Lincoln Electric INVERTEC SVM161-A User manual

SVM161-A
January, 2011
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 T IS
EQUIPMENT WIT OUT READ-
ING T IS MANUAL AND T E
SAFETY PRECAUTIONS CON-
TAINED T ROUG OUT. And,
most importantly, think before you
act and be careful.
SERVICE MANUAL
For use with machine code number: 10860
INVERTEC®V205-T AC/DC ™
V205-TV205-T AC/DCAC/DC
• Sales and Service through Subsidiaries and istributors Worldwide •
Cleveland, Ohio 44117-1199 U.S.A. TEL: [phone] FAX: [phone] WEB SITE: www.lincolnelectric.com
• World's Leader in Welding and Cutting Products •
Copyright © Lincoln Global Inc.
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INVERTEC® V205-T AC/DC™
SAFETY
i i
FOR ENGINE
powered equipment.
1.a. Turn the engine off before troubleshooting and maintenance
work unless the maintenance work requires it to be running.
____________________________________________________
1.b.Operate engines in open, well-ventilated
areas or vent the engine exhaust fumes
outdoors.
____________________________________________________
1.c. o not add the fuel near an open flame weld-
ing arc or when the engine is running. Stop
the engine and allow it to cool before refuel-
ing to prevent spilled fuel from vaporizing on
contact with hot engine parts and igniting. o
not spill fuel when filling tank. If fuel is spilled,
wipe it up and do not start engine until fumes
have been eliminated.
____________________________________________________
1.d. Keep all equipment safety guards, covers and devices in posi-
tion and in good repair.Keep hands, hair, clothing and tools
away from V-belts, gears, fans and all other moving parts
when starting, operating or repairing equipment.
____________________________________________________
1.e. In some cases it may be necessary to remove safety
guards to perform required maintenance. Remove
guards only when necessary and replace them when the
maintenance requiring their removal is complete.
Always use the greatest care when working near moving
parts.
___________________________________________________
1.f. o not put your hands near the engine fan.
o not attempt to override the governor or
idler by pushing on the throttle control rods
while the engine is running.
___________________________________________________
1.g. To prevent accidentally starting gasoline engines while
turning the engine or welding generator during maintenance
work, disconnect the spark plug wires, distributor cap or
magneto wire as appropriate.
ARC WELDING can be hazardous. PROTECT YOURSELF AND OT ERS FROM POSSIBLE SERIOUS INJURY OR DEAT .
KEEP C ILDREN AWAY. PACEMAKER WEARERS S OULD CONSULT WIT T EIR DOCTOR BEFORE OPERATING.
Read and understand the following safety highlights. For additional safety information, it is strongly recommended that you
purchase a copy of “Safety in Welding & Cutting - ANSI Standard Z49.1” from the American Welding Society, P.O. Box 351040,
Miami, Florida 33135 or CSA Standard W117.2-1974. A Free copy of “Arc Welding Safety” booklet E205 is available from the
Lincoln Electric Company, 22801 St. Clair Avenue, Cleveland, Ohio 44117-1199.
BE SURE T AT ALL INSTALLATION, OPERATION, MAINTENANCE AND REPAIR PROCEDURES ARE
PERFORMED ONLY BY QUALIFIED INDIVIDUALS.
WARNING
ELECTRIC AND
MAGNETIC FIELDS
may be dangerous
2.a. Electric current flowing through any conductor causes
localized Electric and Magnetic Fields (EMF). Welding
current creates EMF fields around welding cables and
welding machines
2.b. EMF fields may interfere with some pacemakers, and
welders having a pacemaker should consult their physician
before welding.
2.c. Exposure to EMF fields in welding may have other health
effects which are now not known.
2.d. All welders should use the following procedures in order to
minimize exposure to EMF fields from the welding circuit:
2.d.1. Route the electrode and work cables together - Secure
them with tape when possible.
2.d.2. Never coil the electrode lead around your body.
2.d.3. o not place your body between the electrode and
work cables. If the electrode cable is on your right
side, the work cable should also be on your right side.
2.d.4. Connect the work cable to the workpiece as close as
possible to the area being welded.
2.d.5. o not work next to welding power source.
1.h. To avoid scalding, do not remove the
radiator pressure cap when the engine is
hot.
CALIFORNIA PROPOSITION 65 WARNINGS
iesel engine exhaust and some of its constituents
are known to the State of California to cause can-
cer, birth defects, and other reproductive harm.
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 iesel Engines The Above For Gasoline Engines
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SAFETY
ii ii
INVERTEC® V205-T AC/DC™
FUMES AND GASES
can be dangerous.
5.a. Welding may produce fumes and gases
hazardous to health. Avoid breathing these
fumes and gases.When welding, keep
your head out of the fume. Use enough
ventilation and/or exhaust at the arc to keep
fumes and gases away from the breathing zone. When
welding with electrodes which require special
ventilation such as stainless or hard facing (see
instructions on container or MSDS) or on lead or
cadmium plated steel and other metals or coatings
which produce highly toxic fumes, keep exposure as
low as possible and within applicable OS A PEL and
ACGI TLV limits using local exhaust or mechanical ven-
tilation. In confined spaces or in some circumstances,
outdoors, a respirator may be required. Additional pre-
cautions are also required when welding on galvanized
steel.
