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IM592
®
INVERTEC V200-T November, 1999
10463
For use with machines having Code Numbers:
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 thought-
ful operation on your part. DO
NOT INSTALL, OPERATE OR
REPAIR THIS EQUIPMENT
WITHOUT READING THIS
MANUAL AND THE SAFETY
PRECAUTIONS CONTAINED
THROUGHOUT. And, most
importantly, think before you act
and be careful.
OPERATOR’S MANUAL
� World's Leader in Welding and Cutting Products �
� Sales and Service through Subsidiaries and Distributors Worldwide �
Cleveland, Ohio 44117-1199 U.S.A. TEL: 216.481.8100 FAX: 216.486.1751 WEB SITE: www.lincolnelectric.com
i i
SAFETY
WARNING
CALIFORNIA PROPOSITION 65 WARNINGS
The engine exhaust from this product contains
Diesel engine exhaust and some of its constituents
chemicals known to the State of California to cause
are known to the State of California to cause can-
cancer, birth defects, or other reproductive harm.
cer, birth defects, and other reproductive harm.
The Above For Gasoline Engines
The Above For Diesel Engines
ARC WELDING CAN BE HAZARDOUS. PROTECT YOURSELF AND OTHERS FROM POSSIBLE SERIOUS INJURY OR DEATH.
KEEP CHILDREN AWAY. PACEMAKER WEARERS SHOULD CONSULT WITH THEIR DOCTOR BEFORE OPERATING.
Read and understand the following safety highlights. For additional safety information, it is strongly recommended that 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 THAT ALL INSTALLATION, OPERATION, MAINTENANCE AND REPAIR PROCEDURES ARE
PERFORMED ONLY BY QUALIFIED INDIVIDUALS.
FOR ENGINE 1.h. To avoid scalding, do not remove the
radiator pressure cap when the engine is
powered equipment. hot.
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.
ELECTRIC AND
MAGNETIC FIELDS
____________________________________________________
may be dangerous
1.c. Do not add the fuel near an open flame
welding arc or when the engine is running.
Stop the engine and allow it to cool before 2.a. Electric current flowing through any conductor causes
refueling to prevent spilled fuel from vaporiz- localized Electric and Magnetic Fields (EMF). Welding
ing on contact with hot engine parts and current creates EMF fields around welding cables and
igniting. Do not spill fuel when filling tank. If welding machines
fuel is spilled, wipe it up and do not start
engine until fumes have been eliminated. 2.b. EMF fields may interfere with some pacemakers, and
____________________________________________________ welders having a pacemaker should consult their physician
1.d. Keep all equipment safety guards, covers and devices in before welding.
position and in good repair.Keep hands, hair, clothing and
tools away from V-belts, gears, fans and all other moving 2.c. Exposure to EMF fields in welding may have other health
parts when starting, operating or repairing equipment. effects which are now not known.
____________________________________________________
2.d. All welders should use the following procedures in order to
1.e. In some cases it may be necessary to remove safety
minimize exposure to EMF fields from the welding circuit:
guards to perform required maintenance. Remove
guards only when necessary and replace them when the
2.d.1. Route the electrode and work cables together - Secure
maintenance requiring their removal is complete.
them with tape when possible.
Always use the greatest care when working near moving
parts.
2.d.2. Never coil the electrode lead around your body.
___________________________________________________
1.f. Do not put your hands near the engine fan.
Do not attempt to override the governor or 2.d.3. Do not place your body between the electrode and
idler by pushing on the throttle control rods work cables. If the electrode cable is on your right
while the engine is running. 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.
___________________________________________________
1.g. To prevent accidentally starting gasoline engines while 2.d.5. Do not work next to welding power source.
turning the engine or welding generator during maintenance
work, disconnect the spark plug wires, distributor cap or
magneto wire as appropriate. Mar �95
ii ii
SAFETY
ARC RAYS can burn.
ELECTRIC SHOCK can
4.a. Use a shield with the proper filter and cover
kill. plates to protect your eyes from sparks and
3.a. The electrode and work (or ground) circuits
the rays of the arc when welding or observing
are electrically “hot� when the welder is on. open arc welding. Headshield and filter lens
Do not touch these “hot� parts with your bare should conform to ANSI Z87. I standards.
skin or wet clothing. Wear dry, hole-free
gloves to insulate hands. 4.b. Use suitable clothing made from durable flame-resistant
material to protect your skin and that of your helpers from
3.b. Insulate yourself from work and ground using dry insulation. the arc rays.
Make certain the insulation is large enough to cover your full
area of physical contact with work and ground. 4.c. Protect other nearby personnel with suitable, non-flammable
screening and/or warn them not to watch the arc nor expose
In addition to the normal safety precautions, if welding themselves to the arc rays or to hot spatter or metal.
must be performed under electrically hazardous
conditions (in damp locations or while wearing wet
FUMES AND GASES
clothing; on metal structures such as floors, gratings or
scaffolds; when in cramped positions such as sitting,
can be dangerous.
kneeling or lying, if there is a high risk of unavoidable or
accidental contact with the workpiece or ground) use 5.a. Welding may produce fumes and gases
the following equipment: hazardous to health. Avoid breathing these
� Semiautomatic DC Constant Voltage (Wire) Welder. fumes and gases.When welding, keep
� DC Manual (Stick) Welder. your head out of the fume. Use enough
� AC Welder with Reduced Voltage Control. ventilation and/or exhaust at the arc to keep
fumes and gases away from the breathing zone. When
3.c. In semiautomatic or automatic wire welding, the electrode, welding with electrodes which require special
electrode reel, welding head, nozzle or semiautomatic ventilation such as stainless or hard facing (see
welding gun are also electrically “hot�. instructions on container or MSDS) or on lead or
cadmium plated steel and other metals or coatings
3.d. Always be sure the work cable makes a good electrical which produce highly toxic fumes, keep exposure as
connection with the metal being welded. The connection low as possible and below Threshold Limit Values (TLV)
should be as close as possible to the area being welded. using local exhaust or mechanical ventilation. In
confined spaces or in some circumstances, outdoors, a
3.e. Ground the work or metal to be welded to a good electrical respirator may be required. Additional precautions are
(earth) ground. also required when welding on galvanized steel.
5.b. Do not weld in locations near chlorinated hydrocarbon vapors
3.f. Maintain the electrode holder, work clamp, welding cable and
coming from degreasing, cleaning or spraying operations.
welding machine in good, safe operating condition. Replace
The heat and rays of the arc can react with solvent vapors to
damaged insulation.
form phosgene, a highly toxic gas, and other irritating
products.
3.g. Never dip the electrode in water for cooling.
5.c. Shielding gases used for arc welding can displace air and
3.h. Never simultaneously touch electrically “hot� parts of
cause injury or death. Always use enough ventilation,
electrode holders connected to two welders because voltage
especially in confined areas, to insure breathing air is safe.
between the two can be the total of the open circuit voltage
of both welders.
5.d. Read and understand the manufacturer’s instructions for this
equipment and the consumables to be used, including the
3.i. When working above floor level, use a safety belt to protect
material safety data sheet (MSDS) and follow your
yourself from a fall should you get a shock.
employer’s safety practices. MSDS forms are available from
your welding distributor or from the manufacturer.
3.j. Also see Items 6.c. and 8.
5.e. Also see item 1.b.
Mar �95
iii iii
SAFETY
WELDING SPARKS can CYLINDER may explode
cause fire or explosion. if damaged.
6.a. Remove fire hazards from the welding area.
