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INVERTEC V200-T

OPERATORS MANUAL

IM592N ovem ber, 1999

Safety Depends on You

Linco ln arc w elding and cutting

equipm ent is designed and built

w ith safety in m ind. H ow ever, your

overall safety can be increased by

proper installation ... and thought-

ful operation on your part. DO

NOT INSTALL, OPERATE OR

REPAIR THIS EQUIPMENT

WITHOUT READING THIS

MANUAL AND THE SAFETY

PRECAUTIONS CONTAINED

THROUGHOUT. And , m ost

im portantly, think before you act

and be careful.

For use with machines having Code Numbers: 10463

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

World's Leader in Welding and Cutting Products

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FOR ENGINEpowered equipment.

1.a. Turn the engine off before troubleshooting and maintenancework unless the maintenance work requires it to be running.

____________________________________________________1.b.Operate engines in open, well-ventilated

areas or vent the engine exhaust fumesoutdoors.

____________________________________________________1.c. Do not add the fuel near an open flame

welding arc or when the engine is running.Stop the engine and allow it to cool beforerefueling to prevent spilled fuel from vaporiz-ing on contact with hot engine parts and

igniting. Do not spill fuel when filling tank. Iffuel is spilled, wipe it up and do not startengine until fumes have been eliminated.

____________________________________________________

1.d. Keep all equipment safety guards, covers and devices in

position and in good repair.Keep hands, hair, clothing andtools away from V-belts, gears, fans and all other moving

parts when starting, operating or repairing equipment.

____________________________________________________

1.e. In some cases it may be necessary to remove safetyguards to perform required maintenance. Removeguards only when necessary and replace them when themaintenance requir ing their removal is complete.Always use the greatest care when working near movingparts.

___________________________________________________1.f. Do not put your hands near the engine fan.

Do not attempt to override the governor oridler by pushing on the throttle control rodswhile the engine is running.

___________________________________________________1.g. To prevent accidentally starting gasoline engines while

turning the engine or welding generator during maintenancework, disconnect the spark plug wires, distributor cap ormagneto wire as appropriate.

iSAFETYi

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 youpurchase a copy of Safety in Welding & Cutting - ANSI Standard Z49.1 from the American Welding Society, P.O. Box351040, Miami, Florida 33135 or CSA Standard W117.2-1974. A Free copy of Arc Welding Safety booklet E205 is availablefrom 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.

WARNING

Mar 95

ELECTRIC ANDMAGNETIC FIELDSmay 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 andwelding machines

2.b. EMF fields may interfere with some pacemakers, andwelders having a pacemaker should consult their physician

before welding.

2.c. Exposure to EMF fields in welding may have other health

effects which are now not known.

2.d. All welders should use the following procedures in order to

minimize exposure to EMF fields from the welding circuit:

2.d.1. Route the electrode and work cables together - Securethem with tape when possible.

2.d.2. Never coil the electrode l ead around your body.

2.d.3. Do not place your body between the electrode and

work cables. If the electrode cable is on your rightside, the work cable should also be on your right side.

2.d.4. Connect the work cable to the workpiece as close aspossible to the area being welded.

2.d.5. Do not work next to welding power source.

1.h. To avoid scalding, do not remove theradiator pressure cap when the engine ishot.

CALIFORNIA PROPOSITION 65 WARNINGS

Diesel engine exhaust and some of its constituentsare known to the State of California to cause can-cer, birth defects, and other reproductive harm.

The engine exhaust from this product containschemicals known to the State of California to causecancer, birth defects, or other reproductive harm.

The Above For Diesel Engines The Above For Gasoline Engines

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FOR ELECTRICALLYpowered equipment.

8.a. Turn off input power using the disconnectswitch at the fuse box before working onthe equipment.

8.b. Install equipment in accordance with the U.S. NationalElectrical Code, all local codes and the manufacturersrecommendations.

8.c. Ground the equipment in accordance with the U.S. NationalElectrical Code and the manufacturers recommendations.

CYLINDER may explodeif damaged.7.a. Use only compressed gas cylinders

containing the correct shielding gas for theprocess used and properly operat ingregulators designed for the gas and

pressure used. All hoses, fittings, etc. should be suitable forthe application and maintained in good condition.

7.b. Always keep cylinders in an upright position securelychained to an undercarriage or fixed support.

7.c. Cylinders should be located: Away from areas where they may be struck or subjected tophysical damage.

A safe distance from arc welding or cutting operations andany other source of heat, sparks, or flame.

7.d. Never allow the electrode, electrode holder or any otherelectrically hot parts to touch a cylinder.

7.e. Keep your head and face away from the cylinder valve outletwhen opening the cylinder valve.

7.f. Valve protection caps should always be in place and handtight except when the cylinder is in use or connected foruse.

7.g. Read and follow the instructions on compressed gascylinders, associated equipment, and CGA publication P-l,Precautions for Safe Handling of Compressed Gases inCylinders, available from the Compressed Gas Association1235 Jefferson Davis Highway, Arlington, VA 22202.

iiiSAFETYiii

Mar 95

WELDING SPARKS cancause fire or explosion.6.a. Remove fire hazards from the welding area.

If this is not possible, cover them to preventthe welding sparks from starting a fire.Remember that welding sparks and hot

materials from welding can easily go through small cracksand openings to adjacent areas. Avoid welding nearhydraulic lines. Have a fire extinguisher readily available.

6.b. Where compressed gases are to be used at the job site,special precautions should be used to prevent hazardoussituations. Refer to Safety in Welding and Cutting (ANSIStandard Z49.1) and the operating information for theequipment being used.

