Lincoln Electric INVERTEC 160SX User manual

IM2038
12/2014
rev05
INVERTEC®160SX
PŘÍRUČKA UŽIVATELE
(OPERATOR’S MANUAL IN ENGLISH)
ENGLISH
Lincoln Electric Bester Sp. z o.o.
ul. Jana III Sobieskiego 19A, 58-263 Bielawa, Poland
www.lincolnelectric.eu

English I English
Declaration of conformity
12
Lincoln Electric Bester Sp. z o.o.
Declares that the welding machine:
K12050-1 INVERTEC
®
160SX CE
K12050-2 INVERTEC
®
160SX AUS
conforms to the following directives:
2006/95/CEE, 2004/108/CEE
and has been designed in compliance with the
following standards:
EN 60974-1, EN 60974-10:2007
09.09.2014
PawełLipiński
Operations Director
Lincoln Electric Bester Sp. z o.o., ul. Jana III Sobieskiego 19A, 58-263 Bielawa, Poland
12/05

English II English
12/05
THANKS! For having chosen the QUALITY of the Lincoln Electric products.
Please Examine Package and Equipment for Damage. Claims for material damaged in shipment must be notified
immediately to the dealer.
For future reference record in the table below your equipment identification information. Model Name, Code & Serial
Number can be found on the machine rating plate.
Model Name:
………………………………………………………………………………………………………………………………………….
Code & Serial Number:
………………………………………………………………….. …………………………………………………………………..
Date & Where Purchased
…………………………………………………………………. …………………………………………………………………..
ENGLISH INDEX
Safety .............................................................................................................................................................................. 1
Installation and Operator Instructions .............................................................................................................................. 2
Electromagnetic Compatibility (EMC) .............................................................................................................................. 6
Technical Specifications .................................................................................................................................................. 7
WEEE.............................................................................................................................................................................. 7
Spare Parts...................................................................................................................................................................... 8
Electrical Schematic ........................................................................................................................................................ 8
Accessories ..................................................................................................................................................................... 8

English 1 English
Safety 11/04
WARNING
This equipment must be used by qualified personnel. Be sure that all installation, operation, maintenance and repair
procedures are performed only by qualified person. Read and understand this manual before operating this equipment.
Failure to follow the instructions in this manual could cause serious personal injury, loss of life, or damage to this
equipment. Read and understand the following explanations of the warning symbols. Lincoln Electric is not responsible
for damages caused by improper installation, improper care or abnormal operation.
WARNING: This symbol indicates that instructions must be followed to avoid serious personal injury,
loss of life, or damage to this equipment. Protect yourself and others from possible serious injury or
death.
READ AND UNDERSTAND INSTRUCTIONS: Read and understand this manual before operating this
equipment. Arc welding can be hazardous. Failure to follow the instructions in this manual could cause
serious personal injury, loss of life, or damage to this equipment.
ELECTRIC SHOCK CAN KILL: Welding equipment generates high voltages. Do not touch the
electrode, work clamp, or connected work pieces when this equipment is on. Insulate yourself from the
electrode, work clamp and connected work pieces.
ELECTRICALLY POWERED EQUIPMENT: Turn off input power using the disconnect switch at the
fuse box before working on this equipment. Ground this equipment in accordance with local electrical
regulations.
ELECTRICALLY POWERED EQUIPMENT: Regularly inspect the input, electrode, and work clamp
cables. If any insulation damage exists replace the cable immediately. Do not place the electrode holder
directly on the welding table or any other surface in contact with the work clamp to avoid the risk of
accidental arc ignition.
ELECTRIC AND MAGNETIC FIELDS MAY BE DANGEROUS: Electric current flowing through any
conductor creates electric and magnetic fields (EMF). EMF fields may interfere with some pacemakers
and welders having a pacemaker shall consult their physician before operating this equipment.
CE COMPLIANCE: This equipment complies with the European Community Directives.
ARTIFICIAL OPTICAL RADIATION: According with the requirements in 2006/25/EC Directive and EN
12198 Standard, the equipment is a category 2. It makes mandatory the adoption of Personal Protective
Equipment (PPE) having filter with a protection degree up to a maximum of 15, as required by EN169
Standard.
FUMES AND GASES CAN BE DANGEROUS: Welding may produce fumes and gases hazardous to
health. Avoid breathing these fumes and gases. To avoid these dangers the operator must use enough
ventilation or exhaust to keep fumes and gases away from the breathing zone.
ARC RAYS CAN BURN: 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. Use suitable clothing made from durable
flame-resistant material to protect you skin and that of your helpers. Protect other nearby personnel with
suitable, non-flammable screening and warn them not to watch the arc nor expose themselves to the
arc.

