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SVM161-A
February, 2006
INVERTEC V205-T AC/DC
For use with machine code number 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 READ-
ING THIS MANUAL AND THE
SAFETY PRECAUTIONS CON-
TAINED THROUGHOUT. And,
most importantly, think before
you act and be careful.
AC/DC
V205-T
SERVICE MANUAL
Copyright © 2006 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
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iii
iii
SAFETY
ARC RAYS can burn.
ELECTRIC SHOCK can kill.
3.a.
The electrode and work (or ground) circuits
4.a. Use a shield with the proper filter and cover
plates to protect your eyes from sparks and
the rays of the arc when welding or observing
open arc welding. Headshield and filter lens
should conform to ANSI Z87. I standards.
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.
4.b. Use suitable clothing made from durable flame-resistant
material to protect your skin and that of your helpers from
the arc rays.
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.
4.c. 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.
In addition to the normal safety precautions, if welding
must be performed under electrically hazardous
conditions (in damp locations or while wearing wet
clothing; on metal structures such as floors, gratings or
scaffolds; when in cramped positions such as sitting,
kneeling or lying, if there is a high risk of unavoidable or
accidental contact with the workpiece or ground) use
the following equipment:
FUMES AND GASES
can be dangerous.
5.a. Welding may produce fumes and gases
hazardous to health. Avoid breathing these
fumes and gases.When welding, keep
• Semiautomatic DC Constant Voltage (Wire) Welder.
• DC Manual (Stick) Welder.
• AC Welder with Reduced Voltage Control.
your head out of the fume. Use enough
ventilation and/or exhaust at the arc to keep
3.c. In semiautomatic or automatic wire welding, the electrode,
electrode reel, welding head, nozzle or semiautomatic
welding gun are also electrically “hot”.
fumes and gases away from the breathing zone. When
welding with electrodes which require special
ventilation such as stainless or hard facing (see
instructions on container or MSDS) or on lead or
cadmium plated steel and other metals or coatings
which produce highly toxic fumes, keep exposure as
low as possible and below Threshold Limit Values (TLV)
using local exhaust or mechanical ventilation. In
confined spaces or in some circumstances, outdoors, a
respirator may be required. Additional precautions are
also required when welding on galvanized steel.
3.d. 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.
3.e. Ground the work or metal to be welded to a good electrical
(earth) ground.
3.f. Maintain the electrode holder, work clamp, welding cable and
welding machine in good, safe operating condition. Replace
damaged insulation.
5.b. 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 sol-
vent vapors to form phosgene, a highly toxic gas, and other
irritating products.
3.g. Never dip the electrode in water for cooling.
3.h. 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.
5.c. 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.
3.i. When working above floor level, use a safety belt to protect
yourself from a fall should you get a shock.
5.d. 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.
3.j. Also see Items 6.c. and 8.
5.e. Also see item 1.b.
Mar ‘95
V205-T AC/DC
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iv
iv
SAFETY
WELDING SPARKS can
cause fire or explosion.
CYLINDER may explode
if damaged.
6.a. Remove fire hazards from the welding area.
If this is not possible, cover them to prevent
7.a. Use only compressed gas cylinders
containing the correct shielding gas for the
process used and properly operating
the welding
Remember
sparks from
that welding
starting
sparks
a
and
fire.
hot
regulators designed for the gas and
pressure used. All hoses, fittings, etc. should be suitable for
the application and maintained in good condition.
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.
7.b. Always keep cylinders in an upright position securely
chained to an undercarriage or fixed support.
6.b. Where compressed gases are to be used at the job site,
special precautions should be used to prevent hazardous
situations. Refer to “Safety in Welding and Cutting” (ANSI
Standard Z49.1) and the operating information for the
equipment being used.
7.c. Cylinders should be located:
•Away from areas where they may be struck or subjected to
physical damage.
6.c. 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.
•A safe distance from arc welding or cutting operations and
any other source of heat, sparks, or flame.
7.d. Never allow the electrode, electrode holder or any other
electrically “hot” parts to touch a cylinder.
6.d. 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).
7.e. Keep your head and face away from the cylinder valve outlet
when opening the cylinder valve.
7.f. Valve protection caps should always be in place and hand
tight except when the cylinder is in use or connected for
use.
7.g. Read and follow the instructions on compressed gas
cylinders, associated equipment, and CGA publication P-l,
“Precautions for Safe Handling of Compressed Gases in
Cylinders,” available from the Compressed Gas Association
1235 Jefferson Davis Highway, Arlington, VA 22202.
6.e. Vent hollow castings or containers before heating, cutting or
welding. They may explode.
6.f. 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.
FOR ELECTRICALLY
powered equipment.
6.g. Connect the work cable to the work as close to the welding
area as practical. Work cables connected to the building
framework or other locations away from the welding area
increase the possibility of the welding current passing
through lifting chains, crane cables or other alternate circuits.
This can create fire hazards or overheat lifting chains or
cables until they fail.
8.a. Turn off input power using the disconnect
switch at the fuse box before working on
the equipment.
8.b. Install equipment in accordance with the U.S. National
Electrical Code, all local codes and the manufacturer’s
recommendations.
6.h. Also see item 1.c.
8.c. Ground the equipment in accordance with the U.S. National
Electrical Code and the manufacturer’s recommendations.
Mar ‘95
V205-T AC/DC
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v
v
SAFETY
6. Eloigner les matériaux inflammables ou les recouvrir afin de
prévenir tout risque d’incendie dû aux étincelles.
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 suiv-
antes:
7. Quand on ne soude pas, poser la pince à une endroit isolé de
la masse. Un court-circuit accidental peut provoquer un
échauffement et un risque d’incendie.
8. S’assurer que la masse est connectée le plus prés 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
éloignés de la zone de travail, on augmente le risque de voir
passer le courant de soudage par les chaines de levage,
câbles de grue, ou autres circuits. Cela peut provoquer des
risques d’incendie ou d’echauffement des chaines et des
câbles jusqu’à ce qu’ils se rompent.
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. Eviter toujours
tout contact entre les parties sous tension et la peau nue
ou les vétements mouillés. Porter des gants secs et sans
trous pour isoler les mains.
b. Faire trés 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 couché pour lesquelles une grande
partie du corps peut être en contact avec la masse.
c. Maintenir le porte-électrode, la pince de masse, le câble de
soudage et la machine à souder en bon et sûr état defonc-
tionnement.
9. Assurer une ventilation suffisante dans la zone de soudage.
Ceci est particuliérement important pour le soudage de tôles
galvanisées plombées, ou cadmiées ou tout autre métal qui
produit des fumeés toxiques.
10. Ne pas souder en présence de vapeurs de chlore provenant
d’opérations de dégraissage, nettoyage ou pistolage. La
chaleur ou les rayons de l’arc peuvent réagir avec les vapeurs
du solvant pour produire du phosgéne (gas fortement toxique)
ou autres produits irritants.
d.Ne jamais plonger le porte-électrode dans l’eau pour le
refroidir.
e. Ne jamais toucher simultanément les parties sous tension
des porte-électrodes connectés à deux machines à souder
parce que la tension entre les deux pinces peut être le total
de la tension à vide des deux machines.
11. Pour obtenir de plus amples renseignements sur la sûreté, voir
le code “Code for safety in welding and cutting” CSA Standard
W 117.2-1974.
f. Si on utilise la machine à souder comme une source de
courant pour soudage semi-automatique, ces precautions
pour le porte-électrode s’applicuent aussi au pistolet de
soudage.
PRÉCAUTIONS DE SÛRETÉ POUR
LES MACHINES À SOUDER À
TRANSFORMATEUR ET À
REDRESSEUR
2. Dans le cas de travail au dessus du niveau du sol, se protéger
contre les chutes dans le cas ou on recoit un choc. Ne jamais
enrouler le câble-électrode autour de n’importe quelle partie du
corps.
3. Un coup d’arc peut être plus sévère qu’un coup de soliel, donc:
a. Utiliser un bon masque avec un verre filtrant approprié ainsi
qu’un verre blanc afin de se protéger les yeux du rayon-
nement de l’arc et des projections quand on soude ou
quand on regarde l’arc.
1. Relier à la terre le chassis du poste conformement au code de
l’électricité et aux recommendations du fabricant. Le dispositif
de montage ou la piece à souder doit être branché à une
bonne mise à la terre.
b. Porter des vêtements convenables afin de protéger la peau
de soudeur et des aides contre le rayonnement de l‘arc.
c. Protéger l’autre personnel travaillant à proximité au
soudage à l’aide d’écrans appropriés et non-inflammables.
2. Autant que possible, I’installation et l’entretien du poste seront
effectués par un électricien qualifié.
3. Avant de faires des travaux à l’interieur de poste, la debranch-
er à l’interrupteur à la boite de fusibles.
4. Des gouttes de laitier en fusion sont émises de l’arc de
soudage. Se protéger avec des vêtements de protection libres
de l’huile, tels que les gants en cuir, chemise épaisse, pan-
talons sans revers, et chaussures montantes.
4. Garder tous les couvercles et dispositifs de sûreté à leur place.
5. Toujours porter des lunettes de sécurité dans la zone de
soudage. Utiliser des lunettes avec écrans lateraux dans les
zones où l’on pique le laitier.
V205-T AC/DC
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vi
vi
MASTER TABLE OF CONTENTS FOR ALL SECTIONS
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Page
Safety.................................................................................................................................................i-iv
Installation.............................................................................................................................Section A
Operation...............................................................................................................................Section B
Accessories...........................................................................................................................Section C
Maintenance .........................................................................................................................Section D
Theory of Operation .............................................................................................................Section E
Troubleshooting and Repair.................................................................................................Section F
Safety Precautions......................................................................................................................F-2
How to Use Troubleshooting Guide............................................................................................F-2
Troubleshooting Guide................................................................................................................F-4
Test Procedures ..........................................................................................................................F-9
Replacement Procedures .........................................................................................................F-49
Electrical Diagrams..............................................................................................................Section G
Parts Manual .....................................................................................................................P400 Series
V205-T AC/DC
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A-1
A-1
TABLE OF CONTENTS
- INSTALLATION SECTION -
INSTALLATION ......................................................................................................................Section A
Technical Specifications .............................................................................................................A-2
Select Suitable Location.............................................................................................................A-3
Machine Grounding/High Frequency Interference Protection....................................................A-3
Reconnect Procedures ...............................................................................................................A-4
Output Connections....................................................................................................................A-6
V205-T AC/DC
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A-2
A-2
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
Input Amps
Output Amps Volts at Rated Amperes
Duty Cycle
(Stick) 110
24.4V
23.6V
22.8V
34A
28A
20A
(115V) 35%
60%
100%
90
70
(TIG) 150
120
100
16V
14.8V
14V
34A
25A
20A
(115V) 40%
60%
100%
(Stick) 180
150
130
27.2V
26V
25.2V
30A
23A
19A
(230V) 35%
60%
100%
(TIG) 200
170
140
18V
16V
15.6V
30A
18A
15A
(230V) 40%
60%
100%
OUTPUT
Maximum Open
Circuit Voltage
54 Volts Max.
Type of Output
Output Current
Range
6-200 Amps
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
230/50/60
30A
#12
PHYSICAL DIMENSIONS
Depth
Height
15 in.
381 mm
Width
8.5 in.
216 mm
Weight
Approx. 38 lbs.
17 kgs.
19 in.
