IM585 INVERTEC V100-S & V130-S January, 2002valvolodin.narod.ru/schems/invertec_130.pdfINVERTEC V100-S & V130-S® OPERATOR’S MANUAL IM585 January, 2002 Safety Depends on You Lincoln

INVERTEC V100-S & V130-S®

OPERATOR’S MANUAL

IM585January, 2002

Safety Depends on YouLincoln arc welding and cuttingequipment is designed and builtwith safety in mind. However, youroverall safety can be increased byproper installation ... and thought-ful operation on your part. DONOT INSTALL, OPERATE ORREPAIR THIS EQUIPMENTWITHOUT READING THISMANUAL AND THE SAFETYPRECAUTIONS CONTAINEDTHROUGHOUT. And, mostimportantly, think before you actand be careful.

For use with machines having Code Numbers: V100-S 10461V130-S 10462

Date of Purchase:Serial Number:Code Number:Model:Where Purchased:

• 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

• World's Leader in Welding and Cutting Products •

Copyright © 2002 Lincoln Global Inc.

Rita Wood

FOR ENGINEpowered equipment.

1.a. Turn the engine off before troubleshooting and maintenancework unless the maintenance work requires it to be running.

____________________________________________________1.b.Operate engines in open, well-ventilated

areas or vent the engine exhaust fumes outdoors.

____________________________________________________1.c. Do not add the fuel near an open flame

welding arc or when the engine is running.Stop the engine and allow it to cool beforerefueling to prevent spilled fuel from vaporiz-ing on contact with hot engine parts andigniting. Do not spill fuel when filling tank. Iffuel is spilled, wipe it up and do not startengine until fumes have been eliminated.

____________________________________________________1.d. Keep all equipment safety guards, covers

and devices in posit ion and in goodrepair.Keep hands, hair, clothing and toolsaway from V-belts, gears, fans and all othermoving parts when starting, operating orrepairing equipment.

____________________________________________________

1.e. In some cases it may be necessary to remove safetyguards to perform required maintenance. Removeguards only when necessary and replace them when themaintenance requiring their removal is complete.Always use the greatest care when working near movingparts.

___________________________________________________1.f. Do not put your hands near the engine fan. Do not attempt

to override the governor or idler by pushing on the throttlecontrol rods while the engine is running.

___________________________________________________1.g. To prevent accidentally starting gasoline engines while

turning the engine or welding generator during maintenancework, disconnect the spark plug wires, distributor cap ormagneto wire as appropriate.

iSAFETYi

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 youpurchase a copy of “Safety in Welding & Cutting - ANSI Standard Z49.1” from the American Welding Society, P.O. Box351040, Miami, Florida 33135 or CSA Standard W117.2-1974. A Free copy of “Arc Welding Safety” booklet E205 is availablefrom the Lincoln Electric Company, 22801 St. Clair Avenue, Cleveland, Ohio 44117-1199.

BE SURE THAT ALL INSTALLATION, OPERATION, MAINTENANCE AND REPAIR PROCEDURES AREPERFORMED ONLY BY QUALIFIED INDIVIDUALS.

WARNING

Mar ‘95

ELECTRIC AND MAGNETIC FIELDSmay 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, andwelders having a pacemaker should consult their physicianbefore welding.

2.c. Exposure to EMF fields in welding may have other healtheffects which are now not known.

2.d. All welders should use the following procedures in order tominimize exposure to EMF fields from the welding circuit:

2.d.1. Route the electrode and work cables together - Securethem 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 andwork 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 aspossible to the area being welded.

2.d.5. Do not work next to welding power source.

1.h. To avoid scalding, do not remove theradiator pressure cap when the engine ishot.

CALIFORNIA PROPOSITION 65 WARNINGS

Diesel engine exhaust and some of its constituentsare known to the State of California to cause can-cer, birth defects, and other reproductive harm.

The engine exhaust from this product containschemicals known to the State of California to causecancer, birth defects, or other reproductive harm.

The Above For Diesel Engines The Above For Gasoline Engines

iiSAFETYii

ARC RAYS can burn.4.a. Use a shield with the proper filter and cover

plates to protect your eyes from sparks andthe rays of the arc when welding or observingopen arc welding. Headshield and filter lensshould conform to ANSI Z87. I standards.

4.b. Use suitable clothing made from durable flame-resistantmaterial to protect your skin and that of your helpers fromthe arc rays.

4.c. Protect other nearby personnel with suitable, non-flammablescreening and/or warn them not to watch the arc nor exposethemselves to the arc rays or to hot spatter or metal.

ELECTRIC SHOCK cankill.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 bareskin or wet clothing. Wear dry, hole-free

gloves to insulate hands.

3.b. Insulate yourself from work and ground using dry insulation.Make certain the insulation is large enough to cover your fullarea of physical contact with work and ground.

In addition to the normal safety precautions, if weldingmust be performed under electrically hazardousconditions (in damp locations or while wearing wetclothing; on metal structures such as floors, gratings orscaffolds; when in cramped positions such as sitting,kneeling or lying, if there is a high risk of unavoidable oraccidental contact with the workpiece or ground) usethe 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 semiautomaticwelding gun are also electrically “hot”.

