RETURN TO MAIN MENU IM918 ™ INVERTEC V155-S For use with machines having Code Numbers: April, 2007 11326; 11327 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.
i i SAFETY 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.
ii ii SAFETY ARC RAYS can burn. ELECTRIC SHOCK can kill. 3.a. The electrode and work (or ground) circuits are electrically “hot” when the welder is on. Do not touch these “hot” parts with your bare skin or wet clothing. Wear dry, hole-free gloves to insulate hands. 3.b. Insulate yourself from work and ground using dry insulation. Make certain the insulation is large enough to cover your full area of physical contact with work and ground.
iii iii SAFETY WELDING and CUTTING SPARKS can cause fire or explosion. 6.a. Remove fire hazards from the welding area. If this is not possible, cover them to prevent the welding sparks from starting a fire. Remember that welding sparks and hot materials from welding can easily go through small cracks and openings to adjacent areas. Avoid welding near hydraulic lines. Have a fire extinguisher readily available. 6.b.
iv iv SAFETY PRÉCAUTIONS DE SÛRETÉ 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 LʼArc 1. Protegez-vous contre la secousse électrique: a. Les circuits à lʼélectrode et à la piéce sont sous tension quand la machine à souder est en marche.
v SAFETY EN 60974-10 v
vi SAFETY EN 60974-10: vi
vii vii Thank You 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! CUSTOMER ASSISTANCE POLICY The business of The Lincoln Electric Company is manufacturing and selling high quality welding equipment, consumables, and cutting equipment. Our challenge is to meet the needs of our customers and to exceed their expectations.
viii TABLE OF CONTENTS Page Installation.......................................................................................................................Section A Technical Specifications .......................................................................................................A-1 Safety Precautions .................................................................................................A-2 Select Suitable Location .................................................................
A-1 A-1 INSTALLATION TECHNICAL SPECIFICATION V155-S INPUT - SINGLE PHASE ONLY Input Voltages / 50 /60 Hz. 120Vac ± 10% 230Vac ± 10% Max. Input Current at rated Output 100% 30% 25A 34 A 23A 33 A Input Power at Rated Output 100% 30% 2.2kw 3.0kw 3.0kw 5.0kw RATED OUTPUT Duty Cycle Output Amps Output Volts Input Circuit 75A (Stick) 105A (TIG) 23.0 Vdc 14.2 Vdc 120 Vac 100A (Stick) 100A (TIG) 24.0 Vdc 14.0 Vdc 230 Vac 100A (Stick) 130A (TIG) 24.0 Vdc 15.
A-2 A-2 INSTALLATION Read entire installation section before starting installation. SAFETY PRECAUTIONS WARNING ELECTRIC SHOCK can kill. • Only qualified personnel should perform this installation. • Disconnect input power by removing plug from receptacle before working inside V155-S. Allow machine to sit for 5 minutes minimum to allow the power capacitors to discharge before working inside this equipment. • Insulate yourself from the work and ground. • Always wear dry insulating gloves.
A-3 A-3 INSTALLATION INPUT POWER CONNECTION WARNING Check the input voltage, phase, and frequency supplied to this machine before turning it on. The allowable input voltage is indicated in the technical specification section of this manual and on the rating plate of the machine. Be sure that the machine is grounded. Make sure the power available at the input connection is adequate for normal operation of the machine.
A-4 A-4 INSTALLATION ARFU (Auto-Restore Fuse) FIGURE A.1 The dual input voltage machine is provided with the ARFU device. It operates only when the input is connected to the 120Vac mains and protects from input overcurrent. When active, the "Thermal LED" lights (see "Controls and Operational Features" in the Operation Section). Electrode Holder Note: The ARFU device operates independently from the machine's duty-cycle.
A-5 INSTALLATION REPLACEMENT QUICK DISCONNECT PLUG (FOR STICK ELECTRODE CABLE) The V155-S comes with a factory assembled stick electrode holder, cable and Twist-mate adapter plug. If a replacement cable is ever needed a K852-25 Twistmate plug will be needed. To attach the K852-25 plug: 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.
B-1 OPERATION Read and understand this entire section before operating your machine. B-1 GENERAL DESCRIPTION The Invertec V155-S is an industrial 155 amp arc welding power source which utilizes single phase input power, to produce constant current output. The welding response of this Invertec has been optimized for stick (SMAW) and Touch Start TIG (GTAW). The unit is ideal for industrial applications where portability is important. SAFETY INSTRUCTIONS WARNING ELECTRIC SHOCK can kill.
B-2 B-2 OPERATION CONTROLS AND OPERATIONAL FEATURES 1. Output Current Knob: A Potentiometer used to set the output current used during welding, from 5A to 155A. 2. Welding Mode Switch: With three positions, controls the welding mode of the machine: two for Stick welding (Soft and Crisp) and one for Lift TIG welding. • Soft Stick: For a welding with a low spatter presence. • Crisp Stick: For an aggressive welding, with an increased Arc stability.