483 mm
TEMPERATURE RANGES
OPERATING TEMPERATURE RANGE
-20°C to +40°C
STORAGE TEMPERATURE RANGE
-50°C to +85°C
V205-T AC/DC
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A-3
A-3
INSTALLATION
Read entire installation section before starting
installation.
MACHINE GROUNDING AND HIGH FRE-
QUENCY INTERFERENCE PROTECTION
Safety Precautions
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.
WARNING
ELECTRIC SHOCK can kill.
• Only qualified personnel should per-
form this installation.
The Invertec V205-T AC/DC has been field tested
under recommended installation conditions. It com-
plies with FCC allowable limits for radiation.
• Turn the input power OFF and unplug
the machine from the receptacle
before working on this equipment.
Allow machine to sit for 5 minutes
minimum to allow the power capac-
itors to discharge before working
inside this equipment.
Radiated interference can develop in the following four
ways:
1. Direct interference radiated from the welder.
•
•
Insulate yourself from the work and ground.
Always wear dry insulating gloves.
2. Direct interference radiated from the welding leads.
• Always connect the V205-T to a power supply
grounded according to the National Electrical Code
and local codes.
3. Direct interference radiated from feedback into the
power lines.
------------------------------------------------------------
SELECT SUITABLE LOCATION
4. Interference from re-radiation of “pickup” by
ungrounded metallic objects.
The Invertec will operate in harsh environments. Even
so, it is important that simple preventative measures
are followed in order to assure long life and reliable
operation.
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.
• 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
2. Keep the work and electrode leads as short as pos-
sible and as close together as possible. Lengths
should not exceed 25 ft (7.6m). Tape the electrode
and work leads together into one bundle when prac-
tical.
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 machine dry. Do not place it on wet ground or
in puddles.
V205-T AC/DC
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A-4
A-4
INSTALLATION
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.
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. Keep the torch in good repair and all connections
tight to reduce high frequency leakage.
WARNING
5. The work terminal must be connected to a ground
within ten feet of the welder, using one of the fol-
lowing methods.
ELECTRIC SHOCK can kill.
• Have a qualified electrician install
and service this equipment.
a) A metal underground water pipe in direct con-
tact with the earth for ten feet or more.
• Turn the input power OFF and unplug
the machine from the receptacle
before working on this equipment.
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.
• Allow machine to sit for 5 minutes minimum to
allow the power capacitors to discharge before
working inside this equipment.
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
antennas.
• 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.
6. Keep all panels securely in place.
• Do not remove or defeat the purpose of the
power cord ground pin.
7. 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.
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
type1 circuit breakers. Using fuses or circuit breakers
smaller than recommended may result in “nuisance”
shut-offs from welder inrush currents even if not weld-
ing at high currents.
Failure to observe these recommended installation
procedures can cause radio or TV interference prob-
lems.
The Invertec V205-T AC/DC is recommended for use
on an individual branch circuit.
1Also 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.
V205-T AC/DC
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A-5
A-5
INSTALLATION
230V INPUT
In all cases, the green or green/yellow grounding wire
must be connected to the grounding pin of the plug, usu-
ally identified by a green screw.
The equipment is provided with a 230/115V cable,
6.6ft.(2m) in length with a 230V 6-50P attachment plug.
Attachment plugs must comply with the Standard for
Attachment Plugs and Receptacles, UL498.
The Invertec V205-T AC/DC performs best when con-
nected to 230VAC inputs. This input allows full output
of the machine (200 amps).
The product is considered acceptable for use only when
an attachment plug as specified is properly attached to
the supply cord.
115V INPUT
For use on engine drives, keep in mind the above input
draw restrictions and the following precaution.
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.
Other loads on the circuit and fuse/circuit breaker charac-
teristics will affect the available output. Do not exceed
these welding conditions:
ENGINE DRIVEN GENERATOR
The Invertec V205-T AC/DC can be operated on
engine driven generators as long as the 230 volt auxil-
iary meets the following conditions:
• The AC waveform peak voltage is below 400 volts.
• The AC waveform frequency is between 45 and
65Hz.
The following Lincoln engine drives meet these condi-
tions when run in the high idle mode:
• Ranger 250,305
15A branch circuit
10% duty cycle
Stick: 75A
• Commander 300, 400, & 500
TIG:
105A
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 con-
forming to these conditions. Such drives may deliver
unacceptably high voltage levels to the Invertec V205-
T AC/DC power source.
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.
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.
---------------------------------------------------------------------------
V205-T AC/DC
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A-6
A-6
INSTALLATION
OUTPUT CONNECTIONS
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.
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.
OUTPUT CONNECTION FOR STICK
STRAIN RELIEF BOOT
TIG ADAPTER
• Insulate yourself from work and ground.
• Turn the input line Switch on the Invertec V205-
T AC/DC “off” before connecting or disconnect-
ing output cables or other equipment.
RETAINING COMPOUND
TIG TORCH POWER CABLE WITH GAS FITING
WELDING (FIGURE A.2)
-----------------------------------------------------------
OUTPUT AND GAS CONNECTION FOR
TIG WELDING (FIGURE A.1)
First determine the proper electrode polarity for the
electrode to be used. Consult the electrode data for
this information. Then connect the output cables to the
output terminals corresponding to this polarity. For
instance, for DC(+) welding, connect the electrode
cable (which is connected to the electrode holder) to
the “+” output terminal and the work cable (which is
connected to the work clamp) to the “-” 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.
The TIG Torch Twist-Mate and work cable Twist-Mate
Connectors are supplied with the welder. To connect
the cables, turn the Power Switch “OFF”. Connect the
torch cable Twist-Mate plug into the DC(-) Electrode/Gas
Output Receptacle on the front of the welder and turn
it clockwise until snug,(Do not Overtighten). This is a
quick connect terminal and also provides the gas con-
nection for the shielding gas to the torch.
WARNING
To avoid receiving a high frequency shock, keep
the TIG torch and cable insulation in good condi-
tion.
FIGURE A.2
WORK CABLE
___________________________________________
WORK CABLE CONNECTION
WORK CABLE
-
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.
+
STICK ELECTRODE
HOLDER
FIGURE A.1
TIG TORCH
-
+
WORK CLAMP
WORK CABLE
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A-7
A-7
INSTALLATION
SHIELDING GAS CONNECTION
QUICK DISCONNECT PLUG (FOR STICK ELEC-
TRODE CABLE and WORK CABLE)
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 #032.
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.
WARNING
CYLINDER could explode
if damaged.
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.
• Keep cylinder upright and
chained to a support.
BOOT
WELDING CABLE
• Keep cylinder away from areas where it
could be damaged.
• Never allow the torch or welding electrode to
touch the cylinder.
1.00 in.
TRIM, IF REQ’D
TO FIT OVER CABLE
25 mm
• Keep cylinder away from live electrical cir-
cuits.
___________________________________________
4. Insert copper strands into ferrule.
COPPER FERRULE
WELDING CABLE
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.
5. Slide the copper ferrule into the brass plug.
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.
SET SCREW
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.
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A-8
A-8
NOTES
V205-T AC/DC
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B-1
B-1
TABLE OF CONTENTS
- OPERATION SECTION -
Operation...............................................................................................................................Section B
Safety Instructions......................................................................................................................B-2
General Description....................................................................................................................B-2
Welding Capability......................................................................................................................B-2
Limitations...................................................................................................................................B-2
Rear Control Panel......................................................................................................................B-3
Controls and Settings.................................................................................................................B-4
Set Up Menu...............................................................................................................................B-7
Output Limitations ......................................................................................................................B-8
DC TIG Welding ..........................................................................................................................B-8
Welding Polarity..........................................................................................................................B-8
Steel TIG Welding .....................................................................................................................B-10
Copper TIG Welding .................................................................................................................B-10
Tips for AC TIG Welding...........................................................................................................B-10
AC TIG Welding Quick Start Up ...............................................................................................B-11
DC TIG Welding Quick Start Up...............................................................................................B-12
V205-T AC/DC
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B-2
Read and understand this entire section before
B-2
OPERATION
GENERAL DESCRIPTION
operating your machine.
SAFETY INSTRUCTIONS
WARNING
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 optimized
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 excellent
results:
ELECTRIC SHOCK can kill.
• Do not touch electrically live parts
such as output terminals, electrode or
internal wiring.
TIG (with high frequency or Touch Start Tig Starting).
• TIG AC with square, sinusoidal and triangular wave-
forms
• Tig DC
• Insulate yourself from the work and
ground.
The following items can be connected to the 6 pin
socket on the front panel:
• Remote control potentiometer for Stick welding.
• Always wear dry insulating gloves.
____________________________________
• Remote Foot Amptrol or Hand Amptrol
• Arc Start Switch
FUMES AND GASES
can be dangerous.
NOTE: See Accessories section of this manual for
product numbers and complete description.
• Keep your head out of fumes.
WELDING CAPABILITY
• Use ventilation or exhaust to
remove fumes from breathing
zone.
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 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.
____________________________________
WELDING, CUTTING and
GOUGING SPARKS
can cause fire or explosion
• Keep flammable material away.
The Invertec V205-T is recommended for stick welding
with such popular electrodes as Fleetweld 35,
Fleetweld 37, Fleetweld 180 and Excalibur 7018.
• Do not weld, cut or gouge on
containers that have held com-
bustibles.
LIMITATIONS
____________________________________
The V205-T is not recommended for pipe thawing.
ARC RAYS
can burn.
• Wear eye, ear and body
protection.
____________________________________
Only qualified personnel should operate this
equipment. Observe all safety information
throughout this manual.
V205-T AC/DC
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B-3
B-3
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 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 “l1”
(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
l1 : Power Switch
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B-4
B-4
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. Output/Parameter Adjust Knob
6. Digital Display
5
sec
7. Local/Remote Button
sec
8.Trigger Selection Button
13
9. Welding Process (MODE) Button
10. Electrode Connection (Negative)
11. Remote Control Connector
12. Electrode Connection (Positive)
13. Welding Parameter Drawing
4
1
2
3
10
11
12
1. Input Voltage warning light green LED - Indicates
that the machine is on and input voltage is within
acceptable range.
4. Setup/Parameter Select push button
-
“Setup/Parameter" push button has three (3) differ-
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
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.
Upslope
Weld Current (Peak Current)
Pulse Frequency
% on Time
Background Current
Downslope
Finish Current
Postflow sec.
3. Pulse On/OFF push button - CONSTANT current
- PULSED current
There is a LED for each welding parameter. When
lit, it 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.
V205-T AC/DC
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B-5
B-5
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".
(1)
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.
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).
8. Tig Trigger Sequences -
For the V205-T AC/DC, TIG welding can be done in
either the 2-step or 4-step mode which is selected with
the Trigger Mode Push Button.
2 STEP DIAGRAM 2
(2)
(1)
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.
4-Step Sequence
With the 4-step Selected, the following welding
sequence will occur.
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.
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.
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.
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.
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.
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. 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 increase, or upslope time are presettable. The
default start current is 15 amps and the default ups-
lope time is 0.2 seconds.
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B-6
B-6
OPERATION
9. Welding selection button - Permits selection of the
welding mode. The LED beside the symbol confirm
the selection:
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.
• Stick
• TIG DC
• TIG AC
10. Electrode Connection (Negative) - For quick dis-
connect system using Twist-MateTM cable plugs
with gas pass through for TIG Torches.
