RETURN TO MAIN MENU ® INVERTEC V205-T AC/DC TIG For use with machines having Code Numbers: IM728 October, 2004 10860 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 READING THIS MANUAL AND THE SAFETY PRECAUTIONS CONTAINED THROUGHOUT.
i i SAFETY WARNING CALIFORNIA PROPOSITION 65 WARNINGS Diesel engine exhaust and some of its constituents are known to the State of California to cause cancer, birth defects, and other reproductive harm. The Above For Diesel Engines The engine exhaust from this product contains chemicals known to the State of California to cause cancer, birth defects, or other reproductive harm. The Above For Gasoline Engines ARC WELDING CAN BE HAZARDOUS.
ii ii SAFETY ARC RAYS can burn. 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.
iii iii SAFETY WELDING SPARKS can cause fire or explosion. 6.a. Remove fire hazards from the welding area. If this is not possible, cover them to prevent the welding sparks from starting a fire. Remember that welding sparks and hot materials from welding can easily go through small cracks and openings to adjacent areas. Avoid welding near hydraulic lines. Have a fire extinguisher readily available. 6.b.
iv iv SAFETY PRÉCAUTIONS DE SÛRETÉ Pour votre propre protection lire et observer toutes les instructions et les précautions de sûreté specifiques qui parraissent dans ce manuel aussi bien que les précautions de sûreté générales suivantes: Sûreté Pour Soudage A L’Arc 1. Protegez-vous contre la secousse électrique: a. Les circuits à l’électrode et à la piéce sont sous tension quand la machine à souder est en marche.
v v Thank You for selecting a QUALITY product by Lincoln Electric. We want you to take pride in operating this Lincoln Electric Company product ••• as much pride as we have in bringing this product to you! Please Examine Carton and Equipment For Damage Immediately When this equipment is shipped, title passes to the purchaser upon receipt by the carrier.
vi TABLE OF CONTENTS Page Installation.......................................................................................................................Section A Technical Specifications .......................................................................................................A-1 Select Suitable Location .......................................................................................................A-2 Stacking........................................................................
A-1 A-1 INSTALLATION TECHNICAL SPECIFICATIONS - V205-T AC/DC TIG K1855-1 (Code Number 10860) INPUT - SINGLE PHASE ONLY Max. Input Current 34A at Rated Output 30A at Rated Output Input Voltages / 50 /60 Hz. 115 230 RATED OUTPUT Duty Cycle Output Amps Volts at Rated Amperes Input Amps (115V) 35% 60% 100% (Stick) 110 90 70 24.4V 23.6V 22.8V 34A 28A 20A (115V) 40% 60% 100% (TIG) 150 120 100 16V 14.8V 14V 34A 25A 20A (230V) 35% 60% 100% (Stick) 180 150 130 27.2V 26V 25.
A-2 INSTALLATION A-2 Read entire installation section before starting installation. MACHINE GROUNDING AND HIGH FREQUENCY INTERFERENCE PROTECTION Safety Precautions The Capacitor Discharge Circuit used in the high frequency 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. WARNING ELECTRIC SHOCK can kill.
A-3 A-3 INSTALLATION 3. Be sure the torch and work cable rubber coverings are free of cuts and cracks that allow high frequency 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. 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. 4.
A-4 INSTALLATION 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 output 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.
A-5 A-5 INSTALLATION OUTPUT CONNECTIONS 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 clothing. This unit does not include a TIG torch, but one may be purchased separately.
INSTALLATION A-6 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. A-6 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).
B-1 OPERATION Read and understand this entire section before operating your machine. SAFETY INSTRUCTIONS WARNING ELECTRIC SHOCK can kill. • Do not touch electrically live parts such as output terminals, electrode or internal wiring. • Insulate yourself from the work and ground. B-1 GENERAL DESCRIPTION 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.
B-2 OPERATION REAR CONTROL PANEL (FIGURE B.1) WARNING • I1: Off/On switch turns on the electric power to the welder. It has two positions, "O" off, and "I" on. -----------------------------------------------------------------------* With "l1" in the "I" (ON) position, the welding machine is operational and there is voltage between the positive (+) and negative (-) Terminals in stick welding. In TIG, the welding process needs a trigger closure command at the remote control connection.
B-3 B-3 OPERATION CONTROLS AND SETTINGS All operator controls and adjustments are located on the case front of the V205-T machine. Refer to Figure B.2 and the corresponding explanations. FIGURE B.2 9 8 7 6 1. Input Voltage warning Light Green LED 2. Thermal / Device Warning Light Yellow LED 3. Pulse On/Off Button LOCAL 4. Setup/Parameter Select Button 5 5. Output/Parameter Adjust Knob 6. Digital Display sec 7. Local/Remote Button sec 8.Trigger Selection Button 13 9.
B-4 B-4 OPERATION 2 STEP DIAGRAM 1 5. Output / Parameter Adjust Knob- Allows you 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". (2) (1) 6. Digital Display - displays currently set values for each mode or welding parameter. 7.
B-5 B-5 OPERATION 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 current can be maintained as long or as short as necessary. 9. Welding selection button - Permits selection of the welding mode.
B-6 B-6 OPERATION SET UP MENU 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. • Position the On/Off switch to on "I" at the back of the machine; the input voltage light "Item 1" (green LED) confirms normal operation. • The SETUP mode is confirmed by a center "0" on the Digital display “Item 6”.