6.c. When not welding, make certain no part of the electrodecircuit is touching the work or ground. Accidental contactcan cause overheating and create a fire hazard.

6.d. Do not heat, cut or weld tanks, drums or containers until theproper steps have been taken to insure that such procedureswill not cause flammable or toxic vapors from substancesinside. They can cause an explosion even though they havebeen cleaned. For information, purchase Recommended

Safe Practices for the Preparation for Welding and Cutting ofContainers and Piping That Have Held HazardousSubstances, AWS F4.1 from the American Welding Society

(see address above).

6.e. Vent hollow castings or containers before heating, cutting orwelding. They may explode.

6.f. Sparks and spatter are thrown from the welding arc. Wear oilfree protective garments such as leather gloves, heavy shirt,cuffless trousers, high shoes and a cap over your hair. Wearear plugs when welding out of position or in confined places.Always wear safety glasses with side shields when in awelding area.

6.g. Connect the work cable to the work as close to the welding

area as practical. Work cables connected to the buildingframework or other locations away from the welding areaincrease the possibility of the welding current passingthrough lifting chains, crane cables or other alternate cir-cuits. This can create fire hazards or overheat lifting chainsor cables until they fail.

6.h. Also see item 1.c.

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ivSAFETYiv

PRCAUTIONS DE SRETPour votre propre protection lire et observer toutes les instructions

et les prcautions de sret specifiques qui parraissent dans ce

manuel aussi bien que les prcautions de sret gnrales suiv-

antes:

Sret Pour Soudage A LArc1. Protegez-vous contre la secousse lectrique:

a. Les circuits llectrode et la pice 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 vtements mouills. Porter des gants secs et sans

trous pour isoler les mains.

b. Faire trs attention de bien sisoler de la masse quand on

soude dans des endroits humides, ou sur un plancher

metallique ou des grilles metalliques, principalement dans

les positions assis ou couch pour lesquelles une grande

partie du corps peut tre en contact avec la masse.

c. Maintenir le porte-lectrode, la pince de masse, le cble

de soudage et la machine souder en bon et sr tat

defonctionnement.d.Ne jamais plonger le porte-lectrode dans leau pour le

refroidir.

e. Ne jamais toucher simultanment les parties sous tension

des porte-lectrodes connects deux machines souder

parce que la tension entre les deux pinces peut tre le

total de la tension vide des deux machines.

f. Si on utilise la machine souder comme une source de

courant pour soudage semi-automatique, ces precautions

pour le porte-lectrode sapplicuent aussi au pistolet de

soudage.

2. Dans le cas de travail au dessus du niveau du sol, se protger

contre les chutes dans le cas ou on recoit un choc. Ne jamaisenrouler le cble-lectrode autour de nimporte quelle partie

du corps.

3. Un coup darc peut tre plus svre quun coup de soliel,

donc:

a. Utiliser un bon masque avec un verre filtrant appropri

ainsi quun verre blanc afin de se protger les yeux du ray-

onnement de larc et des projections quand on soude ou

quand on regarde larc.

b. Porter des vtements convenables afin de protger la

peau de soudeur et des aides contre le rayonnement de

larc.

c. Protger lautre personnel travaillant proximit au

soudage laide dcrans appropris et non-inflammables.

4. Des gouttes de laitier en fusion sont mises de larc de

soudage. Se protger avec des vtements de protection libres

de lhuile, tels que les gants en cuir, chemise paisse, pan-

talons sans revers, et chaussures montantes.

5. Toujours porter des lunettes de scurit dans la zone de

soudage. Utiliser des lunettes avec crans lateraux dans les

zones o lon pique le laitier.

6. Eloigner les matriaux inflammables ou les recouvrir afin de

prvenir tout risque dincendie d aux tincelles.

7. 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 dincendie.

8. Sassurer que la masse est connecte le plus prs possiblede la zone de travail quil est pratique de le faire. Si on place

la masse sur la charpente de la construction ou dautres

endroits loigns de la zone de travail, on augmente le risque

de voir passer le courant de soudage par les chaines de lev-

age, cbles de grue, ou autres circuits. Cela peut provoquer

des risques dincendie ou dechauffement des chaines et des

cbles jusqu ce quils se rompent.

9. Assurer une ventilation suffisante dans la zone de soudage.

Ceci est particulirement important pour le soudage de tles

galvanises plombes, ou cadmies ou tout autre mtal qui

produit des fumes toxiques.

10. Ne pas souder en prsence de vapeurs de chlore provenant

doprations de dgraissage, nettoyage ou pistolage. La

chaleur ou les rayons de larc peuvent ragir avec les vapeurs

du solvant pour produire du phosgne (gas fortement toxique)

ou autres produits irritants.

11. Pour obtenir de plus amples renseignements sur la sret,

voir le code Code for safety in welding and cutting CSA

Standard W 117.2-1974.

PRCAUTIONS DE SRET POURLES MACHINES SOUDER TRANSFORMATEUR ET REDRESSEUR

1. Relier la terre le chassis du poste conformement au code de

llectricit 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, Iinstallation et lentretien du poste seront

effectus par un lectricien qualifi.

3. Avant de faires des travaux linterieur de poste, la debranch-

er linterrupteur la boite de fusibles.

4. Garder tous les couvercles et dispositifs de sret leur

place.

Mar. 93

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Thank Youfor selecting a QUALITY product by Lincoln Electric. We want youto take pride in operating this Lincoln Electric Company product as much pride as we have in bringing this product to you!

Read this Operators Manual completely before attempting to use this equipment. Save this manual and keep ithandy for quick reference. Pay particular attention to the safety instructions we have provided for your protection.The level of seriousness to be applied to each is explained below:

WARNING

This statement appears where the information must be followed exactly to avoid serious personal injury orloss of life.