English 2 English
WELDING SPARKS CAN CAUSE FIRE OR EXPLOSION: Remove fire hazards from the welding area
and have a fire extinguisher readily available. Welding sparks and hot materials from the welding
process can easily go through small cracks and openings to adjacent areas. Do not weld on any tanks,
drums, containers, or material until the proper steps have been taken to insure that no flammable or
toxic vapors will be present. Never operate this equipment when flammable gases, vapors or liquid
combustibles are present.
WELDED MATERIALS CAN BURN: Welding generates a large amount of heat. Hot surfaces and
materials in work area can cause serious burns. Use gloves and pliers when touching or moving
materials in the work area.
CYLINDER MAY EXPLODE IF DAMAGED: 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. Always keep cylinders in an upright position securely chained to a fixed support. Do not move or
transport gas cylinders with the protection cap removed. Do not allow the electrode, electrode holder,
work clamp or any other electrically live part to touch a gas cylinder. Gas cylinders must be located
away from areas where they may be subjected to physical damage or the welding process including
sparks and heat sources.
SAFETY MARK: This equipment is suitable for supplying power for welding operations carried out in an
environment with increased hazard of electric shock.
The manufacturer reserves the right to make changes and/or improvements in design without upgrade at the same time
the operator’s manual.
Installation and Operator Instructions
Read this entire section before installation or operation
of the machine.
Location and Environment
This machine can operate in harsh environments.
However, it is important that simple preventative
measures are followed to assure long life and reliable
operation:
Do not place or operate this machine on a surface
with an incline greater than 15° from horizontal.
Do not use this machine for pipe thawing.
This machine must be located where there is free
circulation of clean air without restrictions for air
movement to and from the air vents. Do not cover
the machine with paper, cloth or rags when switched
on.
Dirt and dust that can be drawn into the machine
should be kept to a minimum.
This machine has a protection rating of IP23. Keep it
dry when possible and do not place it on wet ground
or in puddles.
Locate the machine away from radio controlled
machinery. Normal operation may adversely affect
the operation of nearby radio controlled machinery,
which may result in injury or equipment damage.
Read the section on electromagnetic compatibility in
this manual.
Do not operate in areas with an ambient temperature
greater than 40°C.
Input Supply Connection
The Invertec®160SX is a wide input voltage range:
before installing and turning it on, check the supplied
input voltage, phase, and frequency. The allowable input
voltage range, phase, and frequency are indicated in the
technical specification section of this manual and on the
machine’s rating plate. Be sure that the machine is
grounded.
Make sure the power available at the input connection is
adequate for normal operation of the machine. The fuse
rating and cable sizes are both indicated in the technical
specification section of this manual.
Input Supply From Engine Driven Generators
The machine is designed to operate on engine driven
generators as long as the auxiliary can supply adequate
voltage, frequency and power as indicated in the
"Technical Specification" section of this manual. The
auxiliary supply of the generator must also meet the
following conditions:
Vac peak voltage: below 410V.
Vac frequency: in the range of 50 and 60Hz.
RMS voltage of the AC waveform: from 115V to
230V ± 15%.
It is important to check these conditions because many
engine driven generators produce high voltage spikes.
Operation of this machine with engine driven generators
not conforming to these conditions is not recommended
and may damage the machine.

