Life is good 47G2 Flat Panel Television User Manual
Contents
1. Connect the electrode cable to the terminal and the work clamp to the terminal Insert the connector with the key lining up with the keyway and rotate approxi mately 1 4 turn clockwise Do not over tighten For DC welding switch the cable connections at the machine so that the electrode cable is connected to and the work clamp is connected to TIG WELDING GTAW This machine does not include a TIG torch necessary for TIG welding but one may be purchased separately Refer to the accessories section for more information Most TIG welding is done with DC polarity shown here If DC polarity is necessary switch the cable connec tions at the machine See Figure A 2 FIGURE A 2 e 9 J r ST U Connect the torch cable to the terminal of the machine and the work clamp to the terminal Insert the con nector with the key lining up with the keyway and rotate approximately 1 4 turn clockwise Do not over tighten Finally connect the gas hose to the gas regulator on the cylinder of gas to be used Allowable TIG processes Scratch Start TIG INVERTEC 100S LINCOLN 8 1 OPERATION B 1 Read and understand this entire section before operating your machine SAFETY INSTRUCTIONS WARNING e ELECTRIC SHOCK can kill not touch electrically live parts such as output terminals o2. INVERTEC 1 005 pom For use with machines having Code Numbers 11673 Safety Depends on You Lincoln arc welding and cutting equipment is designed and built with safety in mind However your overall safety can be increased by proper installation and thoughtful operation on your part DO NOT INSTALL OPERATE OR REPAIR THIS 100s EQUIPMENT WITHOUT READ wvenrec UNCOUN ING THIS MANUAL AND THE SAFETY PRECAUTIONS CON TAINED THROUGHOUT And most importantly think before you act and be careful OPERATOR S MANUAL 150 9001 7 H os AB RIA ABS Quality CERTIFICATE NUMBER 20275 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 SAFETY A 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 F
3. E 4 TROUBLESHOOTING E 4 Observe all Safety Guidelines detailed throughout this manual PROBLEMS POSSIBLE RECOMMENDED SYMPTOMS CAUSE COURSE OF ACTION es FAILURES Machine fails to come on No Input Voltage Power LED off Eu supply plug or cable Supply fuse blown or breaker tripped Thermal overload Unit has been operated beyond its Thermal LED on capacity rating Airflow through machine is restrict ed or fan has failed The fan works but the output current 1 Check the output current poten is unstable and can not be controlled tiometer and replace it if neces by the potentiometer while welding is sary carried out Verify output cables are attached to the welder and tightly connect ed If all recommended possible areas of misadjustment have been checked and the problem persists Contact your local Authorized Field Service Facility CAUTION If for any reason you do not understand the test procedures or are unable to perform the tests repairs safely contact your Local Authorized Field Service Facility for technical troubleshooting assistance before you proceed INVERTEC 100S LINCOLN B Y LL DIAGRAMS F 1 00 8 921 0 epoo jueuudinbe jueujeoe doi e 10 juawpedaq BdIAIBS si eui j sjaued eiunsoj oue y euo uo pejsed si epoo jej norued 104 doods eu
4. However it is important that simple preventative measures are followed to assure long life and reliable operation 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 This machine has a protection rating of IP21S Keep it dry and do not place it on wet ground or in puddles Do not use in wet or damp locations Store indoors Locate the machine away from radio controlled machinery Normal operation may adversely affect the operation of nearby radio controlled machinery which may result in injury or equipment damage Read the section on electromagnetic compatibility in this manual not operate in areas with an ambient tempera ture greater than 40 C STACKING The INVERTEC 100S cannot be stacked TILTING Place the machine directly on a secure level surface Do not place or operate this machine on a surface with an incline greater than 15 from horizontal The machine may topple over if this procedure is not fol lowed INPUT CONNECTIONS WARNING A grounding conductor is supplied in the input cord and plug it is important that the supply receptacle ground is connect ed INPUT POWER CONNECTION Check the input voltage phase and frequency sup plied to this m
