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鈩?
IM737-A
August, 2007
INVERTEC V160-S
10877; 11031
For use with machines having Code Numbers:
Safety Depends on You
Lincoln arc welding and cutting
equipment is designed and built
with safety in mind. However, your
overall safety can be increased by
proper installation ... and thought-
ful operation on your part. DO
NOT INSTALL, OPERATE OR
REPAIR THIS EQUIPMENT
WITHOUT READING THIS
MANUAL AND THE SAFETY
PRECAUTIONS CONTAINED
THROUGHOUT. And, most
importantly, think before you act
and be careful.
OPERATOR鈥橲 MANUAL
Copyright 漏 2007 Lincoln Global Inc.
鈥? World's Leader in Welding and Cutting Products 鈥?
鈥? Sales and Service through Subsidiaries and Distributors Worldwide 鈥?
Cleveland, Ohio 44117-1199 U.S.A. TEL: 216.481.8100 FAX: 216.486.1751 WEB SITE: www.lincolnelectric.com
SAFETY
i i
WARNING
CALIFORNIA PROPOSITION 65 WARNINGS
The engine exhaust from this product contains
Diesel engine exhaust and some of its constituents
chemicals known to the State of California to cause
are known to the State of California to cause can-
cancer, birth defects, or other reproductive harm.
cer, birth defects, and other reproductive harm.
The Above For Gasoline Engines
The Above For Diesel Engines
ARC WELDING CAN BE HAZARDOUS. PROTECT YOURSELF AND OTHERS FROM POSSIBLE SERIOUS INJURY OR DEATH.
KEEP CHILDREN AWAY. PACEMAKER WEARERS SHOULD CONSULT WITH THEIR DOCTOR BEFORE OPERATING.
Read and understand the following safety highlights. For additional safety information, it is strongly recommended that you
purchase a copy of 鈥淪afety in Welding & Cutting - ANSI Standard Z49.1鈥? from the American Welding Society, P.O. Box
351040, Miami, Florida 33135 or CSA Standard W117.2-1974. A Free copy of 鈥淎rc Welding Safety鈥? 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.
FOR ENGINE 1.h. To avoid scalding, do not remove the
powered equipment. radiator pressure cap when the engine is
hot.
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
outdoors.
ELECTRIC AND
MAGNETIC FIELDS
may be dangerous
____________________________________________________
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 2.a. Electric current flowing through any conductor causes
refueling to prevent spilled fuel from vaporiz- localized Electric and Magnetic Fields (EMF). Welding
ing on contact with hot engine parts and current creates EMF fields around welding cables and
igniting. Do not spill fuel when filling tank. If welding machines
fuel is spilled, wipe it up and do not start
engine until fumes have been eliminated. 2.b. EMF fields may interfere with some pacemakers, and
____________________________________________________ welders having a pacemaker should consult their physician
1.d. Keep all equipment safety guards, covers and devices in before welding.
position and in good repair.Keep hands, hair, clothing and
tools away from V-belts, gears, fans and all other moving 2.c. Exposure to EMF fields in welding may have other health
parts when starting, operating or repairing equipment. effects which are now not known.
____________________________________________________
2.d. All welders should use the following procedures in order to
1.e. In some cases it may be necessary to remove safety
minimize exposure to EMF fields from the welding circuit:
guards to perform required maintenance. Remove
guards only when necessary and replace them when the
2.d.1. Route the electrode and work cables together - Secure
maintenance requiring their removal is complete.
them with tape when possible.
Always use the greatest care when working near moving
parts.
2.d.2. Never coil the electrode lead around your body.
___________________________________________________
1.f. Do not put your hands near the engine fan.
2.d.3. Do not place your body between the electrode and
Do not attempt to override the governor or
idler by pushing on the throttle control rods work cables. If the electrode cable is on your right
while the engine is running. side, the work cable should also be on your right side.
2.d.4. 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 2.d.5. Do not work next to welding power source.
turning the engine or welding generator during maintenance
work, disconnect the spark plug wires, distributor cap or
Mar 驶95
magneto wire as appropriate.
SAFETY
ii ii
ARC RAYS can burn.
ELECTRIC SHOCK can
kill. 4.a. Use a shield with the proper filter and cover
plates to protect your eyes from sparks and
3.a. The electrode and work (or ground) circuits
the rays of the arc when welding or observing
are electrically 鈥渉ot鈥? when the welder is on. open arc welding. Headshield and filter lens
Do not touch these 鈥渉ot鈥? parts with your bare should conform to ANSI Z87. I standards.
skin or wet clothing. Wear dry, hole-free
gloves to insulate hands. 4.b. Use suitable clothing made from durable flame-resistant
material to protect your skin and that of your helpers from
3.b. Insulate yourself from work and ground using dry insulation. the arc rays.
Make certain the insulation is large enough to cover your full
area of physical contact with work and ground. 4.c. Protect other nearby personnel with suitable, non-flammable
screening and/or warn them not to watch the arc nor expose
In addition to the normal safety precautions, if welding themselves to the arc rays or to hot spatter or metal.
must be performed under electrically hazardous
FUMES AND GASES
conditions (in damp locations or while wearing wet
clothing; on metal structures such as floors, gratings or
can be dangerous.
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 5.a. Welding may produce fumes and gases
the following equipment: hazardous to health. Avoid breathing these
鈥? Semiautomatic DC Constant Voltage (Wire) Welder. fumes and gases. When welding, keep
鈥? DC Manual (Stick) Welder. your head out of the fume. Use enough
鈥? AC Welder with Reduced Voltage Control. ventilation and/or exhaust at the arc to keep
fumes and gases away from the breathing zone. When
3.c. In semiautomatic or automatic wire welding, the electrode, welding with electrodes which require special
electrode reel, welding head, nozzle or semiautomatic ventilation such as stainless or hard facing (see
welding gun are also electrically 鈥渉ot鈥?. instructions on container or MSDS) or on lead or
cadmium plated steel and other metals or coatings
3.d. Always be sure the work cable makes a good electrical which produce highly toxic fumes, keep exposure as
connection with the metal being welded. The connection low as possible and below Threshold Limit Values (TLV)
should be as close as possible to the area being welded. using local exhaust or mechanical ventilation. In
confined spaces or in some circumstances, outdoors, a
3.e. Ground the work or metal to be welded to a good electrical respirator may be required. Additional precautions are
(earth) ground. also required when welding on galvanized steel.
3.f. Maintain the electrode holder, work clamp, welding cable and 5. b. The operation of welding fume control equipment is affected
welding machine in good, safe operating condition. Replace by various factors including proper use and positioning of
damaged insulation. the equipment, maintenance of the equipment and the spe-
cific welding procedure and application involved. Worker
3.g. Never dip the electrode in water for cooling. exposure level should be checked upon installation and
periodically thereafter to be certain it is within applicable
3.h. Never simultaneously touch electrically 鈥渉ot鈥? parts of OSHA PEL and ACGIH TLV limits.
electrode holders connected to two welders because voltage
between the two can be the total of the open circuit voltage 5.c. Do not weld in locations near chlorinated hydrocarbon vapors
of both welders. coming from degreasing, cleaning or spraying operations.
