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Lincoln Electric INVERTEC SVM161-A User's Manual

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1. E 3 Main Transformer i essei x etx eb eee Ea Ge He eee geen BG E 4 Output Module and Clamping Board E 4 Output Module Transistor Board E 4 Superimposition Board E 4 p Control Display Board s teaei E 5 High Frequency Board 1 E 5 2 Output Fiter Boa tee Rex RE E 5 5 Insulated Gate Bipolar Transistor IGBT Operation E 6 FIGURE E 1 V205 T BLOCK LOGIC DIAGRAM board Bus board A AC DC Gate drive signals D Fl gt ol s 8 3 8 gt 8 2 Z 3 3 9 8 5 2 bypass 5 2 g S 55 D Main IGBT amp Power board EEN NERES i DC blocki 7 2 5 5 B D m x 2 S E zz Main Output Output Device 9 E 5 5 gj a Transformer board Transistor S e E 5 5 5 o 5 24 VDC Remote 2 4 path D E HF control signal 888 48 24 Control board Display amp LED T board 2 Remote 2 4 1
2. OUTPUT DIODES TO REPLACE ANY OF THE OUTPUT DIODES D1 D2 D3 OR D4 1 Remove input power to the V205 T 9 Apply a thin layer of heatsink compound to the 2 Using a phillips head screwdriver remove the areas of contact on the new diode s case wraparound cover 10 Replace the two output diode mounting screws 3 Perform the Input Filter Capacitor Discharge previously removed Procedure detailed earlier in this section 11 Replace the copper bus bars to their proper 4 Locate the output diodes See Figure F 35 locations 5 Using a phillips head screwdriver remove the 12 Mount the P C board previously removed P C board mounting screws 13 Replace the case wraparound cover 6 Using a phillips head screwdriver and or a 7mm wrench remove the copper bus bars from the diode module that is to be replaced 7 Using a phillips head screwdriver remove the two mounting screws from the output diode 8 Remove and replace the output diode INVERTEC V205 T AC DC LINCOLN B Return to Section TOC Return to Master TOC Return to Section TOC eio OJO f i 5 amp c Return to Section TOC Return to Master TOC Return to Master TOC F 67 TROUBLESHOOTING AND REPAIR OUTPUT TRANSISTOR REMOVAL AND REPLACEMENT A WARNING Service and repair should be performed only by Lincoln Electric factory trained
3. 48 Return to Section TOC Return to Master TOC INVERTEC V205 T AC DC LINCOLN B Return to Section TOC Return to Master TOC Return to Section TOC eio OJO E f i 091 3 c 5 amp c Return to Section TOC Return to Master TOC Return to Master TOC F 31 TROUBLESHOOTING AND REPAIR MAIN INVERTER BOARD POWER FACTOR SECTION TEST A WARNING Service and repair should be performed only by Lincoln Electric factory trained personnel Unauthorized repairs performed on this equipment may result in danger to the technician or 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 If for any reason you do not understand the test procedures or are unable to perform the test repairs safely contact the Lincoln Electric Service Department for electrical trou bleshooting assistance before you proceed Call 1 888 935 3877 TEST DESCRIPTION This procedure will help determine if the Power Factor section on the Main Board is func tioning properly MATERIALS NEEDED Volt Ohmmeter Phillips Head Screwdriver Wiring Diagram INVERTEC V205 T AC DC LINCOLN B F 31 ii TROUBLESHOOTING AND REPAIR diia MAIN INVERTER BOARD POWER FACTOR SECTION TEST continued FIGURE 14 LOCATION ON MAIN BOARD
4. 5 oD amp c Return to Section TOC Return to Master TOC Return to Master TOC po TROUBLESHOOTING AND REPAIR Observe Safety Guidelines detailed in the beginning of this manual PROBLEMS POSSIBLE AREAS OF RECOMMENDED SYMPTOMS MISADJUSTMENT S COURSE OF ACTION WELDING PROBLEMS The machine does not have weld 1 Make sure the machine is prop 1 Check for output voltage feed ing output in the Stick mode Zero erly set up and configured for back from the Output Filter volts open circuit voltage The Stick mode Board See the Output LED on the control panel is blinking machine operates correctly in the TIG mode 2 Check for output voltage feed back through the Bus Board See the Bus Board Test 3 The Control Display Board may be faulty The machine does not have welding 1 Make sure the correct input volt 1 The output rectifier may be output in either the Stick or TIG age is applied to the machine faulty Check and replace if nec modes Zero volts open circuit 230 or 115VAC essary the The Output LED on the control panel is blinking and Wiring Diagram 2 The Output Clamp Board may be faulty 3 The Output Module Transistor Board may be faulty See the Secondary Output Board Assembly Test and Wiring Diagram 4 Perform the Main IGBT Inverter Board Welding Logic and Inverter Test 5 The Superimposition Board may be faulty 6 T
5. X Tungsten electrodes are classified as follows by the American Welding Society AWS 2 Thoria EWTh 2 red 31 596 Lanthana EWLa 1 black INVERTEC V205 T AC DC LINCOLN B Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC eio OJO f i olg gt 5 amp Return to Section TOC Return to Master TOC B 11 B 11 OPERATION PROTECTIVE GAS Both argon and helium work when welding aluminum Argon is preferred due to its lower cost and consump tion rate This gas also tends to stabilize the arc thus making it easy to operate For some applications how ever the use of helium or argon helium blends is rec ommended due to better weld penetration and faster travel speed Helium is especially suitable for welding thick workpieces The recommended gas flow rates are shown in table 5 TABLE 5 Current A Helium cfh min 50 29 14 100 29 14 150 42 20 200 42 20 250 53 25 300 53 25 AC TIG WELDING QUICK START UP A WARNING Q ELECTRIC SHOCK can kill Have an electrician install and service this equipment Turn the input power off at the fuse box dis connect or unplug supply lines and allow machine to sit for five minutes minimum to allow the power capacitors to discharge before working inside this equipment
6. f gt Of dc 5 oD amp c Return to Section TOC Return to Master TOC B9 OPERATION DC Electrode Positive Polarity Direct Current Reverse Polarity see Figure B 5 In this case there is a continuous flow of electrons from the workpiece to the electrode The reverse polar ity is used for welding alloys covered with a layer of refractory oxide With this polarity the electrode functions as anode and is subjected to a high degree of heat the workpiece is bombardment by positive ions sent from the electrode which break the surface oxide In Electrode Positive Polarity high currents cannot be used since they would cause an excessive wear of the electrode NOTE The Invertec V205 T AC DC cannot be used for Electrode Positive TIG welding without special adapters FIGURE B 5 1 D C Pulsed TIG see Figure B 6 The use of pulsed direct current allows better control of the weld pool during certain operating conditions When compared with traditional TIG welding per formed at the same average current pulsed welding results in a smaller heat affected zone which results in fewer deformations and reduced chance of cracking and gas entrapment Increasing the frequency constricts the arc increases stability and improves weld quality FIGURE B 6 DC TIG NOT PULSED t DC PULSED TIG M A
7. LINCOLN B F TABLE OF CONTENTS TROUBLESHOOTING AND REPAIR F o o Troubleshooting and Repair F 1 gt g 5 How to Use Troubleshooting Guide F 2 a PC Board Troubleshooting Procedures and Replacement F 3 Troubleshooting Guide F 4 F 8 Test Procedures External and Internal 1 4 1 F 9 F 11 Input Filter Capacitor Discharge Procedure 13 Input Filter Board Test renei ed beue Up 15 8 Main IGBT Inverter Board Low Voltage F 19 E Control Display Board Test 4 F 23 3 E Bus Board Test ree Rana ene baad EXER F 27 Main Inverter Board Power Factor F 31 Output Filter Board Test 35 Secondary Output Board Assembly Test F 39 Main Inverter Board Welding Logic And Inverter
8. tc gt DOL 01 DOL 01 DOL DOL DOL uonoeg DOL 5 DOL 5 DOL 5 Return to Master Return to Master TOC o 5 o 2 t Return to Master TOC B TABLE OF CONTENTS OPERATION SECTION Operation EUN SII DE UE AE i SIUE B 1 Safety Instictions iu soe eere ber eris ewe apes ooo Qa ve B 2 General Description e uc da B 2 Welding Capability VER ae PES B 2 Munus B 2 Rear Control Paneles seira Eden rede eee Bier 3 Controls Settings 2 eee dad COE REOR EO Pec ne dor dal 4 Set Up essere ip Er ______ __ _____________ B 7 Output Eimitations 2 no x ick EE wea gee B 8 DC TIG Welding bees ERR Query cbr eee dd a B 8 Welding Polary EA a dp d Ea PRU B 8 Steel TIG Welding ciu seine B 10 Copper TIG Welding mex rx eek Ron Rx ee and pela uu We E hd B 10 Tips for AC TIG We
9. ui MAINTENANCE 3 o z lt o 9 E O14 Z 2 4 lt 9 Ie 25 T o gt 5 Fc zio a gt lt lt E tc zt d 5 8 Wy tc n lt 22 o 6 ve 2 gt gt gt a 2 5 g E L T o 0 o L 1 6 od 555 o c Saf e 99 o a F DOL 01 DOL 01 DOL DOL Jelsey ODOL uonoeg oi ODOL uonoeg ODOL 5 ODOL 5 D 4 E O 4 o E o Rio O E 9 tc gt z bi DOL 01 DOL 01 DOL DOL DOL uonoeg DOL 5 DOL 5 DOL 5 E TABLE OF CONTENTS THEORY OF OPERATION SECTION o Theory of Operation 22222525555 quu QNEM e xu 1 gt General Description spp RR EUER ERU ex DOT I d E 2 2 5 Input Board and Bus Board E 2 Main IGBT Inverter Board 2 2 22 4
10. Do not touch electrically hot parts Connect the shielding gas typically argon using a appropriate regulator Connect the foot amptrol torch and work lead to the power source With the work cable connected to a properly grounded work piece turn the power source on The Invertec V205 T AC DC TIG is ready to AC TIG weld with the following features AC TIG Trigger Mode in 2 step mode Local control Pulser off AC Square Wave AC Balance 6595 AC Frequency 100HZ Pre Flow 5sec Post Flow 5 sec High Freq Start Change from Local to Remote control by pushing front panel push button Set the maximum output current desired using the Output Control Initiate the arc by closing the arc start switch The Amptrol will control the output current from 10 amps to current level set by Output Control To change the AC Frequency press and hold the Parameter button for 3 seconds The AC Frequency is now selected and can be varied by the Output Control The frequency is displayed on the digital meter After about 5 seconds the power source will switch back to the welding mode ready to weld with the new selected AC Frequency To change the AC Balance press and hold the Parameter button for 3 seconds AC Frequency is selected press the Parameter button again and AC Balance is selected Adjust the Output Control for the desired AC Balance After about 5 seconds the power source will switch bac
11. F 43 Replacement Procedures 8 Input Filter Board Removal and F 49 Main IGBT Board Removal and F 53 E Control Display Board Removal and Replacement F 57 Output Filter Board Removal and Replacement F 61 Output Diodes Removal and Replacement F 65 Output Transistor Removal and Replacement F 67 Return to Master TOC INVERTEC V205 T AC DC LINCOLN B Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC e 2 Return to Section TOC Return to Master TOC o 5 o gt 2 r TROUBLESHOOTING AND REPAIR HOW TO USE TROUBLESHOOTING GUIDE A 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 fol
12. Faire tr s attention de bien s isoler de la masse quand on soude dans des endroits humides ou sur un plancher met allique ou des grilles metalliques principalement dans les positions assis ou 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 defonc tionnement 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 contre les chutes dans le cas ou on recoit un choc Ne jamais enrouler le c ble lectrode autour de n importe quelle partie du corps Un coup d arc peut tre plus s v re qu un coup de soliel donc a Utiliser un bon masque avec un verre filtrant appropri ainsi qu un verre blanc afin de se prot ger les yeux du rayon nement 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 c
13. gt pup 75 76 77 g Gas 2 Solenoid INVERTEC V205 T AC DC LINCOLN Return to Section Return to Master TOC Return to Section TOC Return to Master TOC eio E EM the 091 olg gt 5 amp c Return to Section TOC Return to Master TOC E 2 THEORY OF OPERATION E 2 FIGURE E 2 GENERAL DESCRIPTION INPUT BOARD amp BUS BOARD Superimposition Current Feedback IGBT Thermostats 48 24 15 15 5 reconnect info turn on AC ckt high volt supply voltage feedback current feedback _ Main amp Power board DC blocking capacitor board turn on AC ckt 15 15 5 set info thermostat info input volt meter input current meter turn on PWM HF control signal Control board Voltage Feedback AC DC Gate drive signals Main Transformer 24 Remote 2 4 path D E board Gas Solenoid GENERAL DESCRIPTION The Invertec V205T AC DC is an inverter based industrial welding power source that utilizes single phase input power to produce constant current AC or DC output for both Stick SMAW and TIG GTAW With 230VAC input applied the V205T is rated at 200 amps 18volts at a 4096 duty cycle With 115VAC applied the machine is rated at 150 amps 16 volts at a 4096 duty cycle The machine has the capabilities to produce several varieties
14. SAFETY PRECAUTIONS A WARNING ELECTRIC SHOCK can kill Have an electrician install and service this equipment Turn the input power off at the fuse box disconnect or unplug supply lines and allow machine to sit for five minutes minimum to allow the power capacitors to discharge before working inside this equipment Return to Section TOC Return to Master TOC Do not touch electrically hot parts INPUT FILTER CAPACITOR DISCHARGE PROCEDURE The machine has internal capacitors which are charged to a high voltage during power on condi tions This voltage is dangerous and must be dis charged 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 Return to Section TOC Return to Master TOC ROUTINE MAINTENANCE Prevent metal powder from accumulating near the aer ation fins and over them Carry out the following periodic controls on the power Source Clean the power source inside by means of low pressure compressed air Check the electric connections and all the connec tion cables e Always use gloves in compliance with the safety standards eio OJO gt Oo 5 2 amp c Return to Section TOC Return to Master TOC INVERTEC V205 T AC DC LINCOLN B
15. amp c Return to Section TOC Return to Master TOC F 26 TROUBLESHOOTING AND REPAIR CONTROL DISPLAY BOARD TEST continued Table F 2 Plug CN1 Test Points High Frequency Ground Start Solenoid Valve Ground for Supplies Table F 4 Plug CN7 Test Points Expected Voltage 5 VDC Ext Ground l NN oe __ Ext Ground FIGURE F 10 PLUGS CN1 2 amp CN7 52 53 54 1 2 3 4 5 6 78 58 44 48 zi 71 72 73 76 CN2 CN7 INVERTEC V205 T AC DC LINCOLN B F 26 Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC eio OJO f i 5 amp c Return to Section TOC Return to Master TOC F 27 TROUBLESHOOTING AND REPAIR el BUS BOARD TEST A WARNING Service and repair should be performed only by Lincoln Electric factory trained personnel Unauthorized repairs performed on this equipment may result in danger to the technician or 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 If for any reason you do not understand the test procedures or are unable to perform the test repairs safely contact the Lincoln Electri
16. standards 4 b Use suitable clothing made from durable flame resistant material to protect your skin and that of your helpers from the arc rays Protect other nearby personnel with suitable non flammable screening and or warn them not to watch the arc nor expose themselves to the arc rays or to hot spatter or metal FUMES AND GASES can be dangerous 5 Welding may produce fumes and gases hazardous to health Avoid breathing these fumes and gases When welding keep your head out of the fume Use enough ventilation and or exhaust at the arc to keep fumes and gases away from the breathing zone When welding with electrodes which require special ventilation such as stainless or hard facing see instructions on container or MSDS or on lead or cadmium plated steel and other metals or coatings which produce highly toxic fumes keep exposure as low as possible and within applicable OSHA PEL and ACGIH TLV limits using local exhaust or mechanical ven tilation In confined spaces or in some circumstances outdoors a respirator may be required Additional pre cautions are also required when welding on galvanized steel The operation of welding fume control equipment is affected by various factors including proper use and positioning of the equipment maintenance of the equipment and the specific welding procedure and application involved Worker expo sure level should be checked upon installation and periodi cally thereaft
17. 2 Safety Precautions icm auc RE Deal A 3 Select Suitable Location sene d aria ee eee EYES PE EEO PEN ERE A 3 Stacking Tilting Environmental 3 Machine Grounding High Frequency Interference Protection A 3 Inp t Connection 222424640 con bre 41 1 Pea ape ba ae dor nd Pan ds A 4 Reconnect Procedures scc sse posee bu ERR ERE ERE CURRERE Pid Pie d xg 4 230V Input 115V Input ii ssi erp re RR Moda ER RR ERE E A 5 Engine Driven Generator 0 5 Output Connections 2 4 i 233 Peed rea Pee Peete a De ean ede aos A 6 Output and Gas Connection For Tig Welding A 6 Output Connection For Stick Welding A 6 Quick Disconnect Plug For Stick Electrode Cable and Work Cable A 7 Shielding Gas Connection 1 A 7 Remote Control Connection A 7 INVERTEC V205 T AC DC LINCOLN B Return to Section TOC Return to Master TOC Return to Secti