4. Release the TIG torch trigger.
11. Remote Control Connector - For the connection
of a Lincoln Foot Amptrol, Hand Amptrol or Arc
Start Switch. See the ACCESSORIES section for
available options.
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).
12. Electrode Connection (Positive) - For quick dis-
connect system using Twist-MateTM cable plugs
4 STEP DIAGRAM 1
(3)
(4)
13. Welding Parameter Display - LED’s show which
mode or welding parameter is activated for adjust-
ment.
• If it is 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.
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
operation shown in (4 step diagram 2)
4 STEP DIAGRAM 2
- 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 seconds and the Weld Current LED
will come on again.
WELDING PARAMETER DEFAULTS AND RANGES
PARAMETER
START CURRENT
UPSLOPE
VALUE
AMPS
SEC.
MIN
6
0
MAX
MAX
10
DEFAULT
15
0.2
WELD CURRENT*
DOWNSLOPE
AMPS
SEC.
6
0
MAX
10
100
1.0
FINISH CURRENT
POSTFLOW
PULSE FREQUENCY
% ON TIME
AMPS
SEC.
HZ
%
6
MAX
60
500
95
8
5.0
0.5
50
0.2
0.1
5
BACKGROUND CURRENT
AC FREQUENCY
AC BALANCE
% OF WELD CURRENT
HZ
% EN
1
20
35
100
150
85
20
100
65
(EN = Electrode Negative)
MODE
TRIGGER
LOCAL / REMOTE
DC TIG
2 STEP
LOCAL
* Maximum Weld Current can be limited by input voltage, Welding Mode, AC TIG waveform and AC TIG frequency.
V205-T AC/DC
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B-7
B-7
OPERATION
- 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".
SET UP MENU
Many additional parameters can be modified via the
Set Up Menu. To access the Set Up Menu:
- 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 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.
- With parameter (9) all the modifications
made in the SETUP mode are cancelled and
the standard values set by Invertec V205-T
AC/DC are restored.
• The SETUP mode is confirmed by a center "0" on the
Digital display “Item 6”.
- To exit the Set Up Menu, return to “0” and
press the Setup/Parameter Push Button
INDICATOR
PARAMETER
DEFAULT
0
1
2
3
4
5
Exit From Set Up
Not Used
Pre Flow Time (0 - 25 seconds)
Arc Force, percent above Peak Current for Stick only (0 - 100%)
Hot Start, percent above Peak Current for Stick only (0 - 100%)
Setting of AC wave Form
0.5 sec.
30%
80%
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.
(6 Amps - Value set for Indicator 7)
Max. Weld Current Value with Remote Control,for TIG only.
(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 H.F. Start in DC TIG (0 = H.F. Start, 1 = touch Start)
This parameter is ignored in AC TIG Mode
Reset all Parameters, (including control panel settings)
Not Used
6
7
10 Amps
Peak Current
8
0
9
10
11
12
Not Used
2 Step Trigger Selection
0 = Restart Disabled
1 = Restart Enabled
4 Step Trigger Selection
0 = Restart Disabled
1
0
13
14
1 = Restart Enabled
Start Power , for TIG only
2.0
This function sets the initial start energy limit.
(1.0 = min., 5.0 = max.)
Note: If 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.
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B-8
B-8
OPERATION
WELDING POLARITY
OUTPUT LIMITATIONS
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.
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 AC Wave Forms (See Set Up Menu)
Square
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.
200 amps max. output
Sinusoidal 150 amps max. output
Triangular 120 amps max output
• Elevated AC Frequencies
Most materials, with the exception of aluminum and
magnesium, are welded with this polarity.
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.
FIGURE B.4
These derated values have been programmed into the
Invertec V205-T AC/DC to ensure reliable operation.
DC TIG WELDING
(see FIGURE B.3)
The TIG (Tungsten lnert Gas) welding process is
based on the presence of an electric arc between a
non-consumable electrode (pure or alloyed tungsten
with an approximate 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) Filler material
6) Pressure reducer
nert gas (typically argon)
) l
3) Non-consumable electrode 7
4) Torch
8)
Power source
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B-9
B-9
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 polar-
ity 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. 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.
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.
FIGURE B.7
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.)
Greater % EN = MORE PENETRATION
Lesser % EN = more CLEANING
50% (EN)
FIGURE B.5
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
D.C.-Pulsed TIG
(see Figure B-6)
A.C.- PULSED TIG
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
DC-PULSED TIG
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B-10
B-10
OPERATION
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.
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 and
preparation of the edges is required.
FILLER MATERIAL:
The filler rods must deposit welds with mechanical
characteristics appropriate for the application.
The two above benefits can be used to maintain a tight
focus of the arc for precise heat control and tight joint
access. Because of the AC inverters abilities in these
areas the following recommendations are made as a
starting point:
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.
• A 2% 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
FILLER MATERIAL:
welding with
a
conventional power source.
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.
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.
TIPS FOR AC TIG WELDING
AC Inverter TIG power sources offer two significant
advantages over conventional Silicon Controlled
Rectifier (SCR) / transformer power sources:
• Set the AC Frequency in the 100 to 120 Hz range.
This is a "Sweet Spot" for most aluminum applica-
tions.
GTAW Process
AC
Electrode Polarity
Electrode Tip Preparation
DC-
Sharpened
Approximate Argon
Gas Flow Rate
C.F.H. (l/min.)
Sharpened
Electrode Type
EWTh-2, EWLa-1
EWTh-2, EWLa-1
Stainless
Steel
3-8 (2-4)
5-10 (3-5)
5-10 (3-5)
9-13 (4-6)
Electrode Size-in. (mm)
Aluminum
3-8 (2-4)
5-10 (3-5)
5-10 (3-5)
5-10 (3-5)
.010
.020
.040
1/16
3/32
1/8
(0.25)
(0.50)
(1.0)
(1.6)
(2.4)
(3.2)
Up to 15 A.
Up to 15 A.
Up to 80 A.
Up to 150 A.
Up to MAX. A.
X
Up to 15 A.
Up to 20 A.
Up to 60 A.
Up to 130 A.
Up to MAX. A.
X
13-17 (6-8) 11-15 (5-7)
15-23 (7-11) 11-15 (5-7)
Tungsten electrodes are classified as follows by the American Welding Society (AWS):
+2% Thoria.......................EWTh-2...red
+1.5% Lanthana ...............EWLa-1...black
V205-T AC/DC
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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.
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 65% EN
• AC Frequency 100HZ
• Pre Flow .5sec.
• Post Flow 5 sec.
• High Freq Start
TABLE 5
Current (A)
50
Helium cfh-(l/min)
29 - (14)
29 - (14)
100
42 - (20)
150
200
250
300
42 - (20)
53 - (25)
53 - (25)
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.
AC TIG WELDING QUICK START UP
WARNING
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.
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.
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 back to the welding mode ready to
weld with the new selected AC Balance.
• 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.
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.
With the work cable connected to a properly grounded
work piece, turn the power source on.
V205-T AC/DC
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B-12
B-12
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, 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.
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 output current from
10 amps to current level set by output control.
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.
V205-T AC/DC
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C-1
C-1
TABLE OF CONTENTS
- ACCESSORIES -
Accessories...........................................................................................................................Section C
Options/Accessories...................................................................................................................C-2
V205-T AC/DC
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C-2
C-2
ACCESSORIES
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: PTA-17 torch,
parts kit, Harris flowmeter/regulator, 10 ft. gas hose,
Twist-mate™ adapter, work clamp and cable.
Factory Installed
Twist-Mate Cable Connectors
1 – standard for Ground Clamp
1 – Gas Pass through for Tig Torch
Strap Packet
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.
Instruction Manual
Field Installed
CABLE PLUGS
K857 - Remote Output Control - For Stick welding.
When the V205-T’s Output Control is in the "REMOTE"
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.
K852-70 - Cable Plug Kit for 1/0-2/0 cable. Attaches to
welding cable to provide quick disconnect from
machine.
Twist-Mate Torch Adapter 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.
K870 - Foot Amptroltm 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 Amptroltm 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.
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
K814 - Arc Start Switch - Energizes the output for TIG
welding if remote output control of the amperage is not
desired. It allows on/off TIG welding at the current set
by the Current Control on the control panel. When
using the Arc Start Switch set the Output Control to the
“LOCAL” position.
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.
Magnum® PTA-9 and PTA-17 TIG Torches - The fol-
lowing standard Magnum® TIG torches with one-piece
cable may be used with the Invertec V205-T.
• K1781-1
• K1781-3
• K1782-1
• K1782-3
PTA-9
PTA-9
12.5 ft
25 ft
medium back cap
medium back cap
long back cap
PTA-17 12.5 ft
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 sep-
arately.
V205-T AC/DC
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D-1
D-1
TABLE OF CONTENTS
-MAINTENANCE-
Maintenance .........................................................................................................................Section D
Input Filter Capacitor Discharge Procedure...............................................................................D-2
Routine Maintenance..................................................................................................................D-2
V205-T AC/DC
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D-2
D-2
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 dis-
charge before working inside this
equipment.
• 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.
------------------------------------------------------------------------
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.
• Always use gloves in compliance with the safety
standards.
V205-T AC/DC
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Section E-1
Section E-1
TABLE OF CONTENTS
-THEORY OF OPERATION SECTION-
Theory of Operation .............................................................................................................Section E
General Description ....................................................................................................................E-2
Input Board and Bus Board........................................................................................................E-2
Main IGBT Inverter Board...........................................................................................................E-3
Main Transformer ........................................................................................................................E-4
Output Module and Clamping Board..........................................................................................E-4
Output Module Transistor Board ...............................................................................................E-4
Superimposition Board ...............................................................................................................E-4
Control/Display Board.................................................................................................................E-5
High Frequency Board................................................................................................................E-5
Output Filter Board .....................................................................................................................E-5
Insulated Gate Bipolar Transistor (IGBT) Operation ...................................................................E-6
FIGURE E.1 – V205-T BLOCK LOGIC DIAGRAM
Fan
Superimposition
board
AC DC Gate drive signals
24 VDC
Bus board
HF
board
Input
board
Voltage Feedback
Current Feedback
Output
Diode
Thermostat
IGBT
Thermostats
Output
Filter bd.
(bypass)
Main IGBT
& Power board
4
IGBT’s
_
+
RF coil
Output
Choke
DC blocking
capacitor board
Current
Hall
Device
Input
Choke
Main
Transformer
Output
Transistor
Module
Output
board
24 VDC Remote 2/4 path (D + E)
HF control signal
+48, +24
888
Display & LED
board
Control board
(D + E)
Remote 2/4
Control
Knob
Remote
75, 76, 77
A, B, C
48 VDC
Gas
Solenoid
V205-T AC/DC
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E-2
E-2
THEORY OF OPERATION
FIGURE E.2 – GENERAL DESCRIPTION, INPUT BOARD & BUS BOARD
Fan
Superimposition
board
AC DC Gate drive signals
24 VDC
Bus board
HF
board
Input
board
Voltage Feedback
Current Feedback
Output
Diode
Thermostat
IGBT
Thermostats
Output
Filter bd.
(bypass)
Main IGBT
& Power board
4
IGBT’s
_
+
RF coil
Output
Choke
DC blocking
capacitor board
Current
Hall
Device
Input
Choke
Main
Transformer
Output
Transistor
Module
Output
board
24 VDC Remote 2/4 path (D + E)
HF control signal
+48, +24
888
Display & LED
board
Control board
(D + E)
Remote 2/4
Control
Knob
Remote
75, 76, 77
A, B, C
48 VDC
Gas
Solenoid
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.