5. b. The operation of welding fume control equipment is affected
by various factors including proper use and positioning of the
equipment, maintenance of the equipment and the specific
welding procedure and application involved. Worker expo-
sure level should be checked upon installation and periodi-
cally thereafter to be certain it is within applicable OSHA PEL
and ACGIH TLV limits.
5.c. o not weld in locations near chlorinated hydrocarbon vapors
coming from degreasing, cleaning or spraying operations.
The heat and rays of the arc can react with solvent vapors to
form phosgene, a highly toxic gas, and other irritating prod-
ucts.
5.d. Shielding gases used for arc welding can displace air and
cause injury or death. Always use enough ventilation,
especially in confined areas, to insure breathing air is safe.
5.e. Read and understand the manufacturer’s instructions for this
equipment and the consumables to be used, including the
material safety data sheet (MS S) and follow your
employer’s safety practices. MS S forms are available from
your welding distributor or from the manufacturer.
5.f. Also see item 1.b.
ARC RAYS can burn.
4.a. Use a shield with the proper filter and cover
plates to protect your eyes from sparks and
the rays of the arc when welding or observing
open arc welding. Headshield and filter lens
should conform to ANSI Z87. I standards.
4.b. Use suitable clothing made from durable flame-resistant
material to protect your skin and that of your helpers from
the arc rays.
4.c. Protect other nearby personnel with suitable, non-flammable
screening and/or warn them not to watch the arc nor expose
themselves to the arc rays or to hot spatter or metal.
ELECTRIC S OCK can kill.
3.a. The electrode and work (or ground) circuits
are electrically “hot” when the welder is on.
o 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.
In addition to the normal safety precautions, if welding
must be performed under electrically hazardous
conditions (in damp locations or while wearing wet
clothing; on metal structures such as floors, gratings or
scaffolds; when in cramped positions such as sitting,
kneeling or lying, if there is a high risk of unavoidable or
accidental contact with the workpiece or ground) use
the following equipment:
• Semiautomatic DC Constant Voltage (Wire) Welder.
• DC Manual (Stick) Welder.
• AC Welder with Reduced Voltage Control.
3.c. In semiautomatic or automatic wire welding, the electrode,
electrode reel, welding head, nozzle or semiautomatic
welding gun are also electrically “hot”.
3.d. Always be sure the work cable makes a good electrical
connection with the metal being welded. The connection
should be as close as possible to the area being welded.
3.e. Ground the work or metal to be welded to a good electrical
(earth) ground.
3.f.
Maintain the electrode holder, work clamp, welding cable and
welding machine in good, safe operating condition. Replace
damaged insulation.
3.g. Never dip the electrode in water for cooling.
3.h. Never simultaneously touch electrically “hot” parts of
electrode holders connected to two welders because voltage
between the two can be the total of the open circuit voltage
of both welders.
3.i. When working above floor level, use a safety belt to protect
yourself from a fall should you get a shock.
3.j. Also see Items 6.c. and 8.
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INVERTEC® V205-T AC/DC™
SAFETY
iii iii
FOR ELECTRICALLY
powered equipment.
8.a. Turn off input power using the disconnect
switch at the fuse box before working on
the equipment.
8.b. Install equipment in accordance with the U.S. National
Electrical Code, all local codes and the manufacturer’s
recommendations.
8.c. Ground the equipment in accordance with the U.S. National
Electrical Code and the manufacturer’s recommendations.
CYLINDER may explode
if damaged.
7.a. Use only compressed gas cylinders
containing the correct shielding gas for the
process used and properly operating
regulators designed for the gas and
pressure used. All hoses, fittings, etc. should be suitable for
the application and maintained in good condition.
7.b. Always keep cylinders in an upright position securely
chained to an undercarriage or fixed support.
7.c. Cylinders should be located:
• Away from areas where they may be struck or subjected to
physical damage.
• A safe distance from arc welding or cutting operations and
any other source of heat, sparks, or flame.
7.d. Never allow the electrode, electrode holder or any other
electrically “hot” parts to touch a cylinder.
7.e. Keep your head and face away from the cylinder valve outlet
when opening the cylinder valve.
7.f. Valve protection caps should always be in place and hand
tight except when the cylinder is in use or connected for
use.
7.g. Read and follow the instructions on compressed gas
cylinders, associated equipment, and CGA publication P-l,
“Precautions for Safe Handling of Compressed Gases in
Cylinders,” available from the Compressed Gas Association
1235 Jefferson avis Highway, Arlington, VA 22202.
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. Where compressed gases are to be used at the job site,
special precautions should be used to prevent hazardous
situations. Refer to “Safety in Welding and Cutting” (ANSI
Standard Z49.1) and the operating information for the
equipment being used.
6.c. When not welding, make certain no part of the electrode
circuit is touching the work or ground. Accidental contact can
cause overheating and create a fire hazard.
6.d. o not heat, cut or weld tanks, drums or containers until the
proper steps have been taken to insure that such procedures
will not cause flammable or toxic vapors from substances
inside. They can cause an explosion even though they have
been “cleaned”. For information, purchase “Recommended
Safe Practices for the
Preparation for Welding and Cutting of
Containers and Piping That Have Held Hazardous
Substances”, AWS F4.1 from the American Welding Society
(see address above).
6.e. Vent hollow castings or containers before heating, cutting or
welding. They may explode.
6.f.