The heat and rays of the arc can react with solvent vapors to
3.i. When working above floor level, use a safety belt to protect form phosgene, a highly toxic gas, and other irritating prod-
yourself from a fall should you get a shock. ucts.
3.j. Also see Items 6.c. and 8. 5.d. 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.
5.e. Read and understand the manufacturer始s instructions for this
equipment and the consumables to be used, including the
material safety data sheet (MSDS) and follow your
employer始s safety practices. MSDS forms are available from
your welding distributor or from the manufacturer.
5.f. Also see item 1.b.
AUG 06
SAFETY
iii iii
WELDING SPARKS can CYLINDER may explode
cause fire or explosion. if damaged.
6.a. Remove fire hazards from the welding area.
7.a. Use only compressed gas cylinders
If this is not possible, cover them to prevent
containing the correct shielding gas for the
the welding sparks from starting a fire.
process used and properly operating
Remember that welding sparks and hot
regulators designed for the gas and
materials from welding can easily go through small cracks
pressure used. All hoses, fittings, etc. should be suitable for
and openings to adjacent areas. Avoid welding near
the application and maintained in good condition.
hydraulic lines. Have a fire extinguisher readily available.
7.b. Always keep cylinders in an upright position securely
6.b. Where compressed gases are to be used at the job site,
chained to an undercarriage or fixed support.
special precautions should be used to prevent hazardous
situations. Refer to 鈥淪afety in Welding and Cutting鈥? (ANSI
7.c. Cylinders should be located:
Standard Z49.1) and the operating information for the
鈥? Away from areas where they may be struck or subjected to
equipment being used.
physical damage.
6.c. When not welding, make certain no part of the electrode
鈥? A safe distance from arc welding or cutting operations and
circuit is touching the work or ground. Accidental contact can
any other source of heat, sparks, or flame.
cause overheating and create a fire hazard.
7.d. Never allow the electrode, electrode holder or any other
6.d. Do not heat, cut or weld tanks, drums or containers until the
electrically 鈥渉ot鈥? parts to touch a cylinder.
proper steps have been taken to insure that such procedures
will not cause flammable or toxic vapors from substances
7.e. Keep your head and face away from the cylinder valve outlet
inside. They can cause an explosion even though they have
when opening the cylinder valve.
been 鈥渃leaned鈥?. For information, purchase 鈥淩ecommended
Safe Practices for the Preparation for Welding and Cutting of
7.f. Valve protection caps should always be in place and hand
Containers and Piping That Have Held Hazardous
tight except when the cylinder is in use or connected for
Substances鈥?, AWS F4.1 from the American Welding Society
use.
(see address above).
7.g. Read and follow the instructions on compressed gas
6.e. Vent hollow castings or containers before heating, cutting or
cylinders, associated equipment, and CGA publication P-l,
welding. They may explode.
鈥淧recautions for Safe Handling of Compressed Gases in
Cylinders,鈥? available from the Compressed Gas Association
6.f. Sparks and spatter are thrown from the welding arc. Wear oil
1235 Jefferson Davis Highway, Arlington, VA 22202.
free protective garments such as leather gloves, heavy shirt,
cuffless trousers, high shoes and a cap over your hair. Wear
FOR ELECTRICALLY
ear plugs when welding out of position or in confined places.
powered equipment.
Always wear safety glasses with side shields when in a
welding area.
6.g. Connect the work cable to the work as close to the welding
8.a. Turn off input power using the disconnect
area as practical. Work cables connected to the building
switch at the fuse box before working on
framework or other locations away from the welding area
the equipment.
increase the possibility of the welding current passing
through lifting chains, crane cables or other alternate cir-
8.b. Install equipment in accordance with the U.S. National
cuits. This can create fire hazards or overheat lifting chains
Electrical Code, all local codes and the manufacturer始s
or cables until they fail.
recommendations.
6.h. Also see item 1.c.
8.c. Ground the equipment in accordance with the U.S. National
Electrical Code and the manufacturer始s recommendations.
6.I. Read and folllow NFPA 51B 鈥? Standard for Fire Prevention
Jan, 07
During Welding, Cutting and Other Hot Work鈥?, available from
NFPA, 1 Batterymarch Park,PO box 9101, Quincy, Ma
022690-9101.
6.j. Do not use a welding power source for pipe thawing.
SAFETY
iv iv
PR脡CAUTIONS DE S脹RET脡 6. Eloigner les mat茅riaux inflammables ou les recouvrir afin de
pr茅venir tout risque d始incendie d没 aux 茅tincelles.
Pour votre propre protection lire et observer toutes les instructions
et les pr茅cautions de s没ret茅 specifiques qui parraissent dans ce
7. Quand on ne soude pas, poser la pince 脿 une endroit isol茅 de
manuel aussi bien que les pr茅cautions de s没ret茅 g茅n茅rales suiv-
la masse. Un court-circuit accidental peut provoquer un
antes:
茅chauffement et un risque d始incendie.
S没ret茅 Pour Soudage A L始Arc
8. S始assurer que la masse est connect茅e le plus pr茅s possible
1. Protegez-vous contre la secousse 茅lectrique:
de la zone de travail qu始il est pratique de le faire. Si on place
la masse sur la charpente de la construction ou d始autres
a. Les circuits 脿 l始茅lectrode et 脿 la pi茅ce sont sous tension
endroits 茅loign茅s de la zone de travail, on augmente le risque
quand la machine 脿 souder est en marche. Eviter toujours
de voir passer le courant de soudage par les chaines de lev-
tout contact entre les parties sous tension et la peau nue
age, c芒bles de grue, ou autres circuits. Cela peut provoquer
ou les v茅tements mouill茅s. Porter des gants secs et sans
des risques d始incendie ou d始echauffement des chaines et des
trous pour isoler les mains.
c芒bles jusqu始脿 ce qu始ils se rompent.
b. Faire tr茅s attention de bien s始isoler de la masse quand on
soude dans des endroits humides, ou sur un plancher
9. Assurer une ventilation suffisante dans la zone de soudage.
metallique ou des grilles metalliques, principalement dans
Ceci est particuli茅rement important pour le soudage de t么les
les positions assis ou couch茅 pour lesquelles une grande
galvanis茅es plomb茅es, ou cadmi茅es ou tout autre m茅tal qui
partie du corps peut 锚tre en contact avec la masse.
produit des fume茅s toxiques.
c. Maintenir le porte-茅lectrode, la pince de masse, le c芒ble
de soudage et la machine 脿 souder en bon et s没r 茅tat
10. Ne pas souder en pr茅sence de vapeurs de chlore provenant
defonctionnement.
d始op茅rations de d茅graissage, nettoyage ou pistolage. La
d.Ne jamais plonger le porte-茅lectrode dans l始eau pour le
chaleur ou les rayons de l始arc peuvent r茅agir avec les vapeurs
refroidir.
du solvant pour produire du phosg茅ne (gas fortement toxique)
e. Ne jamais toucher simultan茅ment les parties sous tension
ou autres produits irritants.
des porte-茅lectrodes connect茅s 脿 deux machines 脿 souder
parce que la tension entre les deux pinces peut 锚tre le
11. Pour obtenir de plus amples renseignements sur la s没ret茅, voir
total de la tension 脿 vide des deux machines.
le code 鈥淐ode for safety in welding and cutting鈥? CSA Standard
f. Si on utilise la machine 脿 souder comme une source de
W 117.2-1974.
courant pour soudage semi-automatique, ces precautions
pour le porte-茅lectrode s始applicuent aussi au pistolet de
soudage.