GENERAL DESCRIPTION
The Invertec V205T AC/DC is an inverter based indus-
trial 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 40% duty cycle. With 115VAC applied the
machine is rated at 150 amps, 16 volts at a 40% duty
cycle. The machine has the capabilities to produce
several varieties of AC waveforms (square, sinusoidal
and triangular). The unit also employs an auto recon-
nect 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 frequen-
cy or touch start function.
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 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
interface with the Bus Board. Some circuits are also
incorporated within the Bus Board. They are the fan
circuit (24VDC) and an input voltage sensing circuit
that is utilized by the auto reconnect circuitry located
on the Main Inverter Board.
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-
The fan fuse F3, 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.
V205-T AC/DC
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E-3
E-3
THEORY OF OPERATION
FIGURE E.3 – MAIN IGBT INVERTER BOARD
Fan
Superimposition
board
AC DC Gate drive signals
24 VDC
Bus board
HF
board
Input
board
Voltage Feedback
Current Feedback
Output
Diode
Thermostat
IGBT
Thermostats
Output
Filter bd.
(bypass)
Main IGBT
& Power board
4
IGBT’s
_
+
RF coil
Output
Choke
DC blocking
capacitor board
Current
Hall
Device
Input
Choke
Main
Transformer
Output
Transistor
Module
Output
board
24 VDC Remote 2/4 path (D + E)
HF control signal
+48, +24
888
Display & LED
board
Control board
(D + E)
Remote 2/4
Control
Knob
Remote
75, 76, 77
A, B, C
48 VDC
Gas
Solenoid
adjust for the 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.
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 cir-
cuit 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 main-
tained on the IGBT electrolytic capacitors. The four
main welding IGBTs are located on a large center
mounted heat sink assembly.
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 pre-
vent output until the machine cools and the ther-
mostats reset.
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 cur-
rent limiting circuit. The capacitors are charged slow-
ly 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 output 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
Low-level analog signals are generated 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.
V205-T AC/DC
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E-4
E-4
THEORY OF OPERATION
FIGURE E.4 – MAIN TRANSFORMER, OUTPUT DIODE MODULE & CLAMPING BOARD,
OUTPUT TRANSISTOR MODULE & SUPERIMPOSITION BOARD
Fan
Superimposition
board
AC DC Gate drive signals
24 VDC
Bus board
HF
board
Input
board
Voltage Feedback
Current Feedback
Output
Diode
Thermostat
IGBT
Thermostats
Output
Filter bd.
(bypass)
Main IGBT
& Power board
4
IGBT’s
_
+
RF coil
Output
Choke
DC blocking
capacitor board
Current
Hall
Device
Input
Choke
Main
Transformer
Output
Transistor
Module
Output
board
24 VDC Remote 2/4 path (D + E)
HF control signal
+48, +24
888
Display & LED
board
Control board
(D + E)
Remote 2/4
Control
Knob
Remote
75, 76, 77
A, B, C
48 VDC
Gas
Solenoid
MAIN TRANSFORMER
OUTPUT MODULE TRANSISTOR
BOARD
This module produces the AC waveforms and fre-
quencies. 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.
The 100KHZ output of the Main IGBT Inverter 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 nor-
mal voltage spikes.
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) for 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.
V205-T AC/DC
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E-5
E-5
THEORY OF OPERATION
FIGURE E.5 – CONTROL/DISPLAY BOARD, HF BOARD & OUTPUT FILTER BOARD
Fan
Superimposition
board
AC DC Gate drive signals
24 VDC
Bus board
HF
board
Input
board
Voltage Feedback
Current Feedback
Output
Diode
Thermostat
IGBT
Thermostats
Output
Filter bd.
(bypass)
Main IGBT
& Power board
4
IGBT’s
_
+
RF coil
Output
Choke
DC blocking
capacitor board
Current
Hall
Device
Input
Choke
Main
Transformer
Output
Transistor
Module
Output
board
24 VDC Remote 2/4 path (D + E)
HF control signal
+48, +24
888
Display & LED
board
Control board
(D + E)
Remote 2/4
Control
Knob
Remote
75, 76, 77
A, B, C
48 VDC
Gas
Solenoid
CONTROL/DISPLAY BOARD
HIGH FREQUENCY (HF) 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
Display Boards functions as the interface between the
user and the V205-T machine.
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
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 tung-
sten 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.
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- 24VDC) 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&C) are also fed into the
Control/Display Board from the 6 pin connector locat-
ed on the front of the machine. Based upon current
and voltage feedback information the Control Board
regulates 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.
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.
V205-T AC/DC
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E-6
E-6
THEORY OF OPERATION
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
coupled to the source. Current will flow through the
conducting IGBT to downstream components as long
as the positive gate signal is present. This is similar to
turning ON a light switch.
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 ter-
minal of the IGBT may be connected to a voltage sup-
ply; but since there is no conduction, the circuit will not
supply current to components connected to the
source. The circuit is turned OFF like a light switch.
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
FIGURE E.6 – IGBT
POSITIVE
VOLTAGE
APPLIED
GATE
GATE
SOURCE
SOURCE
n +
n +
n +
n +
p
BODY REGION
p
BODY REGION
DRAIN DRIFT REGION
DRAIN DRIFT REGION
n -
n -
n +
p +
BUFFER LAYER
n +
p +
BUFFER LAYER
INJECTING LAYER
INJECTING LAYER
DRAIN
DRAIN
B. ACTIVE
A. PASSIVE
V205-T AC/DC
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Section F-1
Section F-1
TABLE OF CONTENTS
TROUBLESHOOTING & REPAIR SECTION
Troubleshooting & Repair Section.................................................................................Section F
How to Use Troubleshooting Guide ....................................................................................F-2
PC Board Troubleshooting Procedures and Replacement .................................................F-3
Troubleshooting Guide ........................................................................................................F-4
Test Procedures
External and Internal diagnostics....................................................................................F-9
Input Filter Capacitor Discharge Procedure .................................................................F-13
Input Filter Board Test...................................................................................................F-15
Main IGBT Inverter Board (Low Voltage) Test...............................................................F-19
Control/Display Board Test ...........................................................................................F-23
Bus Board Test..............................................................................................................F-27
Main Inverter Board (UPFR Section) Test .....................................................................F-31
Output Filter Board Test................................................................................................F-35
Secondary Power Board Test .......................................................................................F-39
Main Inverter Board (Welding Logic) Test .....................................................................F-43
Replacement Procedures
Input Filter Board Removal and Replacement..............................................................F-49
Main IGBT Board Removal and Replacement..............................................................F-53
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
V205-T AC/DC
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F-2
F-2
TROUBLESHOOTING & REPAIR
HOW TO USE TROUBLESHOOTING GUIDE
CAUTION
Service and repair should be performed by only Lincoln Electric Factory Trained Personnel.
Unauthorized repairs performed on this equipment may result in danger to the technician and machine
operator and will invalidate your factory warranty. For your safety and to avoid Electrical Shock, please
observe all safety notes and precautions detailed throughout this manual.
This Troubleshooting Guide is provided to help
you locate and repair possible machine
malfunctions. Simply follow the three-step
procedure listed below.
Step 3. PERFORM COMPONENT TESTS. The
last column, labeled “Recommended Course of
Action” lists the most likely components that may
have failed in your machine. It also specifies the
appropriate test procedure to verify that the
subject component 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.
Step 1. LOCATE PROBLEM (SYMPTOM). Look
under the column labeled “PROBLEM
(SYMPTOMS)”. This column describes possible
symptoms that the machine may exhibit. Find
the listing that best describes the symptom that
the machine is exhibiting. Symptoms are
grouped into three main categories: Output
Problems, Function Problems, and Welding
Problems.
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
referred to test points, components, terminal
strips, 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.
Step 2. PERFORM EXTERNAL TESTS. The
second column, labeled “POSSIBLE AREAS OF
MISADJUSTMENT(S)”, lists the obvious external
possibilities that may contribute to the machine
symptom. Perform these tests/checks in the
order listed. In general, these tests can be
conducted without removing the case
wrap-around cover.
CAUTION
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 troubleshooting assistance before
you proceed. Call 1-800-833-9353.(WELD)
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F-3
F-3
TROUBLESHOOTING & REPAIR
PC BOARD TROUBLESHOOTING PROCEDURES
- 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.
WARNING
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.
- 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 and allow prop-
er failure analysis.
CAUTION
Sometimes machine failures appear to be due to PC
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:
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.
1. Determine to the best of your technical ability
that the PC board is the most likely component
causing the failure symptom.
NOTE: Allow the machine to heat up so that all
electrical components can reach their operating
temperature.
2. Check for loose connections at the PC board to
assure that the PC board is properly connected.
5. Remove the replacement PC board and
substitute it with the original PC board to
recreate the original problem.
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:
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.
PC board can be damaged by static electricity.
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.
- 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
6. Always indicate that this procedure was
followed when warranty reports are to be
submitted.
to
a
equipment frame.
grounded part of the
ATTENTION
Static-Sensitive
Devices
Handle only at
Static-Safe
Workstations
- 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.
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.
- Tools which come in contact with the PC board must
be either conductive, anti-static or static-dissipative.
V205-T AC/DC
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F-4
F-4
TROUBLESHOOTING & REPAIR
Observe Safety Guidelines
detailed in the beginning of this manual.
TROUBLESHOOTING GUIDE
OUTPUT PROBLEMS
(SYMPTOMS)
POSSIBLE AREAS OF
MISADJUSTMENT(S)
RECOMMENDED
COURSE OF ACTION
OUTPUT PROBLEMS
Major physical or electrical damage 1. Contact your local authorized 1. Contact the Lincoln Electric
is evident when the sheet metal
cover(s) are removed.
Lincoln Electric Field Service
Facility for assistance.
Service Department 1-800-833-
9353.
The machine is dead—no fan –no 1. Make sure the input power 1. Check the input power switch for
output—no LEDs.
switch is in the ON position.
proper operation. Also check the
associated leads for loose or
faulty connections. See wiring
diagram.
2. Check the main input fuses. If
open replace.
3. Make sure the correct input volt-
age is applied to the machine.
2. Perform the Input Filter Board
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
input draw of the machine.
faulty. Perform the Input Filter
Board Test.
2. The welding procedure may be 2. The Main IGBT Inverter Board
drawing too much input current
or the duty cycle may be too
high. Reduce the welding cur-
rent and/or reduce the duty
cycle.
may be faulty.
Main IGBT Inverter Board Low
Voltage Supply Test.
Perform the
CAUTION
If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, con-
tact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call
1-800-833-9353(WELD).
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F-5
F-5
TROUBLESHOOTING & REPAIR
TROUBLESHOOTING GUIDE
Observe Safety Guidelines
detailed in the beginning of this manual.
FUNCTION PROBLEMS
(SYMPTOMS)
POSSIBLE AREAS OF
MISADJUSTMENT(S)
RECOMMENDED
COURSE OF ACTION
FUNCTION PROBLEMS
No or low output. Error code “E11” 1. “E11” is an indication that the 1. If the correct input voltage
is flashing on the digital display.
input voltage being applied is
too high. Check for the correct
230VAC or 115VAC is being
applied to the machine the Input
Filter Board may be faulty.