This statement appears where the information must be followed to avoid minor personal injury or damage tothis equipment.

CAUTION

Please Examine Carton and Equipment For Damage ImmediatelyWhen this equipment is shipped, title passes to the purchaser upon receipt by the carrier. Consequently, Claimsfor material damaged in shipment must be made by the purchaser against the transportation company at thetime the shipment is received.

Please record your equipment identification information below for future reference. This information can befound on your machine nameplate.

Model Name & Number _____________________________________

Code & Serial Number _____________________________________

Date of Purchase _____________________________________

Whenever you request replacement parts for or information on this equipment always supply the informationyou have recorded above.

vv

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viTABLE OF CONTENTSPage

Installation.......................................................................................................................Section ATechnical Specifications.......................................................................................................A-1Select Suitable Location.......................................................................................................A-2Stacking................................................................................................................................A-2Lifting and Moving ............ .............. .............. ............. .............. .............. ............. .............. ....A-2Tilting....................................................................................................................................A-2Environmental Rating .............. .............. ............. .............. .............. .............. ............. ...........A-2Machine Grounding and High Frequency Interference Protection .............. .............. ...........A-2

Input Connections ................................................................................................................A-3Input Fuse and Supply Wire ............. .............. .............. ............. .............. .............. .............. .A-3Output Connections..............................................................................................................A-4

Operation.........................................................................................................................Section BGeneral Description..............................................................................................................B-1Operational Features............................................................................................................B-1Welding Capability................................................................................................................B-1Limitations .............. .............. .............. ............. .............. .............. ............. .............. ..............B-1Controls and Settings .............. ............. .............. .............. ............. .............. .............. ...........B-2Operating Steps ...................................................................................................................B-4

Welding in TIG Mode ....................................................................................................B-4Remote Control Operation ............ .............. .............. .............. ............. .............. ...........B-4Welding in Stick Mode...................................................................................................B-5

Recommended Electrode and Tungstens ............. ............. .............. .............. .............. ........B-5Explanation of 2 Step and 4 Step Modes .............. ............. .............. .............. .............. ........B-6Pulser Functions...................................................................................................................B-6

Accessories .....................................................................................................Section CGeneral Options / Accessories..............................................................................C-1TIG Welding Options / Accessories.......................................................................C-1

Maintenance........................................................................................................Section DSafety Precautions ................................................................................................D-1Input Filter Capacitor Discharge Procedure ..........................................................D-1Routine Maintenance.............................................................................................D-1Replacement of Internal Fuse ...............................................................................D-1

Troubleshooting..............................................................................................Section ESafety Precautions.................................................................................................E-1How to Use Troubleshooting Guide.......................................................................E-1Troubleshooting Guide ..........................................................................................E-2

Wiring Diagram................................................................................................Section F

Parts List ..................................................................................................................P308

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A-1INSTALLATION

INVERTEC V200-T

A-1

TECHNICAL SPECIFICATIONS - V200T TIG

For DC TIG Welding at 200A/20% Duty CycleBased on the 1996 U.S. National Electrical Code

CodeNumber10463

Volts at Rated Amperes282625

Type of OutputDC

Input Current atRated Output

45/23 A @ 200 A, 33/16 A @ 150 A,25/13 A @ 120 A

Amps200150120

Maximum OpenCircuit Voltage

80 V

StandardVoltage (1)

230/460/1/50/60

Duty Cycle (2)

20% Duty Cycle60% Duty Cycle100% Duty Cycle

Output CurrentRange

1 - 200 A

INPUT - SINGLE PHASE ONLY

RATED OUTPUT

OUTPUT

RECOMMENDED INPUT WIRE AND FUSE SIZES

Input

Voltage /

phase/

Frequency

230/1/50/60

460/1/50/60

Input

Ampere

Rating on

Nameplate

45

23

Type 75C

Copper Ground

Wire in Conduit

AWG (IEC)

Sizes

10 (5.2 mm2)

12 (4 mm2)

Fuse

(Super Lag)

or Breaker

Size

50

30

Type 75C

Copper Wire in

Conduit AWG

(IEC) Sizes

10 (5.2 mm2)

12 (4 mm2)

Height Width Depth WeightPower 10.04 in. 7.48 in. 17.32 in. Approx. 35 lbs.Source 255 mm 190 mm 440 mm 16 kgs.

PHYSICAL DIMENSIONS

-20C to +40C -25C to +55C

OPERATING TEMPERATURE STORAGE TEMPERATURE

(1) Input voltage m ust be w ithin 10% of rated value.

(2) Duty Cycle is based on a 10 m in. period.

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A-2INSTALLATION

INVERTEC V200-T

A-2

MACHINE GROUNDING AND HIGH FRE-QUENCY INTERFERENCE PROTECTION

The welder must be grounded. See your local and national

electrical codes for proper grounding methods.

The high frequency generator, being similar to a radio

transmitter, can be blamed for radio, TV and electron-

ic equipment interference problems. These problemsmay be the result of radiated interference. Proper

grounding methods can reduce or eliminate radiated

interference.

Radiated interference can develop in the followingfour ways:

1. Direct interference radiated from the welder.

2. Direct interference radiated from the welding leads.

3. Direct interference radiated from feedback into thepower lines.

4. Interference from re-radiation of pickup byungrounded metallic objects.

Keeping these contributing factors in mind, installing

equipment per the following instructions should mini-

mize problems.