PR脡CAUTIONS DE S脹RET脡 POUR
2. Dans le cas de travail au dessus du niveau du sol, se prot茅ger
LES MACHINES 脌 SOUDER 脌
contre les chutes dans le cas ou on recoit un choc. Ne jamais
enrouler le c芒ble-茅lectrode autour de n始importe quelle partie
TRANSFORMATEUR ET 脌
du corps.
REDRESSEUR
3. Un coup d始arc peut 锚tre plus s茅v猫re qu始un coup de soliel,
donc:
a. Utiliser un bon masque avec un verre filtrant appropri茅 1. Relier 脿 la terre le chassis du poste conformement au code de
ainsi qu始un verre blanc afin de se prot茅ger les yeux du ray- l始茅lectricit茅 et aux recommendations du fabricant. Le dispositif
onnement de l始arc et des projections quand on soude ou de montage ou la piece 脿 souder doit 锚tre branch茅 脿 une
quand on regarde l始arc. bonne mise 脿 la terre.
b. Porter des v锚tements convenables afin de prot茅ger la
peau de soudeur et des aides contre le rayonnement de 2. Autant que possible, I始installation et l始entretien du poste seront
l驶arc. effectu茅s par un 茅lectricien qualifi茅.
c. Prot茅ger l始autre personnel travaillant 脿 proximit茅 au
soudage 脿 l始aide d始茅crans appropri茅s et non-inflammables. 3. Avant de faires des travaux 脿 l始interieur de poste, la debranch-
er 脿 l始interrupteur 脿 la boite de fusibles.
4. Des gouttes de laitier en fusion sont 茅mises de l始arc de
soudage. Se prot茅ger avec des v锚tements de protection libres 4. Garder tous les couvercles et dispositifs de s没ret茅 脿 leur
de l始huile, tels que les gants en cuir, chemise 茅paisse, pan- place.
talons sans revers, et chaussures montantes.
5. Toujours porter des lunettes de s茅curit茅 dans la zone de
soudage. Utiliser des lunettes avec 茅crans lateraux dans les
Mar. 驶93
zones o霉 l始on pique le laitier.
v v
for selecting a QUALITY product. We want you to take pride in
operating this product 鈥⑩?⑩?? as much pride as we have in bringing
Thank You 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始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 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 鈥? 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 supply 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.
鈥? 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.
鈥? For On-Line Registration: Go to our WEB SITE at www.lincolnelectric.com. Choose 鈥淨uick Links鈥? and then
鈥淧roduct Registration鈥?. 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:
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.
TABLE OF CONTENTS
vi vi
Page
Installation.......................................................................................................................Section A
Technical Specifications .......................................................................................................A-1
Safety Precautions.................................................................................................A-1
Select Suitable Location .......................................................................................................A-2
Stacking................................................................................................................................A-2
Tilting ....................................................................................................................................A-2
Input Connections ................................................................................................................A-2
Ground Connection........................................................................................................A-2,A-3
ARFU (Auto-Restore Fuse) ...................................................................................A-3
Output Connections..............................................................................................................A-4
Output and Gas Connection for Tig Welding ........................................................................A-4
Output Connection for Stick Welding....................................................................................A-4
Quick Disconnect Plug ..................................................................................................A-5
Output Connection for Tig Welding .......................................................................A-5
Remote Control Connection ..........................................................................................A-5
________________________________________________________________________________
Operation.........................................................................................................................Section B
Safety Instructions ................................................................................................................B-1
General Description..............................................................................................................B-1
Welding Capability................................................................................................................B-1
Limitations ............................................................................................................................B-1
Rear Control Panel ...............................................................................................................B-2
Controls and Settings ...................................................................................................B-2, B-3
DIP Switch Functions (Service Information) .................................................................B-4, B-5
DIP Switch 1: Machine Type ........................................................................................B-4
DIP Switch 6: European/USA Machine Configuration ..................................................B-5
________________________________________________________________________________
Accessories .....................................................................................................Section C
Optional Accessories and Compatible Equipment.................................................C-1
Factory, Field Installed...........................................................................................C-1
________________________________________________________________________
Maintenance ....................................................................................................Section D
Safety Precautions ................................................................................................D-1
Input Filter Capacitor Discharge Procedure ..........................................................D-1
Routine Maintenance.............................................................................................D-1
________________________________________________________________________
Troubleshooting ..............................................................................................Section E
How to Use Troubleshooting Guide .......................................................................E-1
Troubleshooting Guide..................................................................................E-2, E-3
________________________________________________________________________
Wiring Diagram ................................................................................................Section F
________________________________________________________________________
Parts Lists...............................................................................................................P-403
________________________________________________________________________
INSTALLATION
A-1 A-1
TECHNICAL SPECIFICATION V160-S
INPUT - SINGLE PHASE ONLY
Input Voltages / 50 /60 Hz. Max. Input Current at rated Output
115 V (20 A Plug and branch) 20 A
115 V (30 A branch) 25 A
230 V 34 A
RATED OUTPUT
Output Amps Input Circuit
Output Volts
Duty Cycle
60 (Stick) 115V (20A Plug and Branch)
22.4
90 (TIG) 13.6
100%
80 (Stick) 115V (30A Branch)
23.2
110 (TIG) 14.4
160 (Stick) 230V (30A Branch)
26.4
35%
160 (TIG) 16.4
130 (Stick) 230V (30A Branch)
25.2
100%
130 (TIG) 15.2
OUTPUT
Type of Output
Maximum Open Circuit Voltage
Output Current Range
DC
5-160 Amps 48 Volts Max.
RECOMMENDED INPUT WIRE AND FUSE SIZES FOR MAXIMUM RATED OUTPUT
TYPE S, SO ST, STO, OR EXTRA MAXIMUM TIME-DELAY CIRCUIT
INPUT VOLTAGE /
HARD USAGE INPUT CORD AWG BREAKER OR FUSE SIZE (AMPS)
FREQUENCY (HZ)
#12
230/50/60 30
PHYSICAL DIMENSIONS
Height Width Depth Weight
12.6 in. 7.9 in. 16.9 in. Approx. 24.2lbs.