5. are available for welding stainless steel mild steel aluminum and copper alloys See publication C9 10 INVERTEC 100S LINCOLN D 1 MAINTENANCE D 1 SAFETY PRECAUTIONS A WARNING ELECTRIC SHOCK can kill T 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 hot parts INPUT FILTER CAPACITOR DISCHARGE PROCEDURE WARNING For any maintenance or repair operations it is recom mended to contact the nearest technical service cen ter or Lincoln Electric Maintenance or repairs per formed by unauthorized service centers or personnel will null and void the manufacturers warranty 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 The frequency of the maintenance operations may vary in accordance with the working environment Any noticeable damage should be reported immedi ately Check cables and connect
6. 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 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
7. pipe thawing 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 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 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
8. 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 Refer to http www lincolnelectric com safety for additional safety information SAFETY 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 6 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 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 lec
9. IELDS 359 may 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 d 3 Do not place your body
10. IPMENT 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 Keep your head out of fumes Use ventilation or exhaust to remove fumes from breathing zone Los humos fuera de la zona de respiraci n Mantenga la cabeza fuera de los humos Utilice ventilaci n Gardez la t te l cart des fum es Utilisez un ventilateur ou un aspirateur pour ter les fum es des zones de travail Vermeiden Sie das Einatmen von Schweibrauch e Mantenha seu rosto da fumaca eE1i LDS HEMT TELT i amp SUPBBILTHOSSXLCF U e ois OER E Fi 202 e daa S4748 WaHe e 87 m AASPI AH 7 i17 27 amp HSHM lya ul jan gal lads j anulo A ox ui AU je 34 Turn power off before servic ing Desconectar el cable de ali mentaci n de poder de la m quina antes de iniciar cualquier servicio D branchez le courant avant l entretien Strom vor Wartungsarbeiten abschalten Netzstrom v llig ffnen Maschine anhalten N o opere com as tampas removidas D X 2TTPLA AILIEUSD PIRE T9EAYv t ToT F e HENNE HAS xps EET NW ETT Do not operate with panel op
11. LN 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 SAFETY Electromagnetic Compatibility EMC Conformance Products displaying the CE mark are in conformity with European Community Council Directive of 15 Dec 2004 on the approximation of the laws of the Member States relating to electromagnetic compatibility 2004 108 EC It was manufactured in conformity with a national standard that implements a harmonized standard EN 60974 10 Electromagnetic Compatibility EMC Product Standard for Arc Welding Equipment It is for use with other Lincoln Electric equipment It is designed for industrial and professional use Introduction All electrical equipment generates small amounts of electromagnetic emission Electrical emission may be transmitted through power lines or radiated through space similar to a radio transmitter When emissions are received by other equipment electrical interference may result Electrical emissions may affect many kinds of electrical equ
12. ROM POSSIBLE SERIOUS 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 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 PERFORMED ONLY BY QUALIFIED INDIVIDUALS N FOR ENGINE 2 r 1 h 2 scalding Ao niot the powered equipment ob zer pus or pressure cap when the engine is 1 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 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 F
13. SINGLE PHASE ONLY Rated Input Current 120Vac x 1596 20 Amps 9 Rated Output RATED OUTPUT Duty Cycle Output Amps Output Volts Input Circuit 80A Stick 23 2 Vdc 120 Vac OUTPUT Output Current Range Maximum Open Circuit Voltage Type of Output 10 100 Amps 45 Volts Max DC RECOMMENDED INPUT WIRE AND FUSE SIZES FOR MAXIMUM RATED OUTPUT INPUT VOLTAGE TYPE SJT OR HARD USAGE INPUT MAXIMUM TIME DELAY CIRCUIT FREQUENCY HZ CORD BREAKER OR FUSE SIZE AMPS 20 A MEUM PHYSICAL DIMENSIONS Width Length Weight 148mm 315mm 4 6Kg 5 8in 12 4in 10 11bs TEMPERATURE RANGES OPERATING TEMPERATURE RANGE STORAGE TEMPERATURE RANGE 10 C to 40 C 25 C to 55 C INVERTEC 100S LINCOLN 8 A 2 INSTALLATION A 2 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 INVERTEC 1005 Allow machine to sit for 5 minutes mini mum 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 INVERTEC 1005 to a power supply grounded according to the National Electrical Code and local codes SELECT SUITABLE LOCATION This machine can operate in harsh environments