Sparks and spatter are thrown from the welding arc. Wear oil
free protective garments such as leather gloves, heavy shirt,
cuffless trousers, high shoes and a cap over your hair. Wear
ear plugs when welding out of position or in confined places.
Always wear safety glasses with side shields when in a
welding area.
6.g. Connect the work cable to the work as close to the welding
area as practical. Work cables connected to the building
framework or other locations away from the welding area
increase the possibility of the welding current passing through
lifting chains, crane cables or other alternate circuits. This can
create fire hazards or overheat lifting chains or cables until
they fail.
6.h. Also see item 1.c.
6.I. Read and follow NFPA 51B “ Standard for Fire Prevention
uring Welding, Cutting and Other Hot Work”, available from
NFPA, 1 Batterymarch Park,PO box 9101, Quincy, Ma
022690-9101.
6.j. o not use a welding power source for pipe thawing.
Refer to http://www.lincolnelectric.com/safety for additional safety information.
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SAFETY
iv iv
INVERTEC® V205-T AC/DC™
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 suiv-
antes:
Sûreté Pour Soudage A L’Arc
1. Protegez-vous contre la secousse électrique:
a. Les circuits à l’électrode et à la piéce sont sous tension
quand la machine à souder est en marche. Eviter toujours
tout contact entre les parties sous tension et la peau nue
ou les vétements mouillés. Porter des gants secs et sans
trous pour isoler les mains.
b. Faire trés attention de bien s’isoler de la masse quand on
soude dans des endroits humides, ou sur un plancher met-
allique ou des grilles metalliques, principalement dans
les positions assis ou couché pour lesquelles une grande
partie du corps peut être en contact avec la masse.
c. Maintenir le porte-électrode, la pince de masse, le câble de
soudage et la machine à souder en bon et sûr état defonc-
tionnement.
d.Ne jamais plonger le porte-électrode dans l’eau pour le
refroidir.
e. Ne jamais toucher simultanément les parties sous tension
des porte-électrodes connectés à deux machines à souder
parce que la tension entre les deux pinces peut être le total
de la tension à vide des deux machines.
f. Si on utilise la machine à souder comme une source de
courant pour soudage semi-automatique, ces precautions
pour le porte-électrode s’applicuent aussi au pistolet de
soudage.
2. ans le cas de travail au dessus du niveau du sol, se protéger
contre les chutes dans le cas ou on recoit un choc. Ne jamais
enrouler le câble-électrode autour de n’importe quelle partie du
corps.
3. Un coup d’arc peut être plus sévère qu’un coup de soliel, donc:
a. Utiliser un bon masque avec un verre filtrant approprié ainsi
qu’un verre blanc afin de se protéger les yeux du rayon-
nement de l’arc et des projections quand on soude ou
quand on regarde l’arc.
b. Porter des vêtements convenables afin de protéger la peau
de soudeur et des aides contre le rayonnement de l‘arc.
c. Protéger l’autre personnel travaillant à proximité au
soudage à l’aide d’écrans appropriés et non-inflammables.
4. es gouttes de laitier en fusion sont émises de l’arc de
soudage. Se protéger avec des vêtements de protection libres
de l’huile, tels que les gants en cuir, chemise épaisse, pan-
talons sans revers, et chaussures montantes.
5. Toujours porter des lunettes de sécurité dans la zone de
soudage. Utiliser des lunettes avec écrans lateraux dans les
zones où l’on pique le laitier.
6. Eloigner les matériaux inflammables ou les recouvrir afin de
prévenir tout risque d’incendie dû aux étincelles.
7. Quand on ne soude pas, poser la pince à une endroit isolé de
la masse. Un court-circuit accidental peut provoquer un
échauffement et un risque d’incendie.
8. S’assurer que la masse est connectée le plus prés possible de
la zone de travail qu’il est pratique de le faire. Si on place la
masse sur la charpente de la construction ou d’autres endroits
éloignés de la zone de travail, on augmente le risque de voir
passer le courant de soudage par les chaines de levage,
câbles de grue, ou autres circuits. Cela peut provoquer des
risques d’incendie ou d’echauffement des chaines et des
câbles jusqu’à ce qu’ils se rompent.
9. Assurer une ventilation suffisante dans la zone de soudage.
Ceci est particuliérement important pour le soudage de tôles
galvanisées plombées, ou cadmiées ou tout autre métal qui
produit des fumeés toxiques.
10. Ne pas souder en présence de vapeurs de chlore provenant
d’opérations de dégraissage, nettoyage ou pistolage. La
chaleur ou les rayons de l’arc peuvent réagir avec les vapeurs
du solvant pour produire du phosgéne (gas fortement toxique)
ou autres produits irritants.
11. Pour obtenir de plus amples renseignements sur la sûreté, voir
le code “Code for safety in welding and cutting” CSA Standard
W 117.2-1974.
PRÉCAUTIONS DE SÛRETÉ POUR
LES MAC INES À SOUDER À
TRANSFORMATEUR ET À
REDRESSEUR
1. Relier à la terre le chassis du poste conformement au code de
l’électricité et aux recommendations du fabricant. Le dispositif
de montage ou la piece à souder doit être branché à une
bonne mise à la terre.
2. Autant que possible, I’installation et l’entretien du poste seront
effectués par un électricien qualifié.
3. Avant de faires des travaux à l’interieur de poste, la debranch-
er à l’interrupteur à la boite de fusibles.