320 mm 200 mm 430 mm 11 kgs.
TEMPERATURE RANGES
OPERATING TEMPERATURE RANGE STORAGE TEMPERATURE RANGE
-20掳C to +40掳C -50掳C to +85掳C
V160-S
INSTALLATION
A-2 A-2
Read entire installation section before starting TILTING
installation.
Place the machine directly on a secure, level surface.
SAFETY PRECAUTIONS The machine may topple over if this procedure is not
followed.
WARNING INPUT CONNECTIONS
WARNING
ELECTRIC SHOCK can kill.
鈥? Only qualified personnel should per-
form this installation.
ELECTRIC SHOCK can kill.
鈥? Disconnect input power by removing
鈥? Have a qualified electrician install
plug from receptacle before working
and service this equipment.
inside V160-S. Allow machine to sit for
鈥? Disconnect input power by removing
5 minutes minimum to allow the power capacitors
plug from receptacle before working
to discharge before working inside this equip-
inside V160-S. Allow machine to sit for
ment.
5 minutes minimum to allow the power capacitors
鈥? Insulate yourself from the work and ground.
to discharge before working inside this equip-
鈥? Always wear dry insulating gloves. ment.
鈥? Do not touch electrically live parts.
鈥? Always connect the V160-S to a power supply
-----------------------------------------------------------------------
grounded according to the National Electrical Code
GROUND CONNECTION
and local codes.
The frame of the welder must be
------------------------------------------------------------ grounded. A ground terminal marked
SELECT SUITABLE LOCATION
with the symbol is located on the under
panel for this purpose. See your local
and national electrical codes for proper
This machine will operate in harsh environments. grounding methods.
CAUTION
However, it is important that simple preventative
measures are followed to assure long life and reliable
operation. A grounding conductor is supplied in the input
cord, it is important that the supply receptacle
鈥? Do not place or operate this machine on a surface ground is connected.
with an incline greater than 15掳 from horizontal. -----------------------------------------------------------------------
WARNING
鈥? This machine must be located where there is free
circulation of clean air without restrictions for air
This installation should be performed by a quali-
movement to and from the air vents. Do not cover
fied electrician to ensure correct connections of
the machine with paper, cloth or rags when switched
the leads to the plug spades.
on.
鈥? The electrical system must be made by skilled
鈥? Dirt and dust that can be drawn into the machine
technicians with the specific professional and
should be kept to a minimum.
technical qualifications and in compliance with
the regulations in force in the country where the
鈥? Keep the machine dry and do not place it on wet
equipment is installed.
ground or in puddles.
鈥? The welding power source supply cable is pro-
鈥? When operated in ambient temperatures greater
vided with a green or yellow/green wire that must
than 40掳C, the output duty cycle may be reduced.
ALWAYS be earthed. This green or yellow/green
wire must NEVER be used with other voltage
鈥? Do not mount over combustible surfaces.
conductors.
STACKING
鈥? lnstall only plugs that confirm with safety regula-
tions.
The Invertec V160-S cannot be stacked.
------------------------------------------------------------------------
V160-S
INSTALLATION
A-3 A-3
Fuse the input circuit with time delay fuses marked 鈥淒鈥? When the ARFU has been activated due to an input
or delay type1 circuit breakers. Using fuses or circuit over current condition, the output will be turned off and
breakers smaller than recommended may result in the green Power LED will blink indicating an over-cur-
鈥渘uisance鈥? shut-offs from welder inrush currents even rent condition. This condition usually occurs when the
if not welding at high currents. unit is operated beyond its rated duty cycle. The unit
will self-restore after a short time and will be ready for
normal operation once the green Power LED stops
Also called 鈥渋nverse time鈥? or 鈥渢hermal/magnetic鈥? circuit breakers.
1
blinking and remains on.
These circuit breakers have a delay in tripping action that
The Invertec V160-S is recommended for use on an
decreases as the magnitude of the current increases.
individual branch circuit.
NOTE: The ARFU replaces a fuse (F2) that was used
in older V160始s.
115V INPUT
WARNING
The rated output of the V160-S is available when con-
nected to a 30A branch circuit. When connected to a
鈥? Failure to wire as instructed may cause personal
branch circuit with lower ampacity, lower welding cur-
injury or damage to equipment. To be installed or
rent and duty cycle must be used. An output guide is
checked by an electrician or qualified person
provided below. The values are approximate and must
only.
be adjusted downward if the fuse or circuit breaker
------------------------------------------------------------------------
trips off. Other loads on the circuit and fuse/circuit
230V INPUT
breaker characteristics will affect the available output.
Do not exceed these welding conditions:
To achieve the full output capacity of the V160-S,
230VAC inputs should be used. The change over is
15A plug on a 15A branch
accomplished by replacing the 115VAC plug with a 30
10% duty cycle
Amp 230VAC plug (NEMA 6-30P).
Stick: 65A
TIG: 95A
ATTACHMENT PLUG
In all cases, the green or green/yellow grounding wire
15A plug on a 20A branch
must be connected to the grounding pin of the plug,
10% duty cycle
usually identified by a green screw.
Stick: 75A
TIG: 105A
All attachment plugs must comply with the Standard
for Attachment Plugs and Receptacles, UL498.
20A plug on a 20A branch
10% duty cycle
The product is considered acceptable for use only
Stick: 85A
when an attachment plug as specified is properly
TIG: 120A
attached to the supply cord.
The Invertec V160-S is provided with a 115/230V
The Invertec V160-S will auto reconnect to either
cable, 6.6ft.(2m) in length, with a 15Amp 5-15P plug
115V or 230V supplies.
molded onto the cord.
ENGINE DRIVEN GENERATOR
The V160-S is supplied with an additional 20A plug
that can replace the 15A plug to achieve higher out-
For use on engine drives, keep in mind the above
put. To install the supplied 20A plug:
input draw restrictions and the following precaution.
Connect the white (neutral) wire under terminal clamp
The Invertec V160-S can be operated on engine driv-
with silver screw, and black (hot) wire under terminal
en generators as long as the 230 volt auxiliary meets
clamp with brass screw. Connect green wire under
the following conditions:
terminal clamp with green screw.
鈥? The AC waveform peak voltage is below 400 volts*.
ARFU (AUTO-RESTORE FUSE) 鈥? The AC waveform frequency is between 45 and
65Hz.
The dual input voltage machine is provided with an
鈥? The RMS voltage of the AC waveform is always
ARFU device. It only operates when the input is con-
greater than 208VAC *.
nected to an 115V supply and protects from input over
current conditions.
* for 115 VAC input divide these values in half.
V160-S
INSTALLATION
A-4 A-4
OUTPUT CONNECTION FOR STICK
The following Lincoln engine drives meet these condi-
WELDING (FIGURE A.2)
tions when run in the high idle mode:
FIGURE A.2
鈥? Ranger 250,305
鈥? Commander 300, 400, & 500
Many engine drives do not meet these conditions (eg WORK CLAMP
Miller Bobcats, etc). Operation of the Invertec V160-S
is not recommended on engine drives not conforming
to these conditions. Such combinations may overvolt-
age the Invertec V160-S power source.