3.d. Always be sure the work cable makes a good electricalconnection with the metal being welded. The connectionshould 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 andwelding machine in good, safe operating condition. Replacedamaged insulation.

3.g. Never dip the electrode in water for cooling.

3.h. Never simultaneously touch electrically “hot” parts ofelectrode holders connected to two welders because voltagebetween the two can be the total of the open circuit voltageof both welders.

3.i. When working above floor level, use a safety belt to protectyourself from a fall should you get a shock.

3.j. Also see Items 6.c. and 8.

FUMES AND GASEScan be dangerous.5.a. Welding may produce fumes and gases

hazardous to health. Avoid breathing thesefumes and gases.When welding, keepyour head out of the fume. Use enoughventilation and/or exhaust at the arc to keep

fumes and gases away from the breathing zone. Whenwelding with electrodes which require specialventilation such as stainless or hard facing (seeinstructions on container or MSDS) or on lead orcadmium plated steel and other metals or coatingswhich produce highly toxic fumes, keep exposure aslow as possible and below Threshold Limit Values (TLV)using local exhaust or mechanical ventilation. Inconfined spaces or in some circumstances, outdoors, arespirator may be required. Additional precautions arealso required when welding on galvanized steel.

5.b. Do not weld in locations near chlorinated hydrocarbon vaporscoming 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 andcause 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 thisequipment and the consumables to be used, including thematerial safety data sheet (MSDS) and follow youremployer’s safety practices. MSDS forms are available fromyour welding distributor or from the manufacturer.

5.e. Also see item 1.b. Mar ‘95

FOR ELECTRICALLYpowered equipment.

8.a. Turn off input power using the disconnectswitch at the fuse box before working onthe equipment.

8.b. Install equipment in accordance with the U.S. NationalElectrical Code, all local codes and the manufacturer’srecommendations.

8.c. Ground the equipment in accordance with the U.S. NationalElectrical Code and the manufacturer’s recommendations.

CYLINDER may explodeif damaged.7.a. Use only compressed gas cylinders

containing the correct shielding gas for theprocess used and properly operatingregulators designed for the gas and

pressure used. All hoses, fittings, etc. should be suitable forthe application and maintained in good condition.

7.b. Always keep cylinders in an upright position securelychained to an undercarriage or fixed support.

7.c. Cylinders should be located:• Away from areas where they may be struck or subjected tophysical damage.

• A safe distance from arc welding or cutting operations andany other source of heat, sparks, or flame.

7.d. Never allow the electrode, electrode holder or any otherelectrically “hot” parts to touch a cylinder.

7.e. Keep your head and face away from the cylinder valve outletwhen opening the cylinder valve.

7.f. Valve protection caps should always be in place and handtight except when the cylinder is in use or connected foruse.

7.g. Read and follow the instructions on compressed gascylinders, associated equipment, and CGA publication P-l,“Precautions for Safe Handling of Compressed Gases inCylinders,” available from the Compressed Gas Association1235 Jefferson Davis Highway, Arlington, VA 22202.

iiiSAFETYiii

Mar ‘95

WELDING SPARKS cancause fire or explosion.6.a. Remove fire hazards from the welding area.

If this is not possible, cover them to preventthe welding sparks from starting a fire.Remember that welding sparks and hot

materials from welding can easily go through small cracksand openings to adjacent areas. Avoid welding nearhydraulic 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 hazardoussituations. Refer to “Safety in Welding and Cutting” (ANSIStandard Z49.1) and the operating information for theequipment being used.

6.c. When not welding, make certain no part of the electrodecircuit is touching the work or ground. Accidental contactcan cause overheating and create a fire hazard.

6.d. Do not heat, cut or weld tanks, drums or containers until theproper steps have been taken to insure that such procedureswill not cause flammable or toxic vapors from substancesinside. They can cause an explosion even though they havebeen “cleaned”. For information, purchase “RecommendedSafe Practices for the Preparation for Welding and Cutting ofContainers and Piping That Have Held HazardousSubstances”, AWS F4.1 from the American Welding Society(see address above).

6.e. Vent hollow castings or containers before heating, cutting orwelding. They may explode.

6.f. Sparks and spatter are thrown from the welding arc. Wear oilfree protective garments such as leather gloves, heavy shirt,cuffless trousers, high shoes and a cap over your hair. Wearear plugs when welding out of position or in confined places.Always wear safety glasses with side shields when in awelding area.

6.g. Connect the work cable to the work as close to the weldingarea as practical. Work cables connected to the buildingframework or other locations away from the welding areaincrease the possibility of the welding current passingthrough lifting chains, crane cables or other alternate cir-cuits. This can create fire hazards or overheat lifting chainsor cables until they fail.