4. Garder tous les couvercles et dispositifs de sûreté à leur place.
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SAFETY
Elect omagnetic Compatibility (EMC)
Confo mance
Products displaying the CE mark are in conformity with European Community Council Directive of 15 Dec
2004 on the approximation of the laws of the Member States relating to electromagnetic compatibility,
2004/108/EC. It was manufactured in conformity with a national standard that implements a harmonized
standard: EN 60974-10 Electromagnetic Compatibility (EMC) Product Standard for Arc Welding Equipment.
It is for use with other Lincoln Electric equipment. It is designed for industrial and professional use.
Int oduction
All electrical equipment generates small amounts of electromagnetic emission. Electrical emission may be
transmitted through power lines or radiated through space, similar to a radio transmitter. When emissions
are received by other equipment, electrical interference may result. Electrical emissions may affect many
kinds of electrical equipment; other nearby welding equipment, radio and T reception, numerical controlled
machines, telephone systems, computers, etc. Be aware that interference may result and extra precautions
may be required when a welding power source is used in a domestic establishment.
Installation and Use
The user is responsible for installing and using the welding equipment according to the manufacturer’s
instructions. If electromagnetic disturbances are detected then it shall be the responsibility of the user of the
welding equipment to resolve the situation with the technical assistance of the manufacturer. In some cases
this remedial action may be as simple as earthing (grounding) the welding circuit, see Note. In other cases
it could involve construction of an electromagnetic screen enclosing the power source and the work com-
plete with associated input filters. In all cases electromagnetic disturbances must be reduced to the point
where they are no longer troublesome.
Note: The welding circuit may or may not be earthed for safety reasons according to national
codes. Changing the earthing arrangements should only be authorized by a person who is
competent to access whether the changes will increase the risk of injury, e.g., by allowing
parallel welding current return paths which may damage the earth circuits of other equip-
ment.
Assessment of A ea
Before installing welding equipment the user shall make an assessment of potential electromagnetic prob-
lems in the surrounding area. The following shall be taken into account:
a) other supply cables, control cables, signaling and telephone cables; above, below and adjacent to the
welding equipment;
b) radio and television transmitters and receivers;
c) computer and other control equipment;
d) safety critical equipment, e.g., guarding of industrial equipment;
e) the health of the people around, e.g., the use of pacemakers and hearing aids;
f) equipment used for calibration or measurement
g) the immunity of other equipment in the environment. The user shall ensure that other equipment being
used in the environment is compatible. This may require additional protection measures;
h) the time of day that welding or other activities are to be carried out.
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INVERTEC® V205-T AC/DC™
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SAFETY
Elect omagnetic Compatibility (EMC)
The size of the surrounding area to be considered will depend on the structure of the building and other
activities that are taking place. The surrounding area may extend beyond the boundaries of the premises.
Methods of Reducing Emissions
Mains Supply
Welding equipment should be connected to the mains supply according to the manufacturer’s recommenda-
tions. If interference occurs, it may be necessary to take additional precautions such as filtering of the mains
supply. Consideration should be given to shielding the supply cable of permanently installed welding equip-
ment, in metallic conduit or equivalent. Shielding should be electrically continuous throughout its length. The
shielding should be connected to the welding power source so that good electrical contact is maintained
between the conduit and the welding power source enclosure.
Maintenance of the Welding Equipment
The welding equipment should be routinely maintained according to the manufacturer’s recommendations.
All access and service doors and covers should be closed and properly fastened when the welding equip-
ment is in operation. The welding equipment should not be modified in any way except for those changes
and adjustments covered in the manufacturers instructions. In particular, the spark gaps of arc striking and
stabilizing devices should be adjusted and maintained according to the manufacturer’s recommendations.
Welding Cables
The welding cables should be kept as short as possible and should be positioned close together, running at
or close to floor level.
Equipotential Bonding
Bonding of all metallic components in the welding installation and adjacent to it should be considered.
However, metallic components bonded to the work piece will increase the risk that the operator could
receive a shock by touching these metallic components and the electrode at the same time. The operator
should be insulated from all such bonded metallic components.
Ea thing of the Wo kpiece
Where the workpiece is not bonded to earth for electrical safety, not connected to earth because of its size
and position, e.g., ships hull or building steelwork, a connection bonding the workpiece to earth may reduce
emissions in some, but not all instances. Care should be taken to prevent the earthing of the workpiece
increasing the risk of injury to users, or damage to other electrical equipment. Where necessary, the con-
nection of the workpiece to earth should be made by a direct connection to the workpiece, but in some
countries where direct connection is not permitted, the bonding should be achieved by suitable capacitance,
selected according to national regulations.
Sc eening and Shielding
Selective screening and shielding of other cables and equipment in the surrounding area may alleviate
problems of interference. Screening of the entire welding installation may be considered for special applica-
tions. 1
_________________________
1 Portions of the preceding text are contained in EN 60974-10: “Electromagnetic Compatibility (EMC) prod-
uct standard for arc welding equipment.”
