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IM585
INVERTEC ® V100-S & V130-S
For use with machines having Code Numbers:
January, 2002
V100-S 10461 V130-S 10462
Safety Depends on You
Lincoln arc welding and cutting equipment is designed and built with safety in mind. However, your overall safety can be increased by proper installation ... and thoughtful operation on your part. DO NOT INSTALL, OPERATE OR REPAIR THIS EQUIPMENT WITHOUT READING THIS MANUAL AND THE SAFETY PRECAUTIONS CONTAINED THROUGHOUT. And, most importantly, think before you act and be careful.
Date of Purchase: Serial Number: Code Number: Model: Where Purchased:
OPERATOR'S MANUAL
Copyright © 2002 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
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SAFETY
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WARNING
CALIFORNIA PROPOSITION 65 WARNINGS Diesel engine exhaust and some of its constituents are known to the State of California to cause cancer, birth defects, and other reproductive harm. The Above For Diesel Engines The engine exhaust from this product contains chemicals known to the State of California to cause cancer, birth defects, or other reproductive harm. The Above For Gasoline 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 "Safety in Welding & 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.
FOR ENGINE powered equipment.
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.
1.h. To avoid scalding, do not remove the radiator pressure cap when the engine is hot.
____________________________________________________ 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 vaporizing on contact with hot engine parts and igniting. Do not spill fuel when filling tank. If fuel is spilled, wipe it up and do not start engine until fumes have been eliminated. ____________________________________________________ 1.d. Keep all equipment safety guards, covers and devices in 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. ____________________________________________________ 1.e. In some cases it may be necessary to remove safety guards to perform required maintenance. Remove guards only when necessary and replace them when the maintenance requiring their removal is complete. Always use the greatest care when working near moving parts. ___________________________________________________ 1.f. Do not put your hands near the engine fan. Do not attempt to override the governor or idler by pushing on the throttle control rods while the engine is running. ___________________________________________________ 1.g. To prevent accidentally starting gasoline engines while turning the engine or welding generator during maintenance work, disconnect the spark plug wires, distributor cap or magneto wire as appropriate.
ELECTRIC AND MAGNETIC FIELDS 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 2.b. EMF fields may interfere with some pacemakers, and welders having a pacemaker should consult their physician before welding. 2.c. Exposure to EMF fields in welding may have other health effects which are now not known. 2.d. All welders should use the following procedures in order to minimize exposure to EMF fields from the welding circuit: 2.d.1. Route the electrode and work cables together - Secure them with tape when possible. 2.d.2. Never coil the electrode lead around your body. 2.d.3. Do not place your body between the electrode and work cables. If the electrode cable is on your right side, the work cable should also be on your right side. 2.d.4. Connect the work cable to the workpiece as close as possible to the area being welded. 2.d.5. Do not work next to welding power source.
Mar `95
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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.
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ARC RAYS can burn.
4.a. Use a shield with the proper filter and cover plates to protect your eyes from sparks and the rays of the arc when welding or observing open arc welding. Headshield and filter lens should conform to ANSI Z87. I standards. 4.b. Use suitable clothing made from durable flame-resistant material to protect your skin and that of your helpers from the arc rays. 4.c. Protect other nearby personnel with suitable, non-flammable screening and/or warn them not to watch the arc nor expose themselves to the arc rays or to hot spatter or metal.
3.b. Insulate yourself from work and ground using dry insulation. Make certain the insulation is large enough to cover your full area of physical contact with work and ground. In addition to the normal safety precautions, if welding must be performed under electrically hazardous conditions (in damp locations or while wearing wet clothing; on metal structures such as floors, gratings or scaffolds; when in cramped positions such as sitting, kneeling or lying, if there is a high risk of unavoidable or accidental contact with the workpiece or ground) use the following equipment: · Semiautomatic DC Constant Voltage (Wire) Welder. · DC Manual (Stick) Welder. · AC Welder with Reduced Voltage Control. 3.c. In semiautomatic or automatic wire welding, the electrode, electrode reel, welding head, nozzle or semiautomatic welding gun are also electrically "hot". 3.d. 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. 3.e. Ground the work or metal to be welded to a good electrical (earth) ground. 3.f. Maintain the electrode holder, work clamp, welding cable and welding machine in good, safe operating condition. Replace damaged insulation. 3.g. Never dip the electrode in water for cooling. 3.h. 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. 3.i. When working above floor level, use a safety belt to protect yourself from a fall should you get a shock. 3.j. Also see Items 6.c. and 8.
FUMES AND GASES can be dangerous.