6.h. Also see item 1.c.

ivSAFETYiv

PRÉCAUTIONS DE SÛRETÉPour votre propre protection lire et observer toutes les instructionset les précautions de sûreté specifiques qui parraissent dans cemanuel aussi bien que les précautions de sûreté générales suiv-antes:

Sûreté Pour Soudage A L’Arc1. Protegez-vous contre la secousse électrique:

a. Les circuits à l’électrode et à la piéce sont sous tensionquand la machine à souder est en marche. Eviter toujourstout contact entre les parties sous tension et la peau nueou les vétements mouillés. Porter des gants secs et sanstrous pour isoler les mains.

b. Faire trés attention de bien s’isoler de la masse quand onsoude dans des endroits humides, ou sur un planchermetallique ou des grilles metalliques, principalement dans les positions assis ou couché pour lesquelles une grandepartie du corps peut être en contact avec la masse.

c. Maintenir le porte-électrode, la pince de masse, le câblede soudage et la machine à souder en bon et sûr étatdefonctionnement.

d.Ne jamais plonger le porte-électrode dans l’eau pour lerefroidir.

e. Ne jamais toucher simultanément les parties sous tensiondes porte-électrodes connectés à deux machines à souderparce que la tension entre les deux pinces peut être letotal de la tension à vide des deux machines.

f. Si on utilise la machine à souder comme une source decourant pour soudage semi-automatique, ces precautionspour le porte-électrode s’applicuent aussi au pistolet desoudage.

2. Dans le cas de travail au dessus du niveau du sol, se protégercontre les chutes dans le cas ou on recoit un choc. Ne jamaisenrouler le câble-électrode autour de n’importe quelle partiedu 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 appropriéainsi qu’un verre blanc afin de se protéger les yeux du ray-onnement de l’arc et des projections quand on soude ouquand on regarde l’arc.

b. Porter des vêtements convenables afin de protéger lapeau de soudeur et des aides contre le rayonnement del‘arc.

c. Protéger l’autre personnel travaillant à proximité ausoudage à l’aide d’écrans appropriés et non-inflammables.

4. Des gouttes de laitier en fusion sont émises de l’arc desoudage. Se protéger avec des vêtements de protection libresde l’huile, tels que les gants en cuir, chemise épaisse, pan-talons sans revers, et chaussures montantes.

5. Toujours porter des lunettes de sécurité dans la zone desoudage. Utiliser des lunettes avec écrans lateraux dans les

zones où l’on pique le laitier.

6. Eloigner les matériaux inflammables ou les recouvrir afin deprévenir tout risque d’incendie dû aux étincelles.

7. Quand on ne soude pas, poser la pince à une endroit isolé dela masse. Un court-circuit accidental peut provoquer unéchauffement et un risque d’incendie.

8. S’assurer que la masse est connectée le plus prés possiblede la zone de travail qu’il est pratique de le faire. Si on placela masse sur la charpente de la construction ou d’autresendroits éloignés de la zone de travail, on augmente le risquede voir passer le courant de soudage par les chaines de lev-age, câbles de grue, ou autres circuits. Cela peut provoquerdes risques d’incendie ou d’echauffement des chaines et descâbles 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 tôlesgalvanisées plombées, ou cadmiées ou tout autre métal quiproduit des fumeés toxiques.

10. Ne pas souder en présence de vapeurs de chlore provenantd’opérations de dégraissage, nettoyage ou pistolage. Lachaleur ou les rayons de l’arc peuvent réagir avec les vapeursdu 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” CSAStandard W 117.2-1974.

PRÉCAUTIONS DE SÛRETÉ POURLES MACHINES À SOUDER ÀTRANSFORMATEUR ET ÀREDRESSEUR

1. Relier à la terre le chassis du poste conformement au code del’électricité et aux recommendations du fabricant. Le dispositifde montage ou la piece à souder doit être branché à unebonne mise à la terre.

2. Autant que possible, I’installation et l’entretien du poste seronteffectués par un électricien qualifié.

3. Avant de faires des travaux à l’interieur de poste, la debranch-er à l’interrupteur à la boite de fusibles.

4. Garder tous les couvercles et dispositifs de sûreté à leurplace.

Mar. ‘93

Thank You for selecting a QUALITY product by Lincoln Electric. We want youto take pride in operating this Lincoln Electric Company product••• as much pride as we have in bringing this product to you!

Read this Operators Manual completely before attempting to use this equipment. Save this manual and keep ithandy 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:

WARNINGThis statement appears where the information must be followed exactly to avoid serious personal injury orloss of life.

This statement appears where the information must be followed to avoid minor personal injury or damage tothis equipment.

CAUTION

Please Examine Carton and Equipment For Damage ImmediatelyWhen this equipment is shipped, title passes to the purchaser upon receipt by the carrier. Consequently, Claimsfor material damaged in shipment must be made by the purchaser against the transportation company at thetime the shipment is received.

