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Lincoln Electric INVERTEC V200-T User's Manual
Contents
1. Section D Safety eoe e deu ee eee eee D 1 Input Filter Capacitor Discharge Procedure D 1 Routine Maintenance sienne D 1 Replacement of Internal D 1 Troubleshoolting Me tn Section E Safety Precaution Sisian nimia edat dae in dae a dus E 1 How to Use Troubleshooting Guide E 1 Troubleshooting Guide sus E 2 Wiring Diagrairm 112 croire recen EENS Section F Parts EIGENS P308 1 INSTALLATION 1 TECHNICAL SPECIFICATIONS V200T TIG INPUT SINGLE PHASE ONLY Standard Input Current at Voltage Rated Output 230 460 1 50 60 45 23 A 200 A 33 16 A 150 A 25 13 A 120A RATED OUTPUT Duty Cycle Volts at Rated Amperes 2096 Duty Cycle 6096 Duty Cycle 10096 Duty Cycle OUTPUT Output Current Maximum Open Range Circuit Voltage Type of Output 1 200A 80V 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 Input Fuse Input 75 C Copper Ground Voltage Super Lag Ampere Copper Wire in Wire in Conduit phase or Breaker Rating on Conduit AWG AWG IEC Frequency Size Nameplate IEC Sizes Sizes 230 1 50 60 10 5 2 10 5 2 mm2 460 1 50 60 12 4 12 4 PHYSICAL DIMENSIONS Weight
2. pete ee eee RR EROR n Ede re D peo Se Runden A 1 Select Suitable Locatiorni e Leer pe e A 2 Stackitig vermute nta sn uu E EE A 2 Lifting and MOVING er ehe cn lactea o e cd re Ere deas A 2 erae ede on qme ccm e nre A 2 Environmental Rating dece E eere ie el nee A 2 Machine Grounding and High Frequency Interference Protection A 2 eler Il nee LEE A 3 Input Fuse and Supply Wire sise A 3 Output Connections deed cL pee A 4 ov Elle ese Dm Section B General Description irte ceteros B 1 eere uec Bin RUE B 1 Welding Capability 2 25 epe oer heated ip nae B 1 IE nico EE B 1 Controls and Settings icem ete cde tin ea B 2 Operating Steps ee er emn meia edite B 4 Welding in TIG Mode 2 iiie tec tefte e ete exero ds B 4 Remote Control Operation ss B 4 Welding Stick es B 5 Recommended Electrode and Tungstens B 5 Explanation 2 Step and 4 Step Modes AA B 6 Pulser F riCllorns coe otia Ci Ute en ee LU ta ee pte eter ie B 6 Accessories ns uni nil mien Section C General Options Accessories C 1 TIG Welding Options Accessories C 1 Maintena te
3. 2006 3 N31H3ANI H3MOd 5 4 lt L L l Le A 9 gt a 9 v 18 Aol wl 1 09156 DILVW3HOS 11013 bZIVBSOM l f NHOHS SLNANOdNOD TV LON o9zns Hoovos V 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 LINCOLN 8 308 1 308 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 gt Sub Assembly Item No SUB ASSEMBLY PAGE NAME gt gt PAGE gt 308 General Assembly INVERTEC V 200 T 7 30 97 LINCOLN 308 308 General Assembly INVERTEC V 200 T 11 4 98 LINCOLN 308 1 Indicates change this printing Recommended Spare Part P 308 C 1 U
4. gt 2016 21L VA3H2S 1104 NMOHS SIN3NOdNO2 TIV LON 05196504 0021 ES 2 4 2 2 240 60 6 OU VW3H2S 1114 9 d 0 6 IND NMOHS SIN3NOdWOO TV LON M m ILEGOSOM Ua 126 25 b n 10016 9 TNA 2821 s gr al OOLPOSOM E 052 ts AOEZ i 2 Ol m 9EE CV 9ILVW3H9S 1103 NMOHS 10 0 2 11V LON 5 ai ose 9 60050 A vl 4 9 br 1 INO I6 3H 9 9NI lig e P L Fad v lt gt 2 e iti 9 2 G 4 bE PNI ZNO 173 5 H lt E 5 0 2 09p 19 8 19 6 2 bles 2 4 e 2 2 Q HS O9b 9 6 8 A00S VS O a H 17056 3ILVIN3HOS TINA t 14 J a r NMOHS SIN3NOdAOO TV LON 1 4 ZE2FISOM 6
5. 5 Examine the case for breakage Repair or replace the case as required Keep the case in good condition to ensure that high voltage parts are protected and correct spacings are main tained 6 Install machine covers and fasteners REPLACEMENT OF FUSE INTERNAL The Invertec has additional protection provided to some circuits through an internal fuse For replace ment of that fuse proceed as follows 1 Turn off the power to the unit and remove the input plug 2 Allow the machine to stand for 5 minutes to let the input capacitors discharge 3 Remove the machine cover 4 Replace the blown fuse with a new 0 5A 500V slowblow fuse NOTE If the fuse blows again after power is restored the cause could be an internal breakdown in the power unit In this case take the unit to an authorized Lincoln Field Service Shop INVERTEC V200 T LINCOLN 8 TROUBLESHOOTING 1 HOW TO USE TROUBLESHOOTING GUIDE WARNING Service and Repair should only be performed by Lincoln Electric Factory Trained Personnel Unauthorized repairs performed on this equipment may result in danger to the technician and machine operator and will invalidate your factory warranty For your safety and to avoid Electrical Shock please observe all safety notes and precautions detailed throughout this manual This Troubleshooting Guide is provided to help you locate and repair possible machine malfunctions Simply follow the three step procedu
6. equipment and the consumables to be used including the material safety data sheet MSDS and follow your employer s safety practices MSDS forms are available from your welding distributor or from the manufacturer Also see item 1 b Mar 95 m WELDING SPARKS can 2 75 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 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 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 Do 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 Pip
7. 3 on the adjacent PC board 7 Connect the small lead to terminal 15 of the line Switch 8 Reposition insulation to cover line switch 9 Re install wraparound 10 Move the lock pin to allow switch movement for 230 V selection only Connect the green w yellow strip lead to ground per U S National Electrical Code Connect the black and white leads to power Use reverse procedure to reconnect for 460V Do not connect 460V when the switch is configured for 230V or damage will result Power ON OFF Voltage Selector Switch Located on top right of rear panel 0 460 230 Lock pin in this position allows only 230 V input selection Move to opposite side for 460 V operation Figure A 1 INPUT FUSE AND SUPPLY WIRE Lock pin mounting hole Refer to the Technical Specifications pages at the beginning of this chapter for the proper fuse sizes and supply cable sizes Fuse the input circuit with recommended super lag fuses or delay type circuit breakers Install the proper fuse in the fuse holder in the main disconnect panel OUTPUT CONNECTIONS RECEPTACLE Figure A 2 INVERTEC V200 T LINCOLN 8 4 INSTALLATION 4 OUTPUT CONNECTIONS Refer to Figure A 2 for the location of the output terminals A quick disconnect system using Twist Mate cable plugs is used for the welding cable connections The electrode and work cables will require these plugs Refer to the relevant instructions following for mo
