Lincoln Electric SVM161-A Operation, Safety Instructions, General Description, Welding Capability

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B-2

OPERATION

B-2

 

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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.

•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.

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. 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 40% 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 100% 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.

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ARC RAYS can burn.

•Wear eye, ear and body protection.

Only qualified personnel should operate this equipment. Observe all safety information throughout this manual.

LIMITATIONS

The V205-T is not recommended for pipe thawing.

INVERTEC® V205-T AC/DC™

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Contents Invertec V205-T AC/DC Safety Invertec V205-T AC/DCElectric Shock can kill ARC Rays can burn Can be dangerousCylinder may explode Powered equipmentWelding Cutting Sparks can cause fire or If damaged ExplosionPrécautions DE Sûreté Sûreté Pour Soudage a L’ArcSafety Methods of Reducing Emissions Mains Supply Master Table of Contents for ALL Sections Table of Contents Installation Section Installation Operating Temperature Range Storage Temperature RangeTilting Select Suitable LocationStacking Environmental AreaReconnect Procedure Input Connections115V Input Attachment Plug Installation230V Input Engine Driven GeneratorOutput Connections Output and GAS Connection for TIG Welding Figure A.1Work Cable Connection Remote Control Connection Shielding GAS ConnectionInvertec V205-T AC/DC Table of Contents Operation Section General Description Safety InstructionsOperation Welding CapabilityOPERATIONB-3 Rear Control Panel Figure B.1Controls and Settings Figure B.2Step Diagram Local/Remote push button Selects the weldingTIG DC TIG AC SET UP Menu Indicator Parameter DefaultOutput Limitations Welding PolarityFigure B.7 Tips for AC TIG Welding Steel TIG WeldingCopper TIG Welding Filler MaterialAC TIG Welding Quick Start UP Protective GASDC TIG Welding Quick Start UP Table of Contents Accessories Section Compatible Equipment AccessoriesOptional Accessories Cable PlugsTable of Contents Maintenance Section Input Filter Capacitor Discharge Procedure MaintenanceSafety Precautions Routine Maintenance3MAINTENANCE Figure D.1 Major Component LocationsInvertec V205-T AC/DC 1TABLE of CONTENTS-THEORY of Operation Section E-1 Theory of Operation Input Board and BUS BoardMain Igbt Inverter Board Figure E.3 Main Igbt Inverter BoardOutput Module and Clamping Board Main TransformerOutput Module Transistor Board Superimposition BoardCONTROL/DISPLAY Board High Frequency HF BoardOutput Filter Board Insulated Gate Bipolar Transistor Igbt Operation Passive Active1TABLE of Contents Troubleshooting and Repair F-1 Troubleshooting and Repair HOW to USE Troubleshooting GuidePC Board Troubleshooting Procedures Electric Shock can killIgbt Perform the Input Filter Board Igbt Inverter Board Test Secondary Output Board Assembly Test See the Output Filter Troubleshooting and Repair External Diagnostics DisplayTroubleshooting and Repair Internal Diagnostics Figure F.2Internal Diagnostics LEDInvertec V205-T AC/DC Test Description Materials NeededInput Filter Capacitor Discharge Procedure Capacitor Solder Resistor PadsInput Filter Board Test Procedure Input Filter Board TestInput Filter Board Input Filter Board Invertec V205-T AC/DC Main Igbt Inverter Board LOW Voltage Test Main Igbt Inverter Board LOW Voltage Test Figure F.6 Main Igbt Inverter Board LocationMain Igbt Inverter Board LOW Voltage Test LEDTP2 MF2 Figure F.7 Main Igbt Inverter Board LocationCONTROL/DISPLAY Board Test CONTROL/DISPLAY Board Test Figure F.8 CONTROL/DISPLAY Board LocationCN2 Figure F.9 CONTROL/DISPLAY Board LocationCN1 Figure F.10 Plugs CN1, CN2 & CN7BUS Board Test BUS Board Test Figure F.11 BUS Board LocationTable F.7 Plug CN4 Test Points Table F.5 Plug CN2 Test PointsTable F.6 Plug CN3 Test Points Table F.8 Plug CN7 Test PointsCN1 CN2 Main Inverter Board Power Factor Section Test Main Inverter Board Power Factor Section Test Table F.10 Voltage Checks with 115 VAC Applied to MachineTable F.11 Resistance Checks TP9 Gndpwr RL1 Invertec V205-T AC/DC Output Filter Board Test Output Filter Board Test Figure F.16 Output Filter Board LocationFigure F.17 Output Filter Board Plug Location Figure F.18 Output Filter Board Plug CN1Invertec V205-T AC/DC Secondary Output Board Assembly Test Secondary Output Board Assembly Test Figure F.19 Secondary Power Board LocationOFF GA-SA Mode Positive Meter Negative Meter Expected Reading Probe Table F.14 Output Diode Resistance CheckMain Inverter Board Welding Logic and Inverter Section Test Main Inverter Board Welding Logic and Inverter Section TestTable F.15 LED Function Table F.16 Feedback Voltage SignalsTable F.18 LED Check in Stick Mode Table F.17 Voltage Checks with 115 VAC Applied to MachineFigure F.22 Main Board Inverter Section TP9 Ground Power Invertec V205-T AC/DC Input Filter Board Removal and Replacement Input Filter Board Removal and Replacement Figure F.24 Input Filter Board LocationRV1 RV2 Invertec V205-T AC/DC Main Igbt Board Removal and Replacement Main Igbt Board Removal and Replacement Figure F.27 Main Igbt Board LocationRV1 RV2 CN4 RV3 RV4 CN5 RV5 RV7 RV6 Invertec V205-T AC/DC CONTROL/DISPLAY Board Removal and Replacement CONTROL/DISPLAY Board Removal and Replacement Figure F.29 CONTROL/DISPLAY Board LocationCN2 Invertec V205-T AC/DC Output Filter Board Removal and Replacement Removal and Replacement Figure F.32 Output Filter Board LocationPhillips Head Screws CN1 Output Diodes Removal and Replacement Output Diodes Removal and Replacement To Replace ANY of the Output Diodes D1, D2, D3 or D4Output Transistor Removal and Replacement Output Transistor Removal and Replacement Figure F.36 Output Transistor LocationPlug CN1 5mm Allen Bolts Invertec V205-T AC/DC Table of Contents Diagram Section ELECTriCaL DiaGramS
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