English 3 English
Output Connections
A quick disconnect system using Twist-MateTM cable
plugs is used for the welding cable connections. Refer to
the following sections for more information on
connecting the machine for operation of stick welding
(MMA) or TIG welding.
(+) Positive Quick Disconnect: Positive output
connector for the welding circuit.
(-) Negative Quick Disconnect: Negative output
connector for the welding circuit.
Stick Welding (MMA)
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 of the machine for the selected polarity.
Shown here is the connection method for DC(+) welding.
Connect the electrode cable to the (+) terminal and the
work clamp to the (-) terminal. Insert the connector with
the key lining up with the keyway and rotate
approximately ¼ turn clockwise. Do not over tighten.
For DC(-) welding, switch the cable connections at the
machine so that the electrode cable is connected to (-)
and the work clamp is connected to (+).
TIG Welding
This machine does not include a TIG torch necessary for
TIG welding, but one may be purchased separately.
Refer to the accessories section for more information.
Most TIG welding is done with DC(-) polarity shown
here. If DC(+) polarity is necessary switch the cable
connections at the machine.
Connect the torch cable to the (-) terminal of the
machine and the work clamp to the (+) terminal. Insert
the connector with the key lining up with the keyway and
rotate approximately ¼ turn clockwise. Do not over
tighten. Finally, connect the gas hose to the gas
regulator on the cylinder of gas to be used.
Allowable TIG processes:
Lift TIG
Arc Force
Auto Adaptive Arc Force (with MMA welding)
During MMA welding is activated the function Auto
Adaptive Arc Force that increases temporary the output
current, used to clear intermittent connections between
the electrode and the weld puddle that occur during stick
welding.
This is an active control feature that guarantees the best
arrangement between the arc stability and spatter
presence. The feature "Auto Adaptive Arc Force" has
instead of a fixed or manual regulation, an automatic and
multilevel setting: its intensity depends by the output
voltage and it is calculated in real time by the
microprocessor where are also mapped the Arc Force
levels. The control measure in each instant the output
voltage and it determines the amount of the peak of
current to apply; that value is enough to breaks the metal
drop that is being transferred from the electrode to the
workpiece as to guarantee the arc stability, but not too
high to avoid spatters around the welding puddle. That
means:
Electrode / workpiece sticking prevention, also with
low current values.
Spatters reduction.
The welding operations are simplified and the welded
joins looks better, also if not brushed after the welding.
With the MMA welding are also enabled the following
features:
Hot Start: This is a temporary increase in the initial
welding current. This helps ignite the arc quickly and
reliably.
Anti-Sticking: This is a function that decreases the
output current of the machine to a low level when the
operator makes an error and sticks the electrode to
the work piece. This decrease in current allows the
operator to remove the electrode from the electrode
holder without creating large sparks that can damage
the electrode holder.
Refer to the section below for more details.
Controls and Operational Features
Machine Start-Up:
When the machine is turned ON, an auto-test is
executed; during this test all LEDs are turned ON then
OFF. After that the Power ON LED blinks until the
machine has completed the Start-Up sequence.
The Machine is ready to operate when on the Front
Control Panel lights up the Power ON LED with one
of the three LED of the Welding mode command.

English 4 English
Front Panel Controls
Output Current Knob: Potentiometer used
to set the output current used during
welding.
Power ON/OFF LED: This LED lights up
when the machine is ON.
Thermal LED: This indicator will turn on
when the machine is overheated and the
output has been disabled. This normally
occurs when the duty cycle of the
machine has been exceeded. Leave the
machine on to allow the internal
components to cool. When the indicator
turns off, normal operation is again
possible.
VRD LED's (enabled on Australian
Machines only): This machine is provided
by VRD (Voltage Reduction Device)
function: this reduces the voltage at the
output leads.
The VRD function is enabled by factory
default only on machines that meet the
AS 1674.2 Australian Standards. (C-
Tick logo " " on/near the Rating Plate
applied on the machine).
The VRD LED is ON when the Output
Voltage is below 12V with the Machine at
idle (no welding time).
For others machines this function is
disabled (the LED is always OFF).
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.
Lift TIG: When the mode switch is in
the Lift TIG position, the stick welding
functions are disabled and the
machine is ready for Lift TIG welding.
Lift TIG is a method of starting a TIG
weld by first pressing the TIG torch
electrode on the work piece in order
to create a low current short circuit.
Then, the electrode is lifted from the
work piece to start the TIG arc.
Meter: The meter displays the preset
welding current before welding and the
actual welding current during welding.
Error condition list.
If occurs, try to turn Off the machine, wait for a few
seconds, then turn ON again. If the error remains, a
maintenance is required. Please contact the nearest
technical service center or Lincoln Electric and report the
3-digit code displayed on the meter of the Front Panel.
Error code table
Slow blinking: about 1 time per second
Fast blinking: about 10 time per second
9.01
Input overvoltage
LED is blinking slow.
Indicates that an Input Voltage Overrange
protection is active; the Machine restarts
automatically when the Input Voltage returns in
the correct range.
9.02
Input undervoltage
LED is blinking fast.
Indicates that an Input Voltage Underrange
protection is active; the Machine restarts
automatically when the Input Voltage returns in
the correct range.
9.03
DC bus short circuit
LEDs blinks slow together.
Indicates that an Internal Power Circuitry fault
condition is detected.
To restore the machine:
Turn OFF then ON the Mains Switch to restart
the machine.
9.04
Boost voltage lock out
LEDs blinks slow alternatively.
Indicates that an Internal Auxiliary Voltage fault
condition is detected.
To restore the machine:
Turn OFF then ON the Mains Switch to restart
the machine.
9.05
Inverter voltage lock out
LEDs blinks fast alternatively.
Indicates that an Internal Auxiliary Voltage fault
condition is detected.
To restore the machine:
Turn OFF then ON the Mains Switch to restart
the machine.
9.06
DC bus overvoltage
LEDs blinks slow together.
Indicates that an Internal DC bus Overvoltage
condition is detected.
To restore the machine:
Turn OFF then ON the Mains Switch to restart
the machine.
9.09
Communication lost
All LEDs are OFF. The display shown “9.09”.
Indicates that a fault condition in the
communication bus is detected.
To restore the machine:
Turn OFF then ON the Mains Switch to restart
the machine.