8. Approx 35 lbs 16 kgs 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 LINCOLN 8 2 INSTALLATION Read entire installation section before starting installation Safety Precautions WARNING ELECTRIC SHOCK can kill Only qualified personnel should perform this installation Turn the input power OFF at the disconnect switch or fuse box before working on this equipment 0 Do not touch electrically hot parts Always connect the V200 T to a power sup ply grounded per the National Electrical Code and any local codes SELECT SUITABLE LOCATION The Invertec will operate in harsh environments Even SO it is important that simple preventative measures are followed in order to assure long life and reliable 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 sides will not be restricted Dirt 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 V200 T cannot be stacked LIFTING AND MOVING The Invertec V200 T has a lift handle on the top of the case and also comes with a lift carrying strap for
9. while the engine is running 2 d 3 Do 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 iW Connect the work cable to the workpiece as close as possible to the area being welded 1 0 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 Do not work next to welding power source Mar 95 LINCOLN 8 ELECTRIC SHOCK can kill 3 a The electrode and work or ground circuits are electrically hot when the welder is on Do not touch these hot parts with your bare skin or wet clothing Wear dry hole free gloves to insulate hands 3 b Insulate yourself from work and ground using dry insulation Make certain the insulation is large enough to cover your full area of physical contact with work and ground 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
10. TORCH SWITCH M WELDING CURRENT TORCH SWITCH WELDING CURRENT WITHOUT RESTART WITH RESTART As shipped no jumper CRATER CURRENT INVERTEC V200 T LINCOLN 1 ACCESSORIES C1 OPTIONAL ACCESSORIES K870 Foot Amptrol for TIG welding When the V200 T s Output Control is in the REMOTE position the foot Amptrol energizes the output and controls the output remotely The Foot Amptrol connects directly to the 6 pin Amphenol K812 Hand Amptrol for TIG welding When the V200 T s Output Control is in the Remote position the hand Amptrol energizes the output and controls the output remotely The Hand Amptrol connects 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 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 5ft medium back cap K859 5 LA 9 25 ft medium back cap K860 1 LA 17 12 58 long back cap K860 5 LA 17 258 long back cap K860 9 LA 17V 12 5ft long back cup w gas valve K860 13 LA 17V 258 long back cup w gas valve NOTE Each torch requires a quick connector plug 522529 1
11. Wire Welder DC Manual Stick Welder AC Welder with Reduced Voltage Control In semiautomatic or automatic wire welding the electrode electrode reel welding head nozzle or semiautomatic welding gun are also electrically hot 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 Ground the work or metal to be welded to a good electrical earth ground Maintain the electrode holder work clamp welding cable and welding machine in good safe operating condition Replace damaged insulation Never dip the electrode in water for cooling 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 When working above floor level use a safety belt to protect yourself from a fall should you get a shock Also see Items 6 c and 8 L 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 standards 4 b Use suitable clothing made from durable flame resistant 5 b material to protect your skin and that of your helpers from the arc rays Protect other nearby personnel
12. a Lincoln Foot Amptrol Hand Amptrol or Arc Start Switch See the ACCESSORIES section for available options INVERTEC V200 T LINCOLN B 3 OPERATION B 3 Start Crater Potentiometer This potentiometer is used to adjust the START CURRENT and CRATER CURRENT for TIG welding only This potentiometer also adjusts the ARC FORCE when in STICK welding mode Slope Up and Slope Down Time Potentiometers These potentiometers are used to adjust the Slope Up and Slope Down Times respectively for TIG welding only The adjustable range for both timers is 0 to 10 sec Post Flow Time Potentiometer This potentiometer is used to adjust the gas postflow after the arc is extin guished when using a TIG process The postflow time is 0 50 sec Pulse Frequency TIG Spot Timer Potentiometer This potentiometer is used to adjust the Pulse Frequency when the TIG Process Switch is in the PULSER position and to adjust the TIG Spot Time 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 the inverse of the frequency Increasing the knob cw 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 setting fully ccw or 0 the frequency is at max
13. alati oig Gail agil L LINCOLN B 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
14. amps 8 Depress the Amptrol or Arc Start Switch to energize the torch and establish an an arc with the work piece NOTE When the TIG Process Switch is set to 2S or AS TIG position depressing the remote control will start a 0 5 second gas pre flow before energizing the TIG torch When the remote control is released the TIG torch is de energized and gas flow will continue for the set post flow time 0 50 sec INVERTEC V200 T REMOTE CONTROL OPERATION A Foot Amptrol is optional with the V200 T for remote current control while TIG welding An optional Hand Amptrol may also be used An optional Arc Start Switch may be used to start and stop the weld ing if no remote control of the current is desired Refer to the Accessories section of this manual Both the Hand and Foot Amptrol work in a similar manner For simplicity the following explanation will refer only to Amptrols meaning both Foot and Hand models The term minimum refers to a foot pedal in the up position as it would be with no foot pressure or a Hand Amptrol in the relaxed position with no thumb pressure Maximum refers to a fully depressed Foot Amptrol or a fully extended Hand Amptrol When the welder is in TIG modes activating the Amptrol energizes the electrode terminal and varies the output welding current from its minimum value of 1 amp to the maximum value set by the Current Control on the control panel This helps eliminate accident