Perform the Input Filter Board
Test.
input voltage.
115VAC.
230VAC or
2. The Main IGBT Inverter Board
May be Faulty. Perform the
Main IGBT Inverter Board Low
Voltage Supply Test.
No or low output. Error code
“E12” is flashing on the digital dis-
play.
1. “E12” is an indication that the
input voltage being applied is
too low. Check for the correct
input voltage. 230VAC or
115VAC.
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.
2. The Main IGBT Inverter Board
May be Faulty. Perform the
Main IGBT Inverter Board
Low Voltage Supply Test.
No output. Error code “E10” is 1. The welding application may be 1. One of the thermal devices may
flashing on the digital display. The
thermal indicator light is on.
exceeding the recommended
duty cycle.
be faulty. Check and replace if
necessary.
Diagram.
See the Wiring
2. Dirt and dust may have clogged
the cooling channels inside the 2. The Main IGBT Inverter Board
machine. Refer to the may be faulty.
Maintenance Section in this
manual.
3. The air intake and exhaust lou-
vers may be blocked due in
inadequate clearance around
the machine.
4. Make sure the cooling fan is
operating correctly.
CAUTION
If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, con-
tact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed.
Call 1-800-833-9353(WELD).
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F-6
F-6
TROUBLESHOOTING & REPAIR
Observe Safety Guidelines
detailed in the beginning of this manual.
TROUBLESHOOTING GUIDE
FUNCTION PROBLEMS
(SYMPTOMS)
POSSIBLE AREAS OF
MISADJUSTMENT(S)
RECOMMENDED
COURSE OF ACTION
FUNCTION PROBLEMS
Error code “E20”, “E24”, or “E25” 1. Any one of these codes indi- 1. The Control/Display Board is
is flashing on the digital display. cates a memory error. faulty. Replace.
The machine functions normally 1. Check for obstructions that 1. Check the fan fuse F3 located on
except the cooling fan does not
operate.
could prevent the fan from turn-
ing.
the Bus Board Replace if faulty.
2. Perform the Bus Board Test.
3. The Main IGBT Inverter Board
May be Faulty. Perform the
Main IGBT Inverter Board
Low Voltage Supply Test.
No High Frequency when the torch 1. Make sure the HF is in the 1. Check fuse F2 on the Bus
trigger is pulled and the machine is
in the TIG mode.
active mode. See the Set-up
Menu in this manual.
Board.
2. Check for 385VDC at Test
Points 9 and 20. See the Main
IGBT Inverter Board UPFR
Test.
3. Perform the Control/Display
Board Test.
4. The HF board may be faulty.
Replace.
Error code “E14” is flashing of the 1. This is an indication that the 1. Check for excessive welding
digital display
output 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.
CAUTION
If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, con-
tact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call
1-800-833-9353(WELD).
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F-7
F-7
TROUBLESHOOTING & REPAIR
Observe Safety Guidelines
detailed in the beginning of this manual.
TROUBLESHOOTING GUIDE
FUNCTION PROBLEMS
(SYMPTOMS)
POSSIBLE AREAS OF
MISADJUSTMENT(S)
RECOMMENDED
COURSE OF ACTION
FUNCTION PROBLEMS
No current regulation in the Stick 1. Make sure the machine is set- 1. The Superimposition Board may
mode. Low open circuit voltage.
up and configured correctly for
the Stick mode,
be faulty
2. The Output Module Transistor
Board may be faulty. See the
Secondary Power Board Test
and Wiring Diagram
There is no response to changes to 1. Make sure the correct input 1. The Control/Display board may
the output control settings. No cur-
rent regulation in all modes.
voltage is applied to the
machine. 230 or 115VAC.
be faulty.
CAUTION
If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, con-
tact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed.
Call 1-800-833-9353(WELD).
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F-8
F-8
TROUBLESHOOTING & REPAIR
Observe Safety Guidelines
detailed in the beginning of this manual.
TROUBLESHOOTING GUIDE
WELDING PROBLEMS
(SYMPTOMS)
POSSIBLE AREAS OF
MISADJUSTMENT(S)
RECOMMENDED
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
volts open circuit voltage. The
Output LED on the control panel is
blinking. The machine operates
correctly in the TIG mode
erly set-up and configured for
Stick mode.
back from the Output Filter
Board. See the Output Filter
Board Test.
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 weld- 1. Make sure the correct input volt- 1. The output rectifier may be
ing output in either the Stick or TIG
modes. Zero volts open circuit.
The Output LED on the control
panel is blinking.
age is applied to the machine.
230 or 115VAC.
faulty. Check and replace if nec-
essary. See the Secondary
Power Board Test and Wiring
Diagram.
2. The Output Clamp Board may be
faulty.
3. The Output Module Transistor
Board may be faulty. See the
Secondary Power Board Test
and Wiring Diagram.
4. Perform the Main IGBT Inverter
Board Welding Logic and
Inverter Test.
5. The Superimposition Board may
be faulty.
6. The 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
TIG mode does not function prop-
erly.
and configured correctly for the
AC TIG mode.
Board may be faulty. See the
Secondary Power Board Test
and Wiring Diagram.
2. The Superimposition Board may
be faulty.
CAUTION
If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, con-
tact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed.
Call 1-800-833-9353(WELD).
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F-9
F-9
TROUBLESHOOTING & REPAIR
EXTERNAL DIAGNOSTICS
FIGURE F.1 EXTERNAL DIAGNOSTICS
WARNING
STICK
DC TIG
AC TIG
4-STEP
2-STEP
LOCAL
REMOTE
Display
MODE
TRIGGER
WELD
CURRENT
PULSE FREQUENCY
Hz
UPSLOPE
sec
DOWNSLOPE
sec
%
ON TIME
Output Current Control
A
OUTPUT
POSTFLOW
sec
Output
Set-up Parameter
Select Button
BACKGROUND
CURRENT
FINISH
CURRENT
PARAMETER
SELECT HOLD
/
V
AC FREQUENCY Hz
PULSE ON
Power Supply
Alarm
AC BALANCE EN
%
®
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”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 yellow LED.
Indic.
E10
E11
Type of Error
Action
Remove upper cover, check internal temperature, check thermal device status
(N.C.). See machine layout.
Internal Heatsink Overtemp.
Power Supply Overvoltage
Power Supply Undervoltage
Front Panel Memory Error
Remove upper cover, check that the power supply voltage is within the established
range (+/- 15%). Check reading voltage on 15.14.314 CN1 (See Fig. 9)
Remove upper cover, check that the power supply voltage is within the established
range (+/- 15%). Check reading voltage on 15.14.315 CN1 (See Fig. 9)
E12
E13
E14
Remove upper cover, check front panel power supplies. Perform front panel reset*
test and replace if necessary.
Remove upper cover, check front panel power supplies. Perform front panel reset*
test and replace if necessary.
Front Panel Secondary
Memory Error
*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
Power supply rated
voltage
Undervoltage
Overvoltage
138 VAC
276 VAC
92 VAC
184 VAC
115 VAC
230 VAC
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F-10
F-10
TROUBLESHOOTING & REPAIR
INTERNAL DIAGNOSTICS
FIGURE F.2
L6
L4 L5
L1
L7
L2
L3
L8
L9
L10
L11
Under
Small
PCB
L12
L13
Under
Small
PCB
L14
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F-11
F-11
TROUBLESHOOTING & REPAIR
INTERNAL DIAGNOSTICS (Continued)
Definition
LED
Normal Status Conditions
-15VDC supply by 15.14.316 for 15.14.316 logic part
+15VDC supply by 15.14.316 for 15.14.316 logic part
+5VDC supply by 15.14.316 for 15.14.316 logic part
+24VDC supply by 15.14.316 for power front panel
+48VDC supply by 15.14.316 for power front panel
L1
ON [Green]
ON [Green]
ON [Green]
ON [Green]
ON [Green]
ON [Green]
ON [Green]
L2
L3
L4
L5
-15VDC supply by 15.14.316 for 15.14.316 UPFR
part
L6
+15VDC supply by 15.14.316 for 15.14.316 UPFR
part
L7
Output power enabled (See “pot signal” & LED
“Output”)
STICK: ON [Green]
L8
TIG: ON (torch trigger pulled)
OFF = OK
ON = ALARM [Red]
Thermal Alarm
L9
Brightness proportional with
actual output current.
STICK: ON [Green]
TIG: ON (torch trigger pulled)
STICK: ON [Green]
TIG: ON (torch trigger pulled)
STICK: ON [Green]
TIG: ON (torch trigger pulled)
STICK: ON [Green]
TIG: ON (torch trigger pulled)
UPFR on
L10
L11
L12
L13
L14
Gate MOS 11 active (output power enabled)
Gate MOS 12 active (output power enabled)
Gate MOS 16 active (output power enabled)
Gate MOS 15 active (output power enabled)
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F-12
F-12
NOTES
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F-13
F-13
TROUBLESHOOTING & REPAIR
INPUT FILTER CAPACITOR DISCHARGE PROCEDURE
WARNING
Service and repair should be performed by only 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
troubleshooting assistance before you proceed. Call 1-800-833-9353 (WELD).
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
internal components of the machine.
MATERIALS NEEDED
Phillips Screwdriver
Insulated Pliers
Insulated Gloves
High Wattage Resistor (25-1000 ohms and 25 watts minimum)
Volt Meter
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F-14
F-14
TROUBLESHOOTING & REPAIR
INPUT FILTER CAPACITOR DISCHARGE PROCEDURE (continued)
4. Obtain a high resistance and high wattage resistor
(25-1000 ohms and 25 watts minimum). This
resistor is not with the machine. NEVER USE A
SHORTING STRAP FOR THIS PROCEDURE.
WARNING
ELECTRIC SHOCK can kill.
• Have an electrician install and service
this equipment.
5. Locate the eight capacitor solder pads shown in
Figure F.3.
• Turn the input power off at the fuse box
before working on equipment.
6. Using electrically insulated gloves and pliers, hold
the body of the resistor with the pliers and con-
nect the resistor leads across the two capacitor
solder pads. Hold the resistor in place for 10 sec-
onds. DO NOT TOUCH CAPACITOR SOLDER
PADS WITH YOUR BARE HANDS.
• Do not touch electrically hot parts.
• Prior to performing preventative maintenance,
perform the following capacitor discharge procedure
to avoid electric shock.
7. Repeat the discharge procedure for the other
three capacitors.
DISCHARGE PROCEDURE
8. Check the voltage across the terminals of all
capacitors with a DC voltmeter. Voltage should be
zero. If any voltage remains, repeat this capacitor
1. Remove the input power to the machine.
2. Using the phillips head screwdriver remove the
screws securing the case wraparound cover.
discharge procedure.
3. Be careful not to make contact with the capacitor
solder pads located at the top of the IGBT power
board.
FIGURE F.3 – LOCATION OF INPUT FILTER CAPACITOR TERMINALS ON MAIN IGBT INVERTER BOARD
Capacitor Solder
Pads
Resistor
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F-15
F-15
TROUBLESHOOTING & REPAIR
INPUT FILTER BOARD TEST
WARNING
Service and repair should be performed by only 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
troubleshooting assistance before you proceed. Call 1-800-833-9353 (WELD).
DESCRIPTION
This test will help determine if the input filter board is functioning properly.