7.a. Use only compressed gas cylinders
If this is not possible, cover them to prevent
containing the correct shielding gas for the
the welding sparks from starting a fire.
process used and properly operating
Remember that welding sparks and hot
regulators designed for the gas and
materials from welding can easily go through small cracks
pressure used. All hoses, fittings, etc. should be suitable for
and openings to adjacent areas. Avoid welding near
the application and maintained in good condition.
hydraulic lines. Have a fire extinguisher readily available.
7.b. Always keep cylinders in an upright position securely
6.b. Where compressed gases are to be used at the job site,
chained to an undercarriage or fixed support.
special precautions should be used to prevent hazardous
situations. Refer to “Safety in Welding and Cutting� (ANSI
7.c. Cylinders should be located:
Standard Z49.1) and the operating information for the
� Away from areas where they may be struck or subjected to
equipment being used.
physical damage.
6.c. When not welding, make certain no part of the electrode
� A safe distance from arc welding or cutting operations and
circuit is touching the work or ground. Accidental contact
any other source of heat, sparks, or flame.
can cause overheating and create a fire hazard.
7.d. Never allow the electrode, electrode holder or any other
6.d. Do not heat, cut or weld tanks, drums or containers until the
electrically “hot� parts to touch a cylinder.
proper steps have been taken to insure that such procedures
will not cause flammable or toxic vapors from substances
7.e. Keep your head and face away from the cylinder valve outlet
inside. They can cause an explosion even though they have
when opening the cylinder valve.
been “cleaned�. For information, purchase “Recommended
Safe Practices for the Preparation for Welding and Cutting of
7.f. Valve protection caps should always be in place and hand
Containers and Piping That Have Held Hazardous
tight except when the cylinder is in use or connected for
Substances�, AWS F4.1 from the American Welding Society
use.
(see address above).
7.g. Read and follow the instructions on compressed gas
6.e. Vent hollow castings or containers before heating, cutting or
cylinders, associated equipment, and CGA publication P-l,
welding. They may explode.
“Precautions for Safe Handling of Compressed Gases in
Cylinders,� available from the Compressed Gas Association
6.f. Sparks and spatter are thrown from the welding arc. Wear oil
1235 Jefferson Davis Highway, Arlington, VA 22202.
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.
FOR ELECTRICALLY
Always wear safety glasses with side shields when in a
powered equipment.
welding area.
6.g. Connect the work cable to the work as close to the welding
8.a. Turn off input power using the disconnect
area as practical. Work cables connected to the building
switch at the fuse box before working on
framework or other locations away from the welding area
the equipment.
increase the possibility of the welding current passing
through lifting chains, crane cables or other alternate cir-
8.b. Install equipment in accordance with the U.S. National
cuits. This can create fire hazards or overheat lifting chains
Electrical Code, all local codes and the manufacturer’s
or cables until they fail.
recommendations.
6.h. Also see item 1.c.
8.c. Ground the equipment in accordance with the U.S. National
Electrical Code and the manufacturer’s recommendations.
Mar �95
iv iv
SAFETY
zones où l’on pique le laitier.
PRÉCAUTIONS DE SÛRETÉ
6. Eloigner les matériaux inflammables ou les recouvrir afin de
Pour votre propre protection lire et observer toutes les instructions
prévenir tout risque d’incendie dû aux étincelles.
et les précautions de sûreté specifiques qui parraissent dans ce
manuel aussi bien que les précautions de sûreté générales suiv-
7. Quand on ne soude pas, poser la pince à une endroit isolé de
antes:
la masse. Un court-circuit accidental peut provoquer un
échauffement et un risque d’incendie.
Sûreté Pour Soudage A L’Arc
1. Protegez-vous contre la secousse électrique:
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
a. Les circuits à l’électrode et à la piéce sont sous tension
la masse sur la charpente de la construction ou d’autres
quand la machine à souder est en marche. Eviter toujours
endroits éloignés de la zone de travail, on augmente le risque
tout contact entre les parties sous tension et la peau nue
de voir passer le courant de soudage par les chaines de lev-
ou les vétements mouillés. Porter des gants secs et sans
age, câbles de grue, ou autres circuits. Cela peut provoquer
trous pour isoler les mains.
des risques d’incendie ou d’echauffement des chaines et des
b. Faire trés attention de bien s’isoler de la masse quand on
câbles jusqu’� ce qu’ils se rompent.
soude dans des endroits humides, ou sur un plancher
metallique ou des grilles metalliques, principalement dans
9. Assurer une ventilation suffisante dans la zone de soudage.
les positions assis ou couché pour lesquelles une grande
Ceci est particuliérement important pour le soudage de tôles
partie du corps peut être en contact avec la masse.
galvanisées plombées, ou cadmiées ou tout autre métal qui
c. Maintenir le porte-électrode, la pince de masse, le câble
produit des fumeés toxiques.
de soudage et la machine à souder en bon et sûr état
defonctionnement.
10. Ne pas souder en présence de vapeurs de chlore provenant
d.Ne jamais plonger le porte-électrode dans l’eau pour le
d’opérations de dégraissage, nettoyage ou pistolage. La
refroidir.
chaleur ou les rayons de l’arc peuvent réagir avec les vapeurs
e. Ne jamais toucher simultanément les parties sous tension
du solvant pour produire du phosgéne (gas fortement toxique)
des porte-électrodes connectés à deux machines à souder
ou autres produits irritants.
parce que la tension entre les deux pinces peut être le
total de la tension à vide des deux machines.
11. Pour obtenir de plus amples renseignements sur la sûreté,
f. Si on utilise la machine à souder comme une source de
voir le code “Code for safety in welding and cutting� CSA
courant pour soudage semi-automatique, ces precautions
Standard W 117.2-1974.
pour le porte-électrode s’applicuent aussi au pistolet de
soudage.
2. Dans 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
PRÉCAUTIONS DE SÛRETÉ POUR
enrouler le câble-électrode autour de n’importe quelle partie
LES MACHINES À SOUDER À
du corps.
TRANSFORMATEUR ET À
3. Un coup d’arc peut être plus sévère qu’un coup de soliel,
REDRESSEUR
donc:
a. Utiliser un bon masque avec un verre filtrant approprié
ainsi qu’un verre blanc afin de se protéger les yeux du ray- 1. Relier à la terre le chassis du poste conformement au code de
onnement de l’arc et des projections quand on soude ou l’électricité et aux recommendations du fabricant. Le dispositif
quand on regarde l’arc. de montage ou la piece à souder doit être branché à une
b. Porter des vêtements convenables afin de protéger la bonne mise à la terre.
peau de soudeur et des aides contre le rayonnement de
l‘arc. 2. Autant que possible, I’installation et l’entretien du poste seront
c. Protéger l’autre personnel travaillant à proximité au effectués par un électricien qualifié.
soudage à l’aide d’écrans appropriés et non-inflammables.
3. Avant de faires des travaux à l’interieur de poste, la debranch-
4. Des gouttes de laitier en fusion sont émises de l’arc de er à l’interrupteur à la boite de fusibles.
soudage. Se protéger avec des vêtements de protection libres
de l’huile, tels que les gants en cuir, chemise épaisse, pan- 4. Garder tous les couvercles et dispositifs de sûreté à leur
talons sans revers, et chaussures montantes. place.
5. Toujours porter des lunettes de sécurité dans la zone de
soudage. Utiliser des lunettes avec écrans lateraux dans les
Mar. �93
v v
for selecting a QUALITY product by Lincoln Electric. We want you
Thank You to take pride in operating this Lincoln Electric Company product
•â?¢â?? as much pride as we have in bringing this product to you!