WORK CABLE
ELECTRODE
WARNING
OUTPUT CONNECTIONS
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
ELECTRIC SHOCK can kill.
output terminals corresponding to this polarity. For
instance, for DC(+) welding, connect the electrode
鈥? Keep the electrode holder and
cable (which is connected to the electrode holder) to
cable insulation in good condition.
the 鈥?+鈥? output terminal and the work cable (which is
鈥? Do not touch electrically live parts
connected to the work clamp) to the 鈥?-鈥? output termi-
or electrode with skin or wet cloth-
nal. Insert the connector with the key lining up with
ing.
the key way, and rotate approximately 1/4 turn clock-
wise; until the connection is snug. Do not over tighten.
鈥? Insulate yourself from work and ground.
鈥? Turn the input line Switch on the Invertec V160-
S 鈥渙ff鈥? before connecting or disconnecting out-
put cables or other equipment.
The Work Cable and Electrode Cable are supplied
-----------------------------------------------------------
with the welder. To connect the cables, turn the Power
Switch 鈥淥FF鈥?.
OUTPUT AND GAS CONNECTION FOR
TIG WELDING (FIGURE A.1)
FIGURE A.1
GAS HOSE NOZZLE
TIG TORCH
WORK CLAMP
WORK CABLE
This unit does not include a TIG torch, but one may be
purchased separately. The Lincoln (K1781-7 PTA-9FV,
K1782-11 PTA-17FV) and (K1782-6, K1782-8 PTA-
17V) are recommended for use with this machine for
this purpose; however, any similar TIG torch can be
used. To attach the Twist-Mate Plug to a Lincoln
Torch, slide the rubber boot onto the torch cable
(enlarge the boot opening if necessary), screw the fit-
ting on the torch cable into the brass connector snugly
and slide the boot back over the brass connector.
V160-S
INSTALLATION
A-5 A-5
QUICK DISCONNECT PLUG (FOR STICK ELEC- REMOTE CONTROL CONNECTION
TRODE CABLE) A remote control receptacle is provided on the lower
center case front of the welder for connecting a
A quick disconnect system is used for the welding
remote control to the machine. The V160-S will auto-
cable connections. The stick electrode cable will need
matically sense if a remote control connection is
to have a plug attached.
made. In Lift TIG mode (GTAW), WITHOUT a remote
1. Cut off welding cable lug, if present.
control device connected to the V160-S, the output
2. Remove .75 in. (19mm) of welding cable insulation.
will come on automatically. WITH a remote control
3. Slide rubber boot onto cable end. The boot end
device connected to the unit, the output will need to
may be trimmed to match the cable diameter. Use
be triggered, i.e. a Foot Amptrol. Refer to the Optional
soap or other nonpetroleum-based lubricant to
Accessories section of this manual for available
help slide the boot over the cable, if needed.
remote controls.
BOOT
WELDING CABLE
The following items can be connected to the 6 pin
socket on the front panel:
鈥? Remote control potentiometer (K857) for Stick
welding.
.75 in.
TRIM, IF REQ'D
鈥? Remote Foot Amptrol (K870), Hand Amptrol (K963-3).
19 mm TO FIT OVER CABLE
4. Cut 45-50% of the copper strands back 1/4鈥? (6
mm).
WELDING CABLE
.25 in.
6 mm
5. Fold copper strands over cut strands and insert
into ferrule.
COPPER FERRULE
WELDING CABLE
.50 in. max
12 mm max.
6. Slide the copper ferrule into the brass plug.
SET SCREW
BRASS PLUG
COPPER TUBE
7. Tighten set screw to collapse copper tube. Screw
must apply pressure against welding cable. The
top of the set screw will be well below the surface
of the brass plug after tightening.
OUTPUT CONNECTION FOR TIG WELDING
A one piece Gas Valve Tig Torch is recommended for
use with the V160-S. A K960-1 Tig Torch adapter is
required. See accessories section.
V160-S
OPERATION
B-1 B-1
GENERAL DESCRIPTION
Read and understand this entire section before
operating your machine.
SAFETY INSTRUCTIONS
The Invertec V160-S is an industrial 160 amp arc
welding power source which utilizes single phase
input power, to produce constant current output. The
WARNING welding response of this Invertec has been optimized
for stick (SMAW) and Touch Start TIG (GTAW). The
unit is ideal for industrial applications where portability
is important.
ELECTRIC SHOCK can kill.
The Invertec V160-S is recommended for stick weld-
鈥? Do not touch electrically live parts such ing with such popular electrodes as Fleetweld 35,
as output terminals or internal wiring. Fleetweld 37, Fleetweld 180 and LH 78. It features
adjustable arc control to adjust the arc force and start.
鈥? Insulate yourself from the work and
ground. The Invertec V160-S performs DC Touch Start Tig
Starting with excellent results.
鈥? Always wear dry insulating gloves.
WELDING CAPABILITY
____________________________________
The Invertec V160-S is rated at 160 amps, 26.4 volts,
FUMES AND GASES at 35% duty cycle on a ten minute basis. It is capable
can be dangerous. of higher duty cycles at lower output currents. It is
capable of 130 amps, 25.2 volts at at 100% duty
鈥? Keep your head out of fumes. cycle(1). If the duty cycle is exceeded, a thermal pro-
tector will shut off the output until the machine cools.
鈥? Use ventilation or exhaust to See Technical Specifications in A-1 for other rated out-
remove fumes from breathing puts.
zone.
The Invertec V160-S is recommended for stick weld-
____________________________________ ing with such popular electrodes as Fleetweld庐 35,
Fleetweld 37, Fleetweld 180 and Jet-LH 78 MR. It fea-
WELDING, CUTTING and
tures adjustable arc control to adjust the arc force and
GOUGING SPARKS
start.
can cause fire or explosion
LIMITATIONS
鈥? Keep flammable material away.
The V160-S is not recommended for pipe thawing.
鈥? Do not weld, cut or gouge on
containers that have held com-
bustibles.
____________________________________
ARC RAYS
(1)When connected to 230VAC inputs.
can burn.
鈥? Wear eye, ear and body
protection.
____________________________________
Only qualified personnel should operate this equip-
ment. Observe all safety information throughout this
manual.
V160-S
OPERATION
B-2 B-2
REAR CONTROL PANEL 4. Arc Control: The Arc Control simultaneously adjust
the level at Hot Start and Arc Force. Increasing the Arc
1. Power Switch: Controls the input power to the Control setting increases both Hot Start and Arc Force.
machine. Make sure the machine is properly con-
nected to the input supply before turning the 鈥? Hot Start: This is a temporary increase in the output
machine on.(See Figure B.1) current during the start of the stick welding process.
This helps ignite the arc quickly and reliably.