1. Keep the welder power supply lines as short as

possible and enclose as much of them as possible

in rigid metallic conduit or equivalent shielding for a

distance of 50 feet (15.2m). There should be goodelectrical 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

possible and as close together as possible.

Lengths should not exceed 25 ft (7.6m). Tape the

leads together when practical.

3. Be sure the torch and work cable rubber coverings

are free of cuts and cracks that allow high frequen-

cy leakage.

4. Keep the torch in good repair and all connections

tight to reduce high frequency leakage.

5. The work piece must be connected to an earth

ground close to the work clamp, using one of the

following methods:

Read entire installation section before startinginstallation.

Safety Precautions

SELECT SUITABLE LOCATION

The Invertec will operate in harsh environments. Evenso, it is important that simple preventative measuresare followed in order to assure long life and reliableoperation.

The machine must be located where there is free cir-culation of clean air such that air movement in theback and out the sides will not be restricted.

Dirt and dust that can be drawn into the machineshould be kept to a minimum. Failure to observethese precautions can result in excessive operatingtemperatures and nuisance shutdown.

STACKING

The Invertec V200-T cannot be stacked.

LIFTING AND MOVING

The Invertec V200-T has a lift handle on the top of theca se and also c omes with a lift-ca rrying s trap for con-

vience.

TILTING

Place the machine directly on a secure, level surface.

The machine may topple over if this procedure is notfollowed.

ENVIRONMENTAL RATING

The machine has a protection rating of IP23. Keepthe machine dry when possible. Do not place it onwet ground or in puddles.

ELECTRIC SHOCK can kill. Only qualified personnel should

perform this installation. Turn the input power OFF at the

disconnect switch or fuse boxbefore working on thisequipment.

Do not touch electrically hotparts.

Always connect the V200-T to a power sup-ply grounded per the National ElectricalCode and any local codes.

WARNING

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A-3INSTALLATION

INVERTEC V200-T

A-3

a) A metal underground water pipe in direct con-tact with the earth for ten feet or more.

b) A 3/4 (19mm) galvanized pipe or a 5/8 (16mm)solid galvanized iron, steel or copper rod drivenat least eight feet into the ground.

The ground should be securely made and the ground-ing cable should be as short as possible using cableof the same size as the work cable, or larger.Grounding to the building frame electrical conduit or along pipe system can result in re-radiation, effectivelymaking these members radiating antennas.

6. Keep cover and all screws securely in place.

7. Electrical conductors within 50 ft (15.2m) of thewelder should be enclosed in grounded rigid metal-lic conduit or equivalent shielding, wherever possi-ble. Flexible metallic conduit is generally not suit-able.

8. When the welder is enclosed in a metal building,the metal building should be connected to severalgood earth driven electrical grounds (as in 5 (b)above) around the periphery of the building.

Failure to observe these recommended installationprocedures can cause radio or TV and electronicequipment interference problems and result in unsat-isfactory welding performance resulting from lost highfrequency power.

INPUT CONNECTIONS

Be sure the voltage, phase, and frequency of the inputpower is as specified on the rating plate, located onthe rear of the machine.

Supply line entry provision is in the case rear panel.

A power cord is provided and wired into the machine.Follow the power cord connection instructions.Incorrect connection may result in equipment damage.

The Invertec V200-T is internally connected for a 460volt input. The input switch has a lock pin which restrictsmovement for 460 selection only. See figure A.1.

To connect the V200-T for 230 volt input, the followinginput reconnect needs to be completed.

1. Disconnect the machine from the input supply.2. Remove the wraparound by removing the shoul-

der strap brackets and wraparound screws.

3. Provide access to the line switch by bending theinsulation back.

4. When the insulation is bent back, two sleevedleads will become visible.

5. Remove the sleeving from both leads.6. Connect the large lead to push-on terminal

labeled 3 on the adjacent PC board.7. Connect the small lead to terminal 15 of the line

switch.8. Reposition insulation to cover line switch.9. Re-install wraparound.10. Move the lock pin to allow switch movement for

230 V selection only.

Connect the green w/ yellow strip lead to ground perU.S. National Electrical Code. Connect the black andwhite leads to power.

Use reverse procedure to reconnect for 460V. Do notconnect 460V when the switch is configured for 230Vor damage will result.

Figure A.1

INPUT FUSE AND SUPPLY WIRE

Refer to the Technical Specifications pages at thebeginning of this chapter for the proper fuse sizes andsupply cable sizes.

Fuse the input circuit with recommended super lagfuses or delay type circuit breakers.

Install the proper fuse in the fuse holder in the maindisconnect panel.

OUTPUT CONNECTIONS

Figure A.2

2304600

Power ON-OFF/Voltage Selector Switch - Located on top right of rear panel

Lock pin mounting holeLock pin - in this position allows only230 V input selection Move to oppositeside for 460 V operation.

TIG TORCH/GAS OUTLETRECEPTACLE

WORK CABLE RECEPTACLE

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A-4INSTALLATION

INVERTEC V200-T

A-4

OUTPUT CONNECTIONS

Refer to Figure A.2 for the location of the output terminals.A quick-disconnect system using Twist-MateTM cable plugs isused for the welding cable connections. The electrode andwork cables will require these plugs. Refer to the relevantinstructions following for more information on connecting themachine for either welding process.

OUTPUT CONNECTION FOR STICKWELDING

First determine the proper electrode polarity for the elec-trode to be used. Consult the electrode data for this infor-mation. Then connect the output cables to the output termi-nals corresponding to this polarity. For instance, for DC(+)welding, connect the electrode cable (which is connected tothe electrode holder) to the + output terminal and the workcable (which is connected to the work clamp) to the - out-put terminal. Insert the connector with the key lining up withthe keyway, and rotate approximately 1/4 turn clockwise;until the connection is snug. Do not over tighten.