14. achine before turning it on The allow able input voltage is indicated in the technical specifi cation section of this manual and on the rating plate of the machine Be sure that the machine is grounded Make sure the power available at the input connection is adequate for normal operation of the machine The fuse rating and cable sizes are both indicated in the technical specification section of this manual 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 as the magnitude of the current increases The INVERTEC 100S is recommended for use on an individual branch circuit INVERTEC 100S LINCOLN 8 A 3 INSTALLATION A 3 120V INPUT The rated output of the Invertec 1008 is available when connected to a 20A branch circuit When con nected to a branch circuit with lower ampacity lower welding current and duty cycle must be used An out put guide is provided below The values are approxi mate 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 avail able output Do not exceed the
15. agir 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 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 1i 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 LINCO
16. and position e g ships hull or building steelwork a connection bonding the workpiece to earth may reduce emissions in some but not all instances Care should be taken to prevent the earthing of the workpiece increasing the risk of injury to users or damage to other electrical equipment Where necessary the connec tion of the workpiece to earth should be made by a direct connection to the workpiece but in some countries where direct connection is not permitted the bonding should be achieved by suitable capacitance selected according to national regulations Screening and Shielding Selective screening and shielding of other cables and equipment in the surrounding area may alleviate prob lems of interference Screening of the entire welding installation may be considered for special applications 1 1 Portions of the preceding text are contained in EN 60974 10 Electromagnetic Compatibility EMC prod uct standard for arc welding equipment LINCOLN B vii vii for selecting one of our QUALITY products We want you to take J f a n R pride in operating this product as much pride as we have bringing this product to you CUSTOMER ASSISTANCE POLICY The business of our company is manufacturing and selling high quality welding equipment Our challenge is to meet the needs of our customers and to exceed their expectations On occasion purchasers may ask us for advice or information about t
17. available from a welding gas distributor See Figure B 7 shows the basic TIG welding setup FIGURE B 7 GAS BOTTLE d WITH REGULATOR TIG TORCH ADAPTER TORCH WITH GAS VALVE em TUNGSTEN WORKPIECE INVERTEC 100S LINCOLN 8 C1 ACCESSORIES 1 OPTIONAL ACCESSORIES AND COMPATIBLE EQUIPMENT Factory Installed Electrical Holder and Cable Assembly Work Cable and Clamp Strap Packet Instruction Manual Field Installed 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 2 adapter K1782 6 12 50 Ft 1 Piece Cable K1782 8 25 0 Ft 1 Piece Cable PTA 17FV TIG Torch 150 Amp Gas Valve flexible head torch K1782 11 25 0 Ft 1 Piece Cable K1782 13 12 5 Ft 1 Piece Ultra Flex Cable K960 2 TIG Torch Adapter for connection of PTA 17V torches 1 piece cable to power sources without gas passing through the Twist Mate connection CABLE PLUGS K852 25 Cable Plug Kit attaches to welding cable to provide quick disconnect from machine TIG Torch Parts Kit A Parts kit is available for the PTA 17 TIG torch This kit includes back cap collets collet bodies nozzles and tungtens Order KP508 for PTA 17 torches See publication E12 150 for parts kits breakdown Cut Length Consumables TIG welding filler metals
18. 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 AR Connect the work cable to the workpiece as close as possible to the area being welded 1 9 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 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 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 Voltag
19. circuit or greater required LIMITATIONS The INVERTEC 1005 is not recommended for pipe thawing INVERTEC 100S LINCOLN B B 2 OPERATION B 2 CONTROLS AND OPERATIONAL MACHINE START UP When the machine is turned ON an auto test is exe cuted during this test only the Thermal LED is ON after few seconds the Thermal LED turns OFF and the Power ON OFF LED lights up The Machine is ready to operate when the POWER ON LED on the Front Control Panel illuminates green FRONT PANEL CONTROLS Output Current Knob Potentiometer used to set the output current used during welding Power ON OFF LED This LED lights up when the machine is ON 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 Leave the machine on to allow the internal components to cool When the indi cator turns off normal operation is again possible A Power Switch It turns ON OFF the input power to the machine B Input cable This machine is provided with an input cord and mold ed plug Connect it to a grounded outlet C Fan The fan is turned ON OFF by the machine Power Switch ARC WELDING CIRCUIT See Figure B 3 FIGURE B 3 ELECTRODE CABLE WORK CABLE ELECTRODE HOLDER ELECTRODE WORK CLAMP WORKPIECE Current flows through the electrode cable and elec trode holder