2. Fan: The cooling fan will turn ON when the
machine is turned ON and it will continue to run 鈥? Arc Force: This is a temporary increase in the out-
whenever the output of the machine is ON. If the put current during normal stick welding. This tempo-
output of the machine is OFF for more than five min- rary increase in output current is used to clear inter-
utes, the fan will turn OFF. This reduces the amount mittent shorts between the electrode and the weld
of dirt that is deposited inside the machine and puddle that occur during normal stick welding.
reduces power consumption.(See Figure B.1)
5. Power LED: This indicator will blink on and off
Refer to the Output LED section below for more when the machine is first turned on. After approxi-
information about conditions when the output of the mately 2 seconds it will stop blinking and remain on
machine is ON. (See Figure B.1) to signal that the machine is ready. The indicator
will also blink during over current conditions when
CONTROLS AND SETTINGS (See Figure B.2) operating on 115V input.
3. Mode Switch: This switch changes the welding 6. Thermal LED: This indicator will turn on when the
modes of the machine. The V160-S has two weld- machine is overheated and the output has been dis-
ing modes: Stick (SMAW) and Lift TIG (GTAW). abled. This normally occurs when the duty cycle of the
machine has been exceeded. Leave the machine on
When the mode switch is in the Lift TIG position, the to allow the internal components to cool. When the
stick welding functions are disabled and the machine indicator turns off, normal operation is again possible.
is ready for Lift TIG welding. Lift TIG is a method of
starting a TIG weld by first pressing the TIG torch
electrode on the work piece in order to create a low
current short circuit. Then, the electrode is lifted from
the work piece to start the TIG arc.
FIGURE B.1
1. Power Switch
2. Fan
1
1
2
2
V160-S
OPERATION
B-3 B-3
9. Output Current Control: This controls the output
7. Remote LED: This indicator will turn on when a
or welding current of the machine.
remote control is connected to the machine via the
remote control connector. Using a remote control
The function of this control knob is changed if a
will change the function of the output current con-
remote control is connected. If the Remote LED is
trol, refer to the output current control section
ON, this indicates that a remote control is connect-
below.
ed and the function of the output current control will
8. Output LED: This indicator turns on when the out- be:
put of the machine is on.
鈥? Stick Welding Mode: The remote control will adjust
the output current of the machine from 5 to 160A.
鈥? In stick welding mode, the output of the machine is
The output current control knob on the display
automatically turned ON.
panel is not used.
鈥? TIG Welding Modes: The maximum output current
鈥? In Lift TIG welding mode without a remote control,
of the machine is set by the output current control
the output of the machine is automatically turned
knob. The remote control then adjusts the output
ON. In this condition a triggering device is not
current from the minimum output (5A) to the value
needed.
set by the output current control knob. For example,
if the output current control knob on the machine is
鈥? In Lift TIG welding mode with a remote control, the
set to 100A then the remote control will adjust the
output of the machine is turned ON and OFF by the
output current from a minimum of 5A to a maximum
remote device (i.e. hand or foot amptrol) connected
of 100A.
to the remote connector on the front of the
machine. Output must be triggered ON (output LED
10. 鈥淭wist-Mate鈥? Connection (Negative)
lit) to enable Lift TIG starting. After machine output
is triggered ON, the arc must be started within 6.5
11. Remote Control Connector
seconds or output will turn OFF and trigger
sequence must be restarted. (Note: Any remote
12. 鈥淭wist-Mate鈥? Connection (Positive)
control device with trigger-only circuit, such as the
K814 Arc Start Switch, will not be sensed by the
V160-S remote control connection, and therefore
will not allow control of the output).
FIGURE B.2
5 7
8
6
3. Mode Switch
4. Arc Control
3
9 5. Power LED
6. Thermal LED
4 7 Remote LED
8. Output LED
9. Output Current Control
10. Electrode Connection (Negative)
11. Remote Control Connector
12. Electrode Connection (Positive)
10 12
11
V160-S
OPERATION
B-4 B-4
DIP SWITCH FUNCTIONS DIP Switch 1: Machine Type
This controls the output of the V160-S and some
welding waveform functions. It configures the V160-S
This section has 8 DIP switch functions of the V160- to automatically turn ON depending on the position of
S. Read and understand the functions before making the Welding Mode switch. Refer to DIP Switch 6 for
any changes because abnormal operation can occur more information.
with the wrong settings. The machine must be turned
OFF when the DIP Switches are changed. DIP Switch 2 thru 5 non-functional for the V160-S.
WARNING FIGURE B.3
ELECTRIC SHOCK CAN KILL:
Be sure that all installation, opera-
tion, maintenance and repair proce- Front of machine
dures are performed only by qualified
individuals. Lincoln Electric is not
responsible for damages caused by
improper installation, improper care or abnormal
operation.
Before opening the machine to make changes to
the DIP Switches it must first be turned OFF and
disconnected from the input source. Do not open
the machine or change the DIP Switches with
power applied to the machine. Only Lincoln
trained service technicians are authorized to per-
form these modifications.
------------------------------------------------------------------------
The DIP switches are numbered from 1 to 8 shown in
Figure B.3. Switch 1 is on the bottom and switch 8 is
on the top. When a switch is pushed to the right (or to
the back of the machine) it is ON; when it is pushed to
the left (or to the front of the machine) it is OFF. DIP
Switch 8
The standard production settings for the V160-S are
shown with in bold letters ON Table B.1. If a switch
setting has bold letters ON, do not make any changes;
abnormal operation could occur.
TABLE B.1
DIP V160-S V160-S
Switch CE USA
ON ON
1
2 OFF OFF DIP
3 OFF ON Switch 1
4 ON OFF
5 OFF OFF
6 OFF ON
7 OFF OFF
8 OFF OFF
V160-S
OPERATION
B-5 B-5
DIP Switch 6: European/USA Machine
Configuration
This configures several functions of the V160-S as
required by the European and USA markets. For the
European market it is OFF and for the USA market it
is ON.
Specifically, this configures the operation of the TIG
slope timers, remote control, and trigger. However,
this configuration also depends on the position of DIP
Switch 1 which selects the machine type. This setting
can be changed but only if the following functions are
clearly understood.
(DIP Switch 1 = ON)
In TIG welding mode, the following conditions can
exist.
鈥? No TIG slopes are available. If slopes are needed a
foot pedal remote control can be used.
鈥? No remote control connected. With no remote con-
trol connected, the output is ON and a trigger is not
needed. Simple Lift TIG welding is possible.
鈥? Remote control connected. With a remote control
connected, the output is OFF and a trigger is need-
ed. Simple Lift-TIG welding is possible using a 2-
step trigger sequence.
DIP Switch 7 thru 8 non-functional for the V160-S.
START/CRATER CURRENT ADJUSTMENT
It is not possible to change the start/crater current of a
"S" type machine. The values set from the factory
are:
European Machines: 20% (160A welding current =
32A start/crater current)
USA Machines: 10% (160A welding current =
16A start/crater current)
V160-S
ACCESSORIES
C-1 C-1
OPTIONAL ACCESSORIES CABLE PLUGS
AND COMPATIBLE EQUIPMENT
K852-50 - Cable Plug Kit for #1-#2 cable. Attaches to
Factory Installed welding cable to provide quick disconnect from
machine.