MATERIALS NEEDED
Analog Volt/Ohmmeter
Phillips Head Screwdriver
Wiring Diagram
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F-16
F-16
TROUBLESHOOTING & REPAIR
INPUT FILTER BOARD TEST (continued)
FIGURE F.4 INPUT FILTER BOARD
INPUT FILTER BOARD
TEST PROCEDURE
4. Locate the Input Filter board. See Figure F.4.
1. Remove input power to the V205-T.
5. See Note 1 and Note 2.
2. Using a phillips head screwdriver, remove the
case wraparound.
3. Perform the Input Filter Capacitor Discharge
Procedure detailed earlier in this section.
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F-17
F-17
TROUBLESHOOTING & REPAIR
INPUT FILTER BOARD TEST (continued)
FIGURE F.5 INPUT FILTER BOARD
Note 1: A varistor ZN1 is placed between the two
power supply phases, so if an instantaneous
voltage in excess of 275VAC appears on ter-
minals RV1 & RV2, the varistor very rapidly
becomes conductive and thus absorbing a
current peak sufficient to limit the above said
overvoltage; this way the varistor ZN1 pro-
tects 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,
as in the case of atmospheric lightening
strikes. However, if over-voltage is high and
prolonged, the varistor 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.
Note 2: The radio noise suppression circuit has two
purposes: to keep the machine’s radio fre-
quency emisions within limits specified by
standards and to ensure the machine’s immu-
nity against the same type of problems
caused any electronic devices connected to
the same power supply source. The filter con-
sists of a network of capacitors, some of
which are grounded, and a toroidal inductor.
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F-18
F-18
NOTES
V205-T AC/DC
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F-19
F-19
TROUBLESHOOTING & REPAIR
MAIN IGBT INVERTER BOARD LOW VOLTAGE TEST
WARNING
Service and repair should be performed by only 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
troubleshooting assistance before you proceed. Call 1-800-833-9353 (WELD).
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
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F-20
F-20
TROUBLESHOOTING & REPAIR
MAIN IGBT INVERTER BOARD LOW VOLTAGE TEST (CONTINUED)
TEST PROCEDURE
4. Locate the Main IGBT Inverter board. See
Figure F.6.
1. Remove input power to the V205-T
machine.
5. Use the voltmeter to perform the tests
detailed in Table F.1. See the wiring dia-
gram.
2. Using a phillips head screwdriver, remove
the case wraparound cover.
3. Perform the Capacitor Discharge
Procedure detailed earlier in this section.
FIGURE F.6 MAIN IGBT INVERTER BOARD LOCATION
MAIN BOARD
V205-T AC/DC
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F-21
F-21
TROUBLESHOOTING & REPAIR
MAIN IGBT INVERTER BOARD LOW VOLTAGE TEST (CONTINUED)
TABLE F.1 TEST POINTS
Test Point
LED
Value
Machine Mode
ON
ON
ON
ON
ON
ON
ON
ON
TP13-TP14
TP11-TP14
TP12-TP14
TP3-TP5
L2
L3
L1
L4
L5
L6
L7
---
+15 VDC
+5 VDC
+15 VDC
+24 VDC
+48 VDC
+15 VDC
+15 VDC
+14.5 VDC
TP4-TP5
TP17-TP18
TP21-TP18
TP2[+],TP18[-]
V205-T AC/DC
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F-22
F-22
TROUBLESHOOTING & 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
TP2 MF2
L4 TP3
TP4 TP5 L5 L1 L2
L3
TP14
TP12
TP11
TP13
L6
TP17
TP18
TP21
L7
L10
V205-T AC/DC
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F-23
F-23
TROUBLESHOOTING & REPAIR
CONTROL/DISPLAY BOARD TEST
WARNING
Service and repair should be performed by only 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
troubleshooting assistance before you proceed. Call 1-800-833-9353 (WELD).
DESCRIPTION
This test will help determine if the front panel boards work properly.
MATERIALS NEEDED
Volt-Ohmmeter
Phillips Head Screwdriver
Wiring Diagram
V205-T AC/DC
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F-24
F-24
TROUBLESHOOTING & REPAIR
CONTROL/DISPLAY BOARD TEST (CONTINUED)
TEST PROCEDURE
4. Locate the control/display board and asso-
ciated plugs . Do not remove plugs from
the board. See Figure F.8.
1. Remove input power to the V205-T
machine.
2. Using a phillips head screwdriver, remove
the case wraparound cover.
5. Carefully apply the correct input voltage to
the V205-T and check for the correct sec-
ondary voltages per Tables F.2, F3 & F.4.
3. Perform the Capacitor Discharge
Procedure detailed earlier in this section.
FIGURE F.8 CONTROL/DISPLAY BOARD LOCATION
Control/Display Board
V205-T AC/DC
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F-25
F-25
TROUBLESHOOTING & REPAIR
CONTROL/DISPLAY BOARD TEST (CONTINUED)
FIGURE F.9 CONTROL/DISPLAY BOARD LOCATION
CN2
CN7
CN1
V205-T AC/DC
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F-26
F-26
TROUBLESHOOTING & REPAIR
CONTROL/DISPLAY BOARD TEST (CONTINUED)
TABLE F.2 PLUG CN1 TEST POINTS
Wire #
52
Description
Solenoid Valve Ground
Trigger
Expected Voltage
-------
53
-------
54
Trigger
-------
44
Start High Frequency
High Frequency Ground
Start Solenoid Valve
-------
48
-------
58
48 VDC
TABLE F.3 PLUG CN2 TEST POINTS
Wire #
41
Description
Supply
Expected Voltage
24 VDC
42
Supply
48 VDC
45
Ground for Supplies
-------
TABLE F.4 PLUG CN7 TEST POINTS
Wire #
71
Description
Ext
Expected Voltage
5 VDC
72
Ext
-------
73
Ext Ground
Ext Trigger
Ext Ground
Ext Ground
-------
74
-------
75
-------
76
-------
FIGURE F.10 PLUGS CN1, CN2 & CN7
54
52 53
1
5
2
6
3
7
4
8
58
CN1
44
48
71
72
41
2
4
3
6
1
4
73
76
1
3
42
45
2
5
CN2
CN7
V205-T AC/DC
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F-27
F-27
TROUBLESHOOTING & REPAIR
BUS BOARD TEST
WARNING
Service and repair should be performed by only 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
troubleshooting assistance before you proceed. Call 1-800-833-9353 (WELD).
DESCRIPTION
This test will help determine if the BUS board is functioning properly.
MATERIALS NEEDED
Volt/Ohmmeter
Phillips Head Screwdriver
Wiring Diagram
V205-T AC/DC
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F-28
F-28
TROUBLESHOOTING & REPAIR
BUS BOARD TEST (continued)
FIGURE F.11 BUS BOARD LOCATION
BUS BOARD
TEST PROCEDURE
4. Locate the Bus board and associated plugs .
Do not remove plugs from the board. See
Figure F.11.
1. Remove input power to the V205-T machine.
2. Using a phillips head screwdriver, remove the
case wraparound cover.
5. Carefully apply the correct input voltage to
the V205-T and check for the correct volt-
ages per Tables F.5, F.6, F.7, F.8 & F.9
3. Perform
the
Capacitor
Discharge
Procedure detailed earlier in this section.
6. Machine should be set to “STICK” mode.
V205-T AC/DC
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F-29
F-29
TROUBLESHOOTING & REPAIR
BUS BOARD TEST (continued)
TABLE F.5 PLUG CN2 TEST POINTS
Wire #
Description
Thermal Trigger
Expected Voltage
21
22
23
24
26
27
28
29
30
32
-------
-------
Output Hall Probe
Hall Probe
+15 VDC
-------
Ground Gate Switch B
Ground Gate Switch A
Thermal Trigger (AC Unit)
Ground Hall Probe
Hall Probe
-------
-------
-------
-15 VDC
-------
Gate Switch B
Gate Switch A
-------
TABLE F.6 PLUG CN3 TEST POINTS
Wire #
Description
- Superimposition
Ground Superimposition
+ Superimposition
Welding Voltage
Expected Voltage
53.2 VDC(1)
-------
61
65
63
53.2 VDC(1)
64[-], 66[+]
52.6 VDC
(1) In TIG mode only when Remote is pushed, comes on for two sec. then goes to zero. In STICK mode is present all
the time.
TABLE F.7 PLUG CN4 TEST POINTS
Wire #
41
Description
Front Panel Supply
Front Panel Supply Ground
HF Start
Expected Voltage
24 VDC
-------
42
44
-------
45
Front Panel Supply
HF Start Ground
48 VDC
-------
48
TABLE F.8 PLUG CN7 TEST POINTS
Wire #
11
Description
Water Cooling Supply
Water Cooling Supply
Water Cooling Supply
-------
Expected Voltage
-------
-------
-------
-------
Earth Cable
12
Earth Cable
TABLE F.9 PLUG CN1 TEST POINTS
Wire #
Description
Expected Voltage
5[+], 6[-]
Fan
24 VDC
V205-T AC/DC
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F-30
F-30
TROUBLESHOOTING & REPAIR
BUS BOARD TEST (continued)
FIGURE F.12 BUS BOARD PLUG LOCATIONS
CN1
CN2
CN3
F1
CN4
CN7
F2
F3
FIGURE F.13 PLUGS CN2, CN3, CN4
21 22
26
24
23
1
7
2
8
3
9
4
5
6
10 11 12
CN2
32
30
29
27 28
44
41
42
63
61
65
1
4
3
6
2
5
1
5
2
6
3
7
4
8
CN4
CN3
45
48
64
66
V205-T AC/DC
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F-31
F-31
TROUBLESHOOTING & REPAIR
MAIN INVERTER BOARD “UPFR” SECTION TEST
WARNING
Service and repair should be performed by only 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
troubleshooting assistance before you proceed. Call 1-800-833-9353 (WELD).
DESCRIPTION
This procedure will help determine if the UPFR section on the main board is functioning prop-
erly.
MATERIALS NEEDED
Volt/Ohmmeter
Phillips Head Screwdriver
Wiring Diagram
V205-T AC/DC
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F-32
F-32
TROUBLESHOOTING & REPAIR
MAIN INVERTER BOARD “UPFR” SECTION TEST (continued)
FIGURE F.14 UPFR LOCATION ON MAIN BOARD
MAIN BOARD
TEST PROCEDURE
4. Locate the UPFR section on the main board
and associated plugs. Do not remove
plugs from the board. See Figure F.14.
1. Remove input power to the V205-T machine.
2. Using a phillips head screwdriver, remove the
case wraparound cover.
5. Carefully apply the correct input voltage to
the V205-T and check for the correct sec-
ondary voltages per tables F.10 & F11.
Voltage readings were taken with a Fluke
RMS meter. See Figure F.15 for joint loca-
tions.
3. Perform
the
Capacitor
Discharge
Procedure detailed earlier in this section.