Please Examine Carton and Equipment For Damage Immediately
When this equipment is shipped, title passes to the purchaser upon receipt by the carrier. Consequently, Claims
for material damaged in shipment must be made by the purchaser against the transportation company at the
time the shipment is received.
Please record your equipment identification information below for future reference. This information can be
found on your machine nameplate.
Model Name & Number _____________________________________
Code & Serial Number _____________________________________
Date of Purchase _____________________________________
Whenever you request replacement parts for or information on this equipment always supply the information
you have recorded above.
Read this Operators Manual completely before attempting to use this equipment. Save this manual and keep it
handy for quick reference. Pay particular attention to the safety instructions we have provided for your protection.
The level of seriousness to be applied to each is explained below:
WARNING
This statement appears where the information must be followed exactly to avoid serious personal injury or
loss of life.
CAUTION
This statement appears where the information must be followed to avoid minor personal injury or damage to
this equipment.
vi
TABLE OF CONTENTS
Page
Installation.......................................................................................................................Section A
Technical Specifications .......................................................................................................A-1
Select Suitable Location .......................................................................................................A-2
Stacking................................................................................................................................A-2
Lifting and Moving ................................................................................................................A-2
Tilting ....................................................................................................................................A-2
Environmental Rating ...........................................................................................................A-2
Machine Grounding and High Frequency Interference Protection .......................................A-2
Input Connections ................................................................................................................A-3
Input Fuse and Supply Wire .................................................................................................A-3
Output Connections..............................................................................................................A-4
Operation.........................................................................................................................Section B
General Description..............................................................................................................B-1
Operational Features............................................................................................................B-1
Welding Capability................................................................................................................B-1
Limitations ............................................................................................................................B-1
Controls and Settings ...........................................................................................................B-2
Operating Steps ...................................................................................................................B-4
Welding in TIG Mode ....................................................................................................B-4
Remote Control Operation ............................................................................................B-4
Welding in Stick Mode...................................................................................................B-5
Recommended Electrode and Tungstens ............................................................................B-5
Explanation of 2 Step and 4 Step Modes .............................................................................B-6
Pulser Functions...................................................................................................................B-6
Accessories .....................................................................................................Section C
General Options / Accessories ..............................................................................C-1
TIG Welding Options / Accessories.......................................................................C-1
Maintenance........................................................................................................Section D
Safety Precautions ................................................................................................D-1
Input Filter Capacitor Discharge Procedure ..........................................................D-1
Routine Maintenance.............................................................................................D-1
Replacement of Internal Fuse ...............................................................................D-1
Troubleshooting ..............................................................................................Section E
Safety Precautions.................................................................................................E-1
How to Use Troubleshooting Guide.......................................................................E-1
Troubleshooting Guide ..........................................................................................E-2
Wiring Diagram ................................................................................................Section F
Parts List ..................................................................................................................P308
A-1 A-1
INSTALLATION
TECHNICAL SPECIFICATIONS - V200T TIG
INPUT - SINGLE PHASE ONLY
Standard Input Current at Code
Voltage (1) Number
Rated Output
230/460/1/50/60 10463
45/23 A @ 200 A, 33/16 A @ 150 A,
25/13 A @ 120 A
RATED OUTPUT
Duty Cycle Volts at Rated Amperes
(2)
Amps
20% Duty Cycle 28
200
60% Duty Cycle 26
150
100% Duty Cycle 25
120
OUTPUT
Output Current Maximum Open
Range Type of Output
Circuit Voltage
1 - 200 A 80 V DC
RECOMMENDED INPUT WIRE AND FUSE SIZES
For DC TIG Welding at 200A/20% Duty Cycle
Based on the 1996 U.S. National Electrical Code
Type 75°C
Input Copper Ground
Type 75°C
Fuse Input
Voltage / (Super Lag) Ampere Copper Wire in Wire in Conduit
phase/ AWG (IEC)
or Breaker Rating on Conduit AWG
Frequency Sizes
(IEC) Sizes
Size Nameplate
10 (5.2 mm2)
10 (5.2 mm2)
230/1/50/60 50 45
12 (4 mm2)
12 (4 mm2)
460/1/50/60 30 23
PHYSICAL DIMENSIONS
Height Width Depth Weight
Power 10.04 in. 7.48 in. 17.32 in. Approx. 35 lbs.
255 mm 190 mm 440 mm 16 kgs.
Source
OPERATING TEMPERATURE STORAGE TEMPERATURE
-20°C to +40°C -25°C to +55°C
(1) Input voltage must be within ±10% of rated value.
(2) Duty Cycle is based on a 10 min. period.
INVERTEC V200-T
A-2 A-2
INSTALLATION
Read entire installation section before starting MACHINE GROUNDING AND HIGH FRE-
installation.
QUENCY INTERFERENCE PROTECTION
Safety Precautions The welder must be grounded. See your local and national
electrical codes for proper grounding methods.
WARNING
The high frequency generator, being similar to a radio
ELECTRIC SHOCK can kill.
transmitter, can be blamed for radio, TV and electron-
� Only qualified personnel should
ic equipment interference problems. These problems
perform this installation.
may be the result of radiated interference. Proper
� Turn the input power OFF at the
disconnect switch or fuse box grounding methods can reduce or eliminate radiated
before working on this
interference.
equipment.
� Do not touch electrically hot
Radiated interference can develop in the following
parts.
four ways:
� Always connect the V200-T to a power sup-
ply grounded per the National Electrical
1. Direct interference radiated from the welder.
Code and any local codes.
SELECT SUITABLE LOCATION 2. Direct interference radiated from the welding leads.
3. Direct interference radiated from feedback into the
The Invertec will operate in harsh environments. Even
power lines.
so, it is important that simple preventative measures
are followed in order to assure long life and reliable
4. Interference from re-radiation of “pickup� by
operation.
ungrounded metallic objects.
� The machine must be located where there is free cir-
Keeping these contributing factors in mind, installing
culation of clean air such that air movement in the
equipment per the following instructions should mini-
back and out the sides will not be restricted.
mize problems.
� Dirt and dust that can be drawn into the machine
should be kept to a minimum. Failure to observe 1. Keep the welder power supply lines as short as
these precautions can result in excessive operating possible and enclose as much of them as possible
temperatures and nuisance shutdown. in rigid metallic conduit or equivalent shielding for a
distance of 50 feet (15.2m). There should be good
STACKING
electrical contact between this conduit and the
welder case ground. Both ends of the conduit
The Invertec V200-T cannot be stacked.
should be connected to a driven ground and the
entire length should be continuous.
LIFTING AND MOVING
2. Keep the work and electrode leads as short as
The Invertec V200-T has a lift handle on the top of the
case and also comes with a lift-carrying strap for con- possible and as close together as possible.
vience. Lengths should not exceed 25 ft (7.6m). Tape the
leads together when practical.
TILTING
Place the machine directly on a secure, level surface. 3. Be sure the torch and work cable rubber coverings
The machine may topple over if this procedure is not are free of cuts and cracks that allow high frequen-
followed. cy leakage.
ENVIRONMENTAL RATING
4. Keep the torch in good repair and all connections
� The machine has a protection rating of IP23. Keep tight to reduce high frequency leakage.
the machine dry when possible. Do not place it on
wet ground or in puddles.
5. The work piece must be connected to an earth
ground close to the work clamp, using one of the
following methods:
INVERTEC V200-T
A-3 A-3
INSTALLATION
a) A metal underground water pipe in direct con- 3. Provide access to the line switch by bending the
tact with the earth for ten feet or more. insulation back.