20. e 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 5 ARC RAYS can burn 4 a Use a shield with the proper filter and cover AZ plates to protect your eyes from sparks and 2 o e 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 th
21. e 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 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
22. een the end of the electrode and the work The temperature of this arc is about 6000 F 3315 C which is more than enough to melt metal The arc is very bright as well as hot and cannot be looked at with the naked eye without risking painful injury A very dark lens specifically designed for arc welding must be used with a hand or face shield whenever viewing the arc The arc melts the base metal and actually digs into it much as water through a nozzle on a gar den hose digs into the earth The molten metal forms a pool or crater and tends to flow away from the arc As it moves away from the arc it cools and solidifies A slag forms on top of the weld to protect it during cooling The function of the covered electrode is much more than simply to carry current to the arc The electrode is composed of a core rod of metal with an extruded chemical covering The core rod melts in the arc and tiny droplets of molten metal shoot across the arc into the molten pool The electrode provides additional filler metal for the joint to fill the groove or gap between the two pieces of the base metal The cover ing also melts or burns in the arc It has several func tions It makes the arc steadier provides a shield of smoke like gas around the arc to keep oxygen and nitrogen in the air away from the molten metal and provides a flux for the molten pool The flux picks up impurities and forms the protective slag MAKING A WELD Insert the bare
23. en or guards off No operar con panel abierto o guardas quitadas N op rez pas avec les pan neaux ouverts ou avec les dis positifs de protection enlev s Anlage nie ohne Schutzgeh use oder Innenschutzverkleidung in Betrieb setzen Mantenha se afastado das partes moventes N o opere com os paineis NZNRPAN ERYALKEEE THALYS ABLE EI ero Sel ORY AIS Ae y Gis Vil ual la JA ETUR Spanish AVISO DE PRECAUCION French ATTENTION German WARNUNG ATENCAO Chinese LEIA E COMPREENDA AS INSTRU ES DO FABRICANTE PARA ESTE EQUIPAMENTO E AS PARTES DE USO E SIGA AS PRATICAS DE SEGURANCA DO EMPREGADOR f sShoemHox h5 o0idBcmEtEk Re THMUCTSUO TUCRHOESSUIi oCFSU ARAM DA N EP PA AU IS EIE OE BO RES FB HREM LETTRE E34 0 AZo SSE SASA HAS AUX CSAS ESA HHC cables 38 gl aud y Qu al gll odgh geil gial 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
24. 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 SAFETY KE WELDING and CUTTING 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 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
25. formation below for future reference This information can be found on your machine nameplate Product Model Number Code Number or Date Code if available Serial Number if available Date Purchased Where Purchased Whenever you request replacement parts or information on this equipment always supply the information you have recorded above 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 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 or damage to this equipment viii TABLE OF CONTENTS viii Page INStallatiON m Section A Technical Sp cifications te nant cute cede tr gr d ute so ER te uUa A 1 Safety Precautions edere attire Decr EM ce aet anne akt A 2 Select Suitable Location ss A 2 icc re 2 Ili CI sess acere ire ente ede evoca et A 2 Iriput CoDhebliols ER EE Uf A 2 Ground usines A 2 Input Power Connec