15. 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 TIG Torch Parts Kits Parts kits are available for the LA 9 and LA 17 LA 17V TIG torches These kits include back cap collets collet bodies nozzles and tungstens Order KP507 for LA 9 torches Order 508 for LA 17 LA 17V torches See publication E12 150 for parts kits breakdown Cut Length Consumables TIG welding filler metals are available for welding stainless steel mild steel aluminum and copper alloys See publication C9 10 INVERTEC V200 T LINCOLN 8 0 1 MAINTENANCE D 1 SAFETY PRECAUTIONS WARNING ELECTRIC SHOCK can kill Have an electrician install and ser vice this equipment Turn the input power off at the fuse box disconnect supply lines and allow machine to sit for five minutes minimum to allow
16. con vience TILTING Place the machine directly on a secure level surface The machine may topple over if this procedure is not followed ENVIRONMENTAL RATING The machine has a protection rating of IP23 Keep the machine dry when possible Do not place it on wet ground or in puddles A 2 MACHINE GROUNDING AND HIGH FRE QUENCY INTERFERENCE PROTECTION The welder must be grounded See your local and national electrical codes for proper grounding methods The high frequency generator being similar to a radio transmitter can be blamed for radio TV and electron ic equipment interference problems These problems may be the result of radiated interference Proper grounding methods can reduce or eliminate radiated interference Radiated interference can develop in the following four ways 1 Direct interference radiated from the welder 2 Direct interference radiated from the welding leads 3 Direct 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 possible 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 c
17. current to assist ignition of the arc WELDING CAPABILITY The Invertec V200 T is rated at 200 amps 28 volts at 2096 duty cycle on a ten minute basis It is capable of higher duty cycles at lower output currents It is capa ble of 120 amps 25 volts at at 100 duty cycle If the duty cycle is exceeded a thermal protector will shut off the output until the machine cools LIMITATIONS The V200 T is not recommended for pipe thawing The V200 T should not be powered from the auxiliary power supply of an engine welder Special protection circuits may operate causing loss of output INVERTEC V200 T LINCOLN 8 2 CONTROLS AND SETTINGS OPERATION B 2 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 Potentiometer Voltage out of spec Digital Display Overheated LED Gas Available LED Slope Up Time Pot Start Crater Current Pot Welding Process Power LED Slope Down Time Pot L Post Flow Time Pot Pulse Duration Potentiometer Pulse Amplitude Potentiometer Switch Local Remote Switch TIG Process LINCOLN 8 Switch INVER Pulse Frequency TIG Spot Timer V200 T A 02 ER Potentiometer DC Terminal TIG Torch Terminal Power Switch
18. d arc peut tre plus s v re qu un coup de soliel donc REDRESSEUR a Utiliser un bon masque avec un verre filtrant appropri ainsi qu un verre blanc afin de se prot ger les yeux du ray 1 onnement de l arc et des projections quand on soude ou quand on regarde l arc b Porter des v tements convenables afin de prot ger la peau de soudeur et des aides contre le rayonnement de l arc c Prot ger l autre personnel travaillant proximit au soudage l aide d crans appropri s et non inflammables Des gouttes de laitier en fusion sont mises de l arc de soudage Se prot ger avec des v tements de protection libres de l huile tels que les gants en cuir chemise paisse pan talons sans revers et chaussures montantes Toujours porter des lunettes de s curit dans la zone de soudage Utiliser des lunettes avec crans lateraux dans les LINCOLN 8 Relier la terre le chassis du poste conformement au code de l lectricit et aux recommendations du fabricant Le dispositif de montage ou la piece souder doit tre branch une bonne mise la terre Autant que possible l installation et l entretien du poste seront effectu s par un lectricien qualifi Avant de faires des travaux l interieur de poste la debranch er l interrupteur la boite de fusibles Garder tous les couvercles et dispositifs de s ret leur place V V for selecting a QUALITY product by Lincoln Elec
19. la secousse lectrique a Les circuits l lectrode et la pi ce sont sous tension quand la machine souder est en marche Eviter toujours tout contact entre les parties sous tension et la peau nue ou les v tements mouill s Porter des gants secs et sans trous pour isoler les mains Faire tr s attention de bien s isoler de la masse quand on soude dans des endroits humides ou sur un plancher metallique ou des grilles metalliques principalement dans les positions assis ou couch pour lesquelles une grande partie du corps peut tre en contact avec la masse Maintenir le porte lectrode la pince de masse le c ble de soudage et la machine souder en bon et s r tat defonctionnement d Ne jamais plonger le porte lectrode dans l eau pour le refroidir Ne jamais toucher simultan ment les parties sous tension des porte lectrodes connect s deux machines souder parce que la tension entre les deux pinces peut tre le total de la tension vide des deux machines Si on utilise la machine souder comme une source de courant pour soudage semi automatique ces precautions pour le porte lectrode s applicuent aussi au pistolet de soudage 2 Dans le cas de travail au dessus du niveau du sol se prot ger 6 zones l on pique le laitier Eloigner les mat riaux inflammables ou les recouvrir afin de pr venir tout risque d incendie d aux tincelles Quand on ne soude pas poser la pince