5.a. Welding may produce fumes and gases hazardous to health. Avoid breathing these fumes and gases.When welding, keep your head out of the fume. Use enough ventilation and/or exhaust at the arc to keep fumes and gases away from the breathing zone. When welding with electrodes which require special ventilation such as stainless or hard facing (see instructions on container or MSDS) or on lead or cadmium plated steel and other metals or coatings which produce highly toxic fumes, keep exposure as low as possible and below Threshold Limit Values (TLV) using local exhaust or mechanical ventilation. In confined spaces or in some circumstances, outdoors, a respirator may be required. Additional precautions are also required when welding on galvanized steel. 5.b. Do not weld in locations near chlorinated hydrocarbon vapors coming from degreasing, cleaning or spraying operations. The heat and rays of the arc can react with solvent vapors to form phosgene, a highly toxic gas, and other irritating products. 5.c. 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.d. 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. 5.e. Also see item 1.b.
Mar `95
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SAFETY
WELDING SPARKS can cause fire or explosion. CYLINDER may explode if damaged.
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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. 6.b. Where compressed gases are to be used at the job site, special precautions should be used to prevent hazardous situations. Refer to "Safety in Welding and Cutting" (ANSI Standard Z49.1) and the operating information for the equipment being used. 6.c. 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. 6.d. Do not heat, cut or weld tanks, drums or containers until the proper steps have been taken to insure that such procedures will not cause flammable or toxic vapors from substances inside. They can cause an explosion even though they have been "cleaned". For information, purchase "Recommended Safe Practices for the Preparation for Welding and Cutting of Containers and Piping That Have Held Hazardous Substances", AWS F4.1 from the American Welding Society (see address above). 6.e. Vent hollow castings or containers before heating, cutting or welding. They may explode. 6.f. 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. 6.g. 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. 6.h. Also see item 1.c.
7.a. Use only compressed gas cylinders containing the correct shielding gas for the process used and properly operating regulators designed for the gas and pressure used. All hoses, fittings, etc. should be suitable for the application and maintained in good condition. 7.b. Always keep cylinders in an upright position securely chained to an undercarriage or fixed support. 7.c. Cylinders should be located: · Away from areas where they may be struck or subjected to physical damage. · A safe distance from arc welding or cutting operations and any other source of heat, sparks, or flame. 7.d. Never allow the electrode, electrode holder or any other electrically "hot" parts to touch a cylinder. 7.e. Keep your head and face away from the cylinder valve outlet when opening the cylinder valve. 7.f. Valve protection caps should always be in place and hand tight except when the cylinder is in use or connected for use. 7.g. Read and follow the instructions on compressed gas cylinders, associated equipment, and CGA publication P-l, "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. 8.b. Install equipment in accordance with the U.S. National Electrical Code, all local codes and the manufacturer's recommendations. 8.c. Ground the equipment in accordance with the U.S. National Electrical Code and the manufacturer's recommendations.
Mar `95
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SAFETY
PRÉCAUTIONS DE SÛRETÉ
zones où l'on pique le laitier.
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Pour votre propre protection lire et observer toutes les instructions et les précautions de sûreté specifiques qui parraissent dans ce manuel aussi bien que les précautions de sûreté générales suivantes: Sûreté Pour Soudage A L'Arc 1. Protegez-vous contre la secousse électrique: a. Les circuits à l'électrode et à la piéce sont sous tension quand la machine à souder est en marche. Eviter toujours tout contact entre les parties sous tension et la peau nue ou les vétements mouillés. Porter des gants secs et sans trous pour isoler les mains. b. Faire trés 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 couché pour lesquelles une grande partie du corps peut être en contact avec la masse. c. Maintenir le porte-électrode, la pince de masse, le câble de soudage et la machine à souder en bon et sûr état defonctionnement. d.Ne jamais plonger le porte-électrode dans l'eau pour le refroidir. e. Ne jamais toucher simultanément les parties sous tension des porte-électrodes connectés à deux machines à souder parce que la tension entre les deux pinces peut être le total de la tension à vide des deux machines. f. Si on utilise la machine à souder comme une source de courant pour soudage semi-automatique, ces precautions pour le porte-électrode s'applicuent aussi au pistolet de soudage. 2. Dans le cas de travail au dessus du niveau du sol, se protéger contre les chutes dans le cas ou on recoit un choc. Ne jamais enrouler le câble-électrode autour de n'importe quelle partie du corps. 3. Un coup d'arc peut être plus sévère qu'un coup de soliel, donc: a. Utiliser un bon masque avec un verre filtrant approprié ainsi qu'un verre blanc afin de se protéger les yeux du rayonnement de l'arc et des projections quand on soude ou quand on regarde l'arc. b. Porter des vêtements convenables afin de protéger la peau de soudeur et des aides contre le rayonnement de l`arc. c. Protéger l'autre personnel travaillant à proximité au soudage à l'aide d'écrans appropriés et non-inflammables. 4. Des gouttes de laitier en fusion sont émises de l'arc de soudage. Se protéger avec des vêtements de protection libres de l'huile, tels que les gants en cuir, chemise épaisse, pantalons sans revers, et chaussures montantes. 5. Toujours porter des lunettes de sécurité dans la zone de soudage. Utiliser des lunettes avec écrans lateraux dans les