Please record your equipment identification information below for future reference. This information can befound 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 informationyou have recorded above.

vv

vi TABLE OF CONTENTSPage

Installation.......................................................................................................................Section ATechnical Specifications V100-S..........................................................................................A-1Technical Specifications V130-S..........................................................................................A-2Safety Precautions. ..............................................................................................................A-3Select Suitable Location.......................................................................................................A-3Stacking................................................................................................................................A-3Tilting....................................................................................................................................A-3High Frequency Precautions ................................................................................................A-3Input Supply Connections ....................................................................................................A-3Input Fuse and Supply Wire .................................................................................................A-3Output Connections..............................................................................................................A-3

Output Connections ......................................................................................................A-4Output Connection for Stick Welding ............................................................................A-4Output and Gas Connection for TIG Welding ...............................................................A-4

Quick Disconnect Plug .........................................................................................................A-4

Operation.........................................................................................................................Section BSafety Instructions................................................................................................................B-1General Description..............................................................................................................B-1Operational Features............................................................................................................B-1Welding Capability................................................................................................................B-1Limitations ............................................................................................................................B-1Controls and Settings ...........................................................................................................B-2Constant Current Processes ................................................................................................B-3

Manual Arc Welding (Stick) ...........................................................................................B-3TIG Welding ..................................................................................................................B-3

Overload Protection..............................................................................................................B-3Thermal Protection ...............................................................................................................B-3

Accessories .....................................................................................................Section COptions / Accessories............................................................................................C-1

Maintenance ....................................................................................................Section DSafety Precautions ................................................................................................D-1Input Filter Capacitor Discharge Procedure ..........................................................D-1Routine Maintenance.............................................................................................D-1

Troubleshooting ..............................................................................................Section EPC Board Troubleshooting Procedures.................................................................E-1Troubleshooting Chart ...........................................................................................E-2

Diagrams ..........................................................................................................Section FWiring Diagram V100-S .........................................................................................F-1Wiring Diagram V130-S .........................................................................................F-2

Parts Lists ........................................................................................................AppendixV100-S...............................................................................................................P-304V130-S...............................................................................................................P-305

-20°C to +40°C -25°C to +55°C

A-1INSTALLATION

INVERTEC® V100-S & V130-S

A-1

Height Width Depth Weight10.0 in. 5.4 in. 13.8 in. 11.0 lbs.

254 mm 138 mm 351 mm 5.0 Kg

PHYSICAL DIMENSIONS

INPUT Input CurrentVoltage(2) at Rated Output Hertz

32A @ 100A OUTPUT115V 25A @ 85A OUTPUT 50/60 Hz

20A @ 70A OUTPUT

Volts at Duty Cycle(1) Amps Rated Amps

15% Duty Cycle 100 2420% Duty Cycle 85 (20 Amp Circuit) 23.520% Duty Cycle 70 (15 Amp Circuit) 23

Welding Maximum OpenCurrent Range Circuit Voltage

8-100 Amps 67 VDC

INPUT

RECOMMENDED INPUT CABLE AND FUSE SIZESOUTPUT FUSE (SUPERLAG) INPUT POWER EXTENSION EXTENSIONCURRENT OR BREAKER SIZE CURRENT CORD CORD CORD

RATING (up to 50 feet) (more than 50 feet)

100A 30A 32A 30 Amp, 125V, Three Conductor Three ConductorThree-prong plug #10 AWG (5.2 mm2) #8 AWG (8.2 mm2)

(NEMA Type 5-30P) or larger or larger

85A 25A 25A 20Amp, 125V, Three Conductor Three ConductorThree-prong plug #12 AWG (3.3 mm2) #10 AWG (5.2 mm2)




SINGLE PHASE

OPERATING TEMPERATURE STORAGE TEMPERATURE

RATED OUTPUT

(1) Based on a 10 min. period.

(2) Input voltage must be within ±10% of rated value.

Technical Specifications - Invertec V100-S

OUTPUT

A-2INSTALLATION


A-2

-20°C to +40°C -25°C to +55°C

INPUT Input CurrentVoltage(2) at Rated Output Hertz

25A @ 130A OUTPUT230V 19A @ 105A OUTPUT 50/60 Hz

16A @ 90A OUTPUT

Volts at Duty Cycle(1) Amps Rated Amps

20% Duty Cycle 130 25.560% Duty Cycle 105 24.5100% Duty Cycle 90 24

Welding Maximum OpenCurrent Range Circuit Voltage

3-130 Amps 67 VDC

INPUT

RECOMMENDED INPUT CABLE AND FUSE SIZESOUTPUT FUSE (SUPERLAG) INPUT POWER EXTENSION EXTENSIONCURRENT OR BREAKER SIZE CURRENT CORD CORD CORD

RATING (up to 50 feet) (more than 50 feet)



SINGLE PHASE

OPERATING TEMPERATURE STORAGE TEMPERATURE

RATED OUTPUT

(1) Based on a 10 min. period.

(2) Input voltage must be within ±10% of rated value.

Technical Specifications - Invertec V130-S

OUTPUT

Height Width Depth Weight10.0 in. 5.4 in. 13.8 in. 11.0 lbs.

254 mm 138 mm 351 mm 5.0 Kg

PHYSICAL DIMENSIONS

A-3INSTALLATION


A-3

Read this entire installation section before youstart installation.

SAFETY PRECAUTIONS

ELECTRIC SHOCK can kill.• Have an electrician install and ser-

vice this equipment.

• Turn the input power off at the fusebox, disconnect supply lines andallow machine to sit for five minutesminimum to allow the power capaci-tors to discharge before workinginside this equipment.