20. the power capaci tors to discharge before working inside this equipment Do not touch electrically hot parts INPUT FILTER CAPACITOR DISCHARGE PROCEDURE WARNING The machine has internal capacitors which are charged to a high voltage during power on conditions This voltage is dangerous and must be discharged before the machine can be serviced Discharging is done automatically by the machine each time the power is switched off However you must allow the machine to sit for at least 5 minutes to allow time for the process to take place ROUTINE MAINTENANCE 1 Perform the following preventive maintenance procedures at least once every thousand hours of use It is good practice to keep a preventive main tenance record a record tag attached to the machine works best 2 Remove the machine cover requires a 3 mm hex key after allowing the minimum 5 minute power off requirement to let the input capacitors dis charge 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 Printed circuit boards Power switch Fan blades Louvers e Heat sink fins Output terminals 4 Examine capacitors for leakage or oozing If any leakage is noticed take the unit to an authorized Lincoln Field Service Shop
21. 05 33 1 X 35 Name Plate 524105 35 1 X 36 Lincoln Electric Decal 524105 36 2 X 37 Input Connection Decal 524105 37 1 X 38 Rating Plate 524105 38 1 X 39 Gas Input Decal 524105 39 1 X 44 1 Year Warranty Decal 22127 1 1 X 45 Electric Shock Warning Decal 19338 1 X 46 Grounding Warning Decal T13259 1 X 51 Fuse 0 5A 500 Volt Slow Blow 524105 43 1 X Items Not Shown Quick Connect Plug 522529 1 1 X Strain Relief Boot M17255 1 X Twist Mate Connector M15479 1 X INVERTEC V 200 T 11 4 98 LINCOLN NOTES INVERTEC V 200 T LINCOLN B Now Available 12th Edition The Procedure Handbook of Arc Welding With over 500 000 copies of previous editions published since 1933 the Procedure Handbook is considered by many to be the Bible of the arc welding industry This printing will go fast so don t delay Place your order now using the coupon below The hardbound book contains over 750 pages of welding information techniques and procedures Much of this material has never been included in any other book A must for all welders supervisors engineers and designers Many welding instructors will want to use the book as a reference for all students by taking advantage of the low quantity discount prices which include shipping by 4th class parcel post 15 00 postage paid U S A Mainland How To Read Shop Drawings The book contains the latest information and application data on the American Welding Society Standard Welding S
22. ES 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 UNFALLVERHUTUNGSVORSCHRIFTEN DES ARBEITGEBERS SIND EBENFALLS ZU BEACHTEN Keep your head out of fumes Use ventilation or exhaust to remove fumes from breathing zone Los humos fuera de la zona de res piraci n Mantenga la cabeza fuera de los humos Utilice ventilaci n o aspiraci n para gases Gardez la t te l cart des fum es Utilisez un ventilateur ou un aspira teur pour ter les fum es des zones de travail Vermeiden Sie das Einatmen von Schweibrauch Sorgen Sie f r gute Be und Entl ftung des Arbeitsplatzes Mantenha seu rosto da fumaca Use ventilac o e exhaust o para remover fumo da zona respirat ria 9 fsPBHEICTASESUCFEU SH7IAE S XACE E AAS AH 71 97471 587E ASIA oe lue Gal bacs ja d Aach Mall oe Turn power off before servicing Desconectar el cable de ali mentaci n de poder de la m quina antes de iniciar cualquier servicio D branchez le courant avant l entre tien Strom vor Wartungsarbeiten abschalten Netzs
23. Gas Flow Rate C F H I 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 PUG EWP green 1 Thoria EWTh 1 yellow 2 Thoria EWTh 2 red 2 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 296 Thoriated Tungsten in AC and DC applications INVERTEC V200 T Sept97 LINCOLN 6 OPERATION B 6 EXPLANATION OF 2 STEP AND 4 STEP MODES See figure B 2 and the explanations that follow 2 STEP 2 Step mode can be used with either an arc start switch or a hand or foot amptrol The welding cycle begins when the torch switch is held closed and ends when the switch is released 4 STEP 4 Step mode should only be used with an arc start switch The welding cycle begins when the torch switch is pressed and then released The cycle is ended by a further press and release of the switch The pre gas flow is followed by an increase in the we
24. IM592 INVERTEC V2UU T Nov 19 For use with machines having Code Numbers 10463 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 This manual covers equipment which is obsolete and no longer in production by The Lincoln Electric Co Specifications and availability of optional features may have changed OPERATOR S MANUAL LINCOLN ELECTRIC 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 SAFETY Lif WARNING CALIFORNIA PROPOSITION 65 WARNINGS Diesel engine exhaust and some of its constituents The engine exhaust from this product contains are known to the State of California to cause can chemicals known to the State of California to cause cer birth defects and other reproductive harm cancer birth defects or other reproductive harm The Above For Diesel Engines The Above For Gasoline Engines ARC WELDING CAN BE HAZA
25. Local 4 Place the electrode in the electrode holder 5 Turn the Power Switch to the proper input voltage setting to turn on the welder WARNING ES o In Stick Mode the output terminal and electrode will be electrically hot when ever the power switch is turned on 6 Adjust the Current Control to the desired amps 7 Strike an arc and weld NOTE When the Welding Process Switch is set to STICK the output is always on when the power switch is remote control has no effect on the 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 Fleetweld 47 DC 75 95 100 145 135 Jet LH MR DC 85 110 110 160 130 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
26. RDOUS 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 amp 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 powered equipment 1 Turn the engine off before troubleshooting and maintenance work unless the maintenance work requires it to be running SX 1 h To avoid scalding do not remove the radiator pressure cap when the engine is hot 1 b Operate engines in open well ventilated areas or vent the engine exhaust fumes outdoors ELECTRIC AND 3 MAGNETIC FIELDS 1 c Do not add the fuel near an open welding arc or when the engine is running Stop the engine and allow it to cool before refueling to prevent spilled fuel from vaporiz ing on contact with hot engine parts and igniting Do not spill fuel when fil