26. hat 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 Authorized Field Service Facility If you do not understand or are unable to perform the Recommended Course of Action safely contact your local Authorized Field Service Facility CAUTION If for any reason you do not understand the test procedures or are unable to perform the tests repairs safely contact your Local Authorized Field Service Facility for technical troubleshooting assistance before you proceed INVERTEC 100S LINCOLN E 2 TROUBLESHOOTING E 2 Observe all Safety Guidelines detailed throughout this manual PROBLEMS POSSIBLE RECOMMENDED SYMPTOMS CAUSE COURSE OF ACTION WELDING PROBLEMS Excessive spatter 1 Long arc 2 High current Craters 1 Fast movement of the electrode away from piece Inclusions 1 Poor cleanliness or distribution of the Welding passes 2 Improper movement of the elec trode Insufficient penetration 1 High progression speed 2 Welding current too low 3 Narrow chamfering Sticking 1 Arc too short 2 Current too low If all recommended possible areas of misadjustment have been checked 1 Humidity in electrode and the problem persists Contac
27. heir use of our products We respond to our customers based on the best informa tion in our possession at that time We are not in a position to warrant or guarantee such advice and assume no liability with respect to such information 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 As a matter of practical consideration we also cannot assume any responsibility for updating or correcting any such informa tion 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 We are a responsive manufacturer but the selection and use of specific products sold by us is solely within the control of and remains the sole responsibility of the customer Many variables beyond our control 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 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 in
28. ions integrity Replace if necessary e Clean the power source inside by means of low pressure compressed air Keep the machine clean Use a soft dry cloth to clean the external case especially the airflow inlet outlet louvers WARNING Do not open this machine and do not introduce any thing into its openings Power supply must be discon nected from the machine before each maintenance and service After each repair perform proper tests to ensure safety A CAUTION Power supply must be disconnected from the machine before each maintenance and service Always use gloves in compliance with the safety standards INVERTEC 100S LINCOLN E TROUBLESHOOTING 1 HOW TO USE TROUBLESHOOTING GUIDE WARNING Service and Repair should only be performed by Factory Trained Personnel Unauthorized repairs performed on this equipment may result in danger to the technician and machine operator and will invalidate your factory warranty For your safety and to avoid Electrical Shock please observe all safety notes and precautions detailed throughout this manual This 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 t
29. ipment other nearby welding equipment radio and TV reception numerical controlled machines telephone systems computers etc Be aware that interference may result and extra precautions may be required when a welding power source is used in a domestic establishment Installation and Use The user is responsible for installing and using the welding equipment according to the manufacturer s instructions If electromagnetic disturbances are detected then it shall be the responsibility of the user of the welding equipment to resolve the situation with the technical assistance of the manufacturer In some cases this remedial action may be as simple as earthing grounding the welding circuit see Note In other cases it could involve construction of an electromagnetic screen enclosing the power source and the work complete with associated input filters In all cases electromagnetic disturbances must be reduced to the point where they are no longer troublesome Note The welding circuit may or may not be earthed for safety reasons according to national codes Changing the earthing arrangements should only be authorized by a person who is competent to access whether the changes will increase the risk of injury e g by allowing parallel welding current return paths which may damage the earth circuits of other equipment Assessment of Area Before installing welding equipment the user shall make an assessment of potential electromagnetic prob lems in the su
30. jenueui siu Aq 10 ejenooe eq jou eui 1 92 JUILVW3HJSI LAdLNO JNLVI3N ANLISOd quvoga JOH INOO SNid Z 3218 104 LON LX juo 82u819J8J 10 S SIUL 3LON 20 SIY 921495 JO 85 0457 11045 5405 80 paljyonb Aqup 500 021 2818 010 104 00 OUDIAJSS 0 pJo3 Jamod buibBnidun Aq Jawod 0 290002810 24 3dlS IN3NOdWOO GAMAIA Pe ous sJo 02 ui aposado jou of 3ON3no3s ONINSSWNN ALIAVO HOLO3NNOO 89d THM NYJ 39VL10A NING 0L ayog H3LH3ANI LAS INVHOVIG SNIHIM 500 O3 LH3ANI 2009 1V91419313 TWNOILVN Yad GQNNOUYDS OL N33u9 Es IMOTIAA INVERTEC 100S LINCOLN E Spanish AVISO DE PRECAUCION French ATTENTION German WARNUNG Portuguese ATENCAO Chinese Do not touch electrically live parts or electrode with skin or wet clothing Insulate yourself from work No toque las partes o los elec trodos bajo carga con la piel o ropa mojada Aislese del trabajo y de la tier ra Ne laissez ni la peau ni des v tements mouill s entrer en contact avec des pi ces sous ension Isolez vous du travail et de la terre Ber hren Sie keine strom unrenden oder Elektroden mit Ihrem K rper oder feuchter Kleidung Isolieren Sie sich von den Elektroden und dem KARHE 7 v 56nfdcmWn am