• Do not touch electrically hot parts.

----------------------------------------------------------------------

SELECT SUITABLE LOCATIONThe Invertec will operate in harsh environments. Evenso, it is important that simple preventative measuresare followed in order to assure long life and reliableoperation.

• The machine must be located where there is free cir-culation of clean air such that air movement in thesides and out the sides will not be restricted.

• Dirt and dust that can be drawn into the machineshould be kept to a minimum. Failure to observethese precautions can result in excessive operatingtemperatures and nuisance shutdown.

• The machines have a protection rating of IP23. Keepthe machines dry when possible. Do not place themon wet ground or in puddles.

STACKING

These Invertecs cannot be stacked.

TILTING

Place the machine directly on a secure, level surface.The machine may topple over if this procedure is notfollowed.

HIGH FREQUENCY PRECAUTIONS

If possible locate the Invertec away from radio con-trolled machinery. The normal operation of theInvertec may adversely affect the operation of RF con-trolled equipment, which may result in bodily injury ordamage to the equipment.

INPUT SUPPLY CONNECTIONS

Be sure the voltage, phase and frequency of the inputpower is as specified on the rating plate, located onthe rear of the machine.

Both models are supplied with an input supply cablewith a molded plug. The V130-S has a 50A moldedplug and the V100-S is shipped with a molded 15Aplug and an additional 20A plug that can replace the15A plug when necessary to achieve 85A output. Toinstall the supplied 20A plug: Connect the white (neu-tral) wire under terminal clamp with silver screw, andblack (hot) wire under terminal clamp with brassscrew. Connect green wire under terminal clamp withgreen screw. Tighten terminal wire clamp screwssecurely. WARNING: Failure to wire as instructedmay cause personal injury or damage to equipment.To be installed or checked by an electrician or quali-fied person only. In order to achieve full output fromthe V100-S it is necessary to attach a 30A plug(NEMA 5-30P).

INPUT FUSE AND SUPPLY WIRE

Refer to the Technical Specifications pages at thebeginning of this chapter for the proper fuse sizes andsupply cable sizes.

• Fuse the input circuit with recommended super lagfuses or delay type circuit breakers.

• Install the proper fuse in the fuse holder in the maindisconnect panel.

OUTPUT CONNECTIONS

FIGURE A.1 OUTPUT CONNECTIONS

WARNING

OutputTerminals

XX

ON

OFF

XX

XX

XXXX

XXX

A-4INSTALLATION


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 isused for the welding cable connections. The electrode andwork cables included with the machine have these plugs.An extra plug is also included with the machine if TIG weld-ing is desired. Refer to the relevant instructions below formore information on connecting the machine for either ofthese two welding processes.

OUTPUT CONNECTION FOR STICKWELDING

First determine the proper electrode polarity for the elec-trode to be used. Consult the electrode data for this infor-mation. Then connect the output cables to the output termi-nals corresponding to this polarity. For instance, for DC(+)welding, connect the electrode cable (which is connected tothe electrode holder) to the “+” output terminal and the workcable (which is connected to the work clamp) to the “-” out-put terminal. Insert the connector with the key lining up withthe keyway, and rotate approximately 1/4 turn clockwise;until the connection is snug. Do not over tighten.

OUTPUT AND GAS CONNECTIONFOR TIG WELDING

These units do not include a TIG torch, but one may be pur-chased 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 thesemachines for this purpose; however, any similar TIG torchcan be used.

If the torch to be used does not have a mating Twist-Mateplug on the end of the power cable, the power cable mustbe modified to include one. The LA-9 and LA-17V fall in thiscategory. Cut off the lug on the end of the power cable andattach the extra Twist Mate plug included with the machineto the power cable per the instructions following underQUICK DISCONNECT PLUG.

Next connect the torch cable to the appropriate output termi-nal 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 withthe key lining up with the keyway, and rotate approximately1/4 turn clockwise; until the connection is snug. Do not overtighten. Connect the work cable (which is connected to thework clamp) to the “+” output terminal in the same way.Finally, connect the gas hose to the gas regulator on thecylinder of gas to be used.

The machine can easily be switched between stick and TIGwelding at any time by simply swapping the stick (electrode)and TIG (torch) cables, and reversing the connection polari-ty if required.

QUICK DISCONNECT PLUGA quick disconnect system is used for the weldingcable connections. The electrode and work cableshave the plug attached, on both machines an addition-al plug is supplied if TIG welding is to be done. Thewelding plug included with the machine is designed toaccept a welding cable size of #6 to #4 (10mm2 to25mm2).

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. Usesoap or other nonpetroleum-based lubricant tohelp slide the boot over the cable, if needed.

4. Cut 45-50% of the copper strands back 1/4” (6mm).

5. Fold copper strands over cut strands and insertinto ferrule.

6. Slide the copper ferrule into the brass plug.7. Tighten set screw to collapse copper tube. Screw

must apply pressure against welding cable. Thetop of the set screw will be well below the surfaceof the brass plug after tightening.

8. Slide rubber boot over brass plug. The rubber bootmust be positioned to completely cover all electri-cal surfaces after the plug is locked into the recep-tacle.