4. When the insulation is bent back, two sleeved
b) A 3/4� (19mm) galvanized pipe or a 5/8� (16mm) leads will become visible.
solid galvanized iron, steel or copper rod driven 5. Remove the sleeving from both leads.
at least eight feet into the ground. 6. Connect the large lead to push-on terminal
labeled �3� on the adjacent PC board.
The ground should be securely made and the ground- 7. Connect the small lead to terminal 15 of the line
ing cable should be as short as possible using cable switch.
of the same size as the work cable, or larger. 8. Reposition insulation to cover line switch.
Grounding to the building frame electrical conduit or a 9. Re-install wraparound.
long pipe system can result in re-radiation, effectively 10. Move the lock pin to allow switch movement for
making these members radiating antennas. 230 V selection only.
6. Keep cover and all screws securely in place. Connect the green w/ yellow strip lead to ground per
U.S. National Electrical Code. Connect the black and
7. Electrical conductors within 50 ft (15.2m) of the white leads to power.
welder should be enclosed in grounded rigid metal-
lic conduit or equivalent shielding, wherever possi- Use reverse procedure to reconnect for 460V. Do not
ble. Flexible metallic conduit is generally not suit- connect 460V when the switch is configured for 230V
able. or damage will result.
Power ON-OFF/Voltage Selector Switch - Located on top right of rear panel
8. When the welder is enclosed in a metal building, 0
the metal building should be connected to several 460 230
good earth driven electrical grounds (as in 5 (b)
above) around the periphery of the building.
Failure to observe these recommended installation
procedures can cause radio or TV and electronic Lock pin mounting hole
Lock pin - in this position allows only
equipment interference problems and result in unsat- 230 V input selection Move to opposite
side for 460 V operation.
isfactory welding performance resulting from lost high
Figure A.1
frequency power.
INPUT FUSE AND SUPPLY WIRE
INPUT CONNECTIONS
Refer to the Technical Specifications pages at the
Be sure the voltage, phase, and frequency of the input
power is as specified on the rating plate, located on beginning of this chapter for the proper fuse sizes and
the rear of the machine. supply cable sizes.
Supply line entry provision is in the case rear panel. � Fuse the input circuit with recommended super lag
fuses or delay type circuit breakers.
A power cord is provided and wired into the machine.
Follow the power cord connection instructions. � Install the proper fuse in the fuse holder in the main
Incorrect connection may result in equipment damage. disconnect panel.
The Invertec V200-T is internally connected for a 460 OUTPUT CONNECTIONS
volt input. The input switch has a lock pin which restricts
movement for 460 selection only. See figure A.1.
To connect the V200-T for 230 volt input, the following
input reconnect needs to be completed.
1. Disconnect the machine from the input supply.
2. Remove the wraparound by removing the shoul-
TIG TORCH/GAS OUTLET
der strap brackets and wraparound screws. WORK CABLE RECEPTACLE
RECEPTACLE
Figure A.2
INVERTEC V200-T
A-4 A-4
INSTALLATION
OUTPUT CONNECTIONS Turn the Power Switch “OFF�. Connect the torch cable quick
connect plug into the DC- Output Receptacle on the front of
the welder and turn it clockwise until it is tight. This is a
Refer to Figure A.2 for the location of the output terminals.
quick connect terminal and also provides the gas connection
A quick-disconnect system using Twist-MateTM cable plugs is
for the shielding gas to the torch.
used for the welding cable connections. The electrode and
work cables will require these plugs. Refer to the relevant
WARNING
instructions following for more information on connecting the
machine for either welding process.
To avoid receiving a high frequency shock, keep the TIG
OUTPUT CONNECTION FOR STICK torch and cables in good condition.
__________________________________________
WELDING
Next, connect the work cable (which is connected to the
First determine the proper electrode polarity for the elec-
work clamp) to the �+� output terminal in the same way.
trode to be used. Consult the electrode data for this infor-
mation. Then connect the output cables to the output termi-
The machine can easily be switched between stick and TIG
nals corresponding to this polarity. For instance, for DC(+)
welding at any time by simply swapping the stick (electrode)
welding, connect the electrode cable (which is connected to
and TIG (torch) cables, and reversing the connection polari-
the electrode holder) to the �+� output terminal and the work
ty if required.
cable (which is connected to the work clamp) to the �-� out-
put terminal. Insert the connector with the key lining up with
the keyway, and rotate approximately 1/4 turn clockwise;
until the connection is snug. Do not over tighten.
OUTPUT AND GAS CONNECTION
FOR TIG WELDING
This unit does not include a TIG torch, but one may be pur-
chased separately and used with these units to do TIG
(GTAW) welding. The Lincoln LA-9 (K859-1 or K859-5 only
with no gas valve) or LA-17 and LA-17V (K860-1 or K860-5
without gas valve and K860-9 or K860-13 with gas valve)
are recommended for use with these machines for this pur-
pose; 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 fitting on the torch cable into the brass connector
snugly and slide the boot back over the brass connector.
STRAIN RELIEF BOOT
TIG ADAPTER
RETAINING COMPOUND TIG TORCH POWER CABLE WITH GAS FITING
INVERTEC V200-T
INSTALLATION
A-5 A-5
QUICK DISCONNECT PLUG (FOR WORK CABLE) SHIELDING GAS CONNECTION
A quick disconnect system is used for the welding
An adjustable gas pressure regulator and flow gage
cable connections. The electrode and work cables
should be obtained. Obtain the necessary inert shield-
need to have a plug attached.
ing gas (usually argon). Connect the cylinder of gas
with the pressure regulator and flow gage. Install the
1. Cut off welding cable lug, if present.
gas hose between the regulator and gas inlet (located
2. Remove .75 in. (19mm) of welding cable insulation.
on the low left rear of the welder). The gas inlet has a
3. Slide rubber boot onto cable end. The boot end
5/16-18 right hand female thread; CGA #032.
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.
WARNING
BOOT
CYLINDER could explode
WELDING CABLE
if damaged.
•Keep cylinder upright and chained
to a support.
.75 in.
TRIM, IF REQ'D
19 mm TO FIT OVER CABLE
•Keep cylinder away from areas where it could
4. Cut 45-50% of the copper strands back 1/4� (6
be damaged.
mm).
WELDING CABLE
•Never allow the torch to touch the cylinder.
•Keep cylinder away from live electrical circuits.
•Maximum inlet pressure 150 psi.
.25 in.
6 mm ___________________________________________
5. Fold copper strands over cut strands and insert
into ferrule.
REMOTE CONTROL CONNECTION
COPPER FERRULE
WELDING CABLE
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
.50 in. max
Accessories section of this manual for available
12 mm max.
remote controls.
6. Slide the copper ferrule into the brass plug.
7. 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.
SET SCREW
BRASS PLUG
COPPER TUBE
8. Slide rubber boot over brass plug. The rubber boot
must be positioned to completely cover all electri-
cal surfaces after the plug is locked into the recep-
tacle.
INVERTEC V200-T
B-1 B-1
OPERATION
Read and understand this entire section before GENERAL DESCRIPTION
operating your machine.
The Invertec V200-T is an industrial 200 amp arc
SAFETY INSTRUCTIONS welding power source which utilizes single phase
input power, to produce constant current output. The
WARNING welding response of this Invertec has been optimized
for stick (SMAW) and TIG (GTAW). The unit is ideal
for industrial applications where portability is impor-
tant.
ELECTRIC SHOCK can kill.
� Do not touch electrically live parts such OPERATIONAL FEATURES
as output terminals or internal wiring.
The Invertec provides continuous total range output
� Insulate yourself from the work and current adjustment. Additionally, a “hot start� system
ground.
has been built into the welding current control, and
provides a higher striking current to assist ignition of
� Always wear dry insulating gloves.
the arc.