B-3 OPERATION B-3 5. Positive Quick Disconnect: Positive output connector for the welding circuit. AUTO ADAPTIVE ARC FORCE (WITH STICK WELDING) 6. Negative Quick Disconnect: Negative output connector for the welding circuit. The Auto Adaptive Arc Force function is activated during stick welding. This function increases temporary the output current, used to clear intermittent connections between the electrode and the weld puddle that occur during stick welding. REAR CONTROL PANEL (See Figure B.2) 7.
C-1 ACCESSORIES C-1 CABLE PLUGS OPTIONAL ACCESSORIES AND COMPATIBLE EQUIPMENT K852-25 - Cable Plug Kit attaches to welding cable to provide quick disconnect from machine. Factory Installed TIG Torch Parts Kits - Parts kits are available for the PTA-9FV and PTA-17 TIG torch. These kits include back cap, collets, collet bodies, nozzles and tungstens.
D-1 D-1 MAINTENANCE SAFETY PRECAUTIONS WARNING WARNING Do not open this machine and do not introduce anything into its openings. Power supply must be disconnected from the machine before each maintenance and service. After each repair, perform proper tests to ensure safety. ELECTRIC SHOCK can kill. • Have an electrician install and service this equipment.
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.
E-2 E-2 TROUBLESHOOTING Observe all Safety Guidelines detailed throughout this manual PROBLEMS (SYMPTOMS) POSSIBLE CAUSE RECOMMENDED COURSE OF ACTION PROBLEMS IN STICK WELDING Excessive spatter 1. Long arc 2. High current Craters 1. Fast movement of the electrode away from piece. Inclusions 1. Poor cleanliness or distribution of the Welding passes. 2. Improper movement of the electrode. Insufficient penetration 1. High progression speed. 2. Welding current too low. 3. Narrow chamfering.
E-3 E-3 TROUBLESHOOTING Observe all Safety Guidelines detailed throughout this manual PROBLEMS (SYMPTOMS) POSSIBLE CAUSE RECOMMENDED COURSE OF ACTION PROBLEMS IN TIG WELDING Oxidation 1. lnsufficient gas. 2. No protection on the back side. Tungsten inclusions 1. lncorrect electrode sharpening. 2. Electrode too small. 3. Operating failure (contact of the tip with the workpiece). Porosity 1. Dirt on the edges. 2. Dirt on the filler material. 3. Excessive travel speed. 4. Current intensity too low.
E-4 E-4 TROUBLESHOOTING Observe all Safety Guidelines detailed throughout this manual PROBLEMS (SYMPTOMS) POSSIBLE CAUSE RECOMMENDED COURSE OF ACTION ELECTRICAL FAILURES Machine fails to come on (Power LED off) 1. No Input Voltage. 2. Faulty supply plug or cable. 3. Internal fuse tripped. Allow time to Auto reset. Thermal overload (Thermal LED on) 1. Unit has been operated beyond its capacity rating. 2. Airflow through machine is restricted or fan has failed.
V155-S FAN 1 WHITE WIRE TIE 4 2 BLACK RED BLUE JP4 2 1 4 4 PINS 16 PINS 15 16 JP1 DC- DC+ PE JP2 (SCHEMATIC: X0708) W05X0708-1 JP1 Y/G WHITE RED BLACK JP1 PE DC- CONTROL BOARD BLACK RED DC+ RED BLACK (SCHEMATIC: X0519) INVERTER BOARD W05X0519 N1 P1 SHUNT - + DIAGRAMS WHITE RED BLACK NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual.
● Do not touch electrically live parts or WARNING Spanish AVISO DE PRECAUCION French ATTENTION German WARNUNG Portuguese ATENÇÃO ● Keep flammable materials away. ● Wear eye, ear and body protection. ● Mantenga el material combustible ● Protéjase los ojos, los oídos y el electrode with skin or wet clothing. ● Insulate yourself from work and ground. ● No toque las partes o los electrodos bajo carga con la piel o ropa mojada. ● Aislese del trabajo y de la tierra.
● Keep your head out of fumes. ● Use ventilation or exhaust to ● Turn power off before servicing. ● Do not operate with panel open or guards off. remove fumes from breathing zone. ● Los humos fuera de la zona de res- piración. ● Mantenga la cabeza fuera de los humos. Utilice ventilación o aspiración para gases. ● Gardez la tête à l’écart des fumées. ● Utilisez un ventilateur ou un aspira- ● Desconectar el cable de ali- mentación de poder de la máquina antes de iniciar cualquier servicio.
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