18. If fuel is spilled wipe it up and do not start engine until fumes have been eliminated 1 d Keep all equipment safety guards covers and devices in posi tion and in good repair Keep hands hair clothing and tools away from V belts gears fans and all other moving parts when starting operating or repairing equipment 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 14 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 while the engine is running 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 1 h To avoid scalding do not remove the radiator pressure cap when the engine is hot 49 ELECTRIC AND MAGNETIC FIELDS may be dangerous 2 a Electric current flowing through any conductor causes localized Electric and Magnetic Fields EMF Welding current creates EMF fields around welding cables and welding machines EMF fields may interfere with some pacemakers and welders having a pacemaker should consult their physician before welding Exposure to EMF fields in weldi
19. Remove input power to the V205 T 4 Locate the Input Filter board See Figure F 4 2 Using a phillips head screwdriver remove the 5 See Note 1 and Note 2 cane 6 See Figure 5 voltage checks 3 Perform the Input Filter Capacitor Discharge earlier in this section eio OJO f i 3 Oo 09129 Sl amp c Return to Section TOC Return to Master TOC INVERTEC V205 T AC DC LINCOLN B Return to Section TOC Return to Master TOC Return to Section TOC eio te 091 olg gt fom eo cre 5 2 amp Return to Section TOC Return to Master TOC Return to Master TOC F 17 CN 1 1 2 lt _ lt TROUBLESHOOTING AND REPAIR INPUT FILTER BOARD TEST continued FIGURE F 5 INPUT FILTER BOARD EARTH CONNECTION CN 1 3 4 VAC 2 3V 1 2V NOTE 1 A varistor ZN1 is placed between the two power supply phases so if an instanta neous voltage in excess of 275VAC appears on terminals RV1 amp RV2 the varistor very rapidly becomes conductive and thus absorbing a current peak suffi cient to limit the above said overvoltage this way the varistor ZN1 protects the other parts of the machine from energy limited overvoltages This process has no destructive effect on the component if the energy generated by the voltage peak is low a
20. Return to Master TOC Aa INSTALLATION 53 Read entire installation section before starting installation Safety Precautions A WARNING ELECTRIC SHOCK can kill Only qualified personnel should perform this installation Turn the input power OFF and unplug the machine from the recep tacle before working on this equip ment Allow machine to sit for 5 min utes minimum to allow the power capacitors to discharge before working inside this equipment Insulate yourself from the work and ground Always wear dry insulating gloves Always connect the V205 T to a power supply grounded according to the National Electrical Code and local codes SELECT SUITABLE LOCATION The Invertec will operate in harsh environments Even so it is important that simple preventative mea sures are followed in order to assure long life and reli able operation The machine must be located where there is free cir culation of clean air such that air movement in the back and out the front will not be restricted 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 V205 T AC DC can not be stacked TILTING Place the machine directly on a secure level surface The machine may topple over if this procedure is not followed ENVIRONMENTAL AREA Keep the machi
21. Return to Section TOC Return to Master TOC ojo e c s 919 gt 9 2 2 2 PROCEDURE 4 Locate the power factor section on the main board and associated plugs Do not remove 1 Remove input power to the V205 T machine plugs from the board See Figure 15 2 Using a phillips head screwdriver remove th 5 Carefully apply the correct input voltage to the case wraparound cover V205 T and check for the correct secondary 3 Perform the Capacitor Discharge Procedure voltages per tables F 10 amp F11 Voltage read detailed earlier in this section ings were taken with a Fluke RMS meter See Figure F 15 for joint locations TABLE F 10 VOLTAGE CHECKS WITH 115 VAC APPLIED TO MACHINE ON STICK 250 260 VDC ONISTICK 125 VOC ONISTICK 22 VDC 1 eio OJO f i olg gt 5 amp ON STICK 120 VDC 22 VDC 04 oNSTick ___ TABLE F 11 RESISTANCE CHECKS or a or me Return to Section TOC Return to Master TOC INVERTEC V205 T AC DC LINCOLN B Return to Section Return to Master TOC Return to Section TOC Return to Master TOC eio OJO f i 3 Oo fom eo 5 2 amp c Return to Section TOC Return to Master TOC TROUBLESHOOTING AND REPAIR nee
22. cylinders associated equipment and CGA publication Precautions for Safe Handling of Compressed Gases in Cylinders 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 Refer to http Awww lincolnelectric com safety for additional safety information INVERTEC V205 T AC DC LINCOLN B Return to Master Return to Master TOC o 5 o gt 2 tc Return to Master TOC 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 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
23. emu 2 Return to Master o 5 o gt 2 t Return to Master TOC INVERTEC V205 T AC DC LINCOLN B Return to Section TOC Return to Master TOC Return to Section TOC eio gt olg 5 amp c Return to Section TOC Return to Master TOC Return to Master TOC ACCESSORIES ce OPTIONAL ACCESSORIES AND COMPATIBLE EQUIPMENT Factory Installed Twist Mate Cable Connectors 1 standard for Ground Clamp 1 Gas Pass through for Tig Torch Strap Packet Instruction Manual Field Installed K857 Remote Output Control For Stick welding When the V205 T s Output Control is in the position this portable current control provides the same range as the current control on the welder Consists of a 6 pin Amphenol connector which plugs into the remote control Amphenol 25 foot cable length K870 Foot Amptrol for TIG welding When the V205 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 K963 3 Hand Amptrol for TIG welding When the V205 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 Ener
24. lt DRAIN DRIFT REGION n lt BUFFER LAYER p INJECTING LAYER DRAIN A PASSIVE INSULATED GATE BIPOLAR TRANSISTOR IGBT OPERATION An IGBT is a type of transistor IGBT are semiconduc tors well suited for high frequency switching and high current applications Example A in Figure E 6 shows an IGBT in passive mode There is no gate signal zero volts relative to the source and therefore no current flow The drain termi nal of the IGBT may be connected to a voltage supply but since there is no conduction the circuit will not sup ply current to components connected to the source The circuit is turned OFF like a light switch POSITIVE VOLTAGE a APPLIED GATE A BODY REGION lt DRAIN DRIFT REGION INJECTING LAYER DRAIN B ACTIVE Example B shows the IGBT in an active mode When the gate signal a positive DC voltage relative to the source is applied to the gate terminal of the IGBT it is capable of conducting current A voltage supply con nected to the drain terminal will allow the IGBT to con duct and supply current to the circuit components cou pled to the source Current will flow through the con ducting IGBT to downstream components as long as the positive gate signal is present This is similar to turning ON a light switch NOTE Unshaded areas of Block Logic Diagram are the subject of discussion INVERTEC V205 T AC DC
25. remove the board See Figure F 19 case wraparound cover _ 5 Perform the output diode resistance check 3 Perform the Capacitor Discharge Procedure detailed earlier in this section fable 6 Carefully apply the correct input voltage to the V205 T and check for the correct secondary voltages per Table 13 INVERTEC V205 T AC DC LINCOLN B PA TROUBLESHOOTING AND REPAIR SECONDARY OUTPUT BOARD ASSEMBLY TEST continued FIGURE F 20 SECONDARY POWER BOARD TEST POINT LOCATIONS A 10K Ohms 10K Ohms Return to Section TOC Return to Master TOC GA 5 SB GB Return to Section TOC Return to Master TOC TABLE F 13 VOLTAGE CHECKS WITH 115 VAC APPLIED TO MACHINE ON STICK GA SAI 13 VDC ON STICK GB SBI 13 VDC eio i c 5 amp c ON STICK 3p 1E 0 5 VDC ON STICK 1 2 105 VDC ON STICK Outpt Terminals OFF R GA SA 10 K Ohms OFF R GB SB 10 K Ohms Return to Section TOC Return to Master TOC INVERTEC V205 T AC DC LINCOLN B in TROUBLESHOOTING AND REPAIR SECONDARY OUTPUT BOARD ASSEMBLY TEST continued TABLE 14 OUTPUT DIODE RESISTANCE CHECK POSITIVE METER NEGATIVE METER EXPECTED READING PROBE PROBE MACHINE OFF TEST POINT A TEST POINT 3 LOW LESS THAN 200 OHMS MACHINE OFF TEST POINT 3 TEST POINT A HIGH MORE THAN 1000 OHMS MACHINE OFF TEST POINT B TEST POI
26. FERRULE 5 Slide the copper ferrule into the brass plug 4 Insert copper strands into ferrule 6 Tighten set screw to collapse copper tube Screw must apply pressure against welding cable The top of the set screw will be well below the surface of the brass plug after tightening SUREW BRASS PLUG COPPER TUBE 7 Slide rubber boot over brass plug The rubber boot must be positioned to completely cover all electrical surfaces after the plug is locked into the receptacle SHIELDING GAS CONNECTION Obtain the necessary inert shielding gas Connect the cylinder of gas with a pressure regulator and flow gage Install a gas hose between the regulator and gas inlet located on the rear of the welder The gas inlet has a 5 16 18 right hand female thread CGA 7032 A WARNING CYLINDER could explode if damaged e Keep cylinder upright chained to a support Keep cylinder away from areas where it could be damaged Never allow the torch or welding electrode to touch the cylinder Keep cylinder away from live electrical cir cuits REMOTE CONTROL CONNECTION A remote control receptacle is provided on the lower center case front of the welder for connecting a remote control to the machine Refer to the Optional Accessories section of this manual for available remote controls INVERTEC V205 T AC DC LINCOLN B 8 2 o lt o E o E gt 5 eB 2 9
27. MAIN INVERTER BOARD POWER FACTOR SECTION TEST continued FIGURE F 15 POWER FACTOR AREA ON MAIN BOARD NOTE Power Factor Section is located at the upper left section of main board EI n huis 1 9 GNDPWR ac a age t F1 d Db RL1 d o m ERR l Latt ea 068 R82 EL OB tai EE niu nd 1 m a d BE kl 20 ps E MF8 Ar o POWER INPUT 7 230 VAC 115 DDi 77 MF9 amp L10 INVERTEC V205 T AC DC LINCOLN B F 34 E 8 lt o E o LLI amp E l 2 9 oc gt 2 DOL 01 DOL 01 DOL DOL 0 DOL uonoeg DOL 5 DOL 5 DOL 5 Return to Section TOC Return to Master TOC Return to Section TOC eio OJO f i 5 amp c Return to Section TOC Return to Master TOC Return to Master TOC F 35 TROUBLESHOOTING AND REPAIR OUTPUT FILTER BOARD TEST A WARNING Service and repair should be performed only by Lincoln Electric factory trained personnel Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warra
28. OUTPUT CURRENT PRE FLOW POST FLOW GASON GAS Possible variations of this standard sequence is shown in 2 step diagram 2 It is possible to press and hold the TIG torch trigger a second time during downslope to restart After the trigger is pressed the output current will increase to the welding current This operation is shown in 2 step diagram 2 2 STEP DIAGRAM 2 1 2 TORCH BUTTON PRE FLOW POST FLOW GASON GAS OUTPUT CURRENT 4 Step Sequence With the 4 step Selected the following welding sequence will occur 1 Press and hold the Arc Start Switch to start the sequence The machine will open the gas valve to start the flow of the shielding gas After a 0 5 second preflow time to purge air from the torch hose the output of the machine is turned ON At this time the arc is started After the arc is started the output current will be at the Start current This condition can be maintained as long or as short as necessary If the Start current is not necessary do not hold the TIG torch trigger as described at the beginning of this step Instead quickly press and release the trigger In this condition the machine will automatically pass from Step 1 to Step 2 when the arc is started Release the TIG torch trigger to start the main part of the weld The output current will be increased from the start current to the welding current Both the start current and in
29. Other loads on the cir cuit and fuse circuit breaker characteristics will affect the available output Do not exceed these welding con ditions 15A branch circuit 10 duty cycle Stick 75A TIG 105A 20A branch circuit 10 duty cycle Stick 90A TIG 130A ATTACHMENT PLUG INSTALLATION Connect the white neutral wire under terminal clamp with silver screw and black hot wire under terminal clamp with brass screw Connect green wire under ter minal clamp with green screw A WARNING Failure to wire as instructed may cause personal injury or damage to equipment To be installed or checked by an electrician or qualified person only In all cases the green or green yellow grounding wire must be connected to the grounding pin of the plug usually identified by a green screw Attachment plugs must comply with the Standard for Attachment Plugs and Receptacles UL498 The product is considered acceptable for use only when an attachment plug as specified is properly attached to the supply cord For use on engine drives keep in mind the above input draw restrictions and the following precaution ENGINE DRIVEN GENERATOR The Invertec V205 T AC DC can be operated engine driven generators as long as the 230 volt auxil iary meets the following conditions The AC waveform peak voltage is below 400 volts AC waveform frequency is between 45 65 2 The following Lincoln engine drives meet
30. Output Device Transistor Module tum on PNM turn on AC ckt thermostat info HF control signal Control board 24 VDC Remote 2 4 path D E Display amp LED D Remote 2 4 Oe MAIN IGBT INVERTER BOARD The filtered input voltage from the Input Board is applied through an input choke to the Main IGBT Inverter Board This input voltage is rectified regulat ed and a unity power factor output is developed for the main welding IGBTs This unity power factor circuit provides several advantages over a traditional bridge rectifier circuit Among these advantages are that the UPFR operates over a wide range of voltages there is no need for any manual circuit changes when the input voltages are changed from 115VAC to 230VAC and there is absolute voltage stability maintained on the IGBT electrolytic capacitors The four main welding IGBTs are located on a large center mounted heat sink assembly The pre charge and auto reconnect circuits are posi tioned on the Main IGBT Inverter Board When power is first applied to the V205T the rectified DC input volt age is applied to the input capacitors through a current limiting circuit The capacitors are charged slowly and current limited for approximately five seconds After five seconds a relay closes and the pre charge circuit is bypassed and a controlled DC input voltage is applied to the weld capacitors and IGBTs making them ready for welding out
31. The Invertec V205 T AC DC is an industrial 200 amp arc welding power source which utilizes single phase input power to produce constant current output The welding response of this Invertec has been opti mized for stick SMAW and TIG GTAW The unit is ideal for industrial applications where portability is important The Invertec V205 T AC DC is a power source that can perform the following types of welding with excel lent results TIG with high frequency or Touch Start Tig Starting TIG AC with square sinusoidal and triangular wave forms Tig DC The following items can be connected to the 6 pin Socket on the front panel Remote control potentiometer for Stick welding Remote Foot Amptrol or Hand Amptrol Arc Start Switch NOTE See Accessories section of this manual for product numbers and complete description WELDING CAPABILITY The Invertec V205 T AC DC is rated at 200 amps 18 volts at 4096 duty cycle on a ten minute basis It is capable of higher duty cycles at lower output currents It is capable of 140 amps 15 6 volts at 10096 duty cycle If the duty cycle is exceeded a thermal protec tor will shut off the output until the machine cools See Technical Specifications in A 1 for other rated outputs The Invertec V205 T is recommended for stick weld ing with such popular electrodes as Fleetweld 35 Fleetweld 37 Fleetweld 180 and Excalibur 7018 LIMITATIONS The V205 T is not recommend
32. access Because of the AC inverters abilities in these areas the following recommendations are made as a starting point A296 Thoriated tungsten is recommended instead of the Pure tungsten that is normally recommended for AC welding Thoriated tungstens emit electrons eas ier and therefore will improve starting Sharpen the tungsten to a point Normally it is rec ommended to pre ball a pure tungsten when AC welding with a conventional power source However the AC inverter with it s extended AC bal ance control minimized tungsten heating thus allow ing for a pointed tungsten to be used Set the AC Balance control to maximum 85 elec trode negative This can be reduced if the material welded is heavily oxidized however starting at max imum and adjusting to less is desired Set the AC Frequency in the 100 to 120 Hz range This is a Sweet Spot for most aluminum applica tions GTAW Process Electrode Polarity DC AC Approximate Argon Electrode Tip Preparation Sharpened Gas Flow Rate Sharpened Electrode Type EWTh 2 EWLa 1 Electrode Size in mm EWTh 2 EWLa 1 Stainless Aluminum Up to 15 A Up to 15 A 3 8 3 8 mm 010 0 25 020 0 50 Up to 15 A Up to 20 A 5 10 5 10 040 Up to 80 A Up to 60 A 5 10 5 10 Up to 130 A 5 10 9 13 1 0 1 16 1 8 Upto 150A 3 32 2 4 Upto MAX A Up to MAX A 1 8