TABLE F.10 VOLTAGE CHECKS WITH 115 VAC APPLIED TO MACHINE
Generator/Mode
ON/STICK
ON/STICK
ON/STICK
ON/STICK
ON/STICK
ON/STICK
ON/STICK
Component
DD1
Ref. Joint
A[-],K[+]
S[-],D[+]
S[-],G[+]
S[-],D[+]
S[-],G[+]
L10 (LED)
-------
Value
250-260 VDC
125 VDC
2.2 VDC
MF8
MF8
MF9
120 VDC
2.2 VDC
MF9
-------
ON
TP20-TP9
385 VDC +/-5V
TABLE F.11 RESISTANCE CHECKS
Generator/Mode
OFF
Component
F1
Ref. Joint
-------
Value
<1 OHM
46 OHM
OFF
R82
-------
V205-T AC/DC
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F-33
F-33
TROUBLESHOOTING & REPAIR
MAIN INVERTER BOARD “UPFR” SECTION TEST (continued)
FIGURE F.15 UPFR AREA ON MAIN BOARD
NOTE: UPFR Section is located at the upper left section of Main board
TP9 GNDPWR
F1
RL1
R82
TP20
MF8
G
D
S
S
POWER INPUT
K
K
A
A
230 VAC (115)
G
D
S
S
DD1
MF9
L10
V205-T AC/DC
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F-34
F-34
NOTES
V205-T AC/DC
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F-35
F-35
TROUBLESHOOTING AND REPAIR
OUTPUT FILTER BOARD TEST
WARNING
Service and repair should be performed by only 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
troubleshooting assistance before you proceed. Call 1-800-833-9353 (WELD).
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
V205-T AC/DC
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F-36
F-36
TROUBLESHOOTING AND REPAIR
OUTPUT FILTER BOARD TEST (continued)
TEST PROCEDURE
4. Locate the Output Filter board and associated
1. Remove input power to the V205-T machine.
plugs . Do not remove plugs from the
board. See Figure F.16.
2. Using a phillips head screwdriver, remove the
case wraparound cover.
5. Carefully apply the correct input voltage to the
V205-T and check for the correct secondary
voltages per Table F.12.
3. Perform the Capacitor Discharge Procedure
detailed earlier in this section.
FIGURE F.16 OUTPUT FILTER BOARD LOCATION
Output Filter Board
V205-T AC/DC
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F-37
F-37
TROUBLESHOOTING AND REPAIR
OUTPUT FILTER BOARD TEST (continued)
FIGURE F.17 OUTPUT FILTER BOARD PLUG LOCATION
-
CN1
+
TABLE F.12 PLUG CN1 TEST POINTS
Wire #
Description
Trigger
Expected Voltage
53
54
-------
-------
Trigger
64[-],66[+]
65
Output Voltage
Superimposition Common
52.6 VDC
-------
FIGURE F.18 OUTPUT FILTER BOARD PLUG CN1
53
66
1
4
3
6
2
5
CN1
64 65
54
V205-T AC/DC
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F-38
F-38
NOTES
V205-T AC/DC
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F-39
F-39
TROUBLESHOOTING AND REPAIR
SECONDARY POWER BOARD TEST
WARNING
Service and repair should be performed by only 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
troubleshooting assistance before you proceed. Call 1-800-833-9353 (WELD).
DESCRIPTION
This test will help determine if the Secondary Power Board has shorted or damaged compo-
nents.
MATERIALS NEEDED
Volt/Ohmeter
Phillips Head Screwdriver
Wiring Diagram
V205-T AC/DC
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F-40
F-40
TROUBLESHOOTING AND REPAIR
SECONDARY POWER BOARD TEST (continued)
TEST PROCEDURE
4. Locate the Secondary Power board and asso-
1. Remove input power to the V205-T machine.
ciated plugs . Do not remove plugs from the
board. See Figure F.19.
2. Using a phillips head screwdriver, remove the
case wraparound cover.
5. Carefully apply the correct input voltage to the
V205-T and check for the correct secondary
voltages per Table F.13.
3. Perform the Capacitor Discharge Procedure
detailed earlier in this section.
FIGURE F.19 SECONDARY POWER BOARD LOCATION
SECONDARY POWER
BOARD
V205-T AC/DC
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F-41
F-41
TROUBLESHOOTING AND REPAIR
SECONDARY POWER BOARD TEST (continued)
FIGURE F.20 SECONDARY POWER BOARD TEST POINT LOCATIONS
10K Ohms
GA SA
10K Ohms
SB GB
I I
I I
3
2
1
TABLE F.13 VOLTAGE CHECKS WITH 115 VAC APPLIED TO MACHINE
Generator/Mode
ON/STICK
ON/STICK
ON/STICK
ON/STICK
ON/STICK
OFF/-
Test Point
GA[+],SA[-]
GB[+],SB[-]
3[+],1[-]
Value
-13 VDC
+13 VDC
+ 0.5 VDC
+ 105 VDC
+ 52 VDC
10 K Ohms
10 K Ohms
1[+]2[-]
OCV
R GA-SA
R GB-SB
OFF/-
V205-T AC/DC
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F-42
F-42
NOTES
V205-T AC/DC
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F-43
F-43
TROUBLESHOOTING AND REPAIR
MAIN INVERTER BOARD
“WELDING LOGIC AND INVERTER” SECTION TEST
WARNING
Service and repair should be performed by only 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
troubleshooting assistance before you proceed. Call 1-800-833-9353 (WELD).
DESCRIPTION
This test will help determine if all functions of the Welding Logic Circuit and Inverter are func-
tioning properly
MATERIALS NEEDED
Volt/Ohmmeter
Phillips Head Screwdriver
Wiring Diagram
V205-T AC/DC
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F-44
F-44
TROUBLESHOOTING AND REPAIR
MAIN INVERTER BOARD
“WELDING LOGIC AND INVERTER” SECTION TEST (continued)
TEST PROCEDURE
4. Locate the Welding Logic and Inverter section
1. Remove input power to the V205-T machine.
of the Main Inverter board and associated
plugs . Do not remove plugs from the
board. See Figure F.21. See Figures F.22 &
F.23.
2. Using a phillips head screwdriver, remove the
case wraparound cover.
3. Perform the Capacitor Discharge Procedure
detailed earlier in this section.
5. Carefully apply the correct input voltage to the
V205-T and check for the correct secondary
voltages per Tables F.14, F.15, F.16 & F17.
FIGURE F.21 MAIN BOARD LOCATION
MAIN BOARD
V205-T AC/DC
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F-45
F-45
TROUBLESHOOTING AND REPAIR
MAIN INVERTER BOARD
“WELDING LOGIC AND INVERTER” SECTION TEST (continued)
TABLE F.14 LED FUNCTIONS
Machine/Mode
ON/STICK
ON
Component
L8
Value
-------
Condition
ON
Note
POT SIGNAL
THERMAL
ALWAYS
L9
-------
OFF
ON
TP31-TP9
2.56 VDC
-------
TABLE F.15 FEEDBACK VOLTAGE SIGNALS
Machine/Mode
Component
Value
Condition
ON/TIG
ON/STICK
ON/TIG
TP15-TP14
-2 VDC @ 100A WELDING ON:
-4 VDC @ 200A
4.3 VDC O.C.V.
CURRENT
FEEDBACK
TP16-TP14
TP19-TP14
WELDING ON:
VOLTAGE
FEEDBACK
2 VDC @ 100A
4 VDC @ 200A
WELDING ON:
CURRENT
REFERENCE
TABLE F.16 VOLTAGE CHECKS WITH 115 VAC APPLIED TO MACHINE
Generator/Mode
ON/STICK
ON/STICK
ON/STICK
ON/STICK
Component
MF11
G[+],S[-]
D[+],S[-]
178 VDC
260 VDC
260 VDC
34 VDC
3.75 VDC
3.75 VDC
3.75 VDC
3.75 VDC
MF12
MF15
MF16
TABLE F.17 LED (CHECK IN STICK MODE)
Generator/Mode
Component
L11
Value
ON
ON
ON
ON
ON/STICK
ON/STICK
ON/STICK
ON/STICK
L12
L13
L14
V205-T AC/DC
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F-46
F-46
TROUBLESHOOTING AND REPAIR
MAIN INVERTER BOARD
“WELDING LOGIC AND INVERTER” SECTION TEST (continued)
FIGURE F.22 MAIN BOARD (INVERTER SECTION)
TP14
TP15
TP16
TP19
TP31
CN4/1-2
Short Circuit
0.3 Ohms
L8
L9
CN5/1-2
Short Circuit
0.3 Ohms
V205-T AC/DC
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F-47
F-47
TROUBLESHOOTING AND REPAIR
MAIN INVERTER BOARD
“WELDING LOGIC AND INVERTER” SECTION TEST (continued)
FIGURE F.23 MAIN BOARD (LOWER LEFT)
TP9 GROUND
POWER
G
S
S
S
D
D
S
L11
L14
L12
L13
G
S
S
D
G
S
D
S
G
MF11
MF15 VDS
MF16
VDS
MF12
V205-T AC/DC
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F-48
F-48
NOTES
V205-T AC/DC
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F-49
F-49
TROUBLESHOOTING & REPAIR
INPUT FILTER BOARD REMOVAL AND REPLACEMENT
WARNING
Service and repair should be performed by only 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
troubleshooting assistance before you proceed. Call 1-800-833-9353) (WELD).
DESCRIPTION
The following procedure will aid the technician in removing the Input Filter board for replace-
ment.
MATERIALS NEEDED
7mm Nut Driver
Phillips Head Screwdriver
V205-T AC/DC
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F-50
F-50
TROUBLESHOOTING & REPAIR
INPUT FILTER BOARD REMOVAL AND REPLACEMENT (continued)
FIGURE F.24 INPUT FILTER BOARD LOCATION
INPUT FILTER BOARD
PROCEDURE
4. Locate the input filter board. See Figure F.24.
1. Remove input power to the V205-T.
5. Using a 7mm nut driver, label and remove leads
R/L1 and S/L2 from the upper right corner of the
input filter board. See Figure F.25.
2. Using a phillips head screwdriver remove the case
wraparound cover.
6. Using a 7mm nut driver, label and remove leads
RV1 and RV2 from the left side of the main IGBT
board. See Figure F.26. See Wiring Diagram
3. Perform the Input Filter Capacitor Discharge
Procedure detailed earlier in this section.
FIGURE F.25 INPUT FILTER BOARD LEADS
R/L1
S/L1
V205-T AC/DC
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F-51
F-51
TROUBLESHOOTING & REPAIR
INPUT FILTER BOARD REMOVAL AND REPLACEMENT (continued)
FIGURE F.26 MAIN IGBT BOARD LEAD REMOVAL
RV1
RV2
CAUTION
Observe static precautions detailed in PC Board
Troubleshooting Procedures at the beginning of this
section.
10. Slide the new input filter board into its proper posi-
tion on the mounting slides.
7. Clean RTV off of the top of the input filter board
mounting slides.
11. Push on backside of mounting pins to ensure that
the P.C. board is secured in its proper position.
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.
12. Reconnect all previously removed leads to their
proper locations. See Wiring Diagram if neces-
sary.
9. Remove and replace the input filter board.
13. Replace case wraparound assembly.
V205-T AC/DC
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F-52
F-52
NOTES
V205-T AC/DC
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F-53
F-53
TROUBLESHOOTING & REPAIR
MAIN IGBT BOARD REMOVAL AND REPLACEMENT
WARNING
Service and repair should be performed by only 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
troubleshooting assistance before you proceed. Call or 1-800-833-9353 (WELD).
DESCRIPTION
The following procedure will aid the technician in removing the main IGBT board for replace-
ment.