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INVERTEC® V205-T AC/DC™
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Page
Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .i-vi
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Section A
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Section B
Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Section C
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Section D
Theory of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Section E
Troubleshooting and Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Section F
Electrical Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Section G
Parts Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .P-400
- MASTER TABLE OF CONTENTS FOR ALL SECTIONS -
I I
INVERTEC® V205-T AC/DC™

TABLE OF CONTENTS - INSTALLATION SECTION
A-1 A-1
INVERTEC® V205-T AC/DC™
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-1
Technical Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-2
Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-3
Select Suitable Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-3
Stacking, Tilting, Environmental Area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-3
Machine Grounding / High Frequency Interference Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-3
Input Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-4
Reconnect Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-4
230V Input, 115V Input . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-5
Engine riven Generator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-5
Output Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-6
Output and Gas Connection For Tig Welding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-6
Output Connection For Stick Welding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-6
Quick isconnect Plug (For Stick Electrode Cable and Work Cable) . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-7
Shielding Gas Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-7
Remote Control Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-7
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TIME-DELAY CIRCUIT BREAKER
OR FUSE SIZE (AMPS)
30A
eight Width Depth Weight
15 in. 8.5 in. 19 in. Approx. 38 lbs.
381 mm 216 mm 483 mm 17 kgs.
INSTALLATION
A-2 A-2
INVERTEC® V205-T AC/DC™
Input Amps
34A
28A
20A
34A
25A
20A
30A
23A
19A
30A
18A
15A
Type of Output
AC/ C
Output Amps Volts at Rated Amperes
(Stick) 110 24.4V
90 23.6V
70 22.8V
(TIG) 150 16V
120 14.8V
100 14V
(Stick) 180 27.2V
150 26V
130 25.2V
(TIG) 200 18V
170 16V
140 15.6V
Maximum Open
Circuit Voltage
54 Volts Max.
Input Voltages / 50 /60 z.
115
230
Duty Cycle
(115V) 35%
60%
100%
(115V) 40%
60%
100%
(230V) 35%
60%
100%
(230V) 40%
60%
100%
Output Current
Range
6-200 Amps
INPUT - SINGLE P ASE ONLY
RATED OUTPUT
OUTPUT
TEC NICAL SPECIFICATIONS - V205-T AC/DC™ TIG K1855-1 (Code Number 10860)
TEMPERATURE RANGES
OPERATING TEMPERATURE RANGE
-20°C to +40°C
STORAGE TEMPERATURE RANGE
-50°C to +85°C
RECOMMENDED INPUT WIRE AND FUSE SIZES FOR MAXIMUM RATED OUTPUT
INPUT
VOLTAGE /
FREQUENCY
( Z)
115/50/60
230/50/60
TYPE S, SO ST, STO, OR EXTRA
ARD USAGE INPUT CORD AWG
#12
Max. Input Current
34A at Rated Output
30A at Rated Output
P YSICAL DIMENSIONS
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INSTALLATION
A-3 A-3
INVERTEC® V205-T AC/DC™
MAC INE GROUNDING AND IG FRE-
QUENCY INTERFERENCE PROTECTION
The Capacitor ischarge Circuit used in the high fre-
quency generator, may cause many radio, TV and
electronic equipment interference problems. These
problems may be the result of radiated interference.
Proper grounding methods can reduce or eliminate
radiated interference.
The Invertec® V205-T AC/ C™ has been field tested
under recommended installation conditions. It com-
plies with FCC allowable limits for radiation.
Radiated interference can develop in the following four
ways:
1. irect interference radiated from the welder.
2. irect interference radiated from the welding leads.
3. irect interference radiated from feedback into the
power lines.
4. Interference from re-radiation of “pickup” by
ungrounded metallic objects.
Keeping these contributing factors in mind, installing
equipment per the following instructions should mini-
mize problems.
1. Keep the welder power supply lines as short as pos-
sible and enclose as much of them as possible in
rigid metallic conduit or equivalent shielding for a
distance of 50 feet (15.2m). There should be good
electrical contact between this conduit and the
welder case ground. Both ends of the conduit
should be connected to a driven ground and the
entire length should be continuous.
2. Keep the work and electrode leads as short as pos-
sible and as close together as possible. Lengths
should not exceed 25 ft (7.6m). Tape the electrode
and work leads together into one bundle when prac-
tical.
Read entire installation section before starting
installation.
Safety Precautions
------------------------------------------------------------
SELECT SUITABLE LOCATION
The Invertec® will operate in harsh environments.
Even so, it is important that simple preventative mea-
sures are followed in order to assure long life and reli-
able operation.
• The machine must be located where there is free cir-
culation of clean air such that air movement in the
back and out the front will not be restricted.
• irt and dust that can be drawn into the machine
should be kept to a minimum. Failure to observe
these precautions can result in excessive operating
temperatures and nuisance shutdown.
STACKING
The Invertec® V205-T AC/ C™ can not be stacked.
TILTING
Place the machine directly on a secure, level surface.
The machine may topple over if this procedure is not
followed.
ENVIRONMENTAL AREA
Keep the machine dry. o not place it on wet ground or
in puddles.
ELECTRIC S OCK can kill.
• Only qualified personnel should
perform this installation.
• Turn the input power OFF and
unplug the machine from the recep-
tacle before working on this equip-
ment. Allow machine to sit for 5 min-
utes 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.
• Always connect the V205-T to a power supply
grounded according to the National Electrical
Code and local codes.
WARNING
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INSTALLATION
A-4 A-4
INVERTEC® V205-T AC/DC™
3. Be sure the torch and work cable rubber coverings
are free of cuts and cracks that allow high fre-
quency leakage. Cables with high natural rubber
content, such as Lincoln Stable-Arc®better resist
high frequency leakage than neoprene and other
synthetic rubber insulated cables.