B-7 B-7 OPERATION OUTPUT LIMITATIONS WELDING POLARITY The maximum output current as specified in the installation section of this manual is derated in two situations; alternate AC Wave Forms and elevated AC Frequencies. 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. • Alternate AC Wave Forms (See Set Up Menu) Square 200 amps max. output Sinusoidal 150 amps max.
B-8 B-8 OPERATION DC Electrode Positive Polarity. (Direct Current Reverse Polarity) (see Figure B.5) A.C. (Alternating Current) (see Figure B.7) In this case, there is a continuous flow of electrons from the workpiece to the electrode. The reverse polarity is used for welding alloys covered with a layer of refractory oxide. Alternating Current welding is typically used for Tig welding aluminum (and its alloys) or magnesium.
B-9 B-9 OPERATION STEEL TIG WELDING The TIG process is very effective for welding both carbon 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 and preparation of the edges is required. FILLER MATERIAL: The filler rods must deposit welds with mechanical characteristics appropriate for the application.
B-10 OPERATION PROTECTIVE GAS Both argon and helium work when welding aluminum. Argon is preferred, due to its lower cost and consumption rate. This gas also tends to stabilize the arc, thus making it easy to operate. For some applications, however, the use of helium, or argon-helium blends, is recommended 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.
B-11 OPERATION DC TIG WELDING QUICK START UP 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. • Do not touch electrically hot parts.
C-1 ACCESSORIES C-1 TIG TORCH KITS OPTIONAL ACCESSORIES AND COMPATIBLE EQUIPMENT 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: PTA17 torch, parts kit, Harris flowmeter/regulator, 10 ft. gas hose, Twist-mate™ adapter, work clamp and cable.
D-1 MAINTENANCE SAFETY PRECAUTIONS 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. • Do not touch electrically hot parts.
E-1 TROUBLESHOOTING E-1 HOW TO USE TROUBLESHOOTING GUIDE WARNING Service and Repair should only be performed by Lincoln Electric Factory Trained Personnel. Unauthorized repairs performed on this equipment may result in danger to the technician and machine operator and will invalidate your factory warranty. For your safety and to avoid Electrical Shock, please observe all safety notes and precautions detailed throughout this manual.
E-2 E-2 TROUBLESHOOTING Observe all Safety Guidelines detailed throughout this manual PROBLEMS (SYMPTOMS) POSSIBLE AREAS OF MISADJUSTMENT(S) RECOMMENDED COURSE OF ACTION PROBLEMS IN STICK WELDING Excessive spatter 1. Long arc 2. High current Craters 1. Fast movement of the electrode away from piece. Inclusions 1. Poor cleanliness or distribution of the Welding passes. 2. Improper movement of the electrode. Insufficient penetration 1. High progression speed. 2. Welding current too low. 3.
E-3 E-3 TROUBLESHOOTING Observe all Safety Guidelines detailed throughout this manual PROBLEMS (SYMPTOMS) POSSIBLE AREAS OF MISADJUSTMENT(S) RECOMMENDED COURSE OF ACTION PROBLEMS IN TIG WELDING Oxidation 1. lnsufficient gas. 2. No protection on the back side. Tungsten inclusions 1. lncorrect electrode sharpening. 2. Electrode too small. 3. Operating failure (contact of the tip with the workpiece). Porosity 1. Dirt on the edges. 2. Dirt on the filler material. 3. Excessive travel speed. 4.
E-4 E-4 TROUBLESHOOTING Observe all Safety Guidelines detailed throughout this manual PROBLEMS (SYMPTOMS) POSSIBLE AREAS OF MISADJUSTMENT(S) RECOMMENDED COURSE OF ACTION ELECTRICAL FAILURES Machine fails to come on (Green LED off) 1. No Input Voltage. 2. Faulty supply plug or cable. 3. Internal fuse blown. Power output incorrect (Green LED on) 1. Incorrect setting up of the welding parameters. 2. Low mains supply voltage No output current (Green LED on) 1.
* WIRING DIAGRAMS NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual. The specific diagram for a particular code is pasted inside the machine on one of the enclosure panels. If the diagram is illegible, write to the Service Department for a replacement. Give the equipment code number.
NOTES V205-T AC/DC TIG
NOTES V205-T AC/DC TIG
● Do not touch electrically live parts or WARNING Spanish AVISO DE PRECAUCION French ATTENTION German WARNUNG Portuguese ATENÇÃO ● Keep flammable materials away. ● Wear eye, ear and body protection. ● Mantenga el material combustible ● Protéjase los ojos, los oídos y el electrode with skin or wet clothing. ● Insulate yourself from work and ground. ● No toque las partes o los electrodos bajo carga con la piel o ropa mojada. ● Aislese del trabajo y de la tierra.
● Keep your head out of fumes. ● Use ventilation or exhaust to ● Turn power off before servicing. ● Do not operate with panel open or guards off. remove fumes from breathing zone. ● Los humos fuera de la zona de res- piración. ● Mantenga la cabeza fuera de los humos. Utilice ventilación o aspiración para gases. ● Gardez la tête à l’écart des fumées. ● Utilisez un ventilateur ou un aspira- ● Desconectar el cable de ali- mentación de poder de la máquina antes de iniciar cualquier servicio.
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