33. and allow prop er failure analysis 4 Test the machine to determine if the failure symptom has been corrected by the replacement PC board NOTE It is desirable to have a spare known good PC board available for PC board troubleshooting NOTE Allow the machine to heat up so that all electrical components can reach their operating temperature 5 Remove the replacement PC board and substitute it with the original PC board to recreate the original problem a If the original problem does not reappear by substituting the original board then the PC board was not the problem Continue to look for bad connections in the control wiring harness junction blocks and terminal strips b If the original problem is recreated by the substitution of the original board then the PC board was the problem Reinstall the replacement PC board and test the machine 6 Always indicate that this procedure was followed when warranty reports are to be submitted NOTE Following this procedure and writing on the warranty report INSTALLED AND SWITCHED PC BOARDS TO VERIFY PROBLEM will help avoid denial of legitimate PC board warranty claims INVERTEC V205 T AC DC LINCOLN B i TROUBLESHOOTING AND REPAIR Observe Safety Guidelines detailed in the beginning of this manual PROBLEMS POSSIBLE AREAS OF RECOMMENDED SYMPTOMS MISADJUSTMENT S COURSE OF ACTION OUTPUT PROBLEMS Major physical or electrical damage 1 Contact yo
34. of AC waveforms square sinusoidal and triangular The unit also employs an auto reconnect feature that does not require manual intervention when the input power is changed from 115VAC to 230VAC or 230VAC to 115VAC When in the TIG mode the operator may select to use either the high frequency or touch start function INPUT BOARD AND BUS BOARD The single phase input voltage is applied to the V205T through a line switch located on the back of the machine The AC input voltage is filtered and condi tioned by a network of inductors capacitors and a varistor that are all located on the Input Board This fil Output Diode Thermostat Output Filter bd bypass EMI A He Current Output Choke Hall Device Transistor Module Output board 888 Display amp LED D E contol Remote 2 4 Remote 75 76 77 tered input voltage is applied to the Main IGBT Inverter Board Another function of the Input Board is to pre vent high frequency inverter generated noise from being induced back into the supply lines The Bus Board performs several functions within the V205T It accepts and distributes power and informa tion to other circuitry This interfacing is accomplished through harness and ribbon connectors and also via other PC boards that are plugged directly into the Bus Board The Input Board the High Frequency Board and the AC Super Imposition Board plug into
35. personnel Unauthorized repairs performed on this equipment may result in danger to the technician or 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 If for any reason you do not understand the test procedures or are unable to perform the test repairs safely contact the Lincoln Electric Service Department for electrical trou bleshooting assistance before you proceed Call 1 888 935 3877 TEST DESCRIPTION The following procedure will aid the technician in removing the Output Transistor for replacement MATERIALS NEEDED Phillips Head Screwdriver 5mm Allen Wrench Heatsink Compound INVERTEC V205 T AC DC LINCOLN B F 67 ids TROUBLESHOOTING AND REPAIR OUTPUT TRANSISTOR REMOVAL AND REPLACEMENT continued FIGURE F 36 OUTPUT TRANSISTOR LOCATION Return to Section TOC Return to Master TOC 69 E Return to Master Output Transistor ojo bs Bis PROCEDURE o 1 Remove input power to the V205 T 9 Apply a thin layer of heatsink compound to all 2 Using a phillips head screwdriver remove the potniaotsuliacnss case wraparound cover 10 Replace the output transistor mounting bolts 3 Perform the Input Filter Capacitor Discharge previously removed P
36. 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 Piping 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 we
37. such as sitting kneeling or lying if there is a high risk of unavoidable or accidental contact with the workpiece or ground use the following equipment Semiautomatic DC Constant Voltage Wire Welder DC Manual Stick Welder AC Welder with Reduced Voltage Control 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 i SAFETY ARC RAYS can burn 4 a Use a shield with the proper filter and cover plates to protect your eyes from sparks and the rays of the arc when welding or observing open arc welding Headshield and filter lens should conform to ANSI 287
38. 1 888 935 3877 TEST DESCRIPTION The following procedure will aid the technician in removing the Output Filter Board for replacement MATERIALS NEEDED 17mm Wrench 13mm Wrench Large Crescent Wrench Phillips Head Screwdriver 90 Phillips Head Screwdriver INVERTEC V205 T AC DC LINCOLN B F 61 TROUBLESHOOTING AND REPAIR 592 OUTPUT FILTER BOARD REMOVAL AND REPLACEMENT continued FIGURE F 32 OUTPUT FILTER BOARD LOCATION Q 9 is E E c Return to Master TOC Output Filter Board olo e Y 5 5 gt 212 a a dc NS ele 5 3 PROCEDURE 212 1 Remove input power to the V205 T 6 Remove the two phillips head casefront mount 5 5 5 2 Using a phillips head screwdriver remove the located Baling e meta display 5l plate See Figure 33 case wraparound cover 3 Perform the Input Filter Capacitor Discharge Vo philips dps this section around the output terminals on the lower front the machine See Figure F 33 t Uang A philips haad sorowalivel ferus tha 8 Carefully manipulate the casefront off of the four screws at the corners of the nameplate keypad See Figure F 33 machine 5 Gently pull the Control Display board assembly forward and up to gain access to the two case front mounting screw
39. 200 as a check Power supply LED GREEN Indicates the machine switch on status Always present if the panel and therefor the machine is correctly powered Alarm LED YELLOW Indicates a protection status of the equipment Comes on to indicate the presence of a problem The type of alarm is indi cated in the display by an error code see below Display Immediately after the autotest operations above the display briefly shows the software version of control panel e g 01 It indicates the welding parameters requested by the operator with the help of the other keys and immediately after striking of the arc sets to reading mode providing the real value of the current delivered by generator It indicates a protection status via codes with simultaneous switch on of the T eis LED of Error upper cover check internal temperature check thermal device status Internal Heatsink Overtemp N C See machine layout Remove upper cover check that the power supply voltage is within the established Power Supply Overvoltage range 1596 Check reading voltage on 15 14 314 CN1 See Fig 9 Remove upper cover check that the power supply voltage is within the established Power Supply Undervoltage range 1596 Check reading voltage on 15 14 315 CN1 See Fig 9 Remove upper cover check front panel power supplies Perform front panel reset Front Panel Memory Error test and replace if neces
40. 888 935 3877 INVERTEC V205 T AC DC LINCOLN B vf TROUBLESHOOTING AND REPAIR d Observe Safety Guidelines detailed in the beginning of this manual PROBLEMS POSSIBLE AREAS OF RECOMMENDED SYMPTOMS MISADJUSTMENT S COURSE OF ACTION FUNCTION PROBLEMS No current regulation in the Stick 1 Make sure the machine is set up 1 The Superimposition Board may mode Low open circuit voltage and configured correctly for the be faulty Stick mode Return to Section TOC Return to Master TOC 2 The Output Module Transistor Board may be faulty See the Secondary Output Board Assembly Test and Wiring Diagram There is no response to changes to 1 Make sure the correct input volt 1 The Control Display board may the output control settings No cur age is applied to the machine be faulty rent regulation in all modes 230 or 115VAC Return to Section TOC Return to Master TOC eio gt 091 olg o 1 5 oD amp A CAUTION If for any reason you do not understand the test procedures or are unable to perform the tests repairs safely contact the Lincoln Electric Service Department for technical troubleshooting assistance before you proceed Call 1 888 935 3877 Return to Section TOC Return to Master TOC INVERTEC V205 T AC DC LINCOLN B Return to Section TOC Return to Master TOC Return to Section TOC eio OJO
41. 91 3 c 5 amp c Return to Section TOC Return to Master TOC Return to Master TOC F 65 TROUBLESHOOTING AND REPAIR OUTPUT DIODES REMOVAL AND REPLACEMENT A WARNING Service and repair should be performed only by Lincoln Electric factory trained personnel Unauthorized repairs performed on this equipment may result in danger to the technician or 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 If for any reason you do not understand the test procedures or are unable to perform the test repairs safely contact the Lincoln Electric Service Department for electrical trou bleshooting assistance before you proceed Call 1 888 935 3877 TEST DESCRIPTION The following procedure will aid the technician in removing the Output Diodes for replace ment MATERIALS NEEDED Phillips Head Screwdriver 7mm Nutdriver Heatsink Compound INVERTEC V205 T AC DC LINCOLN B F 65 Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC eio OJO f i 3 Oo Sl gt amp Return to Section TOC Return to Master TOC Fon TROUBLESHOOTING AND REPAIR iud OUTPUT DIODES REMOVAL AND REPLACEMENT continued FIGURE F 35 OUTPUT DIODE LOCATION
42. C Alternating Current see Figure B 7 Alternating Current welding is typically used for Tig welding aluminum and its alloys or magnesium The polarity alternates between Electrode Positive and Electrode Negative EN During the positive half wave the oxide is broken During the negative half wave the electrode cools the workpiece melts and penetration occurs FIGURE B 7 30 MAX PENETRATION 50 o 70 MAX CLEANING Greater 95 EN MORE PENETRATION 50 EN Lesser EN more CLEANING Changing the wave balance alters the ratio between the cleaning and the penetrating current A C Pulsed TIG When AC welding a pulsed current can be used with similar effects to those described in pulsed direct cur rent welding FIGURE B 8 AC TIG NOT PULSED AC PULSED TIG Ip F Im HArFH H4tt 4 Ib 4 f 1 to 10Hz T 1 f Hr INVERTEC V205 T AC DC LINCOLN B Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC 69 2 Return to Section TOC Return to Master TOC o 5 o gt 2 tc B 10 STEEL TIG WELDING The TIG process is very effective for welding both car bon steel and alloy steel especially in applications requiring precision results DC Electrode Negative Polarity is required Since this process does not include the removal of impurities proper cleaning an
43. C board is properly connected 3 If the problem persists replace the suspect PC board using standard practices to avoid static electrical damage and electrical shock Read the warning inside the static resistant bag and perform the following procedures PC board can be damaged by static electricity Remove your body s static charge before opening the static shielding bag Wear an anti static wrist strap For safety use a 1 Meg ohm resistive cord connected ATTENTION to a grounded part of the Static Sensitive 2 frame Devices If you don t have a wrist strap touch an un painted grounded part of the equipment frame Keep touching the frame to prevent static build up Be sure not to touch any electrically live parts at the same time Handle only at Static Safe Workstations Tools which come in contact with the PC board must be either conductive anti static or static dissipative Remove the PC board from the static shielding bag and place it directly into the equipment Don t set the PC board on or near paper plastic or cloth which could have a static charge If the PC board can t be installed immediately put it back in the static shield ing bag If the PC board uses protective shorting jumpers don t remove them until installation is complete If you return a PC board to The Lincoln Electric Company for credit it must be in the static shielding bag This will prevent further damage
44. COLN B F 14 Return to Section TOC Return to Master TOC Return to Section TOC eio OJO f i 5 amp c Return to Section TOC Return to Master TOC Return to Master TOC F 15 TROUBLESHOOTING AND REPAIR INPUT FILTER BOARD TEST A WARNING Service and repair should be performed only by Lincoln Electric factory trained personnel Unauthorized repairs performed on this equipment may result in danger to the technician or 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 If for any reason you do not understand the test procedures or are unable to perform the test repairs safely contact the Lincoln Electric Service Department for electrical trou bleshooting assistance before you proceed Call 1 888 935 3877 TEST DESCRIPTION This test will help determine if the Input Filter Board is functioning properly MATERIALS NEEDED Analog Volt Ohmmeter Phillips Head Screwdriver Wiring Diagram INVERTEC V205 T AC DC LINCOLN B F 15 F5 TROUBLESHOOTING AND REPAIR 8 INPUT FILTER BOARD TEST continued FIGURE F4 INPUT FILTER BOARD LOCATION INPUT FILTER BOARD Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC PROCEDURE 1
45. ERTER BOARD Capacitor Solder Resistor Pads WARNING ELECTRIC SHOCK can kill e Have an electrician install and ser vice this equipment the input power off at the fuse box before working on equipment Do not touch electrically hot parts Prior to performing preventative maintenance perform the following capacitor discharge proce dure to avoid electric shock DISCHARGE PROCEDURE Remove the input power to the machine Using the phillips head screwdriver remove the Screws securing the case wraparound cover Be careful not to make contact with the capac itor solder pads located at the top of the IGBT power board Obtain a high resistance and high wattage resistor 25 1000 ohms and 25 watts mini mum This resistor is not with the machine NEVER USE A SHORTING STRAP FOR THIS PROCEDURE Locate the eight capacitor solder pads shown in Figure F 3 Using electrically insulated gloves and pliers hold the body of the resistor with the pliers and connect the resistor leads across the two capacitor solder pads the resistor in place for 10 seconds DO NOT TOUCH CAPACITOR SOLDER PADS WITH YOUR BARE HANDS Repeat the discharge procedure for the other three capacitors Check the voltage across the terminals of all capacitors with a DC voltmeter Voltage should be zero If any voltage remains repeat this capacitor discharge procedure INVERTEC V205 T AC DC LIN
46. INVERTER SECTION TEST continued TABLE F 15 LED FUNCTION 18 ONANDFLASHNG E Return to Section TOC Return to Master TOC OFF THERMAL 258v _ ALWAYS TABLE 16 FEEDBACK VOLTAGE SIGNALS ON TIG TP15 TP14 2 VDC 100A WELDING ON 4 VDC 200A CURRENT FEEDBACK ON STICK TP16 TP14 4 3 VDC WELDING ON OPEN CIRCUIT VOLTAGE VOLTAGE FEEDBACK CONDITION ON TIG TP19 TP14 2 VDC 100A WELDING ON 4 VDC 200A CURRENT REFERENCE TABLE F 17 VOLTAGE CHECKS WITH 115 VAC APPLIED TO MACHINE TABLE F 18 LED CHECK IN STICK MODE ON STICK ON AND FLASHING ON STICK ON AND FLASHING Return to Section TOC Return to Master TOC eio OJO i olg 1 5 amp ON STICK ON AND FLASHING ON STICK ON AND FLASHING Return to Section TOC Return to Master TOC INVERTEC V205 T AC DC LINCOLN B FR TROUBLESHOOTING AND REPAIR dinis MAIN INVERTER BOARD WELDING LOGIC AND INVERTER SECTION TEST continued 5 FIGURE F 22 MAIN BOARD INVERTER SECTION 5 69 tc Return to Master TOC 9 8 P TP14 HE 15 16 gp aR 2 nu 5 9 TP19 TP31 9 8 4 1 2 e E E 5 Short Circuit ale Setoain 5 0 3 Ohms o L9 CN5 1 2 Short Circuit 0 3 Oh
47. NG Service and repair should be performed only by Lincoln Electric factory trained personnel Unauthorized repairs performed on this equipment may result in danger to the technician or 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 Return to Section TOC Return to Master TOC If for any reason you do not understand the test procedures or are unable to perform the test repairs safely contact the Lincoln Electric Service Department for electrical trou bleshooting assistance before you proceed Call 1 888 935 3877 TEST DESCRIPTION The following procedure will aid the technician in removing the Control Display Board for replacement MATERIALS NEEDED Phillips Head Screwdriver Wiring Diagram Return to Section TOC Return to Master TOC eio OJO E f i 091 3 c 5 amp c Return to Section TOC Return to Master TOC INVERTEC V205 T AC DC LINCOLN B nse TROUBLESHOOTING AND REPAIR ds CONTROL DISPLAY BOARD REMOVAL AND REPLACEMENT continued FIGURE F 29 CONTROL DISPLAY BOARD LOCATION Control Display Board Return to Section TOC Return to Master TOC Return to Master TOC o 69 E olo o o c is 5 8 ls PROCEDURE ie 1 Remove the input power to the V205
48. NT 3 LOW LESS THAN 200 OHMS Return to Section TOC Return to Master TOC MACHINE OFF TEST POINT 3 TEST POINT B HIGH MORE THAN 1000 OHMS MACHINE OFF TEST POINT 2 TEST POINT A LOW LESS THAN 200 OHMS MACHINE OFF TEST POINT A TEST POINT 2 HIGH MORE THAN 1000 OHMS MACHINE OFF TEST POINT 2 TEST POINT B LOW LESS THAN 200 OHMS MACHINE OFF TEST POINT B TEST POINT 2 HIGH MORE THAN 1000 OHMS Return to Section TOC Return to Master TOC eio te 091 olg gt fom eo cre 5 5 amp Return to Section TOC Return to Master TOC INVERTEC V205 T AC DC LINCOLN B Return to Section TOC Return to Master TOC Return to Section TOC eio OJO f i 5 amp c Return to Section TOC Return to Master TOC Return to Master TOC F 43 TROUBLESHOOTING AND REPAIR MAIN INVERTER BOARD WELDING LOGIC AND INVERTER SECTION TEST A WARNING Service and repair should be performed only by Lincoln Electric factory trained personnel Unauthorized repairs performed on this equipment may result in danger to the technician or 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 If for any reason you do not understand the test procedures or are unable to perform the test repair