4. Keep the torch in good repair and all connections
tight to reduce high frequency leakage.
5. The work terminal must be connected to a ground
within ten feet of the welder, using one of the fol-
lowing methods.
a) A metal underground water pipe in direct con-
tact with the earth for ten feet or more.
b) A 3/4” (19mm) galvanized pipe or a 5/8”
(16mm) solid galvanized iron, steel or copper
rod driven at least eight feet into the ground.
The ground should be securely made and the
grounding cable should be as short as possible
using cable of the same size as the work cable, or
larger. Grounding to the building frame electrical
conduit or a long pipe system can result in re-radi-
ation, effectively making these members radiating
antennas.
6. Keep all panels securely in place.
7. All electrical conductors within 50 ft (15.2m) of the
welder should be enclosed in grounded, rigid
metallic conduit or equivalent shielding. Flexible
metallic conduit is generally not suitable.
8. When the welder is enclosed in a metal building,
several earth driven electrical grounds connected
(as in 5b above) around the periphery of the build-
ing are recommended.
Failure to observe these recommended installation
procedures can cause radio or TV interference prob-
lems.
INPUT CONNECTIONS
Be sure the voltage, phase, and frequency of the input
power is as specified on the rating plate, located on the
bottom of the machine.
ELECTRIC S OCK can kill.
• ave a qualified electrician install
and service this equipment.
• Turn the input power OFF and
unplug the machine from the recep-
tacle before working on this equip-
ment.
• Allow machine to sit for 5 minutes minimum to
allow the power capacitors to discharge before
working inside this equipment.
• Do not touch electrically hot parts.
• Machine must be plugged into a receptacle that
is grounded according to the National Electrical
Code and local codes.
• Do not remove or defeat the purpose of the
power cord ground pin.
-----------------------------------------------------------------------
RECONNECT PROCEDURE
The Invertec® V205-T AC/ C™ auto reconnects to
either 115V or 230V supply.
Fuse the input circuit with time delay fuses or delay
type1circuit breakers. Using fuses or circuit breakers
smaller than recommended may result in “nuisance”
shut-offs from welder inrush currents even if not weld-
ing at high currents.
The Invertec® V205-T AC/ C™ is recommended for
use on an individual branch circuit.
1Also called “inverse time” or “thermal/magnetic” circuit breakers.
These circuit breakers have a delay in tripping action that decreases
as the magnitude of the current increases.
WARNING
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INSTALLATION
A-5 A-5
INVERTEC® V205-T AC/DC™
In all cases, the green or green/yellow grounding wire
must be connected to the grounding pin of the plug,
usually identified by a green screw.
Attachment plugs must comply with the Standard for
Attachment Plugs and Receptacles, UL498.
The product is considered acceptable for use only
when an attachment plug as specified is properly
attached to the supply cord.
For use on engine drives, keep in mind the above input
draw restrictions and the following precaution.
ENGINE DRIVEN GENERATOR
The Invertec® V205-T AC/ C™ can be operated on
engine driven generators as long as the 230 volt auxil-
iary meets the following conditions:
• The AC waveform peak voltage is below 400 volts.
• The AC waveform frequency is between 45 and
65Hz.
The following Lincoln engine drives meet these condi-
tions when run in the high idle mode:
• Ranger 250,305
• Commander 300, 400, & 500
Some engine drives do not meet these conditions (e.g.
Miller Bobcats, etc). Operation of the Invertec® V205-
T AC/ C™ is not recommended on engine drives not
conforming to these conditions. Such drives may deliv-
er unacceptably high voltage levels to the Invertec®
V205-T AC/ C™ power source.
230V INPUT
The equipment is provided with a 230/115V cable,
6.6ft.(2m) in length with a 230V 6-50P attachment plug.
The Invertec® V205-T AC/ C™ performs best when
connected to 230VAC inputs. This input allows full out-
put of the machine (200 amps).
115V INPUT
A suitable 115V attachment plug must be installed on
the power cord to use the V205-T AC/ C™ with a
115V input supply. The rated output of the V205-T
AC/ C™ is available when connected to a 30A branch
circuit. When connected to a branch circuit with lower
amp rating, lower welding current and duty cycle must
be used. An output guide is provided below. The values
are approximate and must be adjusted downward if the
fuse or circuit breaker trips off. Other loads on the cir-
cuit and fuse/circuit breaker characteristics will affect
the available output. o not exceed these welding con-
ditions:
15A branch circuit
10% duty cycle
Stick: 75A
TIG: 105A
20A branch circuit
10% duty cycle
Stick: 90A
TIG: 130A
ATTAC MENT PLUG INSTALLATION
Connect the white (neutral) wire under terminal clamp
with silver screw, and black (hot) wire under terminal
clamp with brass screw. Connect green wire under ter-
minal clamp with green screw.
Failure to wire as instructed may cause personal
injury or damage to equipment. To be installed or
checked by an electrician or qualified person only.