English 5 English
A. Power Switch: It turns ON / OFF the input power to
the machine.
B. Input cable: This machine is provided with a plugged
input cord. Connect it to the mains.
C. Fan: This machine has a F.A.N. (Fan As Needed)
circuitry inside. The machine automatically turns it
ON or OFF. This feature reduces the amount of dirt
which can be drawn inside the machine and reduces
power consumption. When the machine is turned ON
the fan will turn ON. The fan will continue to run
whenever the machine is welding. The F.A.N. feature
is active after that the machine doesn’t weld for more
than 10 minutes, the fan will be turned OFF and, at
same time, the output will be disabled. To restore the
output and the fan, simply restart to weld.
Maintenance WARNING
For any repair operations, modifications or
maintenances, it is recommended to contact the nearest
Technical Service Center or Lincoln Electric. Repairs
and modifications performed by unauthorized service or
personnel will cause, that the manufacturer’s warranty
will become null and void.
Any noticeable damage should be reported immediately
and repaired.
Routine maintenance (everyday)
Check condition of insulation and connections of the
work leads and insulation of power lead. If any
insulation damage exists replace the lead
immediately.
Remove the spatters from the welding gun nozzle.
Spatters could interfere with the shielding gas flow to
the arc.
Check the welding gun condition: replace it, if
necessary.
Check condition and operation of the cooling fan.
Keep clean its airflow slots.
Periodic maintenance (every 200 working hours but
at list once every year)
Perform the routine maintenance and, in addition:
Keep the machine clean. Using a dry (and low
pressure) airflow, remove the dust from the external
case and from the cabinet inside.
If it is required, clean and tighten all weld terminals.
The frequency of the maintenance operations may vary
in accordance with the working environment where the
machine is placed.
WARNING
Do not touch electrically live parts.
WARNING
Before the case of welding machine will be removed, the
welding machine had to be turned off and the power lead
had to be disconnected from mains socket.
WARNING
Mains supply network must be disconnected from the
machine before each maintenance and service. After
each repair, perform proper tests to ensure safety.

English 6 English
Electromagnetic Compatibility (EMC) 11/04
This machine has been designed in accordance with all relevant directives and standards. However, it may still generate
electromagnetic disturbances that can affect other systems like telecommunications (telephone, radio, and television) or
other safety systems. These disturbances can cause safety problems in the affected systems. Read and understand this
section to eliminate or reduce the amount of electromagnetic disturbance generated by this machine..
This machine has been designed to operate in an industrial area. The operator must install and operate this
equipment as described in this manual. If any electromagnetic disturbances are detected the operator must
put in place corrective actions to eliminate these disturbances with, if necessary, assistance from Lincoln
Electric. The Class A equipment is not intended for use in residential locations where the electrical power is
provided by the public low-voltage supply system. There may be potential difficulties in ensuring electromagnetic
compatibility in those locations, due to conducted as well as radiated disturbances. This equipment is compliant with EN
61000-3-12 and EN 61000-3-11 if the public low voltage system impedance at the point of common coupling is lower
than 0,34 Ω. It is the responsibility of the installer or user of the equipment to ensure, by consultation with the distribution
network operator if necessary, that the system impedance complies with the impedance restrictions.
Before installing the machine, the operator must check the work area for any devices that may malfunction because of
electromagnetic disturbances. Consider the following.
Input and output cables, control cables, and telephone cables that are in or adjacent to the work area and the
machine.
Radio and/or television transmitters and receivers. Computers or computer controlled equipment.
Safety and control equipment for industrial processes. Equipment for calibration and measurement.
Personal medical devices like pacemakers and hearing aids.
Check the electromagnetic immunity for equipment operating in or near the work area. The operator must be sure
that all equipment in the area is compatible. This may require additional protection measures.
The dimensions of the work area to consider will depend on the construction of the area and other activities that are
taking place.
Consider the following guidelines to reduce electromagnetic emissions from the machine.
Connect the machine to the input supply according to this manual. If disturbances occur if may be necessary to take
additional precautions such as filtering the input supply.
The output cables should be kept as short as possible and should be positioned together. If possible connect the
work piece to ground in order to reduce the electromagnetic emissions. The operator must check that connecting the
work piece to ground does not cause problems or unsafe operating conditions for personnel and equipment.
Shielding of cables in the work area can reduce electromagnetic emissions. This may be necessary for special
applications.