49. NVERTER BOARD LOW VOLTAGE TEST A WARNING Service and repair should be performed only by Lincoln Electric factory trained personnel Unauthorized repairs performed on this equipment may result in danger to the technician or 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 If for any reason you do not understand the test procedures or are unable to perform the test repairs safely contact the Lincoln Electric Service Department for electrical trou bleshooting assistance before you proceed Call 1 888 935 3877 TEST DESCRIPTION This test will help determine if all of the auxiliary voltages on the Main IGBT Inverter Board are correct MATERIALS NEEDED Voltmeter Phillips Head Screwdriver Wiring Diagram Voltmeter INVERTEC V205 T AC DC LINCOLN B TROUBLESHOOTING AND REPAIR ree MAIN IGBT INVERTER BOARD LOW VOLTAGE TEST continued FIGURE F 6 MAIN IGBT INVERTER BOARD LOCATION MAIN BOARD Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC PROCEDURE 1 Remove input power to the V205 T machine 4 Locate the Main IGBT Inverter board See 2 Using a phillips head screwdriver remove the Figure Ee case wraparound cover 5 Use the voltmeter to perform the tests detailed 3 Perform the Capac
50. OBLEMS Error code E20 E24 or E25 is 1 Any one of these codes indicates 1 The Control Display Board is flashing on the digital display a memory error faulty Replace The machine functions normally 1 Check for obstructions that could 1 Check the fan fuse F3 located on except the cooling fan does not prevent fan from turning the Bus Board Replace if faulty operate 2 Perform the Bus Board Test 3 The Main IGBT Inverter Board May be Faulty Perform the No High Frequency when the torch 1 Make sure the HF is in the active 1 Check fuse F2 on the Bus Board trigger is pulled and the machine See the Menu rigger is pulled and the machine is mode See the in 2 Check for 385VDC at Test in the TI de thi Points 9 and 20 See the IGBT Inverter Board Test 3 Perform the Control Display 4 The HF board may be faulty Replace Error code E14 is flashing of the 1 This is an indication that the out 1 Check for excessive welding digital display put inductance is too high cable length 2 The Main IGBT Inverter Board may be faulty 3 The Superimposition Board may be faulty 4 The Control Display Board may be faulty A CAUTION If for any reason you do not understand the test procedures or are unable to perform the tests repairs safely contact the Lincoln Electric Service Department for technical troubleshooting assistance before you proceed Call 1
51. OJO gt olg gt 21 5 2 oi oO clo Ground olo Wire olz E E 5 Mounting 2 2 Nuts cc INVERTEC V205 T AC DC LINCOLN 5 60 8 lt o E o LLI amp E l 2 9 oc gt 2 e T DOL 01 uunjeH DOL 01 DOL DOL DOL uonoeg DOL 5 DOL 5 DOL 5 Return to Section TOC Return to Master TOC Return to Section TOC eio OJO f i 5 amp c Return to Section TOC Return to Master TOC Return to Master TOC F 61 TROUBLESHOOTING AND REPAIR OUTPUT FILTER BOARD REMOVAL AND REPLACEMENT A WARNING Service and repair should be performed only by Lincoln Electric factory trained personnel Unauthorized repairs performed on this equipment may result in danger to the technician or 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 If for any reason you do not understand the test procedures or are unable to perform the test repairs safely contact the Lincoln Electric Service Department for electrical trou bleshooting assistance before you proceed Call
52. RETURN TO MAIN MENU SVM161 A January 2011 INVERTEC 205 AC DC For use with machine code number 10860 Return to Master TOC View Safety Info Safety Depends on You Lincoln arc welding and cutting equipment is designed and built with safety in mind However your overall safety can be increased by proper installation and thoughtful operation on your part DO NOT INSTALL OPERATE OR REPAIR THIS EQUIPMENT WITHOUT READ ING THIS MANUAL AND THE SAFETY PRECAUTIONS CON TAINED THROUGHOUT most importantly think before you act and be careful Return to Master TOC View Safety Info View Safety Info 5 o gt 2 tc SERVICE MANUAL View Safety Info LI NCOLN Copyright Lincoln Global Inc 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 Return to Master TOC Return to Master Return to Master TOC o 5 o 2 tc Return to Master TOC i SAFETY i A WARNING Diesel engine exhaust and some of its constituents are known to the State of California to cause can cer birth defects and other reproductive harm CALIFORNIA PROPOSITION 65 WARNINGS 1 The engine exhaust from this product contai
53. ROCEDURE 1 Remove input power to the V205 T machine 4 Locate the control display board and associat ed plugs Do not remove plugs from the 2 Using a phillips head screwdriver remove the board See Figure F8 case wraparound cover 3 Perform the Capacitor Discharge Procedure 5 22 e input voltage to ids detailed earlier in this section uo T ann Sheek Tor COIT Secondary voltages Tables F 2 F3 amp eio OJO f i Oo 09 29 cre 5 5 amp Return to Section TOC Return to Master TOC INVERTEC V205 T AC DC LINCOLN B 25 TROUBLESHOOTING AND REPAIR CONTROL DISPLAY BOARD TEST continued F 25 4 30 FIGURE F 9 CONTROL DISPLAY BOARD LOCATION DOL DOL 0 0 6 0 uinjeH PEPTPERE X 2 gu una a m DOL 2150 DOL DOL DOL 0 Base Rak a an L Exon DIP SWITCHES ALL OFF DOL uunjeH DOL 5 INVERTEC V205 T AC DC LINCOLN 5 ELECTRIC Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC eio OJO i 3 Of c o gt 5
54. T 4 Disconnect the ground lead running from the 2 Using a phillips head screwdriver remove the EST board to the machine frame See c ac four screws from the corners of the name plate keypad on the front of the machine See 5 Carefully remove the board assembly Figure F 30 NOTE The board assembly is attached to the nameplate keypad and is to be replaced as one unit 6 Replace the board assembly Observe static precautions detailed in PC Board Troubleshooting Procedures the beginning of previously removed ground lead this section Failure to do so can result in perma 8 Connect previously removed leads CN1 CN2 CN3 amp CN7 nent damage to equipment 3 Tilt display plate forward and carefully label and 9 Replace the four phillips head screws previous disconnect leads CN1 CN2 CN3 amp CN7 See ly removed from the corners of the name Figure F 31 plate keypad Return to Section TOC Return to Master TOC INVERTEC V205 T AC DC LINCOLN B iie TROUBLESHOOTING AND REPAIR dica CONTROL DISPLAY BOARD REMOVAL AND REPLACEMENT continued FIGURE F 30 METAL DISPLAY PLATE 4 Phillips Head Screws Return to Section TOC Return to Master TOC T BACKGROUND CURRENT cmn UT V205 T AC DC Return to Section TOC Return to Master TOC CN2 CN7 olo
55. Th inde 2 805 0 PEL BIANCD Fire Cc 0 8 gt g L 5 cle mmm gt cael La T in 2 22 1 DEOS EUER 13 J8 1 1 4 5 CNS owe EB Lis Fia Lat 3 1 15 14 317 1 1 15 14 317 ale 4 4 FP172 FP172 4 12 d 2 em ES el 4 Y alia OS 3 Er al E _ Qo DIPSWITCH 1 e 3 4 UBL S E 5 5 vat acc 0 0 00 FES id Ez pr v mmm ma TURON S 2 P 5 CNA3 rel E VE To Ground according to National Electrical Code NOTE This diagram is for reference only It may not be accurate for all machines covered by this manual The wiring diagram specific to your code is pasted inside one of the enclosure panels of your machine LINCOLN amp INVERTEC V205 T AC DC Return to Section TOC Return to Master TOC
56. ads to their proper locations See Wiring Diagram if necessary 13 Replace case wraparound assembly INVERTEC V205 T AC DC LINCOLN B F 51 52 8 lt o E o LLI amp E l 2 9 oc gt 2 N DOL 01 DOL 01 DOL DOL 0 DOL uonoeg DOL 5 DOL 5 DOL 5 Return to Section TOC Return to Master TOC Return to Section TOC eio OJO E f i 091 3 c 5 amp c Return to Section TOC Return to Master TOC Return to Master TOC F 53 TROUBLESHOOTING AND REPAIR MAIN IGBT BOARD REMOVAL AND REPLACEMENT A WARNING Service and repair should be performed only by Lincoln Electric factory trained personnel Unauthorized repairs performed on this equipment may result in danger to the technician or 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 If for any reason you do not understand the test procedures or are unable to perform the test repairs safely contact the Lincoln Electric Service Department for electrical trou bleshooting assistance before you proceed Call 1 888 935 3877 TEST DESCRIPTION The following procedur
57. aster TOC o 5 o gt 2 t Return to Master TOC Gri TABLE OF CONTENTS DIAGRAM SECTION ol TABLE OF CONTENTS ELECTRICAL DIAGRAMS SECTION ELECTRICAL DIAGRAMS ux ke REG EX Race SECTION G WIRING DIAGRAM CODE 10860 ONLY 2 G 2 NOTE Many PC Board Assemblies are now totally encapsulated and are therefore considered to be unservice able INVERTEC V205 T AC DC LINCOLN B ELECTRICAL DIAGRAMS WIRING DIAGRAM V205 T AC DC STANDARD DIAGRAM E 3 11 4 Return to Section TOC Return to Master TOC ES 5 5 Za En 1 5 e 1 T I M7 LE U m 15 14 314 21 1 1 4 i i FE1 15 14 316 olo EIE EE D Re 8 D c r E d p 8 de 124 CNS ig 1 CN2 120 i Fog 8 T 5 t E amp rr a 15 14 315 15142888 1 15414289 l il 1 n E 15 14 286 Ter rag i s 11 ITITI JE TOIT i I Le
58. ay Boards functions as the interface between the user and the V205 T machine The Control Board functions as the support circuitry for the on board CPU micro processor The Control Board receives information and power from the Bus Board and Main IGBT Inverter Board The Control Board supplies power for the Display Board and sup plies signals for the Display Board to show set and actual current values error codes and pre set values It also accepts signals via the Output Filter Board Pins D and E 24VDO to initiate welding output Upon clo sure of D and E a 24VDC relay is activated to indicate that welding output is required The Control Board CPU sends a command to the Main IGBT Inverter Board to activate the welding IGBTs The remote con trol signals Pins A B amp C are also fed into the Control Display Board from the 6 pin connector located on the front of the machine Based upon current and voltage feedback information the Control Board regu lates the welding output to coincide with the pre set welding commands The Control Display Board also activates and controls the High Frequency Board the gas solenoid and the Super Imposition Board 24 VDC Remote 2 4 path D E Display amp LED D E Remote 2 4 Remote TEN UGH HIGH FREQUENCY HF BOARD The HF Board generates a set of pulses of about 900V which are amplified through the high voltage trans former to about 8 to 10KV These pulses that are
59. c Service Department for electrical trou bleshooting assistance before you proceed Call 1 888 935 3877 TEST DESCRIPTION This test will help determine if the BUS Board is functioning properly MATERIALS NEEDED Volt Ohmmeter Phillips Head Screwdriver Wiring Diagram INVERTEC V205 T AC DC LINCOLN B Frag TROUBLESHOOTING AND REPAIR din BUS BOARD TEST continued FIGURE F 11 BUS BOARD LOCATION Return to Section TOC Return to Master TOC BUS BOARD e 69 9 E Return to Master case wraparound cover gt 5 Carefully apply the correct input voltage to the eee V205 T and check for the rl voltages per Tables F 5 F 6 F 7 F 8 8 6 Machine should be set to STICK mode e PROCEDURE 2 2 Sls 1 Remove input power to the V205 T machine 4 Locate the Bus board and associated plugs Do remove plugs from the board See 2 Using phillips head screwdriver remove the Figure F 11 HE dc Return to Section TOC Return to Master TOC INVERTEC V205 T AC DC LINCOLN B Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC e 2 Return to Section TOC Return to Master TOC o 5 o gt 2 F 29 TROUBLESHOOTING AND REPAIR BUS BOARD TEST c
60. chnical troubleshooting assistance before you proceed Call 1 888 935 3877 Return to Section TOC Return to Master TOC INVERTEC V205 T AC DC LINCOLN B Return to Section TOC Return to Master TOC Return to Section TOC eio OJO gt 091 3 Of c o gt 5 amp c Return to Section TOC Return to Master TOC Return to Master TOC F 5 TROUBLESHOOTING AND REPAIR Observe Safety Guidelines detailed in the beginning of this manual PROBLEMS POSSIBLE AREAS OF SYMPTOMS MISADJUSTMENT S No or low output Error code E11 1 is flashing on the digital display No or low output Error code E12 is flashing on the digital display No output Error code E10 is flashing on the digital display The thermal indicator light is on E12 is an indication that the FUNCTION PROBLEMS input voltage being applied is too high Check for the correct input voltage 230VAC or 115VAC 2 input voltage being applied is too low Check for the correct input voltage 230VAC or 115VAC 2 The welding application may be 1 exceeding the recommended duty cycle Dirt and dust may have clogged the cooling channels inside the 2 machine Refer to the Maintenance Section in this manual The air intake and exhaust lou vers may be blocked due in inad equate clearance around the machine Make sure the cooling fan is operating corr
61. crease or upslope time are presettable The default start current is 15 amps and the default ups lope time is 0 2 seconds INVERTEC V205 T AC DC LINCOLN B Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC eio OJO i olg 1 5 amp Return to Section TOC Return to Master TOC Em OPERATION He 3 Press and hold the TIG torch trigger when the main part of the weld is complete The machine will now decrease the output current at a controlled rate or downslope time until the Finish current is reached Both the Downslope Time and the Finish Current are presettable This Finish cur rent can be maintained as long or as short as nec essary 4 Release the TIG torch trigger The output current of the machine will turn OFF and the gas valve will remain open to continue the flow of the shielding gas The duration of this postflow time is adjusted by the Postflow parameter This operation is shown in 4 step diagram 1 4 STEP DIAGRAM 1 3 4 PREFLOW POST FLOW OUTPUT CURRENT GASON GAS Possible variations of this standard sequence are shown below By releasing and re pressing the TIG torch trigger dur ing the downslope step the output will immediately drop to and hold at the Finish Current Releasing the trigger will turn off the output and begin postflow This
62. d Removal Procedure for plug CN7 location 15 Carefully remove the output filter board by slid ing it by the plug and lead assembly 16 Replace the output filter board 17 Maneuver the new board into its proper loca tion from which it was previously removed INVERTEC V205 T AC DC LINCOLN 5 F 63 Return to Section TOC Return to Master TOC Return to Section TOC eio OJO f i olg gt fom eo cre 5 5 amp Return to Section TOC Return to Master TOC Return to Master TOC eet TROUBLESHOOTING AND REPAIR OUTPUT FILTER BOARD REMOVAL AND REPLACEMENT continued FIGURE F 34 OUTPUT FILTER BOARD CN2 CN1 Nut Positive Output Terminal 18 Reconnect lead CN7 previously removed from 23 Replace casefront ihe contolidisplay board aasembly 24 Replace all casefront mounting screws 19 Replace the large nut previously removed from around the positive output terminal 25 Replace the four nameplate keypad mounting screws previously removed 20 Replace the two output filter board mounting 26 Replace the case wraparound cover screws previously removed 21 Reconnect plugs CN1 and CN2 previously removed from the output filter board 22 Reconnect all heavy leads previously removed INVERTEC V205 T AC DC LINCOLN B Return to Section TOC Return to Master TOC Return to Section TOC eio OJO E f i 0
63. d preparation of the edges is required FILLER MATERIAL The filler rods must deposit welds with mechanical characteristics appropriate for the application COPPER TIG WELDING Since the TIG welding is a process characterized by high heat concentration it is particularly suitable for welding materials with high thermal conductivity like copper As with steel the DC Electrode Negative Polarity is employed with argon as protective gas Considering the fluidity of molten copper the use of backup support may prove useful FILLER MATERIAL In order to avoid the oxidation of the molten material filler materials containing phosphorus silicon or other deoxidating materials are typically used The mechan ical properties can also be improved through the use of silver TIPS FOR AC TIG WELDING AC Inverter TIG power sources offer two significant advantages over conventional Silicon Controlled Rectifier SCR transformer power sources OPERATION B 10 1 The AC wave balance can be set to a higher per centage electrode negative which minimizes tung sten heating and erosion 2 The AC frequency can be varied to focus the arc Increasing the AC frequency above 60Hz will narrow the cone shape arc from the tungsten s tip Decreasing the AC frequency below 60Hz will broaden the cone shape arc from the tungsten s tip The two above benefits can be used to maintain a tight focus of the arc for precise heat control and tight joint
64. e will aid the technician in removing the Main IGBT Board for replacement MATERIALS NEEDED 7mm Nutdriver Phillips Head Screwdriver Wiring Diagram INVERTEC V205 T AC DC LINCOLN B F 53 Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC eio OJO f i 3 QJ fom es 5 5 amp Return to Section TOC Return to Master TOC F 54 TROUBLESHOOTING AND REPAIR MAIN IGBT BOARD REMOVAL AND REPLACEMENT continued FIGURE F 27 MAIN IGBT BOARD LOCATION PROCEDURE Remove input power to the V205 T Using a phillips head screwdriver remove the case wraparound cover Perform the Filter Capacitor Discharge Procedure detailed earlier in this section 4 Locate the main IGBT board See Figure F 27 5 VERY CAREFULLY label plugs CN1 CN2 CN3 CN4 CN5 See Figure F 28 and disconnect NOTE All ribbon cable connections are secured by a small amount of RTV on the outside surface to keep the connections secure MAIN BOARD Using a 7mm nut driver label and disconnect leads RV1 RV2 RV3 RV4 RV5 RV6 amp RV7 See Figure 228 Using a phillips head screwdriver remove the thirty two 32 phillips head screws from the main board Note washer positions for replace ment See Figure F 28 Carefully maneuver the main board out of the