____________________________________
FUMES AND GASES WELDING CAPABILITY
can be dangerous.
The Invertec V200-T is rated at 200 amps, 28 volts, at
� Keep your head out of fumes. 20% duty cycle on a ten minute basis. It is capable of
higher duty cycles at lower output currents. It is capa-
� Use ventilation or exhaust to ble of 120 amps, 25 volts at at 100% duty cycle. If the
remove fumes from breathing duty cycle is exceeded, a thermal protector will shut
zone. off the output until the machine cools.
LIMITATIONS
____________________________________
WELDING, CUTTING and
The V200-T is not recommended for pipe thawing.
GOUGING SPARKS
can cause fire or explosion The V200-T should not be powered from the auxiliary
power supply of an engine welder. Special protection
� Keep flammable material away. circuits may operate causing loss of output.
� Do not weld, cut or gouge on
containers that have held com-
bustibles.
____________________________________
ARC RAYS
can burn.
� Wear eye, ear and body
protection.
____________________________________
Only qualified personnel should operate this equip-
ment. Observe all safety information throughout this
manual.
INVERTEC V200-T
B-2 B-2
OPERATION
CONTROLS AND SETTINGS
All operator controls and adjustments are located on the case front of the V200-T machine. Refer to Figure B.1
and the corresponding explanations.
FIGURE B.1 � CASE FRONT CONTROLS.
Welding Current Voltage out of spec/ Digital Display
Potentiometer Overheated LED
Gas Available LED
Power LED
Slope Down
Slope Up
Time Pot.
Time Pot.
Start/Crater
Post Flow
Current Pot.
Time Pot.
Welding Process
Pulse Duration
Switch
Potentiometer
Local/Remote
Switch Pulse Amplitude
Potentiometer
TIG Process
Pulse Frequency/
Switch
TIG Spot Timer
Potentiometer
DC- Terminal/
Remote Control DC+ Terminal
TIG Torch Terminal
Connector
Power Switch/Voltage Selector Switch - Controls Output Terminals - These quick disconnect terminals
the power input to the machine. This rotating switch is provide connection points for the TIG Torch and work
used to turn the machine on and off as well as to cables or electrode and work cables. For TIG welding,
select the input voltage. The switch is located on the connect the torch to the DC- terminal and the work
top right rear panel. When power is applied to the cable to the DC+ terminal. For stick welding positive
machine the Power LED is on. polarity connect the electrode cable to the positive ter-
minal and the work cable to the negative terminal. To
Welding Current Potentiometer - Potentiometer weld negative polarity reverse the electrode and work
used to set the value of the current required by the cables.
welding process. This current setting will be displayed
on the Digital Display. When an Amptrol is used to Remote Control Connector - This receptacle will
remotely control the welding current, this setting con- accept a Lincoln Foot Amptrol, Hand Amptrol or Arc
trols the maximum welding current when the Amptrol Start Switch. See the ACCESSORIES section for
is fully depressed. available options.
Voltage out of spec/ Overheated LED - This LED
will light up when:
A) The input supply voltage is not within limits
pre-set for correct operation.*
B) The machine is overheated as detected by
the internal thermostat.
* Note that input voltages that exceed 20% of nominal
may cause internal damage to the machine.
INVERTEC V200-T
B-3 B-3
OPERATION
Start/Crater Potentiometer - This potentiometer is TIG Process Switch - This switch is used to select
used to adjust the START CURRENT and CRATER the type of TIG process to be performed. In the
CURRENT for TIG welding only. This potentiometer PULSER position - Pulsed TIG welding, in the OFF
also adjusts the ARC FORCE when in STICK welding position - continuous TIG welding and in the TIG
mode. SPOT position - spot TIG welding.
Slope Up and Slope Down Time Potentiometers - Welding Process Switch - This switch is used to
These potentiometers are used to adjust the Slope Up select the type of welding process to be performed. In
and Slope Down Times respectively for TIG welding the 2S position - Two step TIG welding, in the 4S
only. The adjustable range for both timers is 0 to 10 position - 4 step TIG welding and in the STICK posi-
sec. tion - Stick welding. See the section on 2 step and 4
step explanation later in this section.
Post Flow Time Potentiometer - This potentiometer
is used to adjust the gas postflow after the arc is extin- LOCAL/REMOTE Switch - This switch is used to
guished when using a TIG process. The postflow time select where current can be adjusted. In the LOCAL
is 0 - 50 sec. position current is controlled by the Welding Current
Potentiometer. In the REMOTE position any hand or
foot amptrol connected to the Remote Control
Pulse Frequency/TIG Spot Timer Potentiometer - Connector will control the current setting. In both
This potentiometer is used to adjust the Pulse modes, however, the current potentiometer on the
Frequency when the TIG Process Switch is in the case front sets the maximum welding current avail-
PULSER position and to adjust the TIG Spot Time able.
when the TIG Process Switch is in the TIG SPOT
position. The Pulse Frequency range available is 300
Hz to 0.5 Hz. The Pulse Frequency on the V200-T is
actually adjusted in terms of the pulse period, which is Gas Available LED - This LED will light when gas is
the inverse of the frequency. Increasing the knob (cw), available in the TIG welding modes only.
increases the period and because of their inverse
relationship, decreases frequency. Therefore, at the
maximum period setting (fully cw, or �10�) the frequen-
cy is at minimum (0.5 Hz) and at the minimum period Power LED - Indicates inverter is ON. After 5 minutes
setting (fully ccw or �0�) the frequency is at maximum without use, the inverter will go into a sleep mode and
(300 Hz). The spot time range is adjustable up to 10 the LED will go off. Any activity on the output will
sec. immediately “Wake� the inverter up, the LED will come
back on and normal operation will resume.
Pulse Duration Potentiometer - This potentiometer
is active only when the TIG Process Switch is in the
PULSER position. It controls pulse duration or length
of time for pulse within the selected pulse frequency
(see above). Use this potentiometer to select the rela-
tive amount of peak and background current for the
selected overall frequency.
Pulse Amplitude Potentiometer - This potentiometer
is active only when the TIG Process Switch is in the
PULSER position at that time it controls pulse ampli-
tude or height. Use this potentiometer to adjust the
background current as a percentage of the peak (or
maximum) current level.
INVERTEC V200-T
B-4 B-4
OPERATION
REMOTE CONTROL OPERATION
OPERATING STEPS
A Foot Amptrolâ„? is optional with the V200-T for
WELDING IN TIG MODE
remote current control while TIG welding. An optional
Hand Amptrol may also be used. An optional Arc
1. Connect the TIG torch and cable quick connect
Start Switch may be used to start and stop the weld-
plug to the DC- output receptacle. This receptacle
ing if no remote control of the current is desired. Refer
also contains an integral gas connection for the
to the Accessories section of this manual.
torch. Connect the work cable to the DC+ recepta-
cle and to the work piece.
Both the Hand and Foot Amptrol work in a similar
manner. For simplicity, the following explanation will
2. Set the Welding Process Switch to �2S� when
refer only to “Amptrols�, meaning both Foot and Hand
using a hand or foot amptrol. When using an arc
models. The term “minimum� refers to a foot pedal in
start switch, �2S or �4S� can be used.
the “up� position, as it would be with no foot pressure,
or a Hand Amptrol in the relaxed position, with no
3. Set the TIG Process Switch to the desired posi-
thumb pressure. “Maximum� refers to a fully
tion.
depressed Foot Amptrol, or a fully extended Hand
Amptrol.
4. Connect an optional Amptrol or Arc Start Switch to
the Remote Control Connector.