6. Eloigner les matériaux inflammables ou les recouvrir afin de prévenir tout risque d'incendie dû aux étincelles. 7. Quand on ne soude pas, poser la pince à une endroit isolé de la masse. Un court-circuit accidental peut provoquer un échauffement et un risque d'incendie. 8. S'assurer que la masse est connectée le plus prés 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 éloignés de la zone de travail, on augmente le risque de voir passer le courant de soudage par les chaines de levage, câbles de grue, ou autres circuits. Cela peut provoquer des risques d'incendie ou d'echauffement des chaines et des câbles jusqu'à ce qu'ils se rompent. 9. Assurer une ventilation suffisante dans la zone de soudage. Ceci est particuliérement important pour le soudage de tôles galvanisées plombées, ou cadmiées ou tout autre métal qui produit des fumeés toxiques. 10. Ne pas souder en présence de vapeurs de chlore provenant d'opérations de dégraissage, nettoyage ou pistolage. La chaleur ou les rayons de l'arc peuvent réagir avec les vapeurs du solvant pour produire du phosgéne (gas fortement toxique) ou autres produits irritants. 11. Pour obtenir de plus amples renseignements sur la sûreté, voir le code "Code for safety in welding and cutting" CSA Standard W 117.2-1974.
PRÉCAUTIONS DE SÛRETÉ POUR LES MACHINES À SOUDER À TRANSFORMATEUR ET À REDRESSEUR
1. Relier à la terre le chassis du poste conformement au code de l'électricité et aux recommendations du fabricant. Le dispositif de montage ou la piece à souder doit être branché à une bonne mise à la terre. 2. Autant que possible, I'installation et l'entretien du poste seront effectués par un électricien qualifié. 3. Avant de faires des travaux à l'interieur de poste, la debrancher à l'interrupteur à la boite de fusibles. 4. Garder tous les couvercles et dispositifs de sûreté à leur place.
Mar. `93
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for selecting a QUALITY product by Lincoln Electric. We want you to take pride in operating this Lincoln Electric Company product ··· as much pride as we have in bringing this product to you!
Thank You
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. Model Name & Number _____________________________________ Code & Serial Number _____________________________________ Date of Purchase _____________________________________
Whenever you request replacement parts for 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.
TABLE OF CONTENTS
Page Installation.......................................................................................................................Section A Technical Specifications V100-S ..........................................................................................A-1 Technical Specifications V130-S ..........................................................................................A-2 Safety Precautions. ..............................................................................................................A-3 Select Suitable Location .......................................................................................................A-3 Stacking................................................................................................................................A-3 Tilting ....................................................................................................................................A-3 High Frequency Precautions ................................................................................................A-3 Input Supply Connections ....................................................................................................A-3 Input Fuse and Supply Wire .................................................................................................A-3 Output Connections..............................................................................................................A-3 Output Connections ......................................................................................................A-4 Output Connection for Stick Welding ............................................................................A-4 Output and Gas Connection for TIG Welding ...............................................................A-4 Quick Disconnect Plug .........................................................................................................A-4 Operation.........................................................................................................................Section B Safety Instructions ................................................................................................................B-1 General Description..............................................................................................................B-1 Operational Features............................................................................................................B-1 Welding Capability................................................................................................................B-1 Limitations ............................................................................................................................B-1 Controls and Settings ...........................................................................................................B-2 Constant Current Processes ................................................................................................B-3 Manual Arc Welding (Stick) ...........................................................................................B-3 TIG Welding ..................................................................................................................B-3 Overload Protection..............................................................................................................B-3 Thermal Protection ...............................................................................................................B-3