English 7 English
Technical Specifications
NAME INDEX
INVERTEC
®
160SX CE
INVERTEC®160SX AUS
K12050-1
K12050-2
INPUT
Input Voltage Range Input Power at Rated Output EMC Group /
Class
Frequency
50/60Hz
from 115 to 230Vac ±15% (CE model)
240Vac ±15% (AUS model)
Single Phase (CE/AUS model)
3.07kVA @ 100% Duty Cycle
5.17kVA @ 30% Duty Cycle II / A
RATED OUTPUT AT 40°C
Duty Cycle (@ Input Voltage)
(Based on a 10 min. period) Output Current Output Voltage
CE model
100% (@ 115Vac)
30% (@ 115Vac)
100% (@ 115Vac)
30% (@ 115Vac)
70A
100A
100A
150A
22.8Vdc (Stick)
24.0Vdc (Stick)
14.0Vdc (TIG)
16.0Vdc (TIG)
CE/AUS model
100% (@ 230/240Vac)
30% (@ 230/240Vac)
100A
160A
24.0Vdc (Stick) – 14.0Vdc (TIG)
26.4Vdc (Stick) – 16.4Vdc (TIG)
AUS model
(10A Circuit)
100% (@ 240Vac)
25% (@ 240Vac)
90A
160A
23.6Vdc (Stick) – 13.6Vdc (TIG)
26.4Vdc (Stick) – 16.4Vdc (TIG)
OUTPUT RANGE
Welding Current Range Maximum Open Circuit Voltage
160SX / 160SX AUS 5 – 160A ≤80Vdc (CE model)
32Vdc (AUS model)
RECOMMENDED INPUT CABLE AND FUSE SIZES
Fuse (delayed) or
Circuit Breaker (“D” characteristic) Input Power Cable Type of Plug
(Included with Machine)
160SX CE 16A 3 x 2.5mm2
---
160SX AUS 10A 3 x 1.5mm2 AUS 10A-250V
PHYSICAL DIMENSIONS
Height Width Length Weight
244mm 148mm 385mm 9.0kg
Operating Temperature
-10°C to +40°C
Storage Temperature
-25°C to +55°C

English 8 English
WEEE 07/06
Spare Parts 12/05
Part list reading instructions
Do not use this part list for a machine if its code number is not listed. Contact the Lincoln Electric Service
Department for any code number not listed.
Use the illustration of assembly page and the table below to determine where the part is located for your particular
code machine.
Use only the parts marked "X" in the column under the heading number called for in the assembly page (# indicate
a change in this printing).
First, read the Part List reading instructions above then refer to the "Spare Part" manual supplied with the machine,
which contains a picture-descriptive part number cross-reference).
Electrical Schematic
Refer to the "Spare Parts" manual supplied with the machine.
Accessories
K10513-17-4V TIG torch with tap, 4m.
K10513-17-8V TIG torch with tap, 8m.
English
Do not dispose of electrical equipment together with normal waste!
In observance of European Directive 2002/96/EC on Waste Electrical and Electronic Equipment
(WEEE) and its implementation in accordance with national law, electrical equipment that has reached
the end of its life must be collected separately and returned to an environmentally compatible recycling
facility. As the owner of the equipment, you should get information on approved collection systems
from our local representative.
By applying this European Directive you will protect the environment and human health!