WARNUNG ATENCAO ER SIR Chinese LEIA E COMPREENDA AS INSTRU ES DO FABRICANTE PARA ESTE EQUIPAMENTO E AS PARTES DE USO E SIGA AS PR TICAS DE SEGURANCA DO EMPREGADOR GK et GE EA CEA BA EFBRLTE SL LTRHOREMEI A MO HE E R0 REX EA RE ST 7 AZo SSH Hya HAS 0 HHEH eal QU dl ail y Jub Aal oig sl LA LINCOLN 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
54. teps 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 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 Also see item 1 c Read and follow NFPA 51B Standard for Fire Prevention During Welding Cutting and Other Hot Work available from NFPA 1 Batterymarch Park PO box 9101 Quincy Ma 022690 9101 Do not use a welding power source for pipe thaw
55. 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 T are shown with in bold letters OFF Table B 1 If a switch setting has bold letters OFF do not make any changes abnormal operation could occur TABLE B 1 DIP V160 T V160 T Pulse V160 T Switch CE CE USA ON CON OFF 4 2 3 4 5 6 7 8 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 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 B 3 Front of machine Switch 1 V160 T LINCOLN P B 7 OPERATION B 7 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 OFF 1 Press an
56. tory Field Installed aaa RE C 1 m Safety Precautions Input Filter Capacitor Discharge Procedure D 1 Houtine teens 0 1 Troubleshooting nine Section E How to Use Troubleshooting Guide E 1 Troubleshooting Guide rhetor pe ean E E 2 thru E 4 Wiring Diagram EE Section F UNE CERES PERTENECER ENIM P 403 vi A 1 INSTALLATION A 1 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 20A 115 V 30 A branch 25A 230 V 34A RATED OUTPUT 60 Stick 22 4 115V 20A RE and 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 Bi 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 EL 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 V160 T
57. uera de los humos Utilice ventilaci n o aspiraci n para gases Gardez la t te l cart des fum es Utilisez un ventilateur ou un aspira teur pour ter les fum es des zones de travail Vermeiden Sie das Einatmen von Schweibrauch Sorgen Sie f r gute Be und Entl ftung des Arbeitsplatzes Mantenha seu rosto da fumaca Use ventilac o e exhaust o para remover fumo da zona respirat ria eE1i LDSHEMT TELT SRACVHELTIBELTFAL e ois SR OER E I8 202 e dzz 2871 S ACE SE 87 R A ASE Ash 71250712 SSE HSHM bi Ja d auch Les 5 Li AA ze cial ue E gWelsid g Turn power off before servicing Desconectar el cable de ali mentaci n de poder de la m quina antes de iniciar cualquier servicio D branchez le courant avant l entre tien Strom vor Wartungsarbeiten abschal ten Netzstrom v llig ffnen Maschine anhalten opere com as tampas removidas Desligue a corrente antes de fazer servico N o toque as partes el tricas nuas ALFFLA F EACRWI HY PSR HEFRBAL vy Fe HF Y gt sTK EL DAT CH e 2PH AHS HAHAE il A eh Al dell Do not operate with panel open or guards off No operar con panel abierto o guardas quitadas N op rez pas avec les panneaux ouverts ou avec les dispositifs de protection enlev s Anlage nie ohne Schutzgeh use oder Innen
58. uo uo y episui paysed s e 10 y siy Aq e JO 9jenooe jou juo 10 S SIUL ALON SIU 9314195 JO asn np1sur pinoys suosJad un YOLISNNOI stud au Ajp314438 8 Jou og 3404 q p 02 Ja od Hi 1 mm HONR 4 Gu66ndun Aq Jaod 290002510 SJBACI 3jDJado Jou TI NYJ 38V L10A HBIH 920X i Awam Loes aam EZOXSOM i LOZOXSOM LNTDNND THAT ae G6LOXSOM a AWIdSIO Leen e 4izerssueco waesssasauzzuuss a d 9S 1 9 2WuO6SgL9Ssttzl ld H HH 40681957621 df 0ZOX 3I1VW3H3S OZOXSOM 025 8VO8 INdNI 0610 JILYW3HIS 1 0 gt 34 t 10 Y zd s YIWYOASNYAL JH oe p ONG JDA OS 0S L OEZ SLL Ah UN 0 ___ _ 70 UN KL E j 8 HL TL J IHM BNISIM L O9LA 82801 30092 INVHOVIG ONIYIM V160 T LINCOLN E F 2 epoo jueuudinbe e JO eu 01 ejqiBali s eu j SjauUed eunsoj oue y JO euo
59. 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 20 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 out put 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 terminal 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 CLEO These circuit breakers have a delay tripmormal operation once the green Power LED stops decreases as the magnitude of the current blinking and remains on 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 NOTE The ARFU replaces a fuse F2 that was used in older V160 s A W
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