27. Voltage Selector Switch Controls the power input to the machine This rotating switch is used to turn the machine on and off as well as to select the input voltage The switch is located on the top right rear panel When power is applied to the machine the Power LED is on Welding Current Potentiometer Potentiometer used to set the value of the current required by the welding process This current setting will be displayed on the Digital Display When an Amptrol is used to remotely control the welding current this setting con trols the maximum welding current when the Amptrol is fully depressed 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 Remote Control Connector DC Terminal Output Terminals These quick disconnect terminals provide connection points for the TIG Torch and work cables or electrode and work cables For TIG welding connect the torch to the DC terminal and the work cable to the DC terminal For stick welding positive polarity connect the electrode cable to the positive ter minal and the work cable to the negative terminal To weld negative polarity reverse the electrode and work cables Remote Control Connector This receptacle will accept
28. WELDING CABLE 50 in max 12 mm max 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 SCREW ps 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 INSTALLATION SHIELDING GAS CONNECTION An adjustable gas pressure regulator and flow gage should be obtained Obtain the necessary inert shield ing gas usually argon Connect the cylinder of gas with the pressure regulator and flow gage Install the gas hose between the regulator and gas inlet located on the low left rear of the welder The gas inlet has a 5 16 18 right hand female thread CGA 032 WARNING CYLINDER could explode if damaged 3 Keep cylinder upright and chained to a support Keep cylinder away from areas where it could be damaged Never allow the torch to touch the cylinder Keep cylinder away from live electrical circuits Maximum inlet pressure 150 psi 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 avai
29. al high current damage to the work piece and or tung sten and gives a fine control of the current When the welder is in the stick mode a remote control has no effect and is not used It is important to note that in some cases the tung sten will not start an arc at the minimum current because the tungsten may be too large or cold To start an arc reliably it is important to depress the Amptrol far enough so that the machine output current is near the tungsten operating range For example a 3 32 tungsten may be used on DC to weld the full range To start the weld the operator may have to turn the current control up and depress the Amptrol approximately 1 4 of the way down Releasing the Amptrol to its minimum position may not start the arc Also if the current control is set too low the arc may not start 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 97 LINCOLN 5 OPERATION B 5 WELDING IN STICK MODE 1 Put the electrode holder and cable quick connect plug into the proper receptacle for the electrode polarity desired Turn clockwise until tight Connect the work clamp to the other receptacle and the work piece 2 Set the Welding Process Switch to STICK 3 Set the Local Remote Switch to
30. ally not suit able 8 When the welder is enclosed in a metal building the metal building should be connected to several 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 equipment interference problems and result in unsat isfactory welding performance resulting from lost high frequency power INPUT CONNECTIONS Be sure the voltage phase and frequency of the input power is as specified on the rating plate located on the rear of the machine Supply line entry provision is in the case rear panel A power cord is provided and wired into the machine Follow the power cord connection instructions Incorrect connection may result in equipment damage The Invertec V200 T is internally connected for a 460 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 der strap brackets and wraparound screws A 3 3 Provide access to the line switch by bending the insulation back 4 When the insulation is bent back two sleeved leads will become visible 5 Remove the sleeving from both leads 6 Connect the large lead to push on terminal labeled
31. ase 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 possible and as close together as possible Lengths should not exceed 25 ft 7 6m Tape the leads together when practical 3 Be sure the torch and work cable rubber coverings are free of cuts and cracks that allow high frequen leakage 4 Keep the torch in good repair and all connections tight to reduce high frequency leakage 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 LINCOLN 8 A 3 INSTALLATION 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 ground ing 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 radiation effectively making these members radiating antennas 6 Keep cover and all screws securely in place 7 Electrical conductors within 50 ft 15 2m of the welder should be enclosed in grounded rigid metal lic conduit or equivalent shielding wherever possi ble Flexible metallic conduit is gener
32. ers of 50 00 or more for shipment at one time to one location lorders of 50 or less before discount or orders outside of North America must be prepaid with charge check or money order in U S Funds Only l include shipment by 4th Class Book Rate for U S A Mainland Only Please allow up to 4 weeks for delivery IUPS Shipping for North America Only All prepaid orders that request UPS shipment please add 55 00 For order value up to 49 99 10 00 For order value between 50 00 amp 99 99 15 00 For order value between 100 00 amp 149 00 For North America invoiced orders over 50 00 amp credit card orders if UPS is requested it will be invoiced or charged to you at cost Outside U S A Mainland order must be prepaid in U S Funds Please add 2 00 per book for surface mail or 15 00 per book for air parcel post shipment METHOD OF PAYMENT Sorry No C O D Orders CHECK ONE Please Invoice only if order is over 50 00 Check or Money Order Enclosed U S Funds only 1 Credit Card n account ep oae LL Le THIS FORM TO ORDER Order from looks OR FREE INFORMATIVE CATALOGS li incon Welding School 80 New Lessons in Arc Welding Seminar Information ED 45 How to Read Shop Drawings 450 H Educational Video Information ____ Tncenive Management 500 pirum New Approach to industrial Econom