65. ectly RECOMMENDED COURSE OF ACTION E11 is an indication that the 1 If the correct input voltage 230VAC or 115VAC is being applied to the machine the Input Filter Board may be faulty Perform the Input Filter Board Test The Main IGBT Inverter Board May be Faulty Perform the If the correct input voltage 230VAC or 115VAC is being applied to the machine the Input Filter Board may be faulty Perform the Input Filter Board Test The Main IGBT Inverter Board May be Faulty Perform the Main IGBT Inverter Board Low Voltage Supply Test One of the thermal devices may be faulty Check and replace if necessary See the Wiring Diagram The Main IGBT Inverter Board may be faulty A CAUTION If for any reason you do not understand the test procedures or are unable to perform the tests repairs safely contact the Lincoln Electric Service Department for technical troubleshooting assistance before you proceed Call 1 888 935 3877 INVERTEC V205 T AC DC LINCOLN B Return to Section TOC Return to Master TOC Return to Section TOC eio OJO f the 091 olg gt 5 oD amp Return to Section TOC Return to Master TOC Return to Master TOC ru TROUBLESHOOTING AND REPAIR Observe Safety Guidelines detailed in the beginning of this manual PROBLEMS POSSIBLE AREAS OF RECOMMENDED SYMPTOMS MISADJUSTMENT S COURSE OF ACTION FUNCTION PR
66. ed for pipe thawing INVERTEC V205 T AC DC LINCOLN B Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC eio OJO f i 5 amp c Return to Section TOC Return to Master TOC as OPERATION REAR CONTROL PANEL FIGURE B 1 A WARNING 1 Off On switch turns on the electric power to the welder It has two positions O off and With I1 in the I ON position the welding machine is operational and there is voltage between the posi tive and negative Terminals in stick welding In TIG the welding process needs a trigger closure command at the remote control connection Usually via an Arc Start Switch or Foot Amptrol The welder is connected to the supply even if the 41 Power Switch is in the O Off position and there fore there are electrically live parts inside the power source Carefully follow the instructions given in this manual FIGURE B 1 1 Supply cable 2 Gas attachment 11 Power Switch INVERTEC V205 T AC DC LINCOLN B B 3 Return to Section Return to Master TOC Return to Section TOC Return to Master TOC eio OJO nd olg 5 5 amp Return to Section TOC Return to Master TOC OPERATION B a CONTROLS AND SETTINGS All operator controls and adjustment
67. emove leads RV1 and RV2 from the left side of the main IGBT board See Figure F 26 See Wiring Diagram FIGURE F 25 INPUT FILTER BOARD LEADS H L 1 S L1 NOD INVERTEC V205 T AC DC LINCOLN B eio gt 091 Oo 5 5 amp Return to Section TOC Return to Master TOC Return to Section Return to Master TOC Return to Section TOC eio te 091 gt 5 2 amp Return to Section TOC Return to Master TOC Return to Master TOC F 51 TROUBLESHOOTING AND REPAIR INPUT FILTER BOARD REMOVAL AND REPLACEMENT continued FIGURE F 26 MAIN IGBT BOARD LEAD REMOVAL RV1 N RV2 CAUTION Observe static precautions detailed in PC Board Troubleshooting Procedures at the beginning of this section 7 Clean RTV off of the top of the input filter board mounting slides 8 Release the board by simply pressing the two metal buttons at the ends of the board with your thumbs Depressing these buttons will free the plastic lock pins that prevent the P C board from sliding upward 9 Remove and replace the input filter board 10 Slide the new input filter board into its proper position on the mounting slides 11 Push on backside of mounting pins to ensure that the P C board is secured in its proper posi tion 12 Reconnect all previously removed le
68. er K1622 1 One is shipped with the welder torch If you do not care to interchange this part between torches one is required to connect Magnum PTA 9 or PTA 17 TIG torches with one piece cable to the V205 T you may order an additional adapters The quick connect plug provides connection for both gas and welding current K1622 4 Twist Mate adapter for Water Cooled TIG torches Adapter for PTW 18 and 20 Torches TIG Torch Parts Kits Parts kits are available for the PTA 9 and PTA 17 TIG torches These kits include back cap collets collet bodies nozzles and tungstens Order KP507 for PTA 9 torches Order KP508 for PTA 17 torches See publication E12 150 for parts kits breakdown Cut Length Consumables TIG welding filler metals are available for welding stainless steel mild steel alu minum and copper alloys See publication C9 10 INVERTEC V205 T AC DC LINCOLN B Return to Master Return to Master TOC o 5 o gt 2 t Return to Master TOC md TABLE OF CONTENTS MAINTENANCE SECTION E Maintenance vs MINCE IEEE LI E Se So e DUE D 1 Input Filter Capacitor Discharge D 2 Routine Maintenance D 2 Major Component Location 2 4 D 3 INVERTEC V205 T AC DC LINCOLN B
69. er to be certain it is within applicable OSHA PEL and ACGIH TLV limits 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 prod ucts 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 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 INVERTEC V205 T AC DC LINCOLN B Return to Master Return to Master TOC o 5 o gt 2 tc Return to Master TOC SAFETY gt WELDING and CUTTING SPARKS can cause fire or explosion 6 a Remove fire hazards from the welding area If this is not possible cover them to prevent the welding sparks from starting a fire Remember that welding sparks and hot materials from welding can easily go through small cracks and openings to adjacent areas Avoid welding near hydraulic lines Have a fire extinguisher readily available Where compressed gases are to be used at the job site
70. es or circuit breakers smaller than recommended may result in nuisance shut offs from welder inrush currents even if not weld ing at high currents Invertec V205 T AC DC is recommended for use on an individual branch circuit Also called inverse time or thermal magnetic circuit breakers These circuit breakers have a delay in tripping action that decreases as the magnitude of the current increases INVERTEC V205 T AC DC LINCOLN B Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC eio f gt Oo 5 amp Return to Section TOC Return to Master TOC 9 INSTALLATION did 230V INPUT The equipment is provided with a 230 115V cable 6 6ft 2m in length with a 230V 6 50P attachment plug The Invertec V205 T AC DC performs best when connected to 230VAC inputs This input allows full out put of the machine 200 amps 115V INPUT A suitable 115V attachment plug must be installed on the power cord to use the V205 T AC DC with a 115V input supply The rated output of the V205 T AC DC is available when connected to a 30A branch circuit When connected to a branch circuit with lower amp rating lower welding current and duty cycle must be used An output guide is provided below The values are approximate and must be adjusted downward if the fuse or circuit breaker trips off
71. fer ent functions Accesses Welding Parameter Repeatedly pressing the Parameter button will step through the Welding Parameter waveform lights on the front panel Parameters which can be changed Start Current Upslope Weld Current Peak Current Pulse Frequency 96 on Time Background Current Downslope Finish Current Postflow sec There is a LED for each welding parameter When lit t has confirmed the mode or selection chosen Accesses the AC Frequency and AC Balance by pressing and holding the Parameter button for three 3 seconds Accesses the Set Up Menu See Set Up Menu section INVERTEC V205 T AC DC LINCOLN B Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC eio OJO gt gt 5 oD amp Return to Section TOC Return to Master TOC OPERATION 5 Output Parameter Adjust Knob Allows to continuously adjust the current both in TIG and in Stick welding Allows you to change the value shown on Digital Display Item 6 of the parameter selected with Setup Parameter select button Item 4 6 Digital Display displays currently set values for each mode or welding parameter 7 Local Remote push button Selects the welding current adjusting system from front panel from remote control The LED beside the symbol confirms the selection 8 Tig Trigger Se
72. gizes the output for TIG welding if remote output control of the amperage is not desired It allows on off TIG welding at the current set by the Current Control on the control panel When using the Arc Start Switch set the Output Control to the LOCAL position Magnum PTA 9 and 17 TIG Torches The fol lowing standard Magnum TIG torches with one piece cable may be used with the Invertec V205 T K1781 1 9 12 5 4 medium back cap K1781 3 9 25ft medium back K1782 1 PTA 17 12 5 ft long back cap K1782 3 PTA 17 25 ft long back cap NOTE Each torch requires a Twist Mate adapter one is included with the machine Collets collet bodies and nozzles are not included and must be ordered separately TIG TORCH KITS K2266 1 TIG Mate 17 Air Cooled TIG Torch Starter Pack One complete easy to order kit packaged in its own portable carrying case Includes PTA 17 torch parts kit Harris flowmeter regulator 10 ft gas hose Twist mate adapter work clamp and cable K2267 1 TIG Mate 20 Water Cooled TIG Torch Starter Pack One complete easy to order kit pack aged in its own portable carrying case Includes PTW 20 torch parts kit Harris flowmeter regulator 10 ft gas hose Twist Mate adapter work clamp and cable and 10 ft water hose CABLE PLUGS K852 70 Cable Plug Kit for 1 0 2 0 cable Attaches to welding cable to provide quick disconnect from machine Twist Mate Torch Adapt
73. he Hall Effect device may be faulty 7 The Control Display Board may be faulty The machine operates properly in 1 Make sure the machine is set up 1 The Output Module Transistor the Stick and DC TIG modes AC and configured correctly for the Board may be faulty See the TIG mode does not function prop AC TIG mode erly and Wiring Diagram 2 The Superimposition Board may be faulty A CAUTION If for any reason you do not understand the test procedures or are unable to perform the tests repairs safely contact the Lincoln Electric Service Department for technical troubleshooting assistance before you proceed Call 1 888 935 3877 INVERTEC V205 T AC DC LINCOLN B Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC eio OJO nds 0 gt els 5 2 ollo amp Return to Section TOC Return to Master TOC TROUBLESHOOTING AND REPAIR EXTERNAL DIAGNOSTICS Figure F 1 External Diagnostics Display Output Current Control Output Set up Parameter MS Rost lect Button Power Supply Select Butto Al arm CEW NVERTEC V205 T AC DC The front panel controls the status of the equipment and shows it to the operator via the LED s and the display Immediately after switch on of the equipment the front panel executes an autotest operation all LED s will light up and the display shows
74. i 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 11 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 PR CAUTIONS DE S RET POUR LES MACHINES SOUDER TRANSFORMATEUR ET REDRESSEUR 1 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 2 Autant que possible l installation et l entretien du poste seront effectu s par un lectricien qualifi 3 Avant de faires des travaux l interieur de poste la debranch er l interrupteur la boite de fusibles 4 Garder tous les couvercles et dispositifs de s ret leur place INVERTEC V205 T AC DC LINCOLN B Return to Master Return to Master TOC o 5 o gt 2 tc Return to Master TOC SAFETY Electromagnetic Compatibility EMC Conformance Products displaying the CE mark are in conformity with European Community Council Directive of 15 Dec 2004 on the appr
75. itor Discharge Procedure ur Magra detailed earlier in this section eio OJO f i 3 cre Sl gt oO amp c Return to Section TOC Return to Master TOC INVERTEC V205 T AC DC LINCOLN B isa TROUBLESHOOTING AND REPAIR MAIN IGBT INVERTER BOARD LOW VOLTAGE TEST continued Table 1 Test Points Machine Mode Test Point LED Value TP13 TP14 15 VDC 5 VDC 15 VDC 24 VDC Return to Section TOC Return to Master TOC TP11 TP14 TP12 TP14 TP3 TP5 TP17 TP18 415 VDC 415 VDC 414 5 VDC TP21 TP18 Return to Section TOC Return to Master TOC TP2 TP18 eio OJO i 5 amp c Return to Section TOC Return to Master TOC INVERTEC V205 T AC DC LINCOLN B TROUBLESHOOTING AND REPAIR MAIN IGBT INVERTER BOARD LOW VOLTAGE TEST continued FIGURE F 7 MAIN IGBT INVERTER BOARD LOCATION This is an illustration of the upper right corner of the P C board Return to Section TOC Return to Master TOC TP2 MF2 4 4 TP5L5 L1 L2 um ER EN um 69 9 E tc Return to Master TOC Ej 11 I 9 5 5 16 5 5 17 me TP18 21 17 110 Return to Section Return t
76. k to the welding mode ready to weld with the new selected AC Balance To change the Post Flow time repeatedly push the Parameter button until the Post Flow indicator light is on Adjust the Output control to the desired Post Flow time as indicated on digital display INVERTEC V205 T AC DC LINCOLN B DC TIG WELDING QUICK START UP A WARNING ELECTRIC SHOCK can kill Have an electrician install and service this equipment Return to Section TOC Return to Master TOC Turn the input power off at the fuse box dis connect or unplug supply lines and allow machine to sit for five minutes minimum to allow the power capacitors to discharge before working inside this equipment Do not touch electrically hot parts Connect up the shielding gas typically argon using an appropriate regulator Connect foot amptrol torch and work lead to power source With the Work cable connected to a properly grounded work piece turn the power source on Return to Section TOC Return to Master TOC To change to DC TIG Welding Press Mode button to select DC TIG Press Trigger Mode button and set to 2 step Press Local Remote Mode button and set for Remote Pulsing parameters selected by Parameter button and changed using Output Control Set the maximum output current desired using the Output Control Initiate the arc by closing the Foot Amptrol s arc start Switch The Amptrol will control the outpu
77. ld involve construction of an electromagnetic screen enclosing the power source and the work com plete with associated input filters In all cases electromagnetic disturbances must be reduced to the point where they are no longer troublesome Note The welding circuit may or may not be earthed for safety reasons according to national codes Changing the earthing arrangements should only be authorized by a person who is competent to access whether the changes will increase the risk of injury e g by allowing parallel welding current return paths which may damage the earth circuits of other equip ment Assessment of Area Before installing welding equipment the user shall make an assessment of potential electromagnetic prob lems in the surrounding area The following shall be taken into account a other supply cables control cables signaling and telephone cables above below and adjacent to the welding equipment b radio and television transmitters and receivers C computer and other control equipment d safety critical equipment e g guarding of industrial equipment e the health of the people around e g the use of pacemakers and hearing aids f equipment used for calibration or measurement g the immunity of other equipment in the environment The user shall ensure that other equipment being used in the environment is compatible This may require additional protection measures h the time of day that welding or other activi
78. lding IG rere uuo pucr ede ropa res d B 10 TIG Welding Quick Start 0 B 11 DC TIG Welding Quick Start Up 2 B 12 INVERTEC V205 T AC DC LINCOLN B Return to Section TOC Return to Master TOC Return to Section TOC eio OJO f i olg 5 2 amp Return to Section TOC Return to Master TOC Return to Master TOC uis OPERATION Read and understand this entire section before operating your machine SAFETY INSTRUCTIONS A WARNING ELECTRIC SHOCK can kill e not touch electrically live parts such as output terminals electrode or internal wiring Insulate yourself from the work and ground Always wear dry insulating gloves FUMES AND GASES can be dangerous Keep your head out of fumes Use ventilation or exhaust to remove fumes from breathing zone 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 4 5 1 Wear eye ear and body protection Only qualified personnel should operate this equipment Observe all safety information throughout this manual GENERAL DESCRIPTION
79. lding current passing through lifting chains crane cables or other alternate circuits This can create fire hazards or overheat lifting chains or cables until they fail Also see item 1 c Read and follow NFPA 51B Standard for Fire Prevention During Welding Cutting and Other Hot Work available from 1 Batterymarch Park PO box 9101 Quincy 022690 9101 Do not use a welding power source for pipe thawing CYLINDER may explode if damaged 7 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 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
80. lectrode data for this information Then connect the output cables to the output terminals corresponding to this polarity For instance for welding connect the electrode cable which is connected to the electrode holder to the output terminal and the work cable which is connected to the work clamp to the output terminal Insert the connector with the key lining up with the key Way and rotate clockwise until the connection is snug Do not over tighten FIGURE A 2 WORK CABLE WORK CABLE STICK ELECTRODE HOLDER INVERTEC V205 T AC DC LINCOLN B Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC eio OJO nd Oo 5 Dllo amp c Return to Section TOC Return to Master TOC Ber INSTALLATION Por QUICK DISCONNECT PLUG FOR STICK ELECTRODE CABLE and WORK CABLE A quick disconnect system is used for the welding cable connections The stick electrode cable will need to have a plug attached 1 Cut off welding cable lug if present 2 Remove 1 00 in 25mm of welding cable insula tion 3 Slide rubber boot onto cable end The boot end may be trimmed to match the cable diameter Use soap or other nonpetroleum based lubricant to help slide the boot over the cable if needed BOOT WELDING CABLE EN 1 00 4 25 TRIM TO FIT OVER CABLE WELDING CABLE