19 mm

.75 in.

WELDING CABLE

BOOT

TRIM, IF REQ'DTO FIT OVER CABLE

6 mm.25 in.

WELDING CABLE

12 mm max..50 in. max

WELDING CABLE

COPPER FERRULE

SET SCREW

BRASS PLUGCOPPER TUBE

B-1OPERATION


B-1

GENERAL DESCRIPTION

The Invertec V100-S is a light industrial 100 amp arcwelding power source and the V130-S is a light indus-trial 130 amp arc welding power source both of whichutilize single phase input power, to produce constantcurrent output. The welding response of theseInvertecs has been optimized for stick (SMAW) andTIG (GTAW). Both units are perfect for light industrialapplications where portability is important.

OPERATIONAL FEATURES

The Invertecs provide continuous total range outputcurrent adjustment. Additionally, a “hot start” systemhas been built into the welding current control, andprovides a higher striking current to assist ignition ofthe arc.

WELDING CAPABILITY

The Invertec V100-S is rated at 100 amps, 15% dutycycle (based on a 10 minute cycle). It is also rated at85 amps, 20% duty cycle, and 70 amps, 20% dutycycle. The Invertec V130-S is rated at 130 amps, 20%duty cycle (based on a 10 minute cycle). It is alsorated at 105 amps, 60% duty cycle, and 90 amps,100% duty cycle.

LIMITATIONS

The V100-S and V130-S are not recommended forpipe thawing.

The V100-S and V130-S should not be powered fromthe auxiliary power supply of an engine welder.Special protection circuits may operate causing loss ofoutput.

Read and understand this entire section beforeoperating your machine.

SAFETY INSTRUCTIONS

ELECTRIC SHOCK can kill.

• Do not touch electrically live parts suchas output terminals or internal wiring.

• Insulate yourself from the work andground.

• Always wear dry insulating gloves.____________________________________

____________________________________

____________________________________

____________________________________

Only qualified personnel should operate this equip-ment. Observe all safety information throughout thismanual.

WARNING

FUMES AND GASEScan be dangerous.

• Keep your head out of fumes.

• Use ventilation or exhaust toremove fumes from breathingzone.

ARC RAYScan burn.

• Wear eye, ear and bodyprotection.

WELDING, CUTTING and GOUGING SPARKScan cause fire or explosion

• Keep flammable material away.

• Do not weld, cut or gouge oncontainers that have held com-

bustibles.

B-2OPERATIONB-2

Power Switch - Controls the power input to themachine. This rocker switch is lighted. When power isapplied to the machine the light is on.

Knob M1 - Potentiometer used to set the value of thecurrent required by the welding process.

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 bythe internal thermostat.

* Note that input voltages that exceed 20% of nominalmay cause internal damage to the machine.

Output Terminals - These quick disconnect terminalsprovide connection points for the electrode and workcables. For positive polarity welding connect the elec-trode cable to the positive terminal and the work cableto the negative terminal. To weld negative polarityreverse the electrode and work cables.


CONTROLS AND SETTINGS

All operator controls and adjustments are located on the case front of the V100-S and V130-S machines. Refer toFigure B.1 and the corresponding explanations.

FIGURE B.1 — CASE FRONT CONTROLS.

M1

LED 1

PowerSwitch

OutputTerminals

XX

ON

OFF

XX

XX

XXXX

XXX

B-3OPERATIONB-3

CONSTANT CURRENT PROCESSES

MANUAL ARC WELDING (STICK)

The Invertec may be utilized as a manual DC arcwelder. The electrode cable and holder and the workcable and clamp are included.

Excellent stick welding performance is easily achievedwith the following electrodes and current settings:

Machine Electrode Diameter Current

V100-S Fleetweld 35 3/32” Max 90 AmpsFleetweld 180 3/32”Max 90 AmpsFleetweld 37 3/32” Max 100 AmpsLH-78 3/32” Max 100 Amps

V130-S Fleetweld 35 1/8” Max 100 AmpsFleetweld 180 1/8” Max 100 AmpsFleetweld 37 1/8” Max 115 AmpsLH-78 1/8” Max 130 Amps

TIG WELDING

The Invertecs are capable of scratch start TIG weld-ing. A TIG torch, and gas supply with regulator arerequired.

OVERLOAD PROTECTION

The machine is electrically protected from producingexcessive currents. The maximum current obtainablewith the V100-S is approximately 120 amps, and thatof the V130-S is approximately 150 amps.

THERMAL PROTECTION

Thermostats protect the machine from excessiveoperating temperatures. Excessive temperatures maybe caused by a lack of cooling air or operating themachine beyond the duty cycle and output rating. Ifexcessive operating temperature should occur, thethermostats will prevent output voltage or current.

Thermostats are self-resetting once the machine coolssufficiently. If the thermostat shutdown was caused byexcessive output or duty cycle and the fan is operatingnormally, the Power Switch may be left on and thereset should occur within a 15 minute period. If the fanis not operating or if the air flow is obstructed, thisproblem must be resolved before continuing.