31. nt Shielding should be electrically continuous throughout its length The shielding should be connected to the welding power source so that good electrical contact is maintained between the conduit and the welding power source enclosure Maintenance of the Welding Equipment The welding equipment should be routinely maintained according to the manufacturer s recommendations All access and service doors and covers should be closed and properly fastened when the welding equip ment is in operation The welding equipment should not be modified in any way except for those changes and adjustments covered in the manufacturers instructions In particular the spark gaps of arc striking and stabilizing devices should be adjusted and maintained according to the manufacturer s recommendations Welding Cables The welding cables should be kept as short as possible and should be positioned close together running at or close to floor level Equipotential Bonding Bonding of all metallic components in the welding installation and adjacent to it should be considered However metallic components bonded to the work piece will increase the risk that the operator could receive a shock by touching these metallic components and the electrode at the same time The operator should be insulated from all such bonded metallic components Earthing of the Workpiece Where the workpiece is not bonded to earth for electrical safety not connected to earth because of its size
32. p toc t OMIM APSStrBeBA KRAKADI 8 B BRUBRRUT HER Se AA our e xj HUE m s il pia TI 19 ju AULAE Db dans Vile Keep flammable materials away Mantenga el material com bustible fuera del rea de tra bajo Gardez l cart de tout mat riel inflammable Entfernen Sie brennbarres Material e Mantenha inflam veis bem e mavdiu6008Bcosetrs i d amp xf U Ci ie XA e i 9 8 o 0180 SUR nig nisu ALD si yu Wear eye ear and body protec tion Prot jase los ojos los o dos y el 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 l eQRARR HERHSEGSRHR ec HS Z0 Asis due Le Jules c jui Maas 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 EQU
33. part of the electrode into the electrode holder jaws and connect the work clamp to the weld ing piece Make sure to have good electrical contact 1 Turn the welder on 2 Lower your welding helmet to protect your face and eyes 3 Strike the electrode at the work point on the work piece as if striking a match Do not hit the electrode on the workpiece which will damage the stick elec trode and make striking an arc difficult Scratch the electrode slowly over the metal and you will see sparks While scratching lift the electrode 1 8 3 2mm and the arc will establish NOTE If you stop moving the electrode while scratch ing the electrode will stick NOTE Most beginners try to strike the arc by a fast jabbing motion down on the plate Result They either stick or their motion is so fast that they break the arc immediately 4 Immediately after striking the arc try to maintain a distance from the workpiece that is equivalent to the diameter of the electrode used Maintain this distance as constantly as possible during the weld Whenever possible weld from left to right if right handed Hold the electrode at a slight angle as shown See Figure B 5 FIGURE B 5 15 209 Side view End view Correct Welding Position 5 As the electrode burns off the electrode must be fed to the work to maintain correct arc length The easi est way to tell whether the arc has the correct length is by listening to its so
34. r internal wiring 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 T id WELDING CUTTING and y GOUGING SPARKS can cause fire or explosion P Keep flammable material away Do not weld cut or gouge on contain ers that have held combustibles ARC RAYS can burn 4 Only qualified personnel should operate this equip ment Observe all safety information throughout this manual Wear eye ear and body protection GENERAL DESCRIPTION The INVERTECO 1008 is a 100 amp arc welding power source which utilizes single phase input power to produce constant current output The welding response of this Inverter has been optimized for stick SMAW welding WELDING CAPABILITY The INVERTECO 1005 is rated at 80 amps 23 2 volts at 20 duty cycle on a ten minute basis It is capable of higher duty cycles at lower output currents If the duty cycle is exceeded a thermal protector will shut off the output until the machine cools See Table A 1 in the INSTALLATION Section for other rated out puts The INVERTEC 1005 is recommended for the fol lowing Electrode Types and Diameters Sizes in es oe E6013 Fleetweld 35 180 E6011 So 7018 MR emmy Tx X 15 Amp Branch circuit or greater required A 20 Amp Branch