MATERIALS NEEDED
7mm Nut driver
Phillips Head Screwdriver
Wiring Diagram
V205-T AC/DC
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F-54
F-54
TROUBLESHOOTING & REPAIR
MAIN IGBT BOARD REMOVAL & REPLACEMENT (continued)
FIGURE F.27 – MAIN IGBT BOARD LOCATION
MAIN BOARD
PROCEDURE
6. Using a 7mm nut driver, label and disconnect
leads RV1, RV2, RV3, RV4, RV5, RV6 & RV7.
See Figure F.28.
1. Remove input power to the V205-T.
2. Using a phillips head screwdriver remove the
case wraparound cover.
7. Using a phillips head screwdriver, remove the
thirty-two (32) phillips head screws from the
main board. Note washer positions for
replacement. See Figure F.28.
3. Perform the Input Filter Capacitor
Discharge Procedure detailed earlier in this
section.
8. Carefully maneuver the main board out of the
machine. Replace.
4. Locate the main IGBT board. See Figure
F.27.
9. Maneuver new board into its proper location
and secure to machine using the thirty-two
phillips head screws previously removed.
5. VERY CAREFULLY, label and disconnect
plugs CN1, CN2, CN3, CN4 & CN5. See
Figure F.28.
NOTE: All ribbon cable connections are secured
by a small amount of RTV on the outside
surface to keep the connections secure.
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F-55
F-55
TROUBLESHOOTING & REPAIR
MAIN IGBT BOARD REMOVAL & REPLACEMENT (continued)
FIGURE F.28 MAIN BOARD PLUG AND MOUNTING SCREW LOCATIONS
CN2
CN1
CN3
RV1
RV2
RV3
RV4
CN4
CN5
RV5
RV6
RV7
10. Reconnect previously removed leads RV1
thru RV7 to the P.C. board. See Wiring
Diagram if necessary.
12. Replace the case wraparound cover previ-
ously removed.
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.
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F-56
F-56
NOTES
V205-T AC/DC
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F-57
F-57
TROUBLESHOOTING & REPAIR
CONTROL/DISPLAY BOARD REMOVAL AND REPLACEMENT
WARNING
Service and repair should be performed by only 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
troubleshooting assistance before you proceed. Call 1-800-833-9353 (WELD).
DESCRIPTION
The following procedure will aid the technician in removing the control/display board for
replacement.
MATERIALS NEEDED
Phillips Head Screwdriver
Wiring Diagram
V205-T AC/DC
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F-58
F-58
TROUBLESHOOTING & REPAIR
CONTROL/DISPLAY BOARD REMOVAL & REPLACEMENT (continued)
FIGURE F.29 – CONTROL/DISPLAY BOARD LOCATION
Control/Display Board
PROCEDURE
5. Carefully remove the board assembly.
1. Remove the input power to the V205-T.
NOTE: The board assembly is attached to the
nameplate/keypad and is to be replaced as
one unit.
2. Using a phillips head screwdriver remove the
four screws from the corners of the name-
plate/keypad on the front of the machine. See
Figure F.30.
6. Replace the board assembly.
7. Connect previously removed ground lead.
CAUTION
8. Connect previously removed leads CN1, CN2,
CN3, & CN7.
Observe static precautions detailed in PC Board
Troubleshooting Procedures at the beginning of
this section. Failure to do so can result in perma-
nent damage to equipment.
9. Replace the four phillips head screws previous-
ly removed from the corners of the name-
plate/keypad.
3. Tilt display plate forward and carefully label
and disconnect leads CN1, CN2, CN3 & CN7.
See Figure F.31.
4. Disconnect the ground lead running from the
P.C. board to the machine frame. See Figure
F.31.
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F-59
F-59
TROUBLESHOOTING & REPAIR
CONTROL/DISPLAY BOARD REMOVAL & REPLACEMENT (continued)
FIGURE F.30 METAL DISPLAY PLATE
4 Phillips Head Screws
WARNING
STICK
DC TIG
AC TIG
4-STEP
2-STEP
LOCAL
REMOTE
MODE
TRIGGER
WELD
CURRENT
PULSE FREQUENCY
Hz
UPSLOPE
sec
DOWNSLOPE
sec
%
ON TIME
A
OUTPUT
POSTFLOW
sec
BACKGROUND
CURRENT
FINISH
CURRENT
PARAMETER
SELECT HOLD
/
V
AC FREQUENCY Hz
PULSE ON
AC BALANCE EN
%
®
FIGURE F.31
CN2
CN7
CN3
CN1
Ground
Wire
5 Mounting
Nuts
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F-60
F-60
NOTES
V205-T AC/DC
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F-61
F-61
TROUBLESHOOTING & REPAIR
OUTPUT FILTER BOARD
REMOVAL AND REPLACEMENT
WARNING
Service and repair should be performed by only 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
troubleshooting assistance before you proceed. Call 1-800-833-9353 (WELD).
DESCRIPTION
The following procedure will aid the technician in removing the output filter board for replace-
ment.
MATERIALS NEEDED
17mm Wrench
13mm Wrench
Large Crescent Wrench
Phillips Head Screwdriver
90o Phillips Head Screwdriver
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F-62
F-62
TROUBLESHOOTING & REPAIR
OUTPUT FILTER BOARD
REMOVAL AND REPLACEMENT (continued)
FIGURE F.32 OUTPUT FILTER BOARD LOCATION
Output Filter Board
PROCEDURE
NOTE: There is no need to disconnect any leads
1. Remove input power to the V205-T.
from the P.C. boards located behind the
nameplate/keypad.
2. Using a phillips head screwdriver, remove the
case wraparound cover.
6. Remove the two phillips head casefront
mounting screws located behind the metal dis-
play plate. See Figure F.33.
3. Perform the Input Filter Capacitor Discharge
Procedure detailed earlier in this section.
7. Remove the four phillips head screws located
around the output terminals on the lower front
of the machine. See Figure F.33.
4. Using a phillips head screwdriver, remove the
four screws at the corners of the
nameplate/keypad. See Figure F.33.
8. Carefully manipulate the casefront off of the
machine.
5. Gently pull the Control/Display board assembly
forward and up to gain access to the two case-
front mounting screws located beneath. See
Figure F.33.
V205-T AC/DC
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F-63
F-63
TROUBLESHOOTING & REPAIR
OUTPUT FILTER BOARD
REMOVAL AND REPLACEMENT (continued)
FIGURE F.33 CASE FRONT SCREW REMOVAL
Phillips Head Screws
WARNING
STICK
DC TIG
AC TIG
4-STEP
2-STEP
LOCAL
REMOTE
MODE
TRIGGER
WELD
CURRENT
PULSE FREQUENCY
Hz
UPSLOPE
sec
DOWNSLOPE
sec
%
ON TIME
A
OUTPUT
POSTFLOW
sec
BACKGROUND
CURRENT
FINISH
CURRENT
PARAMETER
SELECT HOLD
/
V
AC FREQUENCY Hz
PULSE ON
AC BALANCE EN
%
®
Casefront
Mounting
Screws
Phillips Head Screws
9. Using a 17mm wrench, remove the heavy
lead from the positive output terminal.
13. Remove the large nut holding the output filter
board to the positive terminal. See Figure
F.34.
10. Using a 13mm wrench, remove the heavy lead
from the high frequency transformer.
14. Disconnect plug CN7 from the control/display
board assembly. See Control/Display Board
Removal Procedure for plug CN7 location.
11. Disconnect plugs CN1 and CN2 from the out-
put filter board. See Figure F.34.
15. Carefully remove the output filter board by
sliding it by the the plug and lead assembly.
12. Using a 90o phillips head screwdriver, remove
the output filter board mounting screws.
16. Replace the output filter board.
NOTE: The output terminal assembly may have
to be removed to gain access to the out-
put filter board mounting screws.
17. Maneuver the new board into its proper loca-
tion from which it was previously removed.
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F-64
F-64
TROUBLESHOOTING & 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
the control/display board assembly.
23. Replace casefront.
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
screws previously removed.
26. Replace the case wraparound cover.
21. Reconnect plugs CN1 and CN2 previously
removed from the output filter board.
22. Reconnect all heavy leads previously
removed.
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F-65
F-65
TROUBLESHOOTING & REPAIR
OUTPUT DIODES REMOVAL AND REPLACEMENT
WARNING
Service and repair should be performed by only 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
troubleshooting assistance before you proceed. Call 1-800-833-9353 (WELD).
DESCRIPTION
The following procedure will aid the technician in removing the output diodes for replace-
ment.
MATERIALS NEEDED
Phillips Head Screwdriver
7mm Nut Driver
Heatsink Compound
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F-66
F-66
TROUBLESHOOTING & REPAIR
OUTPUT DIODES REMOVAL AND REPLACEMENT (continued)
FIGURE F.35 OUTPUT DIODE LOCATION
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
areas of contact on the new diode/s.
2. Using a phillips head screwdriver, remove the case
wraparound cover.
10. Replace the two output diode mounting screws
previously removed.
3. Perform the Input Filter Capacitor Discharge
Procedure detailed earlier in this section.
11. Replace the copper bus bars to their proper loca-
tions.
4. Locate the output diodes. See Figure F.35.
12. Mount the P.C. board previously removed.
13. Replace the case wraparound cover.
5. Using a phillips head screwdriver, remove the P.C.
board mounting screws.
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.
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F-67
F-67
TROUBLESHOOTING & REPAIR
OUTPUT TRANSISTOR REMOVAL AND REPLACEMENT
WARNING
Service and repair should be performed by only 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
troubleshooting assistance before you proceed. Call 1-800-833-9353 (WELD).
DESCRIPTION
The following procedure will aid the technician in removing the output transistor for replace-
ment.
MATERIALS NEEDED
Phillips Head Screwdriver
5mm Allen Wrench
Heatsink Compound
V205-T AC/DC
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F-68
F-68
TROUBLESHOOTING & REPAIR
OUTPUT TRANSISTOR REMOVAL AND REPLACEMENT (continued)
PROCEDURE
3. Perform the Input Filter Capacitor Discharge
1. Remove input power to the V205-T.
Procedure detailed earlier in this section.
2. Using a phillips head screwdriver, remove the case
wraparound cover.
4. Locate the output transistor. See Figure F.36.
FIGURE F.36 OUTPUT TRANSISTOR LOCATION
Output
Transistor
5. Disconnect plug CN1 from the output transistor.
10. Replace the output transistor mounting bolts pre-
viously removed.
See Figure F.37.
6. Using a phillips head screwdriver, disconnect leads
11. Reconnect leads 1, 2 & 3 previously removed.
12. Reconnect lead CN1.
1, 2 & 3. See Figure F.37.
7. Using a 5mm allen wrench, remove the output tran-
sistor mounting bolts.
13. Replace the case wraparound cover.
8. Remove and replace the output transistor.
NOTE: Be careful not to bend the copper bus bars.
9. Apply a thin layer of heatsink compound to all con-
tact surfaces.
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F-69
F-69
TROUBLESHOOTING & REPAIR
OUTPUT TRANSISTOR REMOVAL AND REPLACEMENT (continued)
FIGURE F.37 OUTPUT TRANSISTOR LEAD LOCATION
Plug CN1
3
2
1
5mm
Allen Bolts
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F-70
F-70
NOTES
V205-T AC/DC
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G-1
G-1
ELECTRICAL DIAGRAMS
TABLE OF CONTENTS
-ELECTRICAL DIAGRAMS SECTION-
ELECTRICAL DIAGRAMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SECTION G
WIRING DIAGRAM (CODE 10860 ONLY) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . G-2
* NOTE: Many PC Board Assemblies are now totally