------------------------------------------------------------------------
WARNING
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INSTALLATION
A-6 A-6
INVERTEC® V205-T AC/DC™
OUTPUT AND GAS CONNECTION FOR
TIG WELDING (FIGURE A.1)
The TIG Torch Twist-Mate and work cable Twist-Mate
Connectors are supplied with the welder. To connect
the cables, turn the Power Switch “OFF”. Connect the
torch cable Twist-Mate plug into the C(-)
Electrode/Gas Output Receptacle on the front of the
welder and turn it clockwise until snug,( o not
Overtighten). This is a quick connect terminal and also
provides the gas connection for the shielding gas to the
torch.
To avoid receiving a high frequency shock, keep
the TIG torch and cable insulation in good condi-
tion.
___________________________________________
WORK CABLE CONNECTION
Next, connect the work cable to the “+” output terminal
in the same way. To minimize high frequency interfer-
ence, refer to Machine Grounding and igh
Frequency Interference Protection section of this
manual for the proper procedure on grounding the
work clamp and work piece.
OUTPUT CONNECTIONS
ELECTRIC S OCK can kill.
• Keep the electrode holder, TIG
torch and cable insulation in good
condition and in place.
• Do not touch electrically live parts
or electrode with skin or wet cloth-
ing.
• Insulate yourself from work and ground.
• Turn the input line Switch on the Invertec® V205-
T AC/DC™ “off” before connecting or discon-
necting output cables or other equipment.
------------------------------------------------------------------------
WARNING
+
-
WORK CLAMP
WORK CABLE
TIG TORCH
WARNING
FIGURE A.1
This unit does not include a TIG torch, but one may be
purchased separately. The accessories section of this
manual lists a number of Lincoln Electric TIG torches,
and TIG Torch Starter Packs that are recommended for
use with this machine; however, any similar TIG torch
can be used. To attach the Twist-Mate Plug to a Lincoln
Torch, slide the rubber boot onto the torch cable
(enlarge the boot opening if necessary), screw the fit-
ting on the torch cable into the brass connector snugly
and slide the boot back over the brass connector.
OUTPUT CONNECTION FOR STICK
WELDING (FIGURE A.2)
First determine the proper electrode polarity for the
electrode to be used. Consult the electrode data for
this information. Then connect the output cables to the
output terminals corresponding to this polarity. For
instance, for C(+) welding, connect the electrode
cable (which is connected to the electrode holder) to
the “+” output terminal and the work cable (which is
connected to the work clamp) to the “-” output terminal.
Insert the connector with the key lining up with the key-
way, and rotate clockwise; until the connection is snug.
o not over tighten.
TIG ADAPTER
RETAINING COMPOUND
STRAIN RELIEF BOOT
TIG TORCH POWER CABLE WITH GAS FITING
+
-
FIGURE A.2
WORK CABLE
WORK CABLE
STICK ELECTRO E
HOL ER
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INSTALLATION
A-7 A-7
INVERTEC® V205-T AC/DC™
REMOTE CONTROL CONNECTION
A remote control receptacle is provided on the lower
center case front of the welder for connecting a remote
control to the machine. Refer to the Optional
Accessories section of this manual for available
remote controls.
CYLINDER could explode
if damaged.
• Keep cylinder upright and
chained to a support.
• Keep cylinder away from areas where it
could be damaged.
• Never allow the torch or welding electrode to
touch the cylinder.
• Keep cylinder away from live electrical cir-
cuits.
___________________________________________
WARNING
QUICK DISCONNECT PLUG (FOR STICK
ELECTRODE CABLE and WORK CABLE)
A quick disconnect system is used for the welding
cable connections. The stick electrode cable will need
to have a plug attached.
1. Cut off welding cable lug, if present.
2. Remove 1.00 in. (25mm) of welding cable insula-
tion.
3. Slide rubber boot onto cable end. The boot end
may be trimmed to match the cable diameter. Use
soap or other nonpetroleum-based lubricant to help
slide the boot over the cable, if needed.
4. Insert copper strands into ferrule.
5. Slide the copper ferrule into the brass plug.
6. Tighten set screw to collapse copper tube. Screw
must apply pressure against welding cable. The top
of the set screw will be well below the surface of the
brass plug after tightening.
7. Slide rubber boot over brass plug. The rubber boot
must be positioned to completely cover all electrical
surfaces after the plug is locked into the receptacle.
25 mm
1.00 in.
WELDING CABLE
BOOT
TRIM, IF REQ'D
TO FIT OVER CABLE
WELDING CABLE
COPPER FERRULE
SET SCREW
BRASS PLUG
COPPER TUBE
S IELDING GAS CONNECTION
Obtain the necessary inert shielding gas. Connect the
cylinder of gas with a pressure regulator and flow
gage. Install a gas hose between the regulator and gas
inlet (located on the rear of the welder). The gas inlet
has a 5/16-18 right hand female thread; CGA #032.
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NOTES
A-8 A-8
INVERTEC® V205-T AC/DC™
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TABLE OF CONTENTS - OPERATION SECTION
B-1 B-1
INVERTEC® V205-T AC/DC™
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-1
Safety Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-2
General escription . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-2
Welding Capability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-2
Limitations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-2
Rear Control Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-3
Controls and Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-4
Set Up Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-7
Output Limitations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-8
C TIG Welding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-8
Welding Polarity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-8
Steel TIG Welding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-10
Copper TIG Welding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-10
Tips for AC TIG Welding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-10
AC TIG Welding Quick Start Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-11
C TIG Welding Quick Start Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-12
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OPERATION
B-2 B-2
INVERTEC® V205-T AC/DC™
Read and understand this entire section before
operating your machine.