When the welder is in TIG modes activating the
Amptrol energizes the electrode terminal and varies
5. Turn on the cylinder gas valve and adjust the flow
the output welding current from its minimum value of 1
regulator to obtain desired flow.
amp, to the maximum value set by the Current Control
on the control panel. This helps eliminate accidental
6. Turn the power switch to �230� or �460� as appropri-
high current damage to the work piece and/or tung-
ate for your input voltage. NOTE: There will be a
sten, and gives a fine control of the current. When the
0.5 second gas flow when the power is turned on.
welder is in the stick mode a remote control has no
effect and is not used.
7. Set the Current Control on the control panel to the
maximum desired amps.
It is important to note that, in some cases, the tung-
sten will not start an arc at the minimum current
8. Depress the Amptrol or Arc Start Switch to energize
because the tungsten may be too large or cold. To
the torch and establish an an arc with the work
start an arc reliably, it is important to depress the
piece.
Amptrol far enough so that the machine output current
is near the tungsten operating range. For example, a
NOTE: When the TIG Process Switch is set to �2S� or
3/32� tungsten may be used on DC- to weld the full
�4S� TIG position, depressing the remote control will
range. To start the weld, the operator may have to
start a 0.5 second gas pre-flow before energizing the TIG
turn the current control up and depress the Amptrol
torch. When the remote control is released the TIG torch
approximately 1/4 of the way down. Releasing the
is de-energized and gas flow will continue for the set post
Amptrol to its minimum position may not start the arc.
flow time (0 - 50 sec.).
Also if the current control is set too low, the arc may
not start. In most cases, a large or cold tungsten will
not readily establish an arc at low currents. This is
normal. In DC-, the V200-T will start a 3/32, 2% thori-
ated tungsten electrode at 15 amperes provided the
electrode tip is properly grounded and not contaminat-
ed.
Sept97
INVERTEC V200-T
B-5 B-5
OPERATION
WELDING IN STICK MODE
WARNING
1. Put the electrode holder and cable quick connect
In Stick Mode the output terminal and
plug into the proper receptacle for the electrode
electrode will be electrically hot when-
polarity desired. Turn clockwise until tight. Connect
ever the power switch is turned on.
the work clamp to the other receptacle and the work
piece.
2. Set the Welding Process Switch to “STICK�. 6. Adjust the Current Control to the desired amps.
3. Set the Local/Remote Switch to “Local�. 7. Strike an arc and weld.
4. Place the electrode in the electrode holder. NOTE: When the Welding Process Switch is set to
“STICK� the output is always on when the power
5. Turn the Power Switch to the proper input voltage switch is on. A remote control has no effect on the
setting to turn on the welder. welding current and the gas flow and high frequency
TIG arc starter are disabled.
RECOMMENDED ELECTRODE AMPERAGE RANGES - INVERTEC V200-T
The Invertec V200-T is rated from1 - 200 Amps.
SMAW Process
ELECTRODE POLARITY 3/32" 1/8" 5/32"
Fleetweld 180 DC+ 40 - 80 55 - 110 105 - 135
Fleetweld 37 DC+ 70 - 95 100 - 135 145 - Max
Fleetweld 47 DC- 75 - 95 100 - 145 135 - Max
Jet-LH MR DC+ 85 - 110 110 - 160 130 - Max
Blue Max Stainless DC+ 40 - 80 75 - 110 95 - 110
Red Baron Stainless DC+ 40 - 70 60 - 100 90 - 140
Mild steel procedures are based on recommended procedures listed in C2.10 8/94 and the maximum rating of the Invertec V200-T
Jet-LH MR procedures are based on Jet-LH 78 MR
Blue Max procedures are based on C6.1 6/95
Red Baron Procedure are based on ES-503 10/93
GTAW Process
Electrode Polarity DC- Approximate Argon
Electrode Tip Prepration Sharpened Gas Flow Rate
C.F.H. (l/min.)
Electrode Type
EWTh-1, EWCe-2
EWTh-2, EWLa-1 Stainless
Electrode Size (in.) EWG Aluminum Steel
.010 Up to 15 A. 3-8 (2-4) 3-8 (2-4)
.020 Up to 15 A. 5-10 (3-5) 5-10 (3-5)
.040 Up to 80 A. 5-10 (3-5) 5-10 (3-5)
1/16 Up to 150 A. 5-10 (3-5) 9-13 (4-6)
3/32 Up to MAX. A. 13-17 (6-8) 11-15 (5-7)
1/8 X 15-23 (7-11) 11-15 (5-7)
Tungsten electrodes are classified as follows by the American Welding Society (AWS):
Pure ..................................EWP ........green
+1% Thoria .......................EWTh-1 ...yellow
+2% Thoria .......................EWTh-2 ...red
+2% Ceria.........................EWCe-2...orange
+1.5% Lanthana ...............EWLa-1 ...black
+0.15 to 0.40% Zirconia....EWZr .......brown
Ceriated Tungsten is now widely accepted as a substitute for 2% Thoriated Tungsten in AC and DC applications.
Sept97
INVERTEC V200-T
B-6 B-6
OPERATION
EXPLANATION OF 2 STEP AND 4 During this phase, the welding current falls to the
crater current set on the Start/Crater Current
STEP MODES Potentiometer. The speed at which the welding cur-
(See figure B.2 and the explanations that follow) rent decreases is determined by the setting of the
Slope Down Time Potentiometer.
2 STEP
The power source comes equipped with a restart
2 Step mode can be used with either an arc start capability. Any change required in the restart timing
switch or a hand or foot amptrol. The welding cycle can only be made by an authorized service center.
begins when the torch switch is held closed and ends (See Figure B.2 - 4 Step Mode).
when the switch is released.
In the TIG-SPOT mode the UP/ DOWN-SLOPE con-
4 STEP trols and the PULSER function are disabled.
The welding cycle takes an "ON-OFF" type shape with
the welding current jumping very rapidly from 0 to the
4 Step mode should only be used with an arc start
nominal value.
switch. The welding cycle begins when the torch
switch is pressed and then released. The cycle is
PULSER FUNCTION
ended by a further press and release of the switch.
The pre-gas flow is followed by an increase in the Pulsed welding is selected by using the TIG Process
welding current from the level set by the Start/Crater Switch. In this mode the output is modulated to pro-
Current Potentiometer, to the value on the display duce a series of current pulses. By this means pre-
set with the Welding Current Potentiometer. The cise control of heat input and penetration can be
rate of increase is determined by the setting of the achieved on critical applications. The pulse frequency,
Slope Up Time Potentiometer. duration and amplitude may be adjusted by means of
the respective potentiometers.
The slope out phase begins with the release of the
torch switch in the 2 STEP mode or with a second
press of the switch in the 4 STEP mode.
FIGURE B.2 2 Step and 4 Step Modes
2 STEP MODE
TORCH
TORCH
SWITCH
SWITCH
WELDING
WELDING
CURRENT
CURRENT
WITHOUT RESTART
4 STEP MODE WITH RESTART (As shipped
no jumper)
TORCH
TORCH
SWITCH
SWITCH
WELDING
WELDING
CURRENT
CURRENT
CRATER CURRENT
INVERTEC V200-T
C-1 C-1
ACCESSORIES
OPTIONAL ACCESSORIES
K870 - Foot Amptroltm for TIG welding. When the
TIG Torch Parts Kits - Parts kits are available for the
V200-T’s Output Control is in the “REMOTE� position,
LA-9 and LA-17/LA-17V TIG torches. These kits
the foot Amptrol energizes the output and controls the
include back cap, collets, collet bodies, nozzles and
output remotely. The Foot Amptrol connects directly
tungstens.
to the 6 pin Amphenol.