81. low the three step procedure listed below Step 1 LOCATE PROBLEM SYMPTOM Look under the column labeled PROBLEM SYMPTOMS This column describes pos sible symptoms that the machine may exhib it Find the listing that best describes the symptom that the machine is exhibiting Symptoms are grouped into the following categories output problems function prob lems and welding problems Step 2 PERFORM EXTERNAL TESTS The second column labeled POSSIBLE AREAS OF MISADJUSTMENT S lists the obvious external possibilities that may con tribute to the machine symptom Perform these tests checks in the order listed In general these tests can be conducted with out removing the case wrap around cover Step 3 RECOMMENDED COURSE OF ACTION The last column labeled Recommended Course of Action lists the most likely com ponents that may have failed in your machine It also specifies the appropriate test procedure to verify that the subject com ponent is either good or bad If there are a number of possible components check the components in the order listed to eliminate one possibility at a time until you locate the cause of your problem All of the referenced test procedures referred to in the Troubleshooting Guide are described in detail at the end of this chapter Refer to the Troubleshooting and Repair Table of Contents to locate each specific Test Procedure All of the specified test points components terminal strip
82. machine Replace Maneuver new board into its proper location and secure to machine using the thirty two phillips head screws previously removed INVERTEC V205 T AC DC LINCOLN B F 54 Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC e 69 2 2 Return to Section Return to Master TOC o 5 o gt 2 r TROUBLESHOOTING AND REPAIR MAIN IGBT BOARD REMOVAL AND REPLACEMENT continued FIGURE F 28 MAIN BOARD PLUG AND MOUNTING SCREW LOCATION CN2 CN1 RV1 RV2 RV3 RV4 RV7 RV6 1009 10 Reconnect previously removed leads RV1 thru 12 Replace the case wraparound cover previous RV7 to the P C board See Wiring Diagram if ly removed necessary 11 Reconnect previously removed plugs CN1 thru CN5 to the P C board NOTE All ribbon cable connections have an indexing location slot to assure proper replacement INVERTEC V205 T AC DC LINCOLN B 56 8 lt o E o LLI amp E l 2 9 oc gt 2 DOL 01 DOL 01 DOL DOL 0 DOL uonoeg DOL 5 DOL 5 DOL 5 rae TROUBLESHOOTING AND REPAIR Pear CONTROL DISPLAY BOARD REMOVAL AND REPLACEMENT A WARNI
83. ms ar x El a Return to Section Return to Master TOC INVERTEC V205 T AC DC LINCOLN B Return to Section Return to Master TOC Return to Section TOC Return to Master TOC eio OJO f i 3 Oo fom eo 5 2 amp c Return to Section TOC Return to Master TOC FM TROUBLESHOOTING AND REPAIR pM MAIN INVERTER BOARD WELDING LOGIC AND INVERTER SECTION TEST continued FIGURE F 23 MAIN BOARD LOWER LEFT iM z Ro i zii anes E AEREA TP9 GROUND POWER L11 L14 MF11 MF15 MF12 MF16 INVERTEC V205 T AC DC LINCOLN B 48 8 lt o E o LLI amp E l 2 9 oc gt 2 Y DOL 01 DOL 01 DOL DOL 0 DOL uonoeg DOL 5 DOL 5 DOL 5 Return to Section TOC Return to Master TOC Return to Section TOC eio OJO f i 5 amp c Return to Section TOC Return to Master TOC Return to Master TOC F 49 TROUBLESHOOTING AND REPAIR INPUT FILTER BOARD REMOVAL AND REPLACEMENT A WARNING Service and repair should be performed only by Lincoln Electric factory trained personnel Unauthori
84. n Return to Master TOC INVERTEC V205 T AC DC LINCOLN B Return to Section Return to Master TOC Return to Section TOC Return to Master TOC eio OJO f i 3 Of c 5 amp c Return to Section TOC Return to Master TOC did TROUBLESHOOTING AND REPAIR ind OUTPUT FILTER BOARD TEST continued FIGURE F 17 OUTPUT FILTER BOARD PLUG LOCATION Expected Voltage O Wee 2 64 66 Output Voltage 52 6 VDC Superimposition Common __ FIGURE F 18 OUTPUT FILTER BOARD PLUG CN1 66 53 N1 64 65 54 INVERTEC V205 T AC DC LINCOLN B 38 8 lt o E o LLI amp E l 2 9 oc gt 2 DOL 01 DOL 01 DOL DOL 0 DOL uonoeg DOL 5 DOL 5 DOL 5 Return to Section TOC Return to Master TOC Return to Section TOC eio OJO f i 5 amp c Return to Section TOC Return to Master TOC Return to Master TOC F 39 TROUBLESHOOTING AND REPAIR SECONDARY OUTPUT BOARD ASSEMBLY TEST A WARNING Service and repair should be performed only by Lincoln Electric facto
85. n TOC Return to Master TOC o 5 o gt 2 F 11 TROUBLESHOOTING AND REPAIR INTERNAL DIAGNOSTICS Continued cca onee T power enabled See pot signal amp LED STICK ON Green Output TIG ON torch trigger pulled ON ALARM Red actual output current Gate MOS 11 active output power enabled STICK ON Green TIG ON torch trigger pulled Gate MOS 12 active output power enabled STICK ON Green TIG ON torch trigger pulled Gate MOS 16 active output power enabled STICK ON Green TIG ON torch trigger pulled Gate MOS 15 active output power enabled STICK ON Green TIG ON torch trigger pulled INVERTEC V205 T AC DC LINCOLN B F 11 12 8 lt o E o LLI amp E l 2 9 oc gt 2 u DOL 01 DOL 01 DOL DOL DOL uonoeg DOL 5 DOL 5 DOL 5 Return to Section TOC Return to Master TOC Return to Section TOC eio OJO f i 5 amp c Return to Section TOC Return to Master TOC Return to Master TOC F 13 TROUBLESHOOTING AND REPAIR A WARNING Service and repair should be performed only by Lincoln Electric factory trained personnel Unauthorized repair
86. ne dry Do not place it on wet ground or in puddles MACHINE GROUNDING AND HIGH FRE QUENCY INTERFERENCE PROTECTION The Capacitor Discharge Circuit used in the high fre quency generator may cause many radio TV and electronic equipment interference problems These problems may be the result of radiated interference Proper grounding methods can reduce or eliminate radiated interference The Invertec V205 T AC DC has been field tested under recommended installation conditions It com plies with FCC allowable limits for radiation Radiated interference can develop in the following four ways 1 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 pos sible and enclose as much of them as possible in rigid metallic conduit or equivalent shielding for a distance of 50 feet 15 2m There should be good electrical contact between this conduit and the welder case ground Both ends of the conduit should be connected to a driven ground and the entire length should be continuous 2 Keep the work and electrode leads as short as pos sible and as close togethe
87. ng 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 2 d 1 Route the electrode and work cables together Secure them with tape when possible 2 d 2 Never coil the electrode lead around your body 2 d 3 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 Connect the work cable to the workpiece as close as possible to the area being welded Do not work next to welding power source INVERTEC V205 T AC DC LINCOLN B Return to Master Return to Master TOC o 5 o gt 2 tc Return to Master TOC 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
88. nnas Keep all panels securely in place All electrical conductors within 50 ft 15 2m of the welder should be enclosed in grounded rigid metallic conduit or equivalent shielding Flexible metallic conduit is generally not suitable 8 When the welder is enclosed in a metal building several earth driven electrical grounds connected as in 5b above around the periphery of the build ing are recommended Failure to observe these recommended installation procedures can cause radio or TV interference prob lems INPUT CONNECTIONS Be sure the voltage phase and frequency of the input power is as specified on the rating plate located on the bottom of the machine A WARNING ELECTRIC SHOCK can kill Have a qualified electrician install and service this equipment Turn the input power OFF and unplug the machine from the recep tacle before working on this equip ment Allow machine to sit for 5 minutes minimum to allow the power capacitors to discharge before working inside this equipment Do not touch electrically hot parts Machine must be plugged into a receptacle that is grounded according to the National Electrical Code and local codes Do not remove or defeat the purpose of the power cord ground pin RECONNECT PROCEDURE The Invertec V205 T AC DC auto reconnects to either 115V or 230V supply Fuse the input circuit with time delay fuses or delay type circuit breakers Using fus
89. ns chemicals known to the State of California to cause cancer birth defects or other reproductive harm The Above For Diesel Engines Ihe Above For Gasoline 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 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 the engine off before troubleshooting and maintenance work unless the maintenance work requires it to be running 1 b Operate engines in open well ventilated areas or vent the engine exhaust fumes outdoors 1 c Do not add the fuel near an open flame weld ing arc or when the engine is running Stop the engine and allow it to cool before refuel ing to prevent spilled fuel from vaporizing on contact with hot engine parts and igniting Do not spill fuel when filling tank
90. nty For your safety and to avoid electrical shock please observe all safety notes and precautions detailed throughout this manual If for any reason you do not understand the test procedures or are unable to perform the test repairs safely contact the Lincoln Electric Service Department for electrical trou bleshooting assistance before you proceed Call 1 888 935 3877 TEST DESCRIPTION This test will help determine if output voltages and external trigger signals are being processed through the Output Board MATERIALS NEEDED Volt Ohmmeter Phillips Head Screwdriver External DC Ammeter INVERTEC V205 T AC DC LINCOLN B F 35 indi TROUBLESHOOTING AND REPAIR ne OUTPUT FILTER BOARD TEST continued FIGURE F 16 OUTPUT FILTER BOARD LOCATION 69 2 Return to Master TOC Output Filter Board olo P 912 gt QTL ala 2 NS 0 c is Sls PROCEDURE o els 1 Remove input power to the V205 T machine 4 Locate the Output Filter board and associated 2 2 plugs Do not remove plugs from the board 2 2 Using phillips head screwdriver remove the See Figure F 16 case wraparound cover gt z 5 Carefully apply the correct input voltage to the 3 Bu ees E Procedure V205 T and check for the correct secondary voltages Table 12 Return to Sectio
91. o Master TOC INVERTEC V205 T AC DC LINCOLN B guy Return to Section TOC Return to Master TOC Return to Section TOC eio OJO f i 5 amp c Return to Section TOC Return to Master TOC Return to Master TOC F 23 TROUBLESHOOTING AND REPAIR CONTROL DISPLAY BOARD TEST A WARNING Service and repair should be performed only by Lincoln Electric factory trained personnel Unauthorized repairs performed on this equipment may result in danger to the technician or 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 If for any reason you do not understand the test procedures or are unable to perform the test repairs safely contact the Lincoln Electric Service Department for electrical trou bleshooting assistance before you proceed Call 1 888 935 3877 TEST DESCRIPTION This test will help determine if the Front Panel Boards work properly MATERIALS NEEDED Volt Ohmmeter Phillips Head Screwdriver Wiring Diagram INVERTEC V205 T AC DC LINCOLN B F 23 TROUBLESHOOTING AND REPAIR Ev CONTROL DISPLAY BOARD TEST continued FIGURE F 8 CONTROL DISPLAY BOARD LOCATION Control Display Board Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC P
92. on TOC Return to Master TOC 2 Return to Section TOC Return to Master TOC 5 o E 2 tc in INSTALLATION 5 TECHNICAL SPECIFICATIONS V205 T AC DC TIG K1855 1 Code Number 10860 INPUT SINGLE PHASE ONLY Input Voltages 50 60 Hz Max Input Current 115 34A at Rated Output 230 30A at Rated Output RATED OUTPUT Duty Cycle Output Amps Volts at Rated Amperes Input Amps 115V 3596 Stick 110 6096 90 10096 70 24 4V 34A 23 6V 28A 22 8V 20A 115V 40 TIG 150 60 120 100 100 230V 35 60 100 230V 40 Stick 180 150 130 TIG 200 60 170 100 140 OUTPUT Output Current Range 6 200 Amps Maximum Open Circuit Voltage 54 Volts Max Type of Output AC DC RECOMMENDED INPUT WIRE AND FUSE SIZES FOR MAXIMUM RATED OUTPUT INPUT VOLTAGE FREQUENCY HZ TYPE S SO ST STO OR EXTRA HARD USAGE INPUT CORD AWG TIME DELAY CIRCUIT BREAKER OR FUSE SIZE AMPS 115 50 60 12 230 50 60 PHYSICAL DIMENSIONS Weight Approx 38 Ibs 17 kgs TEMPERATURE RANGES OPERATING TEMPERATURE RANGE STORAGE TEMPERATURE RANGE 20 C to 40 C 50 C to 85 C INVERTEC V205 T AC DC LINCOLN B Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC eio OJO gt 091 o 1 5 oD amp Return to Section TOC
93. ontinued TABLE F 5 PLUG CN2 TEST POINTS a C 2 2 Ground Gate Switch 26 Ground Gate Switch A 3 Thermal Trigger AG Uni Ground Hall Probe 30 GasSwihB Gate Switch O TABLE F 6 PLUG CN3 TEST POINTS 65 Ground Superimpositon In TIG mode only when Remote is pushed comes for two sec then goes to zero In STICK mode is present all the time TABLE F 7 PLUG CN4 TEST POINTS Wiss Description Expected Voltage 42 Front Panel Supply Ground Ham Start Ground TABLE F 8 PLUG CN7 TEST POINTS Expected Voltage Water Cooling Supply Earth Cable Water Cooling Supply Water Gooing Supply a E TABLE F 9 PLUG CN1 TEST POINTS Wire Description Expected Voltage 5 6 Fan 24 VDC INVERTEC V205 T AC DC LINCOLN B F 29 20 TROUBLESHOOTING AND REPAIR 530 BUS BOARD TEST continued FIGURE F 12 BUS BOARD PLUG LOCATIONS CN1 CN2 Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC FIGURE F 13 PLUGS CN2 CN3 4 21 22 23 24 26 eio O o gt olg olg 515 51 amp 27 28 29 30 32 41 42 44
94. ontre 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 zones l on pique le laitier i SAFETY iv 6 Eloigner les mat riaux inflammables ou les recouvrir afin de pr venir tout risque d incendie aux tincelles Quand on ne soude pas poser la pince 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 levage 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 cadm
95. operation shown in 4 step diagram 2 4 STEP DIAGRAM 2 3A TORCH A BUTTON OUTPUT CURRENT POST FLOW GAS ON GAS Elo ur P 9 10 11 12 13 Welding selection button Permits selection of the welding mode The LED beside the symbol confirm the selection Stick TIG DC TIG AC Electrode Connection Negative For quick dis connect system using Twist Mate cable plugs with gas pass through for TIG Torches Remote Control Connector For the connection of a Lincoln Foot Amptrol Hand Amptrol or Arc Start Switch See the ACCESSORIES section for available options Electrode Connection Positive For quick dis connect system using Twist Mate cable plugs Welding Parameter Display LED s show which mode or welding parameter is activated for adjust ment If itis necessary to modify the welding parameters Item 13 Wait four seconds after the LED s on the panel have gone out the welding current LED will be lit Press the SETUP Parameter push button Item 4 every time the push button is pressed one of the LED s in the diagram Item 13 comes on in clockwise sequence and the value of the parameter appears on the Digital display Item 6 Stop at the desired parameter Rotate the Output Parameter Adjust Knob Item 5 and modify the parameter value Press the SETUP Parameter Item 4 push button again to pass to another parameter or wait five second
96. oximate melting temperature of 3370 C and the workpiece An inert gas typically argon atmosphere protects the weld pool To avoid inclusions of tungsten in the joint the elec trode should not contact the workpiece For this reason the arc is started through a Hi Freq generator For situations requiring no Hi Freq Touch Start Tig reduces the short circuit current to keep tungsten inclusions to the minimum To improve weld bead quality at the end of the weld it is important to carefully control the downslope of cur rent and ensure proper gas coverage over the weld FIGURE B 3 1 Workpiece 5 Flowmeter 2 Hiller material 6 Pressure reducer 3 Non consumable electrode 7 Inert gas typically argon 4 Torch 8 Power source 8 OPERATION B 8 WELDING POLARITY DC Electrode Negative Polarity Direct Current Straight Polarity see FIGURE B 4 While Welding there is a continuous flow of electrons from the electrode to the workpiece This is the most used polarity ensuring limited wear of the electrode since the majority of the heat concen trates on the anode workpiece Narrow and deep welds are obtained with high travel speeds Most materials with the exception of aluminum and magnesium are welded with this polarity FIGURE B 4 INVERTEC V205 T AC DC LINCOLN B Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC eio