33. ics 500 NA f luames F Lincoln Arc Welding American Century of John C Lincoln 5 00 Foundation Book Information Welding Preheat Calculator JFLF 515 Pipe Welding Charts Additional Shipping Costs ora cost BOOK DIVISION The Lincoln Electric Company 22801 St Clair Avenue Cleveland Ohio 44117 1199 Telephone 216 383 2211 or for fastest service FAX this completed form to 216 361 5901 Tiles Code Quantity Cost L NENNEN 51500 PH Procedure Handbook Twelfth Edition Name Address Telephone Signature as it appears on Charge Card LS ee ee WARNING Spanish AVISO DE PRECAUCION French ATTENTION German WARNUNG Portuguese Japanese ER BIR Korean Do not touch electrically live parts or electrode with skin or wet clothing Insulate yourself from work and ground No toque las partes los electrodos bajo carga con la piel moja da Aislese del trabajo y de la tierra Ne laissez ni la peau ni des v te ments mouill s entrer en contact avec des pi ces sous tension Isolez vous du travail et de la terre Ber hren Sie keine stromf hrenden Teile oder Elektroden mit Ihrem K rper oder feuchter Kleidung Isolieren Sie sich von den Elektroden und dem Erdboden N o toque partes el tricas e elec trodos com a pele ou roupa m
34. imum 300 Hz The spot time range is adjustable up to 10 sec 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 TIG Process Switch This switch is used to select the type of TIG process to be performed In the PULSER position Pulsed TIG welding in the OFF position continuous TIG welding and in the TIG SPOT position spot TIG welding Welding Process Switch This switch is used to select the type of welding process to be performed In the 2S position Two step TIG welding in the 4S position 4 step TIG welding and in the STICK posi tion Stick welding See the section on 2 step and 4 step explanation later in this section LOCAL REMOTE Switch This switch is used to select where current can be adjusted In the LOCAL position current is controlled by the Welding Current Potentiometer In the REMOTE position any hand or foot amptrol connected to the Rem
35. ing That Have Held Hazardous Substances AWS F4 1 from the American Welding Society see address above Vent hollow castings or containers before heating cutting or welding They may explode 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 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 cir cuits This can create fire hazards or overheat lifting chains or cables until they fail 6 h Also see item 1 c LINCOLN 8 CYLINDER may explode eo NA x 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 Always keep cylinders in an upright position securely chained to an undercarriage or fixed support Oylinders should be located Away from areas where they may be struck or subjected to
36. lable remote controls INVERTEC V200 T LINCOLN 8 B 1 OPERATION 1 Read and understand this entire section before operating your machine SAFETY INSTRUCTIONS WARNING ELECTRIC SHOCK can kill Do not touch electrically live parts such as output terminals or internal wiring Insulate yourself from the work and ground Always wear dry insulating gloves FUMES AND GASES 9 can be dangerous DA Keep your head out of fumes Use ventilation or exhaust to remove fumes from breathing zone NE 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 ARC RAYS can burn L Wear eye ear and body protection Only qualified personnel should operate this equip ment Observe all safety information throughout this manual GENERAL DESCRIPTION The Invertec V200 T 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 optimized for stick SMAW and TIG GTAW The unit is ideal for industrial applications where portability is impor tant OPERATIONAL FEATURES The Invertec provides continuous total range output current adjustment Additionally a hot start system has been built into the welding current control and provides a higher striking
37. lding current from the level set by the Start Crater Current Potentiometer to the value on the display set with the Welding Current Potentiometer The rate of increase is determined by the setting of the Slope Up Time Potentiometer 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 During this phase the welding current falls to the crater current set on the Start Crater Current Potentiometer The speed at which the welding cur rent decreases is determined by the setting of the Slope Down Time Potentiometer The power source comes equipped with a restart capability Any change required in the restart timing can only be made by an authorized service center See Figure B 2 4 Step Mode In the TIG SPOT mode the UP DOWN SLOPE con 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 nominal value PULSER FUNCTION Pulsed welding is selected by using the TIG Process Switch In this mode the output is modulated to pro duce a series of current pulses By this means pre cise control of heat input and penetration can be achieved on critical applications The pulse frequency duration and amplitude may be adjusted by means of the respective potentiometers FIGURE B 2 2 Step and 4 Step Modes 2 STEP MODE TORCH WELDING CURRENT 4 STEP MODE
38. ling tank If fuel is spilled wipe it up and do not start engine until fumes have been eliminated 2 Electric current flowing through any conductor causes localized Electric and Magnetic Fields EMF Welding current creates EMF fields around welding cables and welding machines EMF fields may interfere with some pacemakers and welders having a pacemaker should consult their physician before welding 1 d Keep all equipment safety guards covers and devices in position 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 Exposure to EMF fields in welding may have other health effects which are now not known All welders should use the following procedures in order to minimize exposure to EMF fields from the welding circuit 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 2 d 1 Route the electrode and work cables together Secure them with tape when possible 2 4 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 idler by pushing on the throttle control rods
