Page 2 - SAFETY; WARNING; CALIFORNIA PROPOSITION 65 WARNINGS; The Above For Diesel Engines
FOR ENGINEpowered 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....
Page 3 - ii
ii SAFETY ii 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...
Page 4 - iii; Refer to
iii SAFETY iii FOR ELECTRICALLYpowered equipment. 8.a. Turn off input power using the disconnect switch at the fuse box before working onthe equipment. 8.b. Install equipment in accordance with the U.S. National Electr ical Code, all local codes and the manufacturer ’srecommendations. 8.c. Ground th...
Page 5 - iv; PRÉCAUTIONS DE SÛRETÉ
iv SAFETY iv PRÉCAUTIONS DE SÛRETÉ Pour 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’Arc 1. Protegez-vous contre la secouss...
Page 6 - Thank You; Please Examine Carton and Equipment For Damage Immediately
v v Thank You for selecting a QUALITY product. We want you to take pride in operating this product ••• as much pride as we have in bringingthis product to you! Read this Operators Manual completely before attempting to use this equipment. Save this manual and keep it handy for quick reference. Pay p...
Page 7 - TAbLE OF CONTENTS
vi vi TAbLE OF CONTENTS Page Installation .......................................................................................................................Section A Technical Specifications .......................................................................................................A...
Page 8 - INSTALLATION; DC
A-1 INSTALLATION V160-T A-1 Input Circuit 115V (20A Plug and Branch) 115V (30A Branch) 230V (30A Branch) 230V (30A Branch) Maximum Open Circuit Voltage 48 Volts Max. Duty Cycle 100% 35% 100% Output Current Range 5-160 Amps INPUT - SINGLE PHASE ONLY RATED OUTPUT OUTPUT Height Width Depth Weight 12.6 ...
Page 9 - SAFETY PRECAUTIONS; ELECTRIC SHOCK can kill.; SELECT SUITAbLE LOCATION; STACKING
A-2 INSTALLATION V160-T A-2 Read entire installation section before startinginstallation. SAFETY PRECAUTIONS ELECTRIC SHOCK can kill. • Only qualified personnel should per-form this installation. • Disconnect input power by removingplug from receptacle before workinginside V160-T. Allow machine to s...
Page 10 - INPUT CONNECTIONS; GROUND CONNECTION; • lnstall only plugs that are corresponding to safe-
A-3 INSTALLATION V160-T A-3 Keeping these contributing factors in mind, installingequipment per the following instructions should mini-mize problems. 1. Keep the welder power supply lines as short as possible and enclose as much of them as possiblein rigid metallic conduit or equivalent shielding fo...
Page 11 - circuit breakers. Using fuses or circuit; ATTACHMENT PLUG; • The RMS voltage of the AC waveform is always
A-4 INSTALLATION V160-T A-4 Fuse the input circuit with time delay fuses marked “D”or delay type 1 circuit breakers. Using fuses or circuit breakers smaller than recommended may result in“nuisance” shut-offs from welder inrush currents evenif not welding at high currents. 1 Also called inverse time ...
Page 12 - OUTPUT CONNECTIONS; WORK CAbLE CONNECTION; To minimize high frequency interference, refer to
A-5 INSTALLATION V160-T A-5 OUTPUT CONNECTIONS ELECTRIC SHOCK can kill. • K e e p t h e e l e c t ro d e h o l d e r, T I G torch and cables insulation in goodcondition and in place. • Do not touch electrically live parts or electrode with skin or wet clothing. • Insulate yourself from work and grou...
Page 13 - REMOTE CONTROL CONNECTION; • Remote control potentiometer (K857) for Stick; •K e e p c y l i n d e r u p r i g h t a n d; Fold copper strands over cut strands and insert; SHIELDING GAS CONNECTION
A-6 INSTALLATION V160-T A-6 REMOTE CONTROL CONNECTION A remote control receptacle is provided on the lowerc e n t e r c a s e f r o n t o f t h e w e l d e r f o r c o n n e c t i n g aremote control to the machine. Refer to the OptionalA c c e s s o r i e s s e c t i o n o f t h i s m a n u a l f o...
Page 14 - OPERATION; SAFETY INSTRUCTIONS; GENERAL DESCRIPTION; WELDING CAPAbILITY
b-1 OPERATION V160-T b-1 Read and understand this entire section beforeoperating your machine. SAFETY INSTRUCTIONS ELECTRIC SHOCK can kill. • Do not touch electrically live parts such as output terminals or internal wiring. • I n s u l a t e y o u r s e l f f r o m t h e w o r k a n d ground. • Alwa...
Page 15 - REAR CONTROL PANEL
b-2 OPERATION b-2 REAR CONTROL PANEL 1. Power Switch: Controls the input power to the machine. Make sure the machine is properly con-n e c t e d t o t h e i n p u t s u p p l y b e f o r e t u r n i n g t h emachine on.(See Figure B.1) 2. F a n : T h e c o o l i n g f a n w i l l t u r n O N w h e n...
Page 16 - The indicator will also blink
b-3 OPERATION b-3 When the mode switch is in the Lift TIG position, the stick welding functions are disabled and the machine isready for Lift TIG welding. Lift TIG is a method of start- ing a TIG weld by first pressing the TIG torch electrodeon the work piece in order to create a low current shortci...
Page 17 - TRIGGER MODE SEQUENCES; Step Diagram 1
b-4 OPERATION b-4 12. Postflow Control: In the TIG welding modes, this control knob will adjust the shielding gas postflowtime from 0.5 to 30 seconds. (The preflow time isalways 0.5 seconds.) In Stick welding mode, thisfunction is not used. 13. Digital Display: This meter displays the preset weld- i...