C-1ACCESSORIESC-1

OPTIONS / ACCESSORIES

K909-1 - EH-200 Insulated electrode holder designedfor maximum operator comfort and convience.

K859-”L” - LA-9 125 amp air-cooled, lightweight, andversatile TIG torch for thin gauge materials. Includestwo piece cable. Available in 12.5 ft. and 25 ft.lengths.

K860-”L” - LA-17V 150 amp air-cooled compact anddurable TIG torch for thin to medium gauge materials.Includes valve and two piece cable. Available in 12.5ft. and 25 ft. lengths.

KP507 - Parts kit for the LA-9 torch. Kit includes backcap, collets, collet bodies, nozzles and tungstens.

KP508 - Parts kit for the LA-17 torch. Kit includesback cap, collets, collet bodies, nozzles and tung-stens.

K852-25 - Twist-Mate™ plug for connecting weldingcable to output terminals. Contains one plug.


D-1MAINTENANCED-1

SAFETY PRECAUTIONS

ELECTRIC SHOCK can kill.• Have an electrician install and ser-

vice this equipment.

• Turn the input power off at the fusebox, disconnect supply lines andallow machine to sit for five minutesminimum to allow the power capaci-tors to discharge before workinginside this equipment.

• Do not touch electrically hot parts.

----------------------------------------------------------------------

INPUT FILTER CAPACITORDISCHARGE PROCEDURE

The machine has internal capacitors which arecharged to a high voltage during power-on conditions.This voltage is dangerous and must be dischargedbefore the machine can be serviced. Discharging isdone automatically by the machine each time thepower is switched off. However, you must allow themachine to sit for at least 5 minutes to allow time forthe process to take place.------------------------------------------------------------------------

ROUTINE MAINTENANCE

1. Perform the following preventive maintenanceprocedures at least once every thousand hours ofuse. It is good practice to keep a preventive main-tenance record; a record tag attached to themachine works best.

2. Remove the machine cover (requires a 3 mm hexkey) after allowing the minimum 5 minute poweroff requirement to let the input capacitors dis-charge.

Failure to observe this discharge time requirementcould result in severe electrical shock hazard.------------------------------------------------------------------------3. Keeping the machine clean will result in cooler

operation and higher reliability. Be sure to cleanthe following areas with a low pressure airstream.

• Printed circuit boards

• Power switch

• Fan blades

• Louvers

• Heat sink fins

• Output terminals

4. Examine capacitors for leakage or oozing. If anyleakage is noticed, take the unit to an authorizedLincoln Field Service Shop.

5. Examine the case for breakage. Repair orreplace the case as required. Keep the case ingood condition to ensure that high voltage partsare protected and correct spacings are main-tained.

6. Install machine covers and fasteners.


WARNING

WARNING

WARNING

E-1TROUBLESHOOTINGE-1


If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact yourLocal Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed.

CAUTION

This Troubleshooting Guide is provided tohelp you locate and repair possible machinemalfunctions. Simply follow the three-stepprocedure listed below.

Step 1. LOCATE PROBLEM (SYMPTOM).Look under the column labeled “PROBLEM(SYMPTOMS)”. This column describespossible symptoms that the machine mayexhibit. Find the listing that best describesthe symptom that the machine is exhibiting.

Step 2. POSSIBLE CAUSE.The second column labeled “POSSIBLECAUSE” lists the obvious external possibili-ties that may contribute to the machinesymptom.

Step 3. RECOMMENDED COURSE OFACTIONThis column provides a course of action forthe Possible Cause, generally it states tocontact you local Lincoln Authorized FieldService Facility.

If you do not understand or are unable toperform the Recommended Course ofAction safely, contact you local LincolnAuthorized Field Service Facility.

HOW TO USE TROUBLESHOOTING GUIDE

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 andmachine operator and will invalidate your factory warranty. For your safety and to avoidElectrical Shock, please observe all safety notes and precautions detailed throughout this manual.__________________________________________________________________________

WARNING



Observe all Safety Guidelines detailed throughout this manual


CAUTION

PROBLEMS(SYMPTOMS)

POSSIBLE AREAS OFMISADJUSTMENTS(S)

RECOMMENDEDCOURSE OF ACTION

The machine is dead - no output -no fan.

No output but the fan operates nor-mally.

Output turns on momentarily, thenswitches off.

No output - Main input fuses open,indicating excessive current draw.

1. The input power switch must bein the ON position.

2. Make sure the input voltage iscorrect for the machine.

1. The machine may be overheated.Check the thermal indicator light.Wait for the machine to cool andthe thermostats to reset.

1. Check the input voltage. Makesure the input voltage is correctfor the machine.

1. Inspect input leads for possibleshorts or grounds or mis-connec-tions.

2. Install new fuses and reapplypower. If fuses open again, con-sult a Lincoln Authorized FieldService Facility.

If all recommended possible areas ofmisadjustment have been checkedand the problem persists, Contactyour local Lincoln Authorized FieldService Facility.



Observe all Safety Guidelines detailed throughout this manual


CAUTION

PROBLEMS(SYMPTOMS)

POSSIBLE AREAS OFMISADJUSTMENTS(S)

RECOMMENDEDCOURSE OF ACTION

Poor welding, weld settings drift, oroutput power is low.