35. rrounding area The following shall be taken into account a other supply cables control cables signaling and telephone cables above below and adjacent to the welding equipment b radio and television transmitters and receivers C computer and other control equipment d safety critical equipment e g guarding of industrial equipment e the health of the people around e g the use of pacemakers and hearing aids f equipment used for calibration or measurement the immunity of other equipment in the environment The user shall ensure that other equipment being used in the environment is compatible This may require additional protection measures e 2 the time of day that welding or other activities are to be carried out LINCOLN 8 SAFETY vi Electromagnetic Compatibility EMC The size of the surrounding area to be considered will depend on the structure of the building and other activities that are taking place The surrounding area may extend beyond the boundaries of the premises Methods of Reducing Emissions Mains Supply Welding equipment should be connected to the mains supply according to the manufacturer s recommenda tions If interference occurs it may be necessary to take additional precautions such as filtering of the mains supply Consideration should be given to shielding the supply cable of permanently installed welding equip ment in metallic conduit or equivale
36. se pliers to move Always make sure the welder is turned off before set ting down the Electrode Holder TIG WELDING TUNGSTEN INERT GAS WELDING This machine is capable of direct current DC TIG welding which is suitable for hard metals such as steel stainless steel copper and brass The TIG process is good for welding thin materials requiring very good cosmetic appearance with low heat input and low spatter TIG welding uses a tungsten elec trode which delivers electrical current to the work piece by way of an electric arc Unlike stick welding in which the electrode is consumed in the arc the tung sten electrode is not consumed Instead filler metal is added to the weld by manually dipping a filler rod into the weld puddle TIG welding requires a higher skill level than stick welding and practice is required to master the technique For best results a TIG welding class is suggested or obtaining a book on how to TIG weld TIG welding also requires 10096 Argon shielding gas to shield the arc preventing porosity in the weld This is different than stick welding which has a coating on the electrode to produce its own shielding In addition a gas regulator a manual gas valve TIG torch torch parts kit torch adapter and filler metal are required Refer to the accessories section of this manual for an appropriate optional TIG torch parts kit and torch adapter A gas regulator filler metal and a bottle of shielding gas are readily
37. se welding conditions See Table A 1 The Invertec 100 is provided with a 120V cable 6 6ft 2m in length with a 15Amp 5 15P plug molded onto the cord TABLE A 1 BRANCH CIRCUITS 20 Duty 10 Duty Cycle Cycle Plug Branch 15 Am 15 Am OUTPUT CONNECTIONS A quick disconnect system using Twist MateTM cable plugs is used for the welding cable connections Refer to the following sections for more information on connecting the machine for operation of stick welding MMA or TIG welding Positive Quick Disconnect Positive output connector for the welding circuit Negative Quick Disconnect Negative output connector for the welding circuit WARNING ELECTRIC SHOCK can kill e Keep the electrode holder and cable insulation in good condition e Do not touch electrically live parts or electrode with skin or wet cloth ing Insulate yourself from work and ground Turn the input line Switch on the Invertec 100S off before connecting or disconnecting output cables or other equipment STICK WELDING SMAW First determine the proper electrode polarity for the elec trode to be used Consult the electrode data for this information Then connect the output cables to the out put terminals of the machine for the selected polarity Shown here is the connection method for DC welding See Figure A 1 FIGURE A 1 o 4 C gt e a