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Accessories .....................................................................................................Section C Options / Accessories............................................................................................C-1 Maintenance ....................................................................................................Section D Safety Precautions ................................................................................................D-1 Input Filter Capacitor Discharge Procedure ..........................................................D-1 Routine Maintenance.............................................................................................D-1
Troubleshooting ..............................................................................................Section E PC Board Troubleshooting Procedures .................................................................E-1 Troubleshooting Chart ...........................................................................................E-2 Diagrams ..........................................................................................................Section F Wiring Diagram V100-S .........................................................................................F-1 Wiring Diagram V130-S .........................................................................................F-2 Parts Lists ........................................................................................................Appendix V100-S...............................................................................................................P-304 V130-S...............................................................................................................P-305
A-1
INSTALLATION
INPUT SINGLE PHASE
INPUT Voltage(2) 115V Input Current at Rated Output 32A @ 100A OUTPUT 25A @ 85A OUTPUT 20A @ 70A OUTPUT Hertz 50/60 Hz
A-1
Technical Specifications - Invertec V100-S
RATED OUTPUT
Duty Cycle(1) 15% Duty Cycle 20% Duty Cycle 20% Duty Cycle Amps 100 85 (20 Amp Circuit) 70 (15 Amp Circuit) Volts at Rated Amps 24 23.5 23
OUTPUT
Welding Current Range 8-100 Amps Maximum Open Circuit Voltage 67 VDC
RECOMMENDED INPUT CABLE AND FUSE SIZES
OUTPUT FUSE (SUPERLAG) INPUT CURRENT OR BREAKER SIZE CURRENT RATING 100A 30A 32A POWER CORD EXTENSION CORD (up to 50 feet) EXTENSION CORD (more than 50 feet)
30 Amp, 125V, Three Conductor Three Conductor Three-prong plug #10 AWG (5.2 mm2) #8 AWG (8.2 mm2) (NEMA Type 5-30P) or larger or larger 20Amp, 125V, Three Conductor Three Conductor Three-prong plug #12 AWG (3.3 mm2) #10 AWG (5.2 mm2) (NEMA Type 5-20P) or larger or larger 15 Amp, 125V, Three Conductor Three Conductor Three-prong plug #14 AWG (2.0 mm2) #12 AWG (3.3 mm2) (NEMA Type 5-15P) or larger or larger
85A
25A
25A
70A
20A
20A
PHYSICAL DIMENSIONS
Height 10.0 in. 254 mm Width 5.4 in. 138 mm Depth 13.8 in. 351 mm Weight 11.0 lbs. 5.0 Kg
OPERATING TEMPERATURE
-20°C to +40°C
(1) Based on a 10 min. period. (2) Input voltage must be within ±10% of rated value.
STORAGE TEMPERATURE
-25°C to +55°C
INVERTEC® V100-S & V130-S
A-2
INSTALLATION
INPUT SINGLE PHASE
INPUT Voltage(2) 230V Input Current at Rated Output 25A @ 130A OUTPUT 19A @ 105A OUTPUT 16A @ 90A OUTPUT Hertz 50/60 Hz
A-2
Technical Specifications - Invertec V130-S
RATED OUTPUT
Duty Cycle(1) 20% Duty Cycle 60% Duty Cycle 100% Duty Cycle Amps 130 105 90 Volts at Rated Amps 25.5 24.5 24
OUTPUT
Welding Current Range 3-130 Amps Maximum Open Circuit Voltage 67 VDC
RECOMMENDED INPUT CABLE AND FUSE SIZES
OUTPUT FUSE (SUPERLAG) INPUT CURRENT OR BREAKER SIZE CURRENT RATING POWER CORD EXTENSION CORD (up to 50 feet) EXTENSION CORD (more than 50 feet)
130A
40A
25A
50 Amp, 250V, Three Conductor Three Conductor Three-prong plug #6 AWG (13.0 mm2) #4 AWG (20.7 mm2) (NEMA Type 6-50P) or larger or larger
PHYSICAL DIMENSIONS
Height 10.0 in. 254 mm Width 5.4 in. 138 mm Depth 13.8 in. 351 mm Weight 11.0 lbs. 5.0 Kg
OPERATING TEMPERATURE
-20°C to +40°C
(1) Based on a 10 min. period. (2) Input voltage must be within ±10% of rated value.
STORAGE TEMPERATURE
-25°C to +55°C
INVERTEC® V100-S & V130-S
A-3
INSTALLATION
INPUT SUPPLY CONNECTIONS
A-3
Read this entire installation section before you start installation.
SAFETY PRECAUTIONS WARNING
ELECTRIC SHOCK can kill.
· Have an electrician install and service 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 capacitors to discharge before working inside this equipment. · Do not touch electrically hot parts.
Be sure the voltage, phase and frequency of the input power is as specified on the rating plate, located on the rear of the machine. Both models are supplied with an input supply cable with a molded plug. The V130-S has a 50A molded plug and the V100-S is shipped with a molded 15A plug and an additional 20A plug that can replace the 15A plug when necessary to achieve 85A output. To install the supplied 20A plug: Connect the white (neutral) wire under terminal clamp with silver screw, and black (hot) wire under terminal clamp with brass screw. Connect green wire under terminal clamp with green screw. Tighten terminal wire clamp screws securely. WARNING: Failure to wire as instructed may cause personal injury or damage to equipment. To be installed or checked by an electrician or qualified person only. In order to achieve full output from the V100-S it is necessary to attach a 30A plug (NEMA 5-30P).
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SELECT SUITABLE LOCATION
The Invertec will operate in harsh environments. Even so, it is important that simple preventative measures are followed in order to assure long life and reliable operation. · The machine must be located where there is free circulation of clean air such that air movement in the sides and out the sides will not be restricted. · Dirt and dust that can be drawn into the machine should be kept to a minimum. Failure to observe these precautions can result in excessive operating temperatures and nuisance shutdown. · The machines have a protection rating of IP23. Keep the machines dry when possible. Do not place them on wet ground or in puddles.
INPUT FUSE AND SUPPLY WIRE
Refer to the Technical Specifications pages at the beginning of this chapter for the proper fuse sizes and supply cable sizes. · Fuse the input circuit with recommended super lag fuses or delay type circuit breakers. · Install the proper fuse in the fuse holder in the main disconnect panel.
OUTPUT CONNECTIONS
ON
XX XX XX XX
STACKING
These Invertecs cannot be stacked.
OFF
XXX
TILTING
XX
Place the machine directly on a secure, level surface. The machine may topple over if this procedure is not followed.
HIGH FREQUENCY PRECAUTIONS
If possible locate the Invertec away from radio controlled machinery. The normal operation of the Invertec may adversely affect the operation of RF controlled equipment, which may result in bodily injury or damage to the equipment.
Output Terminals
FIGURE A.1 OUTPUT CONNECTIONS
INVERTEC® V100-S & V130-S
A-4
INSTALLATION
QUICK DISCONNECT PLUG
A-4
OUTPUT CONNECTIONS
Refer to Figure A.1 for the location of the output terminals. A quick-disconnect system using Twist-MateTM cable plugs is used for the welding cable connections. The electrode and work cables included with the machine have these plugs. An extra plug is also included with the machine if TIG welding is desired. Refer to the relevant instructions below for more information on connecting the machine for either of these two welding processes.
A quick disconnect system is used for the welding cable connections. The electrode and work cables have the plug attached, on both machines an additional plug is supplied if TIG welding is to be done. The welding plug included with the machine is designed to accept a welding cable size of #6 to #4 (10mm2 to 25mm2). 1. Cut off welding cable lug, if present. 2. Remove .75 in. (19mm) of welding cable insulation. 3. Slide rubber boot onto cable end. The boot end may be trimmed to match the cable diameter. Use soap or other nonpetroleum-based lubricant to help slide the boot over the cable, if needed.
BOOT WELDING CABLE
OUTPUT CONNECTION FOR STICK WELDING
First determine the proper electrode polarity for the electrode to be used. Consult the electrode data for this information. Then connect the output cables to the output terminals corresponding to this polarity. For instance, for DC(+) welding, connect the electrode cable (which is connected to the electrode holder) to the "+" output terminal and the work cable (which is connected to the work clamp) to the "-" output terminal. Insert the connector with the key lining up with the keyway, and rotate approximately 1/4 turn clockwise; until the connection is snug. Do not over tighten.
.75 in. 19 mm
TRIM, IF REQ'D TO FIT OVER CABLE
4. Cut 45-50% of the copper strands back 1/4" (6 mm).
WELDING CABLE
OUTPUT AND GAS CONNECTION FOR TIG WELDING
These units do not include a TIG torch, but one may be purchased separately and used with these units to do TIG (GTAW) welding. The Lincoln LA-9 (K859-3 or K859-7 only; no gas valve) and LA-17V (K860-11 or K860-15 only; includes gas valve) are recommended for use with these machines for this purpose; however, any similar TIG torch can be used. If the torch to be used does not have a mating Twist-Mate plug on the end of the power cable, the power cable must be modified to include one. The LA-9 and LA-17V fall in this category. Cut off the lug on the end of the power cable and attach the extra Twist Mate plug included with the machine to the power cable per the instructions following under QUICK DISCONNECT PLUG. Next connect the torch cable to the appropriate output terminal on the machine. Most TIG welding is done with DC(-) polarity. For this polarity, connect the torch plug to the "-" output terminal on the machine. Insert the connector with the key lining up with the keyway, and rotate approximately 1/4 turn clockwise; until the connection is snug. Do not over tighten. Connect the work cable (which is connected to the work clamp) to the "+" output terminal in the same way. Finally, connect the gas hose to the gas regulator on the cylinder of gas to be used. The machine can easily be switched between stick and TIG welding at any time by simply swapping the stick (electrode) and TIG (torch) cables, and reversing the connection polarity if required.
.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. 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.
SET SCREW
BRASS PLUG COPPER TUBE
8. Slide rubber boot over brass plug. The rubber boot must be positioned to completely cover all electrical surfaces after the plug is locked into the receptacle.
INVERTEC® V100-S & V130-S
B-1
OPERATION
GENERAL DESCRIPTION
B-1
Read and understand this entire section before operating your machine.
SAFETY INSTRUCTIONS WARNING
ELECTRIC SHOCK can kill. · Do not touch electrically live parts such as output terminals or internal wiring. · Insulate yourself from the work and ground. · Always wear dry insulating gloves.
The Invertec V100-S is a light industrial 100 amp arc welding power source and the V130-S is a light industrial 130 amp arc welding power source both of which utilize single phase input power, to produce constant current output. The welding response of these Invertecs has been optimized for stick (SMAW) and TIG (GTAW). Both units are perfect for light industrial applications where portability is important.
OPERATIONAL FEATURES
The Invertecs provide continuous total range output current adjustment. Additionally, a "hot start" system has been built into the welding current control, and provides a higher striking current to assist ignition of the arc.
____________________________________
FUMES AND GASES can be dangerous. · Keep your head out of fumes. · Use ventilation or exhaust to remove fumes from breathing zone.
WELDING CAPABILITY
The Invertec V100-S is rated at 100 amps, 15% duty cycle (based on a 10 minute cycle). It is also rated at 85 amps, 20% duty cycle, and 70 amps, 20% duty cycle. The Invertec V130-S is rated at 130 amps, 20% duty cycle (based on a 10 minute cycle). It is also rated at 105 amps, 60% duty cycle, and 90 amps, 100% duty cycle.
____________________________________
WELDING, CUTTING and GOUGING SPARKS can cause fire or explosion · Keep flammable material away. · Do not weld, cut or gouge on containers that have held combustibles.
LIMITATIONS
The V100-S and V130-S are not recommended for pipe thawing. The V100-S and V130-S should not be powered from the auxiliary power supply of an engine welder. Special protection circuits may operate causing loss of output.
____________________________________
ARC RAYS can burn. · Wear eye, ear and body protection.
____________________________________
Only qualified personnel should operate this equipment. Observe all safety information throughout this manual.
INVERTEC® V100-S & V130-S
B-2
OPERATION
B-2
CONTROLS AND SETTINGS
All operator controls and adjustments are located on the case front of the V100-S and V130-S machines. Refer to Figure B.1 and the corresponding explanations. FIGURE B.1 -- CASE FRONT CONTROLS.
ON
XX XX XX XX
LED 1
Power Switch
OFF XX
XXX
M1
Output Terminals
Power Switch - Controls the power input to the machine. This rocker switch is lighted. When power is applied to the machine the light is on.
Knob M1 - Potentiometer used to set the value of the current required by the welding process.
Output Terminals - These quick disconnect terminals provide connection points for the electrode and work cables. For positive polarity welding connect the electrode cable to the positive terminal and the work cable to the negative terminal. To weld negative polarity reverse the electrode and work cables.
LED 1 - This LED will light up when: A) The input supply voltage is not within limits pre-set for correct operation. V100-S: 95VAC to 125VAC* V130-S: 200VAC to 255VAC* B) The machine is overheated as detected by the internal thermostat.
* Note that input voltages that exceed 20% of nominal may cause internal damage to the machine.
INVERTEC® V100-S & V130-S
B-3
OPERATION
OVERLOAD PROTECTION
B-3
CONSTANT CURRENT PROCESSES
MANUAL ARC WELDING (STICK)
The Invertec may be utilized as a manual DC arc welder. The electrode cable and holder and the work cable and clamp are included. Excellent stick welding performance is easily achieved with the following electrodes and current settings: Machine V100-S Electrode Fleetweld 35 Fleetweld 180 Fleetweld 37 LH-78 Fleetweld 35 Fleetweld 180 Fleetweld 37 LH-78 Diameter 3/32" Max 3/32"Max 3/32" Max 3/32" Max 1/8" Max 1/8" Max 1/8" Max 1/8" Max Current 90 Amps 90 Amps 100 Amps 100 Amps 100 Amps 100 Amps 115 Amps 130 Amps
The machine is electrically protected from producing excessive currents. The maximum current obtainable with the V100-S is approximately 120 amps, and that of the V130-S is approximately 150 amps.
THERMAL PROTECTION
Thermostats protect the machine from excessive operating temperatures. Excessive temperatures may be caused by a lack of cooling air or operating the machine beyond the duty cycle and output rating. If excessive operating temperature should occur, the thermostats will prevent output voltage or current. Thermostats are self-resetting once the machine cools sufficiently. If the thermostat shutdown was caused by excessive output or duty cycle and the fan is operating normally, the Power Switch may be left on and the reset should occur within a 15 minute period. If the fan is not operating or if the air flow is obstructed, this problem must be resolved before continuing.
V130-S
TIG WELDING
The Invertecs are capable of scratch start TIG welding. A TIG torch, and gas supply with regulator are required.
INVERTEC® V100-S & V130-S
C-1
ACCESSORIES
C-1
OPTIONS / ACCESSORIES
K909-1 - EH-200 Insulated electrode holder designed for maximum operator comfort and convience. K859-"L" - LA-9 125 amp air-cooled, lightweight, and versatile TIG torch for thin gauge materials. Includes two piece cable. Available in 12.5 ft. and 25 ft. lengths. K860-"L" - LA-17V 150 amp air-cooled compact and durable TIG torch for thin to medium gauge materials. Includes valve and two piece cable. Available in 12.5 ft. and 25 ft. lengths. KP507 - Parts kit for the LA-9 torch. Kit includes back cap, collets, collet bodies, nozzles and tungstens. KP508 - Parts kit for the LA-17 torch. Kit includes back cap, collets, collet bodies, nozzles and tungstens. K852-25 - Twist-MateTM plug for connecting welding cable to output terminals. Contains one plug.
INVERTEC® V100-S & V130-S
D-1
MAINTENANCE
· · · ·
· 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 capacitors to discharge before working inside this equipment. · Do not touch electrically hot parts.
D-1
SAFETY PRECAUTIONS WARNING
ELECTRIC SHOCK can kill.
· Have an electrician install and service this equipment.
Printed circuit boards Power switch Fan blades Louvers Heat sink fins Output terminals Examine capacitors for leakage or oozing. If any leakage is noticed, take the unit to an authorized Lincoln Field Service Shop. Examine the case for breakage. Repair or replace the case as required. Keep the case in good condition to ensure that high voltage parts are protected and correct spacings are maintained. Install machine covers and fasteners.
· · 4.
---------------------------------------------------------------------5.
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. -----------------------------------------------------------------------6.
ROUTINE MAINTENANCE
1. Perform the following preventive maintenance procedures at least once every thousand hours of use. It is good practice to keep a preventive maintenance record; a record tag attached to the machine works best. Remove the machine cover (requires a 3 mm hex key) after allowing the minimum 5 minute power off requirement to let the input capacitors discharge.
2.
WARNING
Failure to observe this discharge time requirement could result in severe electrical shock hazard. -----------------------------------------------------------------------3. Keeping the machine clean will result in cooler operation and higher reliability. Be sure to clean the following areas with a low pressure air stream. INVERTEC® V100-S & V130-S
E-1
TROUBLESHOOTING
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. __________________________________________________________________________ This Troubleshooting Guide is provided to help you locate and repair possible machine malfunctions. Simply follow the three-step procedure listed below. Step 1. LOCATE PROBLEM (SYMPTOM). Look under the column labeled "PROBLEM (SYMPTOMS)". This column describes possible symptoms that the machine may exhibit. Find the listing that best describes the symptom that the machine is exhibiting. Step 2. POSSIBLE CAUSE. The second column labeled "POSSIBLE CAUSE" lists the obvious external possibilities that may contribute to the machine symptom. Step 3. RECOMMENDED COURSE OF ACTION This column provides a course of action for the Possible Cause, generally it states to contact you local Lincoln Authorized Field Service Facility. If you do not understand or are unable to perform the Recommended Course of Action safely, contact you local Lincoln Authorized Field Service Facility.
CAUTION
If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed. INVERTEC® V100-S & V130-S
E-2 PROBLEMS (SYMPTOMS)
TROUBLESHOOTING
Observe all Safety Guidelines detailed throughout this manual
E-2 RECOMMENDED COURSE OF ACTION
POSSIBLE AREAS OF MISADJUSTMENTS(S)
The machine is dead - no output no fan.
1. The input power switch must be in the ON position. 2. Make sure the input voltage is correct for the machine.
No output but the fan operates normally.
1. The machine may be overheated. Check the thermal indicator light. Wait for the machine to cool and the thermostats to reset.
If all recommended possible areas of misadjustment have been checked and the problem persists, Contact your local Lincoln Authorized Field Service Facility.
Output turns on momentarily, then switches off.
1. Check the input voltage. Make sure the input voltage is correct for the machine. 1. Inspect input leads for possible shorts or grounds or mis-connections. 2. Install new fuses and reapply power. If fuses open again, consult a Lincoln Authorized Field Service Facility.
No output - Main input fuses open, indicating excessive current draw.
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® V100-S & V130-S
E-3 PROBLEMS (SYMPTOMS)
Poor welding, weld settings drift, or output power is low.
TROUBLESHOOTING
Observe all Safety Guidelines detailed throughout this manual
E-3 RECOMMENDED COURSE OF ACTION
POSSIBLE AREAS OF MISADJUSTMENTS(S)
1. Make sure the machine settings are correct for the weld process being used. 2. Make sure the input voltage is correct for the machine.
Poor stick electrode welding performance. The arc pops out.
1. Check for loose or faulty welding cables. If all recommended possible areas of
misadjustment have been checked
2. Is the electrode DRY? Try weld- and the problem persists, Contact ing with another electrode from a your local Lincoln Authorized Field Service Facility. different container. Make sure you have the correct electrode for the application. 3. Make sure the machine settings are correct for the weld process being used.
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® V100-S & V130-S
F-1
DIAGRAMS
INVERTEC® V100-S & V130-S
INVERTEC V100-S WIRING DIAGRAM
8-21-98 M18980
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
DIAGRAMS
INVERTEC® V100-S & V130-S
INVERTEC V130-S WIRING DIAGRAM
8-21-98 M18985
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
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q Do not touch electrically live parts or
q Keep flammable materials away.
q Wear eye, ear and body protection.
WARNING
Spanish
electrode with skin or wet clothing. q Insulate yourself from work and ground.
q No toque las partes o los electrodos q Mantenga el material combustible q Protéjase los ojos, los oídos y el
AVISO DE PRECAUCION
French
bajo carga con la piel o ropa mojada. q Aislese del trabajo y de la tierra.
q Ne laissez ni la peau ni des vête-
fuera del área de trabajo.
cuerpo.
q Gardez à l'écart de tout matériel
q Protégez vos yeux, vos oreilles et
ATTENTION
German
ments mouillés entrer en contact avec des pièces sous tension. q Isolez-vous du travail et de la terre.
q Berühren Sie keine stromführenden
inflammable.
votre corps.
q Entfernen Sie brennbarres Material!
q Tragen Sie Augen-, Ohren- und Kör-
WARNUNG
Portuguese
Teile oder Elektroden mit Ihrem Körper oder feuchter Kleidung! q Isolieren Sie sich von den Elektroden und dem Erdboden!
q Não toque partes elétricas e elecq Mantenha inflamáveis bem guarda-
perschutz!
q Use proteção para a vista, ouvido e
ATENÇÃO
Japanese
trodos com a pele ou roupa molhada. q Isole-se da peça e terra.
dos.
corpo.
Chinese
Korean
Arabic
READ AND UNDERSTAND THE MANUFACTURER'S INSTRUCTION FOR THIS EQUIPMENT AND THE CONSUMABLES TO BE USED AND FOLLOW YOUR EMPLOYER'S SAFETY PRACTICES. SE RECOMIENDA LEER Y ENTENDER LAS INSTRUCCIONES DEL FABRICANTE PARA EL USO DE ESTE EQUIPO Y LOS CONSUMIBLES QUE VA A UTILIZAR, SIGA LAS MEDIDAS DE SEGURIDAD DE SU SUPERVISOR. LISEZ ET COMPRENEZ LES INSTRUCTIONS DU FABRICANT EN CE QUI REGARDE CET EQUIPMENT ET LES PRODUITS A ETRE EMPLOYES ET SUIVEZ LES PROCEDURES DE SECURITE DE VOTRE EMPLOYEUR. LESEN SIE UND BEFOLGEN SIE DIE BETRIEBSANLEITUNG DER ANLAGE UND DEN ELEKTRODENEINSATZ DES HERSTELLERS. DIE UNFALLVERHÜTUNGSVORSCHRIFTEN DES ARBEITGEBERS SIND EBENFALLS ZU BEACHTEN.
q Keep your head out of fumes. q Use ventilation or exhaust to
q Turn power off before servicing.
q Do not operate with panel open or
guards off.
remove fumes from breathing zone.
q Los humos fuera de la zona de resq Desconectar el cable de aliq No operar con panel abierto o
WARNING
Spanish
piración. q Mantenga la cabeza fuera de los humos. Utilice ventilación o aspiración para gases.
q Gardez la tête à l'écart des fumées. q Utilisez un ventilateur ou un aspira-
mentación de poder de la máquina antes de iniciar cualquier servicio.
guardas quitadas.
AVISO DE PRECAUCION
French
q Débranchez le courant avant l'entre-
q N'opérez pas avec les panneaux
tien.
ED
teur pour ôter les fumées des zones de travail.
q Vermeiden Sie das Einatmen von q Strom vor Wartungsarbeiten
ouverts ou avec les dispositifs de protection enlevés.
ATTENTION
German
Schweibrauch! q Sorgen Sie für gute Be- und Entlüftung des Arbeitsplatzes!
q Mantenha seu rosto da fumaça. q Use ventilação e exhaustão para
abschalten! (Netzstrom völlig öffnen; Maschine anhalten!)
NT SE Y E SU IM P W ER S 1 SED
q Anlage nie ohne Schutzgehäuse
oder Innenschutzverkleidung in Betrieb setzen!
WARNUNG
Portuguese
q Não opere com as tampas removidas. q Desligue a corrente antes de fazer
q Mantenha-se afastado das partes
moventes. ou guardas removidas.
remover fumo da zona respiratória.
serviço. q Não toque as partes elétricas nuas.
q Não opere com os paineis abertos
ATENÇÃO
Japanese
RA
Chinese
AR
W
Korean
Arabic
LEIA E COMPREENDA AS INSTRUÇÕES DO FABRICANTE PARA ESTE EQUIPAMENTO E AS PARTES DE USO, E SIGA AS PRÁTICAS DE SEGURANÇA DO EMPREGADOR.
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