OUTPUT AND GAS CONNECTIONFOR TIG WELDING

This unit does not include a TIG torch, but one may be pur-chased separately and used with these units to do TIG(GTAW) welding. The Lincoln LA-9 (K859-1 or K859-5 onlywith no gas valve) or LA-17 and LA-17V (K860-1 or K860-5without gas valve and K860-9 or K860-13 with gas valve)are recommended for use with these machines for this pur-pose; however, any similar TIG torch can be used. To attachthe Twist-Mate Plug to a Lincoln Torch, slide the rubber bootonto the torch cable (enlarge the boot opening if necessary),

screw the fitting on the torch cable into the brass connectorsnugly and slide the boot back over the brass connector.

Turn the Power Switch OFF. Connect the torch cable quickconnect plug into the DC- Output Receptacle on the front ofthe welder and turn it clockwise until it is tight. This is aquick connect terminal and also provides the gas connectionfor the shielding gas to the torch.

To avoid receiving a high frequency shock, keep the TIGtorch and cables in good condition.

__________________________________________

Next, connect the work cable (which is connected to thework clamp) to the + output terminal in the same way.

The machine can easily be switched between stick and TIGwelding at any time by simply swapping the stick (electrode)and TIG (torch) cables, and reversing the connection polari-ty if required.

WARNING

TIG ADAPTER

RETAINING COMPOUND

STRAIN RELIEF BOOT

TIG TORCH POWER CABLE WITH GAS FITING

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A-5INSTALLATION

INVERTEC V200-T

A-5

SHIELDING GAS CONNECTION

An adjustable gas pressure regulator and flow gageshould be obtained. Obtain the necessary inert shield-ing gas (usually argon). Connect the cylinder of gaswith the pressure regulator and flow gage. Install thegas hose between the regulator and gas inlet (locatedon the low left rear of the welder). The gas inlet has a5/16-18 right hand female thread; CGA #032.

REMOTE CONTROL CONNECTION

A remote control receptacle is provided on the lower

center case front of the welder for connecting aremote control to the machine. Refer to the OptionalAccessories section of this manual for availableremote controls.

CYLINDER could explodeif damaged.

Keep cylinder upright and chainedto a support.

Keep cylinder away from areas where it couldbe damaged.

Never allow the torch to touch the cylinder.

Keep cylinder away from live electrical circuits.

Maximum inlet pressure 150 psi.___________________________________________

WARNING

QUICK DISCONNECT PLUG (FOR WORK CABLE)A quick disconnect system is used for the weldingcable connections. The electrode and work cablesneed to have a plug attached.

1. Cut off welding cable lug, if present.2. Remove .75 in. (19mm) of welding cable insulation.3. Slide rubber boot onto cable end. The boot end

may be trimmed to match the cable diameter. Usesoap or other nonpetroleum-based lubricant tohelp slide the boot over the cable, if needed.

4. Cut 45-50% of the copper strands back 1/4 (6mm).

5. Fold copper strands over cut strands and insertinto ferrule.

6. Slide the copper ferrule into the brass plug.

7. Tighten set screw to collapse copper tube. Screwmust apply pressure against welding cable. Thetop of the set screw will be well below the surfaceof the brass plug after tightening.

8. Slide rubber boot over brass plug. The rubber bootmust be positioned to completely cover all electri-cal surfaces after the plug is locked into the recep-tacle.

19 mm

.75 in.

WELDING CABLE

BOOT

TRIM, IF REQ'DTO FIT OVER CABLE

6 mm.25 in.

WELDING CABLE

12 mm max..50 in. max

WELDING CABLE

COPPER FERRULE

SET SCREW

BRASS PLUG

COPPER TUBE

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B-2OPERATIONB-2

INVERTEC V200-T

Power Switch/Voltage Selector Switch - Controlsthe power input to the machine. This rotating switch isused to turn the machine on and off as well as toselect the input voltage. The switch is located on thetop right rear panel. When power is applied to themachine the Power LED is on.

Welding Current Potentiometer - Potentiometerused to set the value of the current required by thewelding process. This current setting will be displayedon the Digital Display. When an Amptrol is used toremotely control the welding current, this setting con-trols the maximum welding current when the Amptrol

is fully depressed.

Voltage out of spec/ Overheated LED - This LEDwill light up when:

A) The input supply voltage is not within limitspre-set for correct operation.*

B) The machine is overheated as detected bythe internal thermostat.

* Note that input voltages that exceed 20% of nominalmay cause internal damage to the machine.

Output Terminals - These quick disconnect terminalsprovide connection points for the TIG Torch and workcables or electrode and work cables. For TIG welding,connect the torch to the DC- terminal and the workcable to the DC+ terminal. For stick welding positivepolarity connect the electrode cable to the positive ter-minal and the work cable to the negative terminal. Toweld negative polarity reverse the electrode and workcables.

Remote Control Connector - This receptacle willaccept a Lincoln Foot Amptrol, Hand Amptrol or ArcStart Switch. See the ACCESSORIES section for

available options.

CONTROLS AND SETTINGS

All operator controls and adjustments are located on the case front of the V200-T machine. Refer to Figure B.1and the corresponding explanations.

FIGURE B.1 CASE FRONT CONTROLS.

Power LED

Gas Available LED

Digital DisplayVoltage out of spec/Overheated LED

Welding CurrentPotentiometer

Slope DownTime Pot.

Slope UpTime Pot.

Post FlowTime Pot.

Start/CraterCurrent Pot.