SAFETY INSTRUCTIONS
ELECTRIC S OCK can kill.
• Do not touch electrically live parts
such as output terminals, electrode or
internal wiring.
• Insulate yourself from the work and
ground.
• Always wear dry insulating gloves.
Only qualified personnel should operate this
equipment. Observe all safety information
throughout this manual.
GENERAL DESCRIPTION
The Invertec® V205-T AC/ C™ is an industrial 200
amp arc welding power source which utilizes single
phase input power, to produce constant current output.
The welding response of this Invertec® has been opti-
mized for stick (SMAW) and TIG (GTAW). The unit is
ideal for industrial applications where portability is
important.
The Invertec® V205-T AC/ C™ is a power source that
can perform the following types of welding with excel-
lent results:
TIG (with high frequency or Touch Start Tig Starting).
• TIG AC with square, sinusoidal and triangular wave-
forms
• Tig C
The following items can be connected to the 6 pin
socket on the front panel:
• Remote control potentiometer for Stick welding.
• Remote Foot Amptrol or Hand Amptrol
• Arc Start Switch
NOTE: See Accessories section of this manual for
product numbers and complete description.
WELDING CAPABILITY
The Invertec® V205-T AC/ C™ is rated at 200 amps,
18 volts, at 40% duty cycle on a ten minute basis. It is
capable of higher duty cycles at lower output currents.
It is capable of 140 amps, 15.6 volts at 100% duty
cycle. If the duty cycle is exceeded, a thermal protec-
tor will shut off the output until the machine cools. See
Technical Specifications in A-1 for other rated outputs.
The Invertec® V205-T is recommended for stick weld-
ing with such popular electrodes as Fleetweld 35,
Fleetweld 37, Fleetweld 180 and Excalibur 7018.
LIMITATIONS
The V205-T is not recommended for pipe thawing.
WARNING
FUMES AND GASES
can be dangerous.
• Keep your head out of fumes.
• Use ventilation or exhaust to
remove fumes from breathing
zone.
ARC RAYS
can burn.
• Wear eye, ear and body
protection.
WELDING, CUTTING and
GOUGING SPARKS
can cause fire or explosion
• Keep flammable material away.
• Do not weld, cut or gouge on
containers that have held com-
bustibles.
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OPERATION
B-3 B-3
INVERTEC® V205-T AC/DC™
REAR CONTROL PANEL (FIGURE B.1)
• I1: Off/On switch turns on the electric power to
the welder. It has two positions, "O" off, and
"I" on.
------------------------------------------------------------------------
* With "l1" in the "I" (ON) position, the welding machine
is operational and there is voltage between the posi-
tive (+) and negative (-) Terminals in stick welding. In
TIG, the welding process needs a trigger closure
command at the remote control connection. (Usually
via an Arc Start Switch or Foot Amptrol)
* The welder is connected to the supply even if the “l1”
(Power Switch) is in the "O" (Off) position, and there-
fore there are electrically live parts inside the power
source. Carefully follow the instructions given in this
manual.
FIGURE B.1
* 1 : Supply cable
* 2 : Gas attachment
l1 : Power Switch
WARNING
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OPERATION
B-4 B-4
INVERTEC® V205-T AC/DC™
1. Input Voltage warning light green LED - Indicates
that the machine is on and input voltage is within
acceptable range.
2. Thermal Shutdown Light (yellow LED) - Indicates
thermal over load or output disabled for incorrect
supply voltage.
• With the "Yellow LE " on, and an alarm code blink-
ing on " igital isplay Item 6" (see Troubleshooting
Section E, "Possible electrical problems"), the
machine will not supply power at the output.
• If over-heating occurs, the "Yellow LE " will stay on
until the machine has sufficiently cooled. Leave the
power source on to allow the fan to cool the unit.
3. Pulse On/OFF push button - CONSTANT current
- PULSE current
4. Setup/Parameter Select push button -
“Setup/Parameter" push button has three (3) differ-
ent functions:
•Accesses Welding Parameter. Repeatedly pressing
the Parameter button will step through the Welding
Parameter waveform lights on the front panel.
Parameters which can be changed.
Start Current
Upslope
Weld Current (Peak Current)
Pulse Frequency
% on Time
Background Current
ownslope
Finish Current
Postflow sec.
There is a LE for each welding parameter. When
lit, it has confirmed the mode or selection chosen.
•Accesses the "AC Frequency" and "AC Balance"
by pressing and holding the Parameter button for
three (3) seconds.
•Accesses the "Set Up Menu". See Set Up Menu
section.
CONTROLS AND SETTINGS
All operator controls and adjustments are located on
the case front of the V205-T machine. Refer to Figure
B.2 and the corresponding explanations.
2. Thermal / Device Warning Light Yellow LED
6. Digital Display
1. Input Voltage warning Light Green LED
5. Output/Parameter Adjust Knob
4. Setup/Parameter Select Button
9. Welding Process (MODE) Button
7. Local/Remote Button
3. Pulse On/Off Button
8.Trigger Selection Button
10. Electrode Connection (Negative)
11. Remote Control Connector
12. Electrode Connection (Positive)
13. Welding Parameter Drawing
sec
sec
LOCAL
1
9
10 11 12
13
876
5
4
3
2
FIGURE B.2
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