Electrical Holder and Cable Assembly
TIG Torch Parts Kits - Parts kits are available for the
Work Cable and Clamp
PTA-17 TIG torch. This kit includes back cap, collets,
Strap Packet
collet bodies, nozzles and tungstens.
Instruction Manual
Order KP508 for PTA-17 torches
See publication E12.150 for parts kits breakdown.
Field Installed Cut Length Consumables - TIG welding filler metals
are available for welding stainless steel, mild steel,
K870 - Foot Amptroltm for TIG welding. When the aluminum and copper alloys. See publication C9.10.
V160-S始s Output Control is in the 鈥淩EMOTE鈥? 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 Amptroltm for TIG welding. When the
V160-S始s Output Control is in the 鈥淩emote鈥? position,
the hand Amptrol energizes the output and controls
the output remotely. The Hand Amptrol connects
directly to the 6 pin Amphenol.
PTA-17V TIG Torch - 150 Amp air-cooled compact
and durable Tig Torch with integral gas valve for gas
control at the torch. The following 1-piece cable torches
can be used with a K960-1 adapter:
鈥? K1782-6 (12.50 Ft.) 1-Piece Cable
鈥? K1782-8 (25.0 Ft.) 1-Piece Cable
PTA-9FV TIG Torch - Gas Valve flexible head torch:
鈥? K1781-7 (25.0 Ft.) 1-Piece Cable
PTA-17FV TIG Torch - Gas Valve flexible head torch:
鈥? K1782-11 (25.0 Ft.) 1-Piece Cable
K960-1-TIG Torch Adapter - for connection of PTA-
17V torches (1-piece cable) to power sources without
gas passing through the Twist Mate connection.
NOTE: Any remote control with trigger-only circuit,
such as the K814 Arc Start Switch, will not be sensed
by the V160-S remote control connection, and there-
fore will not allow control of the output.
V160-S
MAINTENANCE
D-1 D-1
SAFETY PRECAUTIONS
CAUTION
ELECTRIC SHOCK can kill.
WARNING
鈥? Disconnect the power supply before every oper-
鈥? Have an electrician install and serv-
ation.
ice this equipment.
------------------------------------------------------------------------
鈥? Always use gloves in compliance with the safety
鈥? Turn the input power off at the fuse
standards.
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.
鈥? Do not touch electrically hot 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
鈥isconnect the power supply before every opera-
tion.
------------------------------------------------------------------------
Carry out the following periodic controls on the power
source:
鈥? Clean the power source inside by means of low-
pressure compressed air.
鈥? Check the electric connections and all the connec-
tion cables.
V160-S
TROUBLESHOOTING
E-1 E-1
HOW TO USE TROUBLESHOOTING GUIDE
WARNING
Service and Repair should only be performed by Lincoln Electric Factory Trained Personnel.
Unauthorized repairs performed on this equipment may result in danger to the technician and
machine operator and will invalidate your factory warranty. For your safety and to avoid Electrical
Shock, please observe all safety notes and precautions detailed throughout this manual.
__________________________________________________________________________
Step 3. RECOMMENDED COURSE OF ACTION
This Troubleshooting Guide is provided to help you
locate and repair possible machine malfunctions. This column provides a course of action for the
Simply follow the three-step procedure listed below. Possible Cause, generally it states to contact your
local Lincoln Authorized Field Service Facility.
Step 1. LOCATE PROBLEM (SYMPTOM).
Look under the column labeled 鈥淧ROBLEM (SYMP- If you do not understand or are unable to perform the
TOMS)鈥?. This column describes possible symptoms Recommended Course of Action safely, contact your
that the machine may exhibit. Find the listing that local Lincoln Authorized Field Service Facility.
best describes the symptom that the machine is
exhibiting.
Step 2. POSSIBLE CAUSE.
The second column labeled 鈥淧OSSIBLE CAUSE鈥? lists
the obvious external possibilities that may contribute
to the machine symptom.
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.
V160-S
TROUBLESHOOTING
E-2 E-2
Observe all Safety Guidelines detailed throughout this manual
PROBLEMS POSSIBLE AREAS OF RECOMMENDED
(SYMPTOMS) MISADJUSTMENTS(S) 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.
3. 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
your local Lincoln Authorized Field
Porosity 1. Humidity in electrode. Service Facility.
2. Long arc.
Cracks 1. Current too high.
2. Dirty materials.
3. Hydrogen in weld (present on
electrode coating).
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.
V160-S
TROUBLESHOOTING
E-3 E-3
Observe all Safety Guidelines detailed throughout this manual
PROBLEMS POSSIBLE AREAS OF RECOMMENDED
(SYMPTOMS) MISADJUSTMENT(S) COURSE OF ACTION
PROBLEMS IN TIG WELDING
Oxidation 1. lnsufficient gas.
2. No protection on the back side.
Tungsten inclusions 1. lncorrect electrode sharpening.
2. Electrode too small.
3. Operating failure (contact of the
tip with the workpiece).
Porosity 1. Dirt on the edges.
2. Dirt on the filler material.
3. Excessive travel speed.
If all recommended possible areas of
4. Current intensity too low.
misadjustment have been checked
and the problem persists, Contact
Hot cracking 1 Unsuitable filler material.
your local Lincoln Authorized
2. High heat supply.
Field Service Facility.
3. Dirty materials.
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.
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.
V160-S
TROUBLESHOOTING
E-4 E-4
Observe all Safety Guidelines detailed throughout this manual
PROBLEMS POSSIBLE AREAS OF RECOMMENDED
(SYMPTOMS) MISADJUSTMENT(S) COURSE OF ACTION
ELECTRICAL FAILURES
Machine fails to come on 1. No Input Voltage.
(Power LED off)
2. Faulty supply plug or cable.
3. Internal fuse blown.
Power Input incorrect 1. Input voltage out of range (less
Input over-current than 95 or greater than 265VAC).
(Power LED Flashing)
2. Input current too high due to oper-
ating beyond rated duty cycle.
If all recommended possible areas of
misadjustment have been checked
No output current 1. While in TIG mode, Trigger circuit
and the problem persists, Contact
(Power LED on) not mode at 6 pin amphenol.
your local Lincoln Authorized
(Output LED off)
Field Service Facility.
Thermal overload 1. Unit has been operated beyond its
(Thermal LED on) capacity rating.
2. Airflow through machine is
restricted or fan has failed.
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.