Welding ProcessSwitch

Local/RemoteSwitch

TIG ProcessSwitch

Pulse DurationPotentiometer

Pulse Amplitude

Potentiometer

Pulse Frequency/TIG Spot TimerPotentiometer

DC- Terminal/TIG Torch Terminal

Remote ControlConnector

DC+ Terminal

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B-4OPERATIONB-4

OPERATING STEPS

WELDING IN TIG MODE

1. Connect the TIG torch and cable quick connectplug to the DC- output receptacle. This receptaclealso contains an integral gas connection for thetorch. Connect the work cable to the DC+ recepta-

cle and to the work piece.

2. Set the Welding Process Switch to 2S whenusing a hand or foot amptrol. When using an arcstart switch, 2S or 4S can be used.

3. Set the TIG Process Switch to the desired posi-tion.

4. Connect an optional Amptrol or Arc Start Switch tothe Remote Control Connector.

5. Turn on the cylinder gas valve and adjust the flowregulator to obtain desired flow.

6. Turn the power switch to 230 or 460 as appropri-ate for your input voltage. NOTE: There will be a0.5 second gas flow when the power is turned on.

7. Set the Current Control on the control panel to themaximum desired amps.

8. Depress the Amptrol or Arc Start Switch to energizethe torch and establish an an arc with the workpiece.

NOTE: When the TIG Process Switch is set to 2S or4S TIG position, depressing the remote control willstart a 0.5 second gas pre-flow before energizing the TIGtorch. When the remote control is released the TIG torchis de-energized and gas flow will continue for the set postflow time (0 - 50 sec.).

REMOTE CONTROL OPERATION

A Foot Amptrol is optional with the V200-T forremote current control while TIG welding. An optionalHand Amptrol may also be used. An optional ArcStart Switch may be used to start and stop the weld-ing if no remote control of the current is desired. Referto the Accessories section of this manual.

Both the Hand and Foot Amptrol work in a similarmanner. For simplicity, the following explanation willrefer only to Amptrols, meaning both Foot and Handmodels. The term minimum refers to a foot pedal inthe up position, as it would be with no foot pressure,or a Hand Amptrol in the relaxed position, with nothumb pressure. Maximum refers to a fullydepressed Foot Amptrol, or a fully extended HandAmptrol.

When the welder is in TIG modes activating theAmptrol energizes the electrode terminal and varies

the output welding current from its minimum value of 1amp, to the maximum value set by the Current Controlon the control panel. This helps eliminate accidentalhigh current damage to the work piece and/or tung-sten, and gives a fine control of the current. When thewelder is in the stick mode a remote control has noeffect and is not used.

It is important to note that, in some cases, the tung-sten will not start an arc at the minimum currentbecause the tungsten may be too large or cold. Tostart an arc reliably, it is important to depress theAmptrol far enough so that the machine output current

is near the tungsten operating range. For example, a3/32 tungsten may be used on DC- to weld the fullrange. To start the weld, the operator may have toturn the current control up and depress the Amptrolapproximately 1/4 of the way down. Releasing theAmptrol to its minimum position may not start the arc.Also if the current control is set too low, the arc maynot start. In most cases, a large or cold tungsten willnot readily establish an arc at low currents. This isnormal. In DC-, the V200-T will start a 3/32, 2% thori-ated tungsten electrode at 15 amperes provided theelectrode tip is properly grounded and not contaminat-ed.

INVERTEC V200-T Sept97

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B-5OPERATIONB-5

WELDING IN STICK MODE

1. Put the electrode holder and cable quick connectplug into the proper receptacle for the electrodepolarity desired. Turn clockwise until tight. Connectthe work clamp to the other receptacle and the workpiece.

2. Set the Welding Process Switch to STICK.

3. Set the Local/Remote Switch to Local.

4. Place the electrode in the electrode holder.

5. Turn the Power Switch to the proper input voltagesetting to turn on the welder.

6. Adjust the Current Control to the desired amps.

7. Strike an arc and weld.

NOTE: When the Welding Process Switch is set toSTICK the output is always on when the powerswitch is on. A remote control has no effect on thewelding current and the gas flow and high frequencyTIG arc starter are disabled.

INVERTEC V200-T

In Stick Mode the output terminal andelectrode will be electrically hot when-ever the power switch is turned on.

WARNING

RECOMMENDED ELECTRODE AMPERAGE RANGES - INVERTEC V200-TThe Invertec V200-T is rated from1 - 200 Amps.

SMAW ProcessELECTRODE POLARITY 3/32" 1/8" 5/32"

Fleetweld 180 DC+ 40 - 80 55 - 110 105 - 135Fleetweld 37 DC+ 70 - 95 100 - 135 145 - MaxFleetweld 47 DC- 75 - 95 100 - 145 135 - MaxJet-LH MR DC+ 85 - 110 110 - 160 130 - Max

Blue Max Stainless DC+ 40 - 80 75 - 110 95 - 110Red Baron Stainless DC+ 40 - 70 60 - 100 90 - 140Mild steel procedures are based on recommended procedures listed in C2.10 8/94 and the maximum rating of the Invertec V200-TJet-LH MR procedures are based on Jet-LH 78 MRBlue Max procedures are based on C6.1 6/95Red Baron Procedure are based on ES-503 10/93

GTAW ProcessElectrode Polarity DC- Approximate Argon

Electrode Tip Prepration Sharpened Gas Flow Rate

Electrode TypeC.F.H. (l/min.)