97. oximation of the laws of the Member States relating to electromagnetic compatibility 2004 108 EC It was manufactured in conformity with a national standard that implements a harmonized standard EN 60974 10 Electromagnetic Compatibility EMC Product Standard for Arc Welding Equipment It is for use with other Lincoln Electric equipment It is designed for industrial and professional use Introduction All electrical equipment generates small amounts of electromagnetic emission Electrical emission may be transmitted through power lines or radiated through space similar to a radio transmitter When emissions are received by other equipment electrical interference may result Electrical emissions may affect many kinds of electrical equipment other nearby welding equipment radio and TV reception numerical controlled machines telephone systems computers etc Be aware that interference may result and extra precautions may be required when a welding power source is used in a domestic establishment Installation and Use The user is responsible for installing and using the welding equipment according to the manufacturer s instructions If electromagnetic disturbances are detected then it shall be the responsibility of the user of the welding equipment to resolve the situation with the technical assistance of the manufacturer In some cases this remedial action may be as simple as earthing grounding the welding circuit see Note In other cases it cou
98. put demands when the IGBTs are gated on The auto reconnect circuit receives and processes a low level voltage signal from the Bus Board This low level signal is utilized to adjust for the Knob Remote 75 76 77 different voltage requirements needed by the weld IGBT circuits A signal is also sent to the Control Board so that when the input voltage is reduced the output of the machine will be limited accordingly The Auxiliary power portion of the board generates several voltages through flyback topology and a 50KHZ switching frequency These various voltages 24 15 5 48 and 15 are utilized to operate the control and protection electronics the gas solenoid the trigger circuit and the fan motor The Main IGBT Inverter Board receives command and pre set signals from the Control Display board It also receives feedback information both voltage and cur rent from the Output Filter Board and Hall Effect Device via the Bus Board It processes this informa tion and generates the correct pulse width modulation signal PWM that is applied to the gates of the weld IGBTs This controls and regulates the output of the machine The thermostats signals are connected to the Main IGBT Inverter Board This status information is passed on to the Control Board In the case of an over temperature condition the Control Board will prevent output until the machine cools and the thermostats reset Low level analog signals are genera
99. quences For the V205 T AC DC TIG welding can be done either the 2 step or 4 step mode which is selected with the Trigger Mode Push Button 2 Step Sequence With the Trigger Mode switch in the 2 step position the following welding sequence will occur This sequence is shown in 2 step diagram 1 1 Press and hold the Arc Start Switch to start the sequence The machine will open the gas valve to start the flow of the shielding gas After a 0 5 second preflow time to purge air from the torch hose the output of the machine is turned ON At this time the arc is started After the arc is started the output current will be increased from the start current to the welding cur rent Both the start current and increase or upslope time are presettable The default start current is 15 amps and the default upslope time is 0 2 seconds 2 Release the Arc Start Switch to stop welding The machine will now decrease the output current at a controlled rate or downslope time until the Finish current also commonly referred to as Crater Current is reached and the output of the machine is turned OFF Both the Downslope Time and the Finish Current are can be preset After the arc is turned OFF the gas valve will remain open to continue the flow of the shielding gas to the hot electrode and work piece The duration of this postflow shielding gas is adjusted by the Postflow Parameter 2 STEP DIAGRAM 1 1 TORCH BUTTON
100. r as possible Lengths should not exceed 25 ft 7 6m Tape the electrode and work leads together into one bundle when prac tical INVERTEC V205 T AC DC LINCOLN B Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC eio OJO E f i gt 5 2 amp Return to Section TOC Return to Master TOC INSTALLATION Bt 3 Be sure the torch and work cable rubber coverings are free of cuts and cracks that allow high fre quency leakage Cables with high natural rubber content such as Lincoln Stable Arc better resist high frequency leakage than neoprene and other synthetic rubber insulated cables 4 Keep the torch in good repair and all connections tight to reduce high frequency leakage 5 The work terminal must be connected to a ground within ten feet of the welder using one of the fol lowing methods a Ametal underground water pipe in direct con tact with the earth for ten feet or more b A 3 4 19mm galvanized pipe or a 5 8 16mm solid galvanized iron steel or copper rod driven at least eight feet into the ground The ground should be securely made and the grounding cable should be as short as possible using cable of the same size as the work cable or larger Grounding to the building frame electrical conduit or a long pipe system can result in re radi ation effectively making these members radiating ante
101. r the Output Module Transistor Board The Superimposition Board plugs directly into the Bus Board NOTE Unshaded areas of Block Logic Diagram are the subject of discussion INVERTEC V205 T AC DC LINCOLN B Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC e 2 Return to Section TOC Return to Master TOC 5 o gt 2 r ES THEORY OF OPERATION FIGURE 5 CONTROL DISPLAY BOARD HF BOARD amp OUTPUT FILTER BOARD Voltage Feedback AC DC Gate drive signals Current Feedback Thermostats reconnect info turn on AC ckt voltage feedback Een current feedback 48 24 15 15 5 Main IGBT amp Power board DC blocking capacitor board Main Output Transformer board Output Diode Thermostat Output Filter bd bypass Y Qu AM O e c Output RF coil AN Choke Current Output Transistor Module Device thermostat info input volt meter input current meter tum on AC ckt tum HF control signal 48 24 Control board 48 VDC Gas Solenoid CONTROL DISPLAY BOARD The Control Display Board assembly is actually two boards mounted together They should be replaced together The Display portion houses the control panel LEDs push buttons and output encoders The Displ
102. regulations Screening and Shielding Selective screening and shielding of other cables and equipment in the surrounding area may alleviate problems of interference Screening of the entire welding installation may be considered for special applica tions 1 1 Portions of the preceding text are contained in EN 60974 10 Electromagnetic Compatibility EMC prod uct standard for arc welding equipment INVERTEC V205 T AC DC LINCOLN B MASTER TABLE OF CONTENTS FOR ALL SECTIONS RETURN TO MAIN MENU Accessories Section gt gt Section D Theory of Operation _ _ Section E Troubleshooting and Repair Section F Electrical Diagrams 2 0 i eee xksa ee ee oA Section G Parts Martial aua rccte ace Coeur dcc daa cu d ca da e f ca a E P 400 INVERTEC V205 T AC DC LINCOLN B Return to Master Return to Master TOC o 5 o 2 t Return to Master TOC A 1 TABLE OF CONTENTS INSTALLATION SECTION Installation S LI S D 1 Technical Specifications 1
103. repeated at a frequency of about 80HZ are applied to the high frequency transformer that is located in the negative welding output leg of the machine This high frequency pulse is transferred to the TIG torch via the high frequency transformer This allows the remote starting of the TIG arc without the need for the tungsten electrode to touch the work This high frequency pulse is removed when the welding arc is established The command signals are received from the micro processor on the Control Board and last for about 1 second maximum The HF Board receives it s power from the 385 VDC derived from the electrolytic capacitors on the Main IGBT Inverter Board OUTPUT FILTER BOARD This PC board located at the welding output terminals protects the internal circuitry of the machine from high voltage and high frequency pulses that may be fed back into the unit via the welding cables torch cable or remote control equipment This unwanted noise is shunted to case ground NOTE Unshaded areas of Block Logic Diagram are the subject of discussion INVERTEC V205 T AC DC LINCOLN B Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC eio gt gt 5 5 amp Return to Section TOC Return to Master TOC ES THEORY OF OPERATION ER FIGURE E 6 IGBT GATE SOURCE BODY REGION n
104. rocedure detailed earlier in this section 11 Reconnect leads 1 2 amp 3 previously removed 4 Locate the output transistor See Figure F 36 12 Reconnect lead CN1 5 Disconnect plug CN1 from the output transistor 13 Replace the case wraparound cover See Figure F 37 6 Using a phillips head screwdriver disconnect leads 1 2 amp 3 See Figure F 37 7 Using a 5mm allen wrench remove the output transistor mounting bolts 8 Remove and replace the output transistor NOTE Be careful not to bend the copper bus bars Return to Section TOC Return to Master TOC INVERTEC V205 T AC DC LINCOLN B TROUBLESHOOTING AND REPAIR OUTPUT TRANSISTOR REMOVAL AND REPLACEMENT continued EIE 5 5 FIGURE F 37 OUTPUT TRANSISTOR LEAD LOCATION ej Plug CN1 5 5 xe 9 ma cc 3 5 5 5mm oO 8 Allen Bolts 2 ele gjg 1 eio OJO f i gt 5 5 amp c Return to Section TOC Return to Master TOC INVERTEC V205 T AC DC LINCOLN B 70 8 lt o E o LLI amp E l 2 9 oc gt 2 e n DOL 01 DOL 01 DOL DOL 0 DOL uonoeg DOL 5 DOL 5 DOL 5 Return to Master Return to M
105. ry trained personnel Unauthorized repairs performed on this equipment may result in danger to the technician or 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 If for any reason you do not understand the test procedures or are unable to perform the test repairs safely contact the Lincoln Electric Service Department for electrical trou bleshooting assistance before you proceed Call 1 888 935 3877 TEST DESCRIPTION This test will help determine if the Secondary Output Board Assembly has shorted or dam aged components MATERIALS NEEDED Volt Ohmmeter Phillips Head Screwdriver Wiring Diagram INVERTEC V205 T AC DC LINCOLN B F 39 Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC eio OJO f i olg gt 09 29 cre 5 5 amp Return to Section TOC Return to Master TOC TROUBLESHOOTING AND REPAIR SECONDARY OUTPUT BOARD ASSEMBLY TEST continued FIGURE F 19 SECONDARY POWER BOARD LOCATION 7 7 of N OUTPUT TRANSISTOR OUTPUT DIODES PROCEDURE 1 Remove input power to the V205 T machine 4 Locate the Secondary Power board and associ ated plugs Do not remove plugs from the 2 Using a phillips head screwdriver
106. s etc can be found on the referenced electrical wiring diagrams and schematics Refer to the Electrical Diagrams Section Table of Contents to locate the appropriate diagram CAUTION If for any reason do not understand the test procedures or are unable to perform the tests repairs safely contact the Lincoln Electric Service Department for technical troubleshooting assistance before you proceed Call 1 888 935 3877 INVERTEC V205 T AC DC LINCOLN B F 2 Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC 42 2 Return to Section Return to Master TOC o 5 o 2 tc TROUBLESHOOTING AND REPAIR Fs PC BOARD TROUBLESHOOTING PROCEDURES A WARNING K ELECTRIC SHOCK can kill Have an electrician install and service this equipment Turn the input power OFF at the fuse box before working on equipment Do not touch electrically hot parts CAUTION Sometimes machine failures appear to be due to board failures These problems can sometimes be traced to poor electrical connections To avoid prob lems when troubleshooting and replacing PC boards please use the following procedure 1 Determine to the best of your technical ability that the PC board is the most likely component causing the failure symptom 2 Check for loose connections at the PC board to assure that the P
107. s and the Weld Current LED will come on again WELDING PARAMETER DEFAULTS AND RANGES PARAMETER VALUE MN DEFAULT STARTCURRENT ams 6 Max 15 _ eec o 45 5 o WELD CURRENT 6 6 o DOWNSLOPE SEG 10 FINISH CURRENT AMPS POSTFLOW ER T oa 2 PULSE FREQUENCY ON TIME 8 9 5o ___ _____ BACKGROUND CURRENT OFWELDCURRENT 3 10 20 HZ AC FREQUENCY AC BALANCE 96 EN EN Electrode Negative MODE TIG 2 STEP ____ eee ee E Maximum Weld Current can be limited by input voltage Welding Mode AC TIG waveform and AC TIG frequency INVERTEC V205 T AC DC ue Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC eio OJO 8 gt 5 Dllo amp c Return to Section TOC Return to Master TOC E OPERATION SET UP MENU Rotate the Output Parameter Adjust Knob the Digital Display shows the numbers corre sponding to the parameters in sequence stop at the desired parameter and push the Setup Parameter Push Button The number on the Digital display Item 6 is replaced by the value of the parameter that can be modified through the Output Parameter adjust knob Item 5 Position the On Off switch to on I at the back of the With parame
108. s are located on the case front of the V205 T machine Refer to Figure B 2 and the corresponding explanations FIGURE B 2 1 Input Voltage warning Light Green LED 7 5 3 A OOO pou OS WPOS T ACDC D 2 Thermal Device Warning Light Yellow LED 3 Pulse On Off Button 4 Setup Parameter Select Button X 5 5 Output Parameter Adjust Knob 6 Digital Display 7 Local Remote Button 8 Trigger Selection Button 9 Welding Process MODE Button 10 Electrode Connection Negative 11 Remote Control Connector 12 Electrode Connection Positive 13 Welding Parameter Drawing 1 Input Voltage warning light green LED Indicates that the machine is on and input voltage is within acceptable range 2 Thermal Shutdown Light yellow LED Indicates thermal over load or output disabled for incorrect supply voltage With the Yellow LED on and an alarm code blink ing on Digital Display Item 6 see Troubleshooting Section E Possible electrical problems the machine will not supply power at the output If over heating occurs the Yellow LED will stay on until the machine has sufficiently cooled Leave the power source on to allow the fan to cool the unit 3 Pulse On OFF push button CONSTANT current PULSED current 4 Setup Parameter 02 Select push button Setup Parameter push button has three 3 dif
109. s in the case of atmospher ic lightening strikes However if over voltage is high and prolonged the varis tor cannot dissipate this high energy and fails For example the machine is improperly connected to 275VAC or the over voltage is caused by non stabilized power units of inadequate capacity POWER SUPPLY IN 230V 115V 230V 1151 POWER SUPPLY OUT 230V 115V NOTE 2 The radio noise suppression circuit has two purposes to keep the machine s radio frequency emissions within limits specified by standards and to ensure the machine s immunity against the same type of problems caused any electronic devices connected to the same power supply source The filter consists of a network of capacitors some of which are grounded and a toroidal inductor INVERTEC V205 T AC DC LINCOLN B F 17 18 8 lt o E o LLI amp E l 2 9 oc gt 2 u DOL 01 DOL 01 DOL DOL DOL uonoeg DOL 5 DOL 5 DOL 5 Return to Section TOC Return to Master TOC Return to Section TOC eio OJO f i 5 amp c Return to Section TOC Return to Master TOC Return to Master TOC F 19 TROUBLESHOOTING AND REPAIR F 19 MAIN IGBT I
110. s located beneath See Figure F 33 NOTE There is no need to disconnect any leads from the P C boards located behind the nameplate keypad Return to Section TOC Return to Master TOC INVERTEC V205 T AC DC LINCOLN B Return to Section TOC Return to Master TOC Return to Section TOC eio OJO f i O0 gt 21 5 2 amp Return to Section TOC Return to Master TOC Return to Master TOC F 63 TROUBLESHOOTING AND REPAIR OUTPUT FILTER BOARD REMOVAL AND REPLACEMENT continued FIGURE F 33 CASE FRONT SCREW REMOVAL Phillips Head Screws Paname ER ACFREDUENCY Epy Casefront Mounting Screws Phillips Head Screws 9 Using a 17mm wrench remove the heavy lead from the positive output terminal 10 Using a 13mm wrench remove the heavy lead from the high frequency transformer 11 Disconnect plugs CN1 and CN2 from the out put filter board See Figure F 34 12 Using a 90 phillips head screwdriver remove the output filter board mounting screws NOTE The output terminal assembly may have to be removed to gain access to the output filter board mounting screws 13 Remove the large nut holding the output filter board to the positive terminal See 14 Disconnect plug CN7 from the control displa board assembly See Control Display Boar
111. s performed on this equipment may result in danger to the technician or 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 If for any reason you do not understand the test procedures or are unable to perform the test repairs safely contact the Lincoln Electric Service Department for electrical trou bleshooting assistance before you proceed Call 1 888 935 3877 TEST DESCRIPTION This procedure will drain off any charge stored in the four Capacitors that are part of the Main IGBT Inverter Board Assembly This procedure MUST be performed as a safety precaution before conducting any test or repair procedure that requires you to touch inter nal components of the machine MATERIALS NEEDED Phillips Screwdriver Insulated Pliers Insulated Gloves High Wattage Resistor 25 1000 ohms and 25 watts minimum Volt Meter INVERTEC V205 T AC DC LINCOLN B F 13 INPUT FILTER CAPACITOR DISCHARGE PROCEDURE Return to Section TOC Return to Master TOC Return to Section TOC eio OJO f i olg 5 amp Return to Section TOC Return to Master TOC Return to Master TOC F 14 TROUBLESHOOTING AND REPAIR INPUT FILTER CAPACITOR DISCHARGE PROCEDURE continued FIGURE F 3 LOCATION OF INPUT FILTER CAPACITOR TERMINALS ON MAIN IGBT INV