V160-S
F-1
WIRING DIAGRAM CODE 10877
V160-S WIRING DIAGRAM
S1
RED
WHITE 2 1 BLUE
+
W1
AC1 DC+ DC+
115/230/1/50/60
BLACK
4 3 DC-A -
AC2 W2
DC-
Vac BLACK BROWN
INVERTER BOARD
W05X0190
INPUT BOARD
GREEN (SCHEMATIC: X0190)
GND W05X0250 Y/G
OR GND
(SCHEMATIC: X0203)
GREEN /YELLOW
1
JP1
FAN
2 1 2 3 4 5 6 7 8 9 10
JP2
3
JP1
4
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
V160-S
DIAGRAMS
26 25 24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
DISPLAY BOARD
J1
W05X0245
(SCHEMATIC: X0245)
WELD CONTROLLER
W05X0233
(SCHEMATIC: X0233) JP1
12345678
WARNING: HIGH VOLTAGE CAN KILL
* Do not operate with covers removed.
* Disconnect input power by unplugging CBA
D E
REMOTE
power cord before servicing.
* Do not touch electrically live parts. CONNECTOR
* Only qualified persons should install,
CW
use or service this machine.
X0261
NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual. The specific diagram for a particular code is pasted inside
the machine on one of the enclosure panels. If the diagram is illegible, write to the Service Department for a replacement. Give the equipment code number.
F-1
F-2
WIRING DIAGRAM CODE 11031
V160-S WIRING DIAGRAM
WHITE BLUE RED
2 1
AC1 DC+ W1
DC+
+
BLACK BROWN BLACK
4 3
115/230/1/50/60
AC2 DC-A W2
DC-
Vac
S1 -
INVERTER BOARD
GREEN
W05X0190
OR INPUT BOARD
(SCHEMATIC:
YELLOW / GREEN W05X0250
GND Y/G X0190)
GND
(SCHEMATIC:
X0203)
1
JP1
FAN
2 1 2 3 4 5 6 7 8 9 10
JP2
3
4
JP1
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
V160-S
26 25 24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
DIAGRAMS
DISPLAY BOARD J1
W05X0371
WELD CONTROLLER
(SCHEMATIC: X0371)
W05X0338
JP1
(SCHEMATIC: X0233)
WARNING: HIGH VOLTAGE CAN KILL *
* Do not operate with covers removed.
* Disconnect input power by unplugging J1
power cord before servicing.
* Do not touch electrically live parts. REMOTE BOARD
* Only qualified persons should install, Y/G W05X0322
EARTH
use or service this machine.
W07X0261rev03
(SCHEMATIC: X0322)
*
RIBBON CABLE
NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual. The specific diagram for a particular code is pasted inside
the machine on one of the enclosure panels. If the diagram is illegible, write to the Service Department for a replacement. Give the equipment code number.
F-2
NOTES
V160-S
WARNING
G Do not touch electrically live parts or G Keep flammable materials away. G Wear eye, ear and body protection.
electrode with skin or wet clothing.
AVISO DE
G Insulate yourself from work and
ground.
Spanish
PRECAUCION
G No toque las partes o los electrodos G Mantenga el material combustible G Prot茅jase los ojos, los o铆dos y el
bajo carga con la piel o ropa moja- fuera del 谩rea de trabajo. cuerpo.
da.
G Aislese del trabajo y de la tierra.
ATTENTION
French G Ne laissez ni la peau ni des v锚te- G Gardez 脿 l鈥櫭ヽart de tout mat茅riel G Prot茅gez vos yeux, vos oreilles et
ments mouill茅s entrer en contact inflammable. votre corps.
avec des pi猫ces sous tension.
G Isolez-vous du travail et de la terre.
WARNUNG
German G Ber眉hren Sie keine stromf眉hrenden G Entfernen Sie brennbarres Material! G Tragen Sie Augen-, Ohren- und K枚r-
Teile oder Elektroden mit Ihrem perschutz!
K枚rper oder feuchter Kleidung!
G Isolieren Sie sich von den
ATEN脟脙O
Portuguese
Elektroden und dem Erdboden!
G N茫o toque partes el茅tricas e elec- G Mantenha inflam谩veis bem guarda- G Use prote莽茫o para a vista, ouvido e
trodos com a pele ou roupa molha- dos. corpo.
da.
G Isole-se da pe莽a e terra.
Japanese
Chinese
Korean
Arabic
READ AND UNDERSTAND THE MANUFACTURER鈥橲 INSTRUCTION FOR THIS EQUIPMENT AND THE CONSUMABLES TO BE
USED AND FOLLOW YOUR EMPLOYER鈥橲 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 ELEKTRODENEINSATZ DES HER-
STELLERS. DIE UNFALLVERH脺TUNGSVORSCHRIFTEN DES ARBEITGEBERS SIND EBENFALLS ZU BEACHTEN.
WARNING
G Keep your head out of fumes. G Turn power off before servicing. G Do not operate with panel open or
G Use ventilation or exhaust to guards off.
AVISO DE
remove fumes from breathing zone.
Spanish
PRECAUCION
G Los humos fuera de la zona de res- G Desconectar el cable de ali- G No operar con panel abierto o
piraci贸n. mentaci贸n de poder de la m谩quina guardas quitadas.
G Mantenga la cabeza fuera de los antes de iniciar cualquier servicio.
humos. Utilice ventilaci贸n o
ATTENTION
aspiraci贸n para gases.
French
G D茅branchez le courant avant l鈥檈ntre- G N鈥檕p茅rez pas avec les panneaux
G Gardez la t锚te 脿 l鈥櫭ヽart des fum茅es.
G Utilisez un ventilateur ou un aspira- tien. ouverts ou avec les dispositifs de
protection enlev茅s.
teur pour 么ter les fum茅es des zones
WARNUNG
de travail.
German
G Strom vor Wartungsarbeiten G Anlage nie ohne Schutzgeh盲use
G Vermeiden Sie das Einatmen von
abschalten! (Netzstrom v枚llig 枚ff- oder Innenschutzverkleidung in
Schweibrauch!
G Sorgen Sie f眉r gute Be- und nen; Maschine anhalten!) Betrieb setzen!
Entl眉ftung des Arbeitsplatzes!
ATEN脟脙O
Portuguese
G N茫o opere com as tampas removidas. G Mantenha-se afastado das partes
G Mantenha seu rosto da fuma莽a.
G Desligue a corrente antes de fazer
G Use ventila莽茫o e exhaust茫o para moventes.
servi莽o. G N茫o opere com os paineis abertos
remover fumo da zona respirat贸ria.
G N茫o toque as partes el茅tricas nuas. ou guardas removidas.
Japanese
Chinese
Korean
Arabic
LEIA E COMPREENDA AS INSTRU脟脮ES DO FABRICANTE PARA ESTE EQUIPAMENTO E AS PARTES DE USO, E SIGA AS
PR脕TICAS DE SEGURAN脟A DO EMPREGADOR.
鈥? World's Leader in Welding and Cutting Products 鈥?
鈥? Sales and Service through Subsidiaries and Distributors Worldwide 鈥?
Cleveland, Ohio 44117-1199 U.S.A. TEL: 216.481.8100 FAX: 216.486.1751 WEB SITE: www.lincolnelectric.com
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