EWTh-1, EWCe-2EWTh-2, EWLa-1 Stainless

Electrode Size (in.) EWG Aluminum Steel.010 Up to 15 A. 3-8 (2-4) 3-8 (2-4)

.020 Up to 15 A. 5-10 (3-5) 5-10 (3-5)

.040 Up to 80 A. 5-10 (3-5) 5-10 (3-5)1/16 Up to 150 A. 5-10 (3-5) 9-13 (4-6)3/32 Up to MAX. A. 13-17 (6-8) 11-15 (5-7)1/8 X 15-23 (7-11) 11-15 (5-7)

Tungsten electrodes are classified as follows by the American Welding Society (AWS):

Pure ................ ..................EWP........green

+1% Thoria.......................EWTh-1...yellow

+2% Thoria.......................EWTh-2...red

+2% Ceria.........................EWCe-2...orange

+1.5% Lanthana ...............EWLa-1...black

+0.15 to 0.40% Zirconia....EWZr.......brown

Ceriated Tungsten is now widely accepted as a substitute for 2% Thoriated Tungsten in AC and DC applications.

Sept97

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B-6OPERATIONB-6

EXPLANATION OF 2 STEP AND 4STEP MODES(See figure B.2 and the explanations that follow)

2 STEP

2 Step mode can be used with either an arc startswitch or a hand or foot amptrol. The welding cyclebegins when the torch switch is held closed and endswhen the switch is released.

4 STEP

4 Step mode should only be used with an arc startswitch. The welding cycle begins when the torchswitch is pressed and then released. The cycle isended by a further press and release of the switch.

The pre-gas flow is followed by an increase in thewelding current from the level set by the Start/Crater

Current Potentiometer, to the value on the displayset with the Welding Current Potentiometer. Therate of increase is determined by the setting of theSlope Up Time Potentiometer.

The slope out phase begins with the release of thetorch switch in the 2 STEP mode or with a secondpress of the switch in the 4 STEP mode.

During this phase, the welding current falls to thecrater current set on the Start/Crater CurrentPotentiometer. The speed at which the welding cur-rent decreases is determined by the setting of theSlope Down Time Potentiometer.

The power source comes equipped with a restartcapability. Any change required in the restart timingcan only be made by an authorized service center.(See Figure B.2 - 4 Step Mode).

In the TIG-SPOT mode the UP/ DOWN-SLOPE con-trols and the PULSER function are disabled.The welding cycle takes an "ON-OFF" type shape withthe welding current jumping very rapidly from 0 to thenominal value.

PULSER FUNCTION

Pulsed welding is selected by using the TIG ProcessSwitch. In this mode the output is modulated to pro-

duce a series of current pulses. By this means pre-cise control of heat input and penetration can beachieved on critical applications. The pulse frequency,duration and amplitude may be adjusted by means ofthe respective potentiometers.

INVERTEC V200-T

2 STEP MODE

TORCHSWITCH

WELDING

CURRENT

TORCHSWITCH

WELDINGCURRENT

4 STEP MODE

TORCHSWITCH

WELDINGCURRENT

TORCHSWITCH

WELDINGCURRENT

WITHOUT RESTART

WITH RESTART (As shipped no jumper)

CRATER CURRENT

FIGURE B.2 2 Step and 4 Step Modes

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D-1MAINTENANCED-1

INVERTEC V200-T

SAFETY PRECAUTIONS

ELECTRIC SHOCK can kill. Have an electrician install and ser-

vice this equipment.

Turn the input power off at the fusebox, disconnect supply lines andallow machine to sit for five minutesminimum to allow the power capaci-tors to discharge before workinginside this equipment.

Do not touch electrically hot parts.

----------------------------------------------------------------------

INPUT FILTER CAPACITORDISCHARGE PROCEDURE

The machine has internal capacitors which are

charged to a high voltage during power-on conditions.

This voltage is dangerous and must be discharged

before the machine can be serviced. Discharging is

done automatically by the machine each time the

power is switched off. However, you must allow the

machine to sit for at least 5 minutes to allow time for

the process to take place.

------------------------------------------------------------------------

ROUTINE MAINTENANCE

1. Perform the following preventive maintenanceprocedures at least once every thousand hours ofuse. It is good practice to keep a preventive main-tenance record; a record tag attached to themachine works best.

2. Remove the machine cover (requires a 3 mm hexkey) after allowing the minimum 5 minute poweroff requirement to let the input capacitors dis-charge.

Failure to observe this discharge time requirementcould result in severe electrical shock hazard.------------------------------------------------------------------------3. Keeping the machine clean will result in cooler

operation and higher reliability. Be sure to cleanthe following areas with a low pressure airstream.

Printed circuit boards

Power switch

Fan blades

Louvers

Heat sink fins

Output terminals

4. Examine capacitors for leakage or oozing. If any

leakage is noticed, take the unit to an authorized

Lincoln Field Service Shop.

5. Examine the case for breakage. Repair or

replace the case as required. Keep the case in

good condition to ensure that high voltage parts

are protected and correct spacings are main-

tained.

6. Install machine covers and fasteners.

REPLACEMENT OF INTERNALFUSE

The Invertec has additional protection provided tosome circuits through an internal fuse. For replace-ment of that fuse proceed as follows:

1. Turn off the power to the unit and remove the

input plug.

2. Allow the machine to stand for 5 minutes to letthe input capacitors discharge.

3. Remove the machine cover.

4. Replace the blown fuse with a new 0.5A 500Vslowblow fuse.

NOTE: If the fuse blows again after power is restored,the cause could be an internal breakdown inthe power unit. In this case, take the unit to anauthorized Lincoln Field Service Shop.

WARNING

WARNING

WARNING

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E-1TROUBLESHOOTINGE-1

INVERTEC V200-T

If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact yourLocal Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed.