39. olha da Isole se da pe a e terra ORBPOBARA ELE het EE LATE OHLMPT APYORAPHRBS NTWSHRELTFSU e RREAN 945 CE EC SUE d TH ecran a sis HIE amp Ju Gu gone uil oh ye puni AI gh la pally All apad Jai DA dua aa e Keep flammable materials away Mantenga el material combustible fuera del area de trabajo Gardez l cart de tout mat riel inflammable Entfernen Sie brennbarres Material Mantenha inflam veis bem guarda dos e naedoe6008 THEN EA e i ML Aal uie s ALD a pis Wear eye ear and body protection Prot jase los ojos los o dos y el cuerpo Prot gez vos yeux vos oreilles et votre corps Tragen Sie Augen Ohren und K r perschutz Use prote o para a vista ouvido corpo HRUBS ISUCRSREUCT RRR ez 12 Sal amp s ESSA due lan cl ysl gua e A dang 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 L
40. ote Control Connector will control the current setting In both modes however the current potentiometer on the case front sets the maximum welding current avail able Gas Available LED This LED will light when gas is available in the TIG welding modes only Power LED Indicates inverter is ON After 5 minutes without use the inverter will go into a sleep mode and the LED will go off Any activity on the output will immediately Wake the inverter up the LED will come back on and normal operation will resume INVERTEC V200 T LINCOLN B 4 OPERATION B 4 OPERATING STEPS WELDING IN TIG MODE 1 Connect the TIG torch and cable quick connect plug to the DC output receptacle This receptacle also contains an integral gas connection for the torch Connect the work cable to the DC recepta cle and to the work piece 2 Set the Welding Process Switch to 2S when using a hand or foot amptrol When using an arc start switch 2S or 4S can be used 3 Set the TIG Process Switch to the desired posi tion 4 Connect an optional Amptrol or Arc Start Switch to the Remote Control Connector 5 Turn on the cylinder gas valve and adjust the flow regulator to obtain desired flow 6 Turn the power switch to 230 or 460 as appropri ate for your input voltage NOTE There will be a 0 5 second gas flow when the power is turned on 7 Set the Current Control on the control panel to the maximum desired
41. physical damage safe distance from arc welding or cutting operations and any other source of heat sparks or flame Never allow the electrode electrode holder or any other electrically hot parts to touch a cylinder Keep your head and face away from the cylinder valve outlet when opening the cylinder valve Valve protection caps should always be in place and hand tight except when the cylinder is in use or connected for use Read and follow the instructions on compressed gas cylinders associated equipment and CGA publication 1 Precautions for Safe Handling of Compressed Gases in Oylinders available from the Compressed Gas Association 1235 Jefferson Davis Highway Arlington VA 22202 FOR ELECTRICALLY powered equipment 8 a Turn off input power using the disconnect switch at the fuse box before working on the equipment Install equipment in accordance with the U S National Electrical Code all local codes and the manufacturer s recommendations Ground the equipment in accordance with the U S National Electrical Code and the manufacturer s recommendations Mar 95 PR CAUTIONS DE S RET Pour votre propre protection lire et observer toutes les instructions et les pr cautions de s ret specifiques qui parraissent dans ce manuel aussi bien que les pr cautions de s ret g n rales suiv antes S ret Pour Soudage A L Arc 1 Protegez vous contre
42. re information on connecting the machine for either welding process OUTPUT CONNECTION FOR STICK WELDING First determine the proper electrode polarity for the elec trode to be used Consult the electrode data for this infor mation Then connect the output cables to the output termi nals corresponding to this polarity For instance for DC 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 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 TIG ADAPTER RETAINING COMPOUND Tu
43. re listed below Step 1 LOCATE PROBLEM SYMPTOM Look under the column labeled PROBLEM SYMPTOMS This column describes possible symptoms that the machine may exhibit Find the listing that best describes the symptom that the machine is exhibiting Step 2 POSSIBLE CAUSE The second column labeled POSSIBLE CAUSE lists the obvious external possibili ties that may contribute to the machine symptom Step 3 RECOMMENDED COURSE OF ACTION This column provides a course of action for the Possible Cause generally it states to contact you local Lincoln Authorized Field Service Facility If you do not understand or are unable to perform the Recommended Course of Action safely contact you local 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 LINCOLN 8 2 TROUBLESHOOTING E 2 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 The input power switch must be no fan in the ON position Make sure the input voltage is correct for the machine Check continuity of the 0 5 amp slow blow fuse located on the P C Board No outpu
44. rn 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 quick connect terminal and also provides the gas connection for the shielding gas to the torch WARNING To avoid receiving a high frequency shock keep the TIG torch and cables in good condition Next connect the work cable which is connected to the work clamp to the output terminal in the same way The machine can easily be switched between stick and TIG welding at any time by simply swapping the stick electrode and TIG torch cables and reversing the connection polari ty if required INVERTEC V200 T LINCOLN 5 QUICK DISCONNECT PLUG FOR WORK CABLE A quick disconnect system is used for the welding cable connections The electrode and work cables need to have a plug attached 1 Cut off welding cable lug if present 2 Remove 75 in 19mm of welding cable insulation 3 Slide rubber boot onto cable end The boot end may be trimmed to match the cable diameter Use soap or other nonpetroleum based lubricant to help slide the boot over the cable if needed BOOT WELDING CABLE y EN 75 19 TRIM IF REQ D TO FIT OVER CABLE 4 Cut 45 5096 of the copper strands back 1 4 6 mm WELDING CABLE EMT 6mm 5 Fold copper strands over cut strands and insert into ferrule COPPER FERRULE