Order KP507 for LA-9 torches
Order KP508 for LA-17/LA-17V torches
K812 - Hand Amptroltm for TIG welding. When the
See publication E12.150 for parts kits breakdown.
V200-T’s Output Control is in the “Remote� position,
Cut Length Consumables - TIG welding filler metals
the hand Amptrol energizes the output and controls
are available for welding stainless steel, mild steel,
the output remotely. The Hand Amptrol connects
aluminum and copper alloys. See publication C9.10.
directly to the 6 pin Amphenol.
K814 - Arc Start Switch - Energizes the output for
TIG welding if remote output control of the amperage
is not desired. It allows on/off TIG welding at the cur-
rent set by the Current Control on the control panel.
When using the Arc Start Switch set the Output
Control to the “LOCAL� position.
Magnum® LA-9 and LA-17/LA-17V TIG Torches -
The following standard Magnum® TIG torches with
one-piece cable may be used with the Invertec V200-T.
� K859-1 LA-9 12.5 ft medium back cap
� K859-5 LA-9 25 ft medium back cap
� K860-1 LA-17 12.5 ft long back cap
� K860-5 LA-17 25 ft long back cap
� K860-9 LA-17V 12.5 ft long back cup;w/gas valve
� K860-13 LA-17V 25 ft long back cup;w/gas valve
NOTE: Each torch requires a quick connector plug
(S22529-1) and strain relief boot (M17255) be
installed onto the cable. Collets, collet bodies, and
nozzles are not included and must be ordered sepa-
rately.
CABLE PLUGS
K852-70 - Cable Plug Kit for 1/0-2/0 cable. Attaches
to welding cable to provide quick disconnect from
machine.
Quick Connect Plug (S22529-1) and Strain Relief
Boot (M17255) - One of each is shipped with the
welder to connect the Magnum LA-9 torch. If you do
not care to interchange these parts between torches
(one of each is required to connect Magnum LA-9 or
LA-17/LA-17V TIG torches with one-piece cable to the
V200-T) you may order additional sets. The quick con-
nect plug provides connection for both gas and weld-
ing current.
INVERTEC V200-T
D-1 D-1
MAINTENANCE
SAFETY PRECAUTIONS � Printed circuit boards
WARNING � Power switch
ELECTRIC SHOCK can kill.
� Fan blades
� Have an electrician install and ser-
vice this equipment.
� Louvers
� Turn the input power off at the fuse
box, disconnect supply lines and � Heat sink fins
allow machine to sit for five minutes
minimum to allow the power capaci- � Output terminals
tors to discharge before working
inside this equipment.
4. Examine capacitors for leakage or oozing. If any
leakage is noticed, take the unit to an authorized
� Do not touch electrically hot parts.
Lincoln Field Service Shop.
----------------------------------------------------------------------
5. Examine the case for breakage. Repair or
INPUT FILTER CAPACITOR replace the case as required. Keep the case in
DISCHARGE PROCEDURE good condition to ensure that high voltage parts
are protected and correct spacings are main-
WARNING tained.
6. Install machine covers and fasteners.
The machine has internal capacitors which are
charged to a high voltage during power-on conditions.
This voltage is dangerous and must be discharged
REPLACEMENT OF INTERNAL
before the machine can be serviced. Discharging is
FUSE
done automatically by the machine each time the
power is switched off. However, you must allow the
The Invertec has additional protection provided to
machine to sit for at least 5 minutes to allow time for
some circuits through an internal fuse. For replace-
the process to take place.
ment of that fuse proceed as follows:
------------------------------------------------------------------------
1. Turn off the power to the unit and remove the
input plug.
ROUTINE MAINTENANCE
2. Allow the machine to stand for 5 minutes to let
1. Perform the following preventive maintenance the input capacitors discharge.
procedures at least once every thousand hours of
use. It is good practice to keep a preventive main- 3. Remove the machine cover.
tenance record; a record tag attached to the
machine works best. 4. Replace the blown fuse with a new 0.5A 500V
slowblow fuse.
2. Remove the machine cover (requires a 3 mm hex
key) after allowing the minimum 5 minute power
NOTE: If the fuse blows again after power is restored,
off requirement to let the input capacitors dis-
the cause could be an internal breakdown in
charge.
the power unit. In this case, take the unit to an
authorized Lincoln Field Service Shop.
WARNING
Failure to observe this discharge time requirement
could result in severe electrical shock hazard.
------------------------------------------------------------------------
3. Keeping the machine clean will result in cooler
operation and higher reliability. Be sure to clean
the following areas with a low pressure air
stream.
INVERTEC V200-T
E-1 E-1
TROUBLESHOOTING
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.
__________________________________________________________________________
This Troubleshooting Guide is provided to
help you locate and repair possible machine
malfunctions. Simply follow the three-step
procedure listed below.
Step 3. RECOMMENDED COURSE OF
Step 1. LOCATE PROBLEM (SYMPTOM).
ACTION
Look under the column labeled “PROBLEM
This column provides a course of action for
(SYMPTOMS)�. This column describes
the Possible Cause, generally it states to
possible symptoms that the machine may
contact you local Lincoln Authorized Field
exhibit. Find the listing that best describes
Service Facility.
the symptom that the machine is exhibiting.
If you do not understand or are unable to
Step 2. POSSIBLE CAUSE.
perform the Recommended Course of
The second column labeled “POSSIBLE
Action safely, contact you local Lincoln
CAUSE� lists the obvious external possibili-
Authorized Field Service Facility.
ties that may contribute to the machine
symptom.
CAUTION
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.
INVERTEC V200-T
E-2 E-2
TROUBLESHOOTING
Observe all Safety Guidelines detailed throughout this manual
PROBLEMS POSSIBLE AREAS OF RECOMMENDED
(SYMPTOMS) MISADJUSTMENTS(S) COURSE OF ACTION
The machine is dead - no output - 1. The input power switch must be
no fan. in the ON position.
2. Make sure the input voltage is
correct for the machine.
3. Check continuity of the 0.5-amp
slow blow fuse located on the
P.C. Board.
No output but the fan operates nor- 1. The machine may be overheated. If all recommended possible areas of
misadjustment have been checked
mally. Check the thermal indicator light.
and the problem persists, Contact
Wait for the machine to cool and
your local Lincoln Authorized Field
the thermostats to reset.
Service Facility.
Output turns on momentarily, then 1. Check the input voltage. Make
switches off. sure the input voltage is correct
for the machine.
No output - Main input fuses open, 1. Inspect input leads for possible
indicating excessive current draw. shorts or grounds or mis-connec-
tions.
2. Install new fuses and reapply
power. If fuses open again, con-
sult a Lincoln Authorized Field
Service Facility.
CAUTION
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.
INVERTEC V200-T
F-1
DIAGRAMS
INVERTEC V200-T
WIRING DIAGRAM
8-21-98
M18986
F-1
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 a replacement. Give the equipment code number..
PARTS
PARTS LIST FOR
INVERTEC V200-T
This parts list is provided as an informative guide only.
This information was accurate at the time of printing. However, since these
pages are regularly updated in Lincoln Electric’s official Parts Book (BK-34),
always check with your Lincoln parts supplier for the latest parts information.
INVERTEC® V200-T
P-308-A.1 P-308-A.1
INVERTEC V-200-T
For Codes: 10463
Do Not use this Parts List for a machine if its code number is not listed. Contact the Service Department for any
code numbers not listed.
Use the Illustration of Sub-Assemblies page and the table below to determine which sub assembly page and col-
umn the desired part is located on for your particular code machine.