CAUTION

This Troubleshooting Guide is provided tohelp you locate and repair possible machinemalfunctions. Simply follow the three-stepprocedure listed below.

Step 1. LOCATE PROBLEM (SYMPTOM).

Look under the column labeled PROBLEM

(SYMPTOMS). This column describespossible symptoms that the machine mayexhibit. Find the listing that best describesthe symptom that the machine is exhibiting.

Step 2. POSSIBLE CAUSE.

The second column labeled POSSIBLECAUSE lists the obvious external possibili-ties that may contribute to the machinesymptom.

Step 3. RECOMME NDED CO URSE O FACTION

This column provides a course of action forthe Possible Cause, generally it states tocontact you local Lincoln Authorized FieldService Facility.

If you do not understand or are unable toperform the Recommended Course ofAction safely, contact you local LincolnAuthorized Field Service Facility.

HOW TO USE TROUBLESHOOTING GUIDE

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 andmachine operator and will invalidate your factory warranty. For your safety and to avoidElectrical Shock, please observe all safety notes and precautions detailed throughout thismanual.__________________________________________________________________________

WARNING

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E-2TROUBLESHOOTINGE-2

INVERTEC V200-T

Observe all Safety Guidelines detailed throughout this manual

If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact yourLocal Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed.

CAUTION

PROBLEMS(SYMPTOMS)

POSSIBLE AREAS OFMISADJUSTMENTS(S)

RECOMMENDEDCOURSE OF ACTION

The machine is dead - no output -no fan.

No output but the fan operates nor-

mally.

Output turns on momentarily, thenswitches off.

No output - Main input fuses open,indicating excessive current draw.

1. The input power switch must bein the ON position.

2. Make sure the input voltage iscorrect for the machine.

3. Check continuity of the 0.5-ampslow blow fuse located on theP.C. Board.

1. The machine may be overheated.

Check the thermal indicator light.Wait for the machine to cool andthe thermostats to reset.

1. Check the input voltage. Makesure the input voltage is correctfor the machine.

1. Inspect input leads for possibleshorts or grounds or mis-connec-tions.

2. Install new fuses and reapplypower. If fuses open again, con-sult a Lincoln Authorized FieldService Facility.

If all recommended possible areas of

misadjustment have been checkedand the problem persists, Contactyour local Lincoln Authorized FieldService Facility.

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F-1DIAGRAMSF-1

NOTE:Thisdiagrami

sforreferenceonly.

Itmaynotbeaccurateforallmachinescoveredbythismanu

al.Thespecificdiagramf

oraparticu

larcodeispastedinside

t h

h i

f t h

l

l

I f t h

d i

i

i l l

i b

l

i t

t

t h

S

i

D

t

t f

l

t

G i

t h

i

t

d

b

INVERT

ECV200-T

WIRING

DIAGRAM

8-21-98

M18986

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PARTS

INVERTEC V200-T

PARTS LIST FORINVERTEC V200-T

This parts list is provided as an informative guide only.

This information was accurate at the time of printing. However, since thesepages are regularly updated in Lincoln Electrics official Parts Book (BK-34),always check with your Lincoln parts supplier for the latest parts information.

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7-30-97INVERTEC V-200-T

Do Not use this Parts List for a machine if its code number is not listed. Contact the Service Department for anycode numbers not listed.

Use the Illustration of Sub-Assemblies page and the table below to determine which sub assembly page and col-umn the desired part is located on for your particular code machine.

P-308-A.1P-308-A.1

INVERTEC V-200-T

For Codes: 10463

CODE NO.

10463 1

GeneralA

ssembly

P308-C

SUB ASSEMBLYPAGE NAME

PAGE NO.

Sub Assembly ItemNo.

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11-4-98INVERTEC V-200-T

P-308-CP-308-C

General Assembly

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INVERTEC V-200-T

NOTES

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WARNING

AVISO DEPRECAUCION

ATTENTION

WARNUNG

ATENO

Spanish

French

German

Portuguese

Japanese

Chinese

Korean

Arabic

LEIA E COMPREENDA AS INSTRUES DO FABRICANTE PARA ESTE EQUIPAMENTO E AS PARTES DE USO, E SIGA ASPRTICAS DE SEGURANA DO EMPREGADOR.

Keep your head out of fumes. Use ventilati on or exhaust to

remove fumes from breathing zone.

Los humos fuera de la zona de re s-piracin.

Mantenga la cabeza fuera de loshumos. Utilice ventilacin oaspiracin para gases.

Gardez la tte lcart des fumes. Utilisez un ventilateur ou un aspira-

teur pour ter les fume s des zonesde travail.

Vermeiden Sie das Einatmen vonSchweibrauch!

Sorgen Sie fr gute Be- undEntlftung des Arbeitsplatzes!

Mantenha seu rosto da fumaa. Use ventilao e exhausto para

remover fumo da zona respiratria.

Turn power off before servicing.

Desconectar el cable de ali -mentacin de poder de la mquinaantes de iniciar cualquier servicio.

Dbranchez le courant avant lentre-tien.

Strom vor Wartungsarbeitenabschalten! (Netzstrom vllig ff-nen; Maschine anhalten!)

No opere com as tampas removidas. Desligue a corrente antes de fazer

servio. No toque as partes eltricas nuas.

Do not operate with panel open orguards off.

No operar con panel abierto oguardas quitadas.

Noprez pas avec les panneauxouverts ou avec les di spositifs deprotection enlevs.

Anlage nie ohne Schutzgehuseoder Innenschutzverkleidung i nBetrieb setzen!

Mantenha-se afastado das partesmoventes.

No opere com os paineis abertosou guardas removidas.

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