45. se only the parts marked x in the column under the heading number called for in the model index page ITEM DESCRIPTION PART NO 1 2 13141516 7 8 9 1 Solenoid Valve 524105 1 1 X 2 91 High Frequency PCB Adjusted 0 3mm 524105 2 1 X Not Shown 3 High Frequency Transformer 524105 3 1 X 4 50 OHM 80 W Resistor Faston Terminal 524105 4 2 X 5 Plastic Knob 524105 5 1 X 6 _ 6 to 4mm Knob Adapter 524105 6 7 X 7 Plastic Knob 524105 7 7 X 8 Control Panel 524105 8 1 X 9 Ventilation Grating Black 524105 9 1 X 10 Line Switch 24105 10 1 X 11 Bottom Panel 524105 11 1 X 12 Input PCB 524105 12 1 X 13 Allen Key Screw 24105 13 4 X 14 Output Assembly 524105 14 1 X 15 Shoulder Strap 524105 15 1 X 16 Handle S24105 16 1 X 17 Control PCB Tested amp Adjusted 524105 17 1 X 18 Output Transformer 524105 18 1 X 19 Inverter Tested amp Adjusted 524105 19 1 X 20 Fan 524104 15 1 X 21 Remote Connector amp PCB 524105 21 1 X 22 Output Connector W Gas M13896 7 1 X 23 Output Connector M13896 3 1 X 24 Plastic Support 524105 24 1 X 25 Supply Cord 524105 25 1 X 26 Rear Gas Connector 524105 26 1 X 27 Supply Cord Strain Relief 524103 12 1 X 28 Aluminum Cover Red 524105 28 1 X 29 Rear Panel 524105 29 1 X 30 Front Panel 524105 30 1 X 31 Output Choke S24105 31 1 X 32 High Frequency Filter PCB 524105 32 1 X 33 5241
46. t but the fan operates nor The machine may be overheated Ur all recommended possible areas of mally Check the thermal indicator light misadjustment have been checked Wait for the machine to cool and and the problem persists Contact the thermostats to reset your local Lincoln Authorized Field Service Facility Output turns on momentarily then Check the input voltage Make switches off sure the input voltage is correct for the machine No output Main input fuses open Inspect input leads for possible indicating excessive current draw shorts or grounds or mis connec tions 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 LINCOLN 8 1 LL DIAGRAMS 9868 HIN juauudmbs eui SAID PAWL e 3u8uniedog MNS an a QUM si Weep oun sieued amnsopu Jo euo uo eux opoo 5 SUL jenueuu sm parao je egein25e eq OU y Ajo 40 SI SUL 310N 86 1 lt 8 1 002 93183ANI
47. tric We want you hank You to take pride in operating this Lincoln Electric Company product 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 amp Number Code amp 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 TABLE CONTENTS Page E UE DT REM Section A Technical Specifications
48. trom v llig nen Maschine anhalten N o opere com as tampas removidas Desligue a corrente antes de fazer servico N o toque as partes el tricas nuas e EFFERRI vF e AHS pha NM ee ale Do operate with panel open or guards off No operar con panel abierto o guardas quitadas N op rez pas avec les panneaux ouverts ou avec les dispositifs de protection enlev s Anlage nie ohne Schutzgeh use oder Innenschutzverkleidung in Betrieb setzen Mantenha se afastado das partes moventes opere com os paineis abertos ou guardas removidas CRRRIARRARS SHR Ro emago Yel cuts Vil lu Qai ye Aale Al ll WARNING Spanish AVISO DE PRECAUCION French ATTENTION German WARNUNG Portuguese ATENCAO Japanese ZS BR LEIA E COMPREENDA AS INSTRUC ES DO FABRICANTE PARA ESTE EQUIPAMENTO E AS PARTES DE USO E SIGA AS PRATICAS DE SEGURANCA DO EMPREGADOR SRM OBHOX HD OHBRBEE lt K MA ETISRUCESU CL TRHORERE HS DD REAR RRA BA CLR FERAE SR SP ETT EUR 59 OR Ss ool SAD A Seil oz ZFM BEHE veel d illai d AAL
49. une endroit isol de la masse Un court circuit accidental peut provoquer un chauffement et un risque d incendie S assurer que la masse est connect e le plus pr s 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 loign s de la zone de travail on augmente le risque de voir passer le courant de soudage par les chaines de lev age c bles de grue ou autres circuits Cela peut provoquer des risques d incendie ou d echauffement des chaines et des c bles jusqu ce qu ils se rompent Assurer une ventilation suffisante dans la zone de soudage Ceci est particuli rement important pour le soudage de t les galvanis es plomb es ou cadmi es ou tout autre m tal qui produit des fume s toxiques Ne pas souder en pr sence de vapeurs de chlore provenant d op rations de d graissage nettoyage ou pistolage La chaleur ou les rayons de l arc peuvent r agir avec les vapeurs du solvant pour produire du phosg ne gas fortement toxique ou autres produits irritants Pour obtenir de plus amples renseignements sur la s ret voir le code Code for safety in welding and cutting CSA Standard W 117 2 1974 contre les chutes dans le cas ou on recoit un choc Ne jamais PR CAUTIONS DE 0 RET POUR enrouler le c ble lectrode autour de n importe quelle partie du corps LES MACHINES SOUDER TRANSFORMATEUR ET Un coup
50. 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 9 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 below Threshold Limit Values TLV using local exhaust or mechanical ventilation In confined spaces or in some circumstances outdoors a respirator may be required Additional precautions are also required when welding on galvanized steel Do 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 products be LINCOLN 8 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 Read and understand the manufacturer s instructions for this
51. ymbols Detailed discussion tells how engineers and draftsmen use the short cut language of symbols to pass on assembly and welding information to shop personnel Practical exercises and examples develop the reader s ability to visualize mechanically drawn objects as they will appear in their assembled form 187 pages with more than 100 illustrations Size 8 1 2 x 11 Durable cloth covered board binding 4 50 postage paid U S A Mainland New Lessons in Arc Welding Lessons simply written cover manipulatory techniques machine and electrode characteristics related subjects such as distortion and supplemental information on arc welding applications speeds and costs Practice materials exercises questions and answers are suggested for each lesson 528 pages well illustrated 6 x 9 size bound in simulated gold embossed leather 5 00 postage paid U S A Mainland Need Welding Training The Lincoln Electric Company operates the oldest and most respected Arc Welding School in the United States at its corporate headquarters in Cleveland Ohio Over 100 000 stu dents have graduated Tuition is low and the training is hands on For details write Lincoln Welding School 22801 St Clair Ave Cleveland Ohio 44117 1199 and ask for bulletin ED 80 or call 216 383 2259 and ask for the Welding School Registrar Lincoln Welding School BASIC COURSE 5 weeks of fundamentals 700 00 There is a 10 discount on all ord
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