Sub Assembly Item
No.
General Assembly
SUB ASSEMBLY
PAGE NAME
PAGE NO. P308-C
CODE NO.
10463 1
7-30-97
INVERTEC V-200-T
P-308-C P-308-C
General Assembly
11-4-98
INVERTEC V-200-T
P-308-C.1 P-308-C.1
# Indicates a change this printing. Use only the parts marked “x� in the column under the
heading number called for in the model index page.
* Recommended Spare Part
123456789
ITEM DESCRIPTION PART NO. QTY.
1 Solenoid Valve S24105-1 1 X
2 HF 91 High Frequency PCB (Adjusted 0.3mm) S24105-2 1 X
(Not Shown)
3 High Frequency Transformer S24105-3 1 X
4 50 OHM 80 W Resistor (Faston Terminal) S24105-4 2 X
5 Plastic Knob S24105-5 1 X
6 6 to 4mm Knob Adapter S24105-6 7 X
7 Plastic Knob S24105-7 7 X
8 Control Panel S24105-8 1 X
9 Ventilation Grating (Black) S24105-9 1 X
10 Line Switch S24105-10 1 X
11 Bottom Panel S24105-11 1 X
12 Input PCB S24105-12 1 X
13 Allen Key Screw S24105-13 4 X
14 Output Assembly S24105-14 1 X
15 Shoulder Strap S24105-15 1 X
16 Handle S24105-16 1 X
17 Control PCB (Tested & Adjusted) S24105-17 1 X
18 Output Transformer S24105-18 1 X
19 Inverter (Tested & Adjusted) S24105-19 1 X
20 Fan S24104-15 1 X
21 Remote Connector & PCB S24105-21 1 X
22 Output Connector W/Gas M13896-7 1 X
23 Output Connector M13896-3 1 X
24 Plastic Support S24105-24 1 X
25 Supply Cord S24105-25 1 X
26 Rear Gas Connector S24105-26 1 X
27 Supply Cord Strain Relief S24103-12 1 X
28 Aluminum Cover (Red) S24105-28 1 X
29 Rear Panel S24105-29 1 X
30 Front Panel S24105-30 1 X
31 Output Choke S24105-31 1 X
32 High Frequency Filter PCB S24105-32 1 X
33 Bolt S24105-33 1 X
35 Name Plate S24105-35 1 X
36 Lincoln Electric Decal S24105-36 2 X
37 Input Connection Decal S24105-37 1 X
38 Rating Plate S24105-38 1 X
39 Gas Input Decal S24105-39 1 X
44 1 Year Warranty Decal S22127-1 1 X
45 Electric Shock Warning Decal S19338 1 X
46 Grounding Warning Decal T13259 1 X
51 Fuse, 0.5A/500 Volt Slow Blow S24105-43 1 X
Items Not Shown:
Quick Connect Plug S22529-1 1 X
Strain Relief Boot M17255 1 X
Twist-Mate Connector M15479 1 X
11-4-98
INVERTEC V-200-T
NOTES
INVERTEC V-200-T
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q Do not touch electrically live parts or q Keep flammable materials away. q Wear eye, ear and body protection.
WARNING electrode with skin or wet clothing.
q Insulate yourself from work and
ground.
Spanish
q No toque las partes o los electrodos q Mantenga el material combustible q Protéjase los ojos, los oÃdos y el
AVISO DE bajo carga con la piel o ropa moja- fuera del área de trabajo. cuerpo.
da.
PRECAUCION q Aislese del trabajo y de la tierra.
French q Ne laissez ni la peau ni des vête- q Gardez à l’écart de tout matériel q Protégez vos yeux, vos oreilles et
ments mouillés entrer en contact inflammable. votre corps.
ATTENTION avec des pièces sous tension.
q Isolez-vous du travail et de la terre.
German q Berühren Sie keine stromführenden q Entfernen Sie brennbarres Material! q Tragen Sie Augen-, Ohren- und Kör-
Teile oder Elektroden mit Ihrem perschutz!
WARNUNG Körper oder feuchter Kleidung!
q Isolieren Sie sich von den
Elektroden und dem Erdboden!
Portuguese
q Não toque partes elétricas e elec- q Mantenha inflamáveis bem guarda- q Use proteção para a vista, ouvido e
trodos com a pele ou roupa molha- dos. corpo.
ATENÇÃO da.
q Isole-se da peça e terra.
Japanese
Chinese
Korean
Arabic
READ AND UNDERSTAND THE MANUFACTURER’S INSTRUCTION FOR THIS EQUIPMENT AND THE CONSUMABLES TO BE
USED AND FOLLOW YOUR EMPLOYER’S SAFETY PRACTICES.
SE RECOMIENDA LEER Y ENTENDER LAS INSTRUCCIONES DEL FABRICANTE PARA EL USO DE ESTE EQUIPO Y LOS
CONSUMIBLES QUE VA A UTILIZAR, SIGA LAS MEDIDAS DE SEGURIDAD DE SU SUPERVISOR.
LISEZ ET COMPRENEZ LES INSTRUCTIONS DU FABRICANT EN CE QUI REGARDE CET EQUIPMENT ET LES PRODUITS A
ETRE EMPLOYES ET SUIVEZ LES PROCEDURES DE SECURITE DE VOTRE EMPLOYEUR.
LESEN SIE UND BEFOLGEN SIE DIE BETRIEBSANLEITUNG DER ANLAGE UND DEN ELEKTRODENEINSATZ DES HER-
STELLERS. DIE UNFALLVERHÃœTUNGSVORSCHRIFTEN DES ARBEITGEBERS SIND EBENFALLS ZU BEACHTEN.
q Keep your head out of fumes. q Turn power off before servicing. q Do not operate with panel open or
WARNING
q Use ventilation or exhaust to guards off.
remove fumes from breathing zone.
Spanish
q Los humos fuera de la zona de res- q Desconectar el cable de ali- q No operar con panel abierto o
AVISO DE
piración. mentación de poder de la máquina guardas quitadas.
q Mantenga la cabeza fuera de los antes de iniciar cualquier servicio.
PRECAUCION
humos. Utilice ventilación o
aspiración para gases.
French
q Débranchez le courant avant l’entre- q N’opérez pas avec les panneaux
q Gardez la tête à l’écart des fumées.
tien. ouverts ou avec les dispositifs de
q Utilisez un ventilateur ou un aspira-
ATTENTION
protection enlevés.
teur pour ôter les fumées des zones
de travail.
ED
German
q Strom vor Wartungsarbeiten q Anlage nie ohne Schutzgehäuse
q Vermeiden Sie das Einatmen von
1 SED
abschalten! (Netzstrom völlig öff- oder Innenschutzverkleidung in
Schweibrauch!
WARNUNG
nen; Maschine anhalten!) Betrieb setzen!
q Sorgen Sie für gute Be- und
Entlüftung des Arbeitsplatzes!
W ER
Portuguese
q Não opere com as tampas removidas. q Mantenha-se afastado das partes
q Mantenha seu rosto da fumaça.
q Desligue a corrente antes de fazer moventes.
q Use ventilação e exhaustão para
ATENÇÃO
IM P
serviço. q Não opere com os paineis abertos
remover fumo da zona respiratória.
q Não toque as partes elétricas nuas. ou guardas removidas.
E SU
S Japanese
SE Y
NT
RA
Chinese
AR
Korean
W
Arabic
LEIA E COMPREENDA AS INSTRUÇÕES DO FABRICANTE PARA ESTE EQUIPAMENTO E AS PARTES DE USO, E SIGA AS
PRÃTICAS DE SEGURANÇA DO EMPREGADOR.
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