Page 18 - Step Diagram 1
b-5 OPERATION b-5 V160-T 4-Step Sequence Note: 4-Step works with Arc Start Switch only. Amptrol™ type devices will not work properly and should notbe used. The Arc Start Switch's actuator is alsoreferred to as the "Tig torch trigger" in the followingsequence. 1. P r e s s a n d h o l d t h e...
Page 19 - DIP SWITCH FUNCTIONS; OFF
b-6 OPERATION b-6 DIP SWITCH FUNCTIONS T he following sections explain the 8 DIP switch func- tions of the V160. Read and understand the functionsbefore making any changes because abnormal opera-tion can occur with the wrong settings. The machinem u s t b e t u r n e d O F F w h e n t h e D I P S w ...
Page 20 - DIP Switch 3: 2 Step Restart Enable; Press and hold the TIG torch trigger to start the
b-7 OPERATION b-7 DIP Switch 3: 2 Step Restart Enable This controls the 2 Step Restart function. When theswitch is ON the 2 Step Restart function is enabled. 2-Step Restart Disabled (DIP Switch 3 = OFF) 1. Press and hold the TIG torch trigger to start the sequence. The machine will open the gas valv...
Page 21 - DIP Switch 4: 4 Step Restart Enable
b-8 OPERATION b-8 DIP Switch 4: 4 Step Restart Enable This controls the 4 Step Restart function. When theswitch is ON the 4 Step Restart function is enabled.("Foot pedal" remote controls should never be usedwith the 4 step sequences.) 4-Step Restart Disabled (DIP Switch 4 = OFF) 1. Press and...
Page 22 - Press and hold the TIG torch trigger when the main
b-9 OPERATION b-9 4-Step Restart Enabled (DIP Switch 4 = ON) Same as step 1. Same as step 2. 3. Press and hold the TIG torch trigger when the main part of the weld is complete. The machine will nowdecrease the output current at a controlled rate( d o w n s l o p e ) , u n t i l t h e S t a r t / C r...
Page 23 - DIP Switch 5: Low OCV Enable; • European Machine Configuration (DIP Switch 6 =
b-10 OPERATION b-10 DIP Switch 5: Low OCV Enable This controls the OCV of the machine. When theDIP switch is OFF the OCV is set to the normal levelas stated in the manuals for the machines. Whenthe DIP switch is ON the OCV is reduced to 20V.This low OCV mode was created for the Australianmarkets and...
Page 25 - ACCESSORIES; OPTIONAL ACCESSORIES; AND COMPATIbLE EQUIPMENT; K870 - Foot Amptrol; CAbLE PLUGS; TIG Torch Parts Kits -
C-1 ACCESSORIES C-1 OPTIONAL ACCESSORIES AND COMPATIbLE EQUIPMENT Factory Installed 1-Twist-Mate Torch Connector (W/Gas Pass Through)1- Ground Lead and Plug Assembly Strap PacketInstruction Manual Field Installed K870 - Foot Amptrol tm for TIG welding. When the V160-T’s Output Control is in the “REM...
Page 26 - MAINTENANCE; ELECTRIC SHOCK; INPUT FILTER CAPACITOR; ROUTINE MAINTENANCE; • Clean the power source inside by means of low-; • Disconnect the power supply before every oper-; • Always use gloves in compliance with the safety
D-1 MAINTENANCE D-1 V160-T SAFETY PRECAUTIONS ELECTRIC SHOCK can kill. • Have an electrician install and serv- ice this equipment. • Turn the input power off at the fuse box, disconnect supply lines andallow machine to sit for five minutesminimum to allow the power capaci-tors to discharge before wo...
Page 27 - TROUbLESHOOTING; Local Lincoln Authorized Field Service Facility; for technical troubleshooting assistance before you proceed.; CAUTION; Step 3. RECOMMENDED COURSE OF ACTION; HOW TO USE TROUbLESHOOTING GUIDE
E-1 TROUbLESHOOTING E-1 V160-T 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. CAUTION This Troubleshooting Guide i...
Page 28 - Observe all Safety Guidelines detailed throughout this manual; C o n t a c t
E-2 TROUbLESHOOTING E-2 V160-T Observe all Safety Guidelines detailed throughout this manual PRObLEMS (SYMPTOMS) POSSIbLE CAUSE RECOMMENDED COURSE OF ACTION Excessive spatter Craters Inclusions Insufficient penetration Sticking Porosity Cracks 1. Long arc2. High current 1. Fast movement of the elect...
Page 29 - Oxidation; Contact
V160-T E-3 TROUbLESHOOTING E-3 Observe all Safety Guidelines detailed throughout this manual PRObLEMS (SYMPTOMS) POSSIbLE CAUSE RECOMMENDED COURSE OF ACTION Oxidation Tungsten inclusions Porosity Hot cracking 1. lnsufficient gas.2. No protection on the back side. 1. lncorrect electrode sharpening.2....
Page 31 - DIAGRAMS
F-1 DIAGRAMS F-1 V160-T 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 ...
Page 32 - WIRIN; REMOTE; WIRING DIAGRAM CODE 1
F-2 DIAGRAMS F-2 V160-T V1 60 -T WIRIN G DIAGRA M 1 2 4 3 AC1 AC2 GND S1 BLUE BROWN WHITE BL ACK YEL LOW / GREEN 115/230/1/50/ 60 Vac FAN JP2 DC-A DC+ Y/G BL ACK RED DC+ DC- GND 12 3 6 5 41 0 11 9 8 71 2 15 13 14 16 13 5 4 21 0 67 9 8 JP1 JP1 1 3 54 2 10 6 7 98 11 13 12 J1 14 15 16 17 24 23 22 21 20...
Page 33 - NOTES