112. s safely contact the Lincoln Electric Service Department for electrical trou bleshooting assistance before you proceed Call 1 888 935 3877 TEST DESCRIPTION This test will help determine if all functions of the Welding Logic Circuit and Inverter are functioning properly MATERIALS NEEDED Volt Ohmmeter Phillips Head Screwdriver Wiring Diagram INVERTEC V205 T AC DC LINCOLN B F 43 PT TROUBLESHOOTING AND REPAIR DM MAIN INVERTER BOARD WELDING LOGIC AND INVERTER SECTION TEST continued FIGURE F 21 MAIN BOARD LOCATION MAIN BOARD Return to Section TOC Return to Master TOC e 69 E Return to Master 2 Using a phillips head screwdriver remove the DIUI MID siad wraparound cover plugs Do not remove plugs from the board i See Figure F 21 See Figures F 22 amp 2 2 cap 9 Procedure 5 Carefully apply the correct input voltage to the V205 T and check for the correct secondary voltages per Tables F 15 olo c is o o 2 PROCEDURE c 1 Remove input power to the V205 T machine 4 Locate the Welding Logic and Inverter section 212 2 Return to Section Return to Master TOC INVERTEC V205 T AC DC LINCOLN B TROUBLESHOOTING AND REPAIR rm MAIN INVERTER BOARD WELDING LOGIC AND
113. sary Front Panel Secondary Remove upper cover check front panel power supplies Perform front panel reset Memory Error test and replace if necessary Note to reset front panel memory see procedure in Set up parameters chapter below Normally when cause s of alarm s is are removed press one of the keys to exit from alarm status or switch off and on the machine Thermal alarm will be automatically reset by letting go down internal temperature machine will execute a new autotest and then start as in normal operation In case of error code E10 see also the three thermal switches in fig below In case of error codes E11 E12 check input power supply voltage with reference to the following table Under Overvoltage alarm thresholds Pompey 115 VA 92 VAC 138 VAC 230 VAG 184 VAC 276 VAC INVERTEC V205 T AC DC LINCOLN B rm TROUBLESHOOTING AND REPAIR ru INTERNAL DIAGNOSTICS olo slz FIGURE F 2 918 plz ole ele 5 5 17 6 L4 45 L1 12 L3 qc e 69 9 E Return to Master TOC ojo eI 11 9 E Under Small ed PCB 5 2 2 2 L14 Return to Section TOC Return to Master TOC INVERTEC V205 T AC DC LINCOLN B Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC e 2 Return to Sectio
114. t current from 10 amps to current level set by output control eio OJO f gt olg 5 amp To change the Post Flow time repeatedly push the Parameter button until the Post Flow indicator light is on Adjust the Output control to the desired Post Flow time as indicated on digital display To change from High Frequency to Lift Start turn power source off Press and hold the Parameter button while the power source is turned on A 0 in the center of the digital display indicates the Set Up Menu is now active Rotate the Output Control until 8 is displayed Press the Parameter button again and rotate the Output Control until 1 is displayed Press the Parameter button to accept this setting Rotate the Output Control until 0 is displayed Press the para meter button to exit the Set Up Menu Return to Section TOC Return to Master TOC INVERTEC V205 T AC DC LINCOLN B E OPERATION E TABLE OF CONTENTS ACCESSORIES SECTION E o D Accessorles 2 A 1 9 gt g 5 Options ACCESSONIES seed dese Eee See ee ewe eee eae de 2 a Factory Installed sse REA Ga ee Pa Pew 2 Field Installed norm RR eee MERE REE LEE 2 Tig Torch c 2 Cable souks eke sua
115. ted on the Main IGBT Inverter Board and sent to the Control Display Board for meter set and actual display values NOTE Unshaded areas of Block Logic Diagram are the subject of discussion INVERTEC V205 T AC DC LINCOLN B Return to Section Return to Master TOC Return to Section TOC Return to Master TOC eio OJO E f i olg o gt 5 2 amp Return to Section TOC Return to Master TOC E 4 THEORY OF OPERATION E 4 FIGURE E 4 MAIN TRANSFORMER OUTPUT DIODE MODULE amp CLAMPING BOARD OUTPUT TRANSISTOR MODULE amp SUPERIMPOSITION BOARD AC DC Gate drive signals Current Feedback reconnect info turn on AC ckt voltage feedback current feedback 48 24 15 15 5 Main IGBT amp Power board DC blocking capacitor board turn on AC ckt thermostat info input volt meter input current meter turn PWM control signal 48 24 Control board Voltage Feedback Main Transformer 24 VDC Remote 2 4 path D E Display amp LED board Output Diode Thermostat Output Filter bd bypass Ud pus ME Output RF coil O Choke E Current Hall _ Output Device Transistor Module Output board 888 D E Knob Remote 2 4 Ou Gas Solenoid MAIN TRANSFORMER The 100KHZ output of the Main IGBT Inver
116. ter 9 all the modifications machine the input voltage light Item 1 green LED 2 ares Mrs je E confirms normal operation Sara Iae VESS EYANS AC DC are restored To exit the Set Up Menu return to 0 and press the Setup Parameter Push Button Many additional parameters can be modified via the Set Up Menu To access the Set Up Menu Position the ON OFF switch to OFF 0 Depress and hold the Parameter select Push Button The SETUP mode is confirmed by a center on the Digital display Item 6 INDICATOR PARAMETER DEFAULT Hot Start percent above Peak Current for Stick only 0 10096 Setting of AC wave Form 2 Square 0 Sinusoidal 1 Triangular 2 Square NOTE This parameter limits maximum weld current see OUTPUT LIMITATIONS section of the manual Min Weld Current Value with Remote Control for TIG only 10 Amps 6 Amps Value set for Indicator 7 Max Weld Current Value with Remote Control for TIG only Peak Current Value set for Indicator 6 Peak Current NOTE Peak Current Max Weld Current can be limited by input voltage welding mode AC TIG waveform and AC TIG frequency Touch Start or Start in DC TIG 0 Start 1 touch Start This parameter is ignored in AC TIG Mode 2 Step Trigger Selection 0 Restart Disabled 1 Restart Enabled Start Power for TIG only This function sets the initial start energy limit 1 0 2 min 5 0 2 max Note If
117. ter Board is coupled through a DC Blocking Capacitor Board to the primary of the Main Transformer The transformer reduces the high voltage low current input applied to the primary winding and through transformer action develops a lower secondary voltage capable of high output currents OUTPUT MODULE AND CLAMPING BOARD The AC output of the Main Transformer is applied to the Output Modules for full wave rectification The Clamping Diodes function as a filter eliminating any pulsed over voltages that may be present at the Output Modules The Clamping Board protects the Output Modules from damage due to higher than normal volt age spikes Control Remote 7 76 77 OUTPUT MODULE TRANSISTOR BOARD This module produces the AC waveforms and frequen cies It receives command signals from the Superimposition Board Depending on which of the two IGBTs is active at any given moment the welding output of the machine can be either positive or nega tive AC or DC SUPERIMPOSITION BOARD The Super Imposition Board receives signals from the Control Display Board to control the status of the sec ondary inverter portion of the V205T machine This board also generates voltage pulses at about 200VDC that facilitate the re striking of the arc when the TIG AC welding current is being utilized The Superimposition Board internally generates the auxil iary power supply for the isolated piloting of the power elements IGBTs fo
118. the Bus Board Circuitry located on the Main IGBT Inverter Board the Control Board the Output Module Board the Output Filter Board and the Hall Effect Device inter face with the Bus Board Some circuits are also incor porated within the Bus Board They are the fan circuit 24VDC and an input voltage sensing circuit that is uti lized by the auto reconnect circuitry located on the Main Inverter Board The fan fuse the 400VDC fuse F2 and the water cooler F1 not used are also located on the Bus Board NOTE Unshaded areas of Block Logic Diagram are the subject of discussion INVERTEC V205 T AC DC LINCOLN B Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC eio OJO f i QJ gt 5 oD amp Return to Section TOC Return to Master TOC E THEORY OF OPERATION FIGURE MAIN INVERTER BOARD Superimposition Bus board Current Feedback IGBT Thermostats voltage feedback reconnect info 48 24 15 15 5 turn on AC high volt supply Main IGBT amp Power board DC blocking capacitor board Voltage Feedback Transformer board AC Oe drive sigoale eessrsssusakaes Output Diode Thermostat Output Filter bd bypass Output Current Hall Output
119. the machine does not initiate a welding arc it will repeat the starting sequence with an increased start energy up to this limit Set this number to a higher setting than the factory default if needed to improve starting of large diameter tungstens electrodes i y y 4 Step Trigger Selection 0 Restart Disabled 1 Restart Enabled INVERTEC V205 T AC DC LINCOLN B Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC eio f gt 5 2 c Return to Section TOC Return to Master TOC OUTPUT LIMITATIONS The maximum output current as specified in the instal lation section of this manual is derated in two situa tions alternate AC Wave Forms and elevated AC Frequencies Alternate Wave Forms See Set Up Menu Square 200 amps max output Sinusoidal 150 amps max output Triangular 120 amps max output Elevated AC Frequencies Above 85Hz AC output the square wave out put is limited to 170 amps Elevated AC Frequencies do not effect the output of Sinusoidal and Triangular Waveforms These derated values have been programmed into the Invertec V205 T AC DC to ensure reliable opera tion DC TIG WELDING see FIGURE B 3 The TIG Tungsten Inert Gas welding process is based on the presence of an electric arc between a non consumable electrode pure or alloyed tungsten with an appr
120. these condi tions when run in the high idle mode Ranger 250 305 Commander 300 400 amp 500 Some engine drives do not meet these conditions e g Miller Bobcats etc Operation of the Invertec V205 T AC DC is not recommended on engine drives not conforming to these conditions Such drives may deliv er unacceptably high voltage levels to the Invertec V205 T AC DC power source INVERTEC V205 T AC DC LINCOLN B Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC 42 E tc Return to Section TOC Return to Master TOC o 5 o gt 2 Ab INSTALLATION AG OUTPUT CONNECTIONS A WARNING ELECTRIC SHOCK can kill Keep the electrode holder TIG torch and cable insulation in good condition and in place Do not touch electrically live parts or electrode with skin or wet cloth ing Insulate yourself from work and ground Turn the input line Switch on the Invertec V205 T AC DC off before connecting or discon necting output cables or other equipment OUTPUT AND GAS CONNECTION FOR TIG WELDING FIGURE A 1 The TIG Torch Twist Mate and work cable Twist Mate Connectors are supplied with the welder To connect the cables turn the Power Switch DFF Connect the torch cable Twist Mate plug into the DC Electrode Gas Output Receptacle on the front of the welder and
121. ties are to be carried out INVERTEC V205 T AC DC LINCOLN Return to Master Return to Master TOC o 5 o gt 2 tc Return to Master TOC vi SAFETY vi Electromagnetic Compatibility EMC The size of the surrounding area to be considered will depend on the structure of the building and other activities that are taking place The surrounding area may extend beyond the boundaries of the premises Methods of Reducing Emissions Mains Supply Welding equipment should be connected to the mains supply according to the manufacturer s recommenda tions If interference occurs it may be necessary to take additional precautions such as filtering of the mains supply Consideration should be given to shielding the supply cable of permanently installed welding equip ment in metallic conduit or equivalent Shielding should be electrically continuous throughout its length The shielding should be connected to the welding power source so that good electrical contact is maintained between the conduit and the welding power source enclosure Maintenance of the Welding Equipment The welding equipment should be routinely maintained according to the manufacturer s recommendations All access and service doors and covers should be closed and properly fastened when the welding equip ment is in operation The welding equipment should not be modified in any wa
122. turn it clockwise until snug Do not Overtighten This is a quick connect terminal and also provides the gas connection for the shielding gas to the torch A WARNING To avoid receiving a high frequency shock keep the TIG torch and cable insulation in good condi tion WORK CABLE CONNECTION Next connect the work cable to the output terminal in the same way To minimize high frequency interfer ence refer to Machine Grounding and High Frequency Interference Protection section of this manual for the proper procedure on grounding the work clamp and work piece FIGURE A 1 TIG TORCH S gt WORK CLAMP WORK CABLE This unit does not include a TIG torch but one may be purchased separately The accessories section of this manual lists a number of Lincoln Electric TIG torches and TIG Torch Starter Packs that are recommended for use with this machine however any similar TIG torch can be used To attach the Twist Mate Plug to a Lincoln Torch slide the rubber boot onto the torch cable enlarge the boot opening if necessary screw the fit ting on the torch cable into the brass connector snugly and slide the boot back over the brass connector TIG ADAPTER STRAIN RELIEF BOOT RETAINING COMPOUND TIG TORCH POWER CABLE WITH GAS FITING OUTPUT CONNECTION FOR STICK WELDING FIGURE A 2 First determine the proper electrode polarity for the electrode to be used Consult the e
123. ur local authorized 1 Contact the Lincoln Electric is evident when the sheet metal Lincoln Electric Field Service Service Department 1 800 833 cover s are removed Facility for assistance 9353 Return to Section TOC Return to Master TOC The machine is dead no fan 1 Make sure the input power switch 1 Check the input power switch for output no LEDs is in the ON position proper operation Also check the associated leads for loose or faulty connections See Wiring Diagram 2 Perform the Input Filter Board Check the main input fuses open replace Make sure the correct input volt age is applied to the machine Test The main input fuses or breakers 1 Make certain the fuses or break 1 The Input Filter Board may be repeatedly fail ers are properly sized for the faulty Perform the Filter input draw of the machine Board Test The welding procedure may 2 The Main IGBT Inverter Board drawing too much input current or the duty cycle be too high IGBT Inverter Board Low Reduce the welding current Voltage Supply Test and or reduce the duty cycle Return to Section TOC Return to Master TOC eio gt 091 olg o 1 5 2 oD amp A CAUTION If for any reason you do not understand the test procedures or are unable to perform the tests repairs safely contact the Lincoln Electric Service Department for te
124. y except for those changes and adjustments covered in the manufacturers instructions In particular the spark gaps of arc striking and stabilizing devices should be adjusted and maintained according to the manufacturer s recommendations Welding Cables The welding cables should be kept as short as possible and should be positioned close together running at or close to floor level Equipotential Bonding Bonding of all metallic components in the welding installation and adjacent to it should be considered However metallic components bonded to the work piece will increase the risk that the operator could receive a shock by touching these metallic components and the electrode at the same time The operator should be insulated from all such bonded metallic components Earthing of the Workpiece Where the workpiece is not bonded to earth for electrical safety not connected to earth because of its size and position e g ships hull or building steelwork a connection bonding the workpiece to earth may reduce emissions in some but not all instances Care should be taken to prevent the earthing of the workpiece increasing the risk of injury to users or damage to other electrical equipment Where necessary the con nection of the workpiece to earth should be made by a direct connection to the workpiece but in some countries where direct connection is not permitted the bonding should be achieved by suitable capacitance selected according to national
125. zed repairs performed on this equipment may result in danger to the technician or 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 If for any reason you do not understand the test procedures or are unable to perform the test repairs safely contact the Lincoln Electric Service Department for electrical trou bleshooting assistance before you proceed Call 1 888 935 3877 TEST DESCRIPTION The following procedure will aid the technician in removing the Input Filter Board for replacement MATERIALS NEEDED 7mm Nutdriver Phillips Head Screwdriver INVERTEC V205 T AC DC LINCOLN B F 49 ren TROUBLESHOOTING AND REPAIR 5750 INPUT FILTER BOARD REMOVAL REPLACEMENT continued FIGURE F 24 INPUT FILTER BOARD LOCATION INPUT FILTER BOARD Return to Section TOC Return to Master TOC e c 912 FEE gt Sl PROCEDURE 1 Remove input power to the V205 T 4 Locate the input filter board See Figure F 24 2 Using a phillips head screwdriver remove the 5 Using a 7mm nut driver label and remove leads case wraparound cover R L1 and S L2 from the upper right corner of the input filter board See Figure F 25 3 Perform the Input Filter Capacitor Discharge Procedure detailed earlier in this section 6 Using a 7mm nut driver label and r

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