38. t 2 Long arc your local Lincoln Authorized Field Service Facility Cracks 1 Current too high 2 Dirty materials 3 Hydrogen in weld present on electrode coating A CAUTION If for any reason you do not understand the test procedures or are unable to perform the tests repairs safely contact your Local Authorized Field Service Facility for technical troubleshooting assistance before you proceed INVERTEC 100S LINCOLN 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 Incorrect electrode sharpening Electrode too small Operating failure contact of the tip with the workpiece Dirt on the edges Dirt on the filler material Excessive travel speed Current intensity too low If all recommended possible areas of misadjustment have been checked Hot cracking 1 Unsuitable filler material probe persists Contact 2 High heat supply your local Lincoln Authorized 3 Dirty materials Field Service Facility CAUTION If for any reason you do not understand the test procedures or are unable to perform the tests repairs safely contact your Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed INVERTEC 100S LINCOLN
39. tion ER A 2 2 cT ne A 3 Output COnnection x E aE ei rte bred iR red rec A 3 Stick WeldiNg A 3 eru m Section B Safety Instructions ses B 1 General Desctiptioh 2 d nasce eee ddl andere dis ce a pne de trina Tec ag es ned dede est B 1 Welding Capability er c B 1 Ce 1 Controls and Operational Features ss B 2 Arc Welding CCUR neemeni 2 iiec ettet um D eres B 2 2 B 3 4 ACCOSSONIES Section C Optional Accessories and Compatible C 1 Factory Field Installed iei icit teda cin dr eee C 1 Maintenance Section D Safety Pr cautions an aua D 1 Input Filter Capacitor Discharge D 1 Routine D 1 TroubleshOOtiNg Section E How to Use Troubleshooting Guide E 1 Troubleshooting Guide ss E 2 thru E 4 Winng Diagram less Section F 1 INSTALLATION 1 TECHNICAL SPECIFICATION INVERTEC 1005 INPUT
40. to the electrode and across the arc On the work side of the arc the current flows through the base metal to the work cable and back to the welding machine The circuit must be complete for the current to flow To weld the work clamp must be tightly connected to clean base metal Remove paint rust etc as neces sary to get a good connection Connect the work clamp as close as possible to the area you wish to weld Avoid allowing the welding circuit to pass through hinges bearings electronic components or similar devices that can be damaged An electric arc is made between the work and the end of a small metal rod the electrode which is clamped in a holder and the holder is held by the person doing the welding A gap is made in the welding circuit see Figure B 3 by holding the tip of the electrode 1 16 1 8 away from the work or base metal being welded The electric arc is established in this gap and is held and moved along the joint to be welded melting the metal as it is moved ELECTRIC ARC See Figure B 4 Action that takes place in the electric arc FIGURE B 4 Covering Electrode Solidilied slag f M Y Shielding gases VA gg i ye INVERTEC 100S LINCOLN 8 B 3 OPERATION B 3 This figure closely resembles what is actually seen during welding The arc stream is seen in the middle of the figure This is the electric arc created by the electric current flowing through the space betw
41. trodes 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
42. und A nice short arc has a distinctive crackling sound very much like eggs frying in a pan The incorrect long arc has a hollow blowing or hissing sound 6 The important thing to watch while welding is the puddle of molten metal right behind the arc Do NOT watch the arc itself It is the appearance of the puddle and the ridge where the molten puddle solidifies that indicate correct welding speed The ridge should be approximately 3 8 9 5mm behind the electrode See Figure B 6 FIGURE B 6 Ridge where puddle solidifies K Most beginners tend to weld too fast resulting in a thin uneven wormy looking bead They are not watching the molten metal Molten puddle IMPORTANT For general welding it is not necessary to weave the arc neither forwards and backwards nor sideways Weld along at a steady pace You will find it easier NOTE When welding on thin plate you will find that you will have to increase the welding speed whereas when welding on heavy plate it is necessary to go more slowly in order to get good penetration INVERTEC 100S LINCOLN B B 4 OPERATION B 4 7 Once the electrode is burned down move the elec trode quickly from the weld to extinguish the arc 8 Turn the machine off and remove the stub by open ing the jaws of the electrode holder and insert a new electrode Note The welded work piece and electrode stub are hot after welding Allow them to cool down before touching or u
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