Poor stick electrode welding performance. The arc pops out.

1. Make sure the machine settingsare correct for the weld processbeing used.

2. Make sure the input voltage iscorrect for the machine.

1. Check for loose or faulty weldingcables.

2. Is the electrode DRY? Try weld-ing with another electrode from adifferent container. Make sureyou have the correct electrode forthe application.

3. Make sure the machine settingsare correct for the weld processbeing used.

If all recommended possible areas ofmisadjustment have been checkedand the problem persists, Contactyour local Lincoln Authorized FieldService Facility.

F-1DIAGRAMSF-1


INV

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F-2DIAGRAMSF-2


INV

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For details write: Lincoln Welding School22801 St. Clair Ave. Cleveland, Ohio 44117-1199.

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WARNING

AVISO DEPRECAUCION

ATTENTION

WARNUNG

ATENÇÃO

Spanish

French

German

Portuguese

Japanese

Chinese

Korean

Arabic

READ AND UNDERSTAND THE MANUFACTURER’S INSTRUCTION FOR THIS EQUIPMENT AND THE CONSUMABLES TO BEUSED AND FOLLOW YOUR EMPLOYER’S SAFETY PRACTICES.

SE RECOMIENDA LEER Y ENTENDER LAS INSTRUCCIONES DEL FABRICANTE PARA EL USO DE ESTE EQUIPO Y LOSCONSUMIBLES 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 AETRE 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 UNFALLVERHÜTUNGSVORSCHRIFTEN DES ARBEITGEBERS SIND EBENFALLS ZU BEACHTEN.

● Do not touch electrically live parts orelectrode with skin or wet clothing.

● Insulate yourself from work andground.

● No toque las partes o los electrodosbajo carga con la piel o ropa moja-da.

● Aislese del trabajo y de la tierra.

● Ne laissez ni la peau ni des vête-ments mouillés entrer en contactavec des pièces sous tension.

● Isolez-vous du travail et de la terre.

● Berühren Sie keine stromführendenTeile oder Elektroden mit IhremKörper oder feuchter Kleidung!

● Isolieren Sie sich von denElektroden und dem Erdboden!

● Não toque partes elétricas e elec-trodos com a pele ou roupa molha-da.

● Isole-se da peça e terra.

● Keep flammable materials away.

● Mantenga el material combustiblefuera del área de trabajo.

● Gardez à l’écart de tout matérielinflammable.

● Entfernen Sie brennbarres Material!

● Mantenha inflamáveis bem guarda-dos.

● Wear eye, ear and body protection.

● Protéjase los ojos, los oídos y elcuerpo.

● Protégez vos yeux, vos oreilles etvotre corps.

● Tragen Sie Augen-, Ohren- und Kör-perschutz!

● Use proteção para a vista, ouvido ecorpo.

WARNING

AVISO DEPRECAUCION

ATTENTION

WARNUNG

ATENÇÃO

Spanish

French

German

Portuguese

Japanese

Chinese

Korean

Arabic

LEIA E COMPREENDA AS INSTRUÇÕES DO FABRICANTE PARA ESTE EQUIPAMENTO E AS PARTES DE USO, E SIGA ASPRÁTICAS DE SEGURANÇA DO EMPREGADOR.

● Keep your head out of fumes.● Use ventilation or exhaust to

remove fumes from breathing zone.

● Los humos fuera de la zona de res-piración.

● Mantenga la cabeza fuera de loshumos. Utilice ventilación oaspiración para gases.

● Gardez la tête à l’écart des fumées.● Utilisez un ventilateur ou un aspira-

teur pour ôter les fumées des zonesde travail.

● Vermeiden Sie das Einatmen vonSchweibrauch!

● Sorgen Sie für gute Be- undEntlüftung des Arbeitsplatzes!

● Mantenha seu rosto da fumaça.● Use ventilação e exhaustão para

remover fumo da zona respiratória.

● Turn power off before servicing.

● Desconectar el cable de ali-mentación de poder de la máquinaantes de iniciar cualquier servicio.

● Débranchez le courant avant l’entre-tien.

● Strom vor Wartungsarbeitenabschalten! (Netzstrom völlig öff-nen; Maschine anhalten!)

● Não opere com as tampas removidas.● Desligue a corrente antes de fazer

serviço.● Não toque as partes elétricas nuas.

● Do not operate with panel open orguards off.

● No operar con panel abierto oguardas quitadas.

● N’opérez pas avec les panneauxouverts ou avec les dispositifs deprotection enlevés.

● Anlage nie ohne Schutzgehäuseoder Innenschutzverkleidung inBetrieb setzen!

● Mantenha-se afastado das partesmoventes.

● Não opere com os paineis abertosou guardas removidas.

Rita Wood

• 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

• World's Leader in Welding and Cutting Products •

Documents

IM585 INVERTEC V100-S & V130-S January, 2002valvolodin.narod.ru/schems/invertec_130.pdfINVERTEC V100-S & V130-S® OPERATOR’S MANUAL IM585 January, 2002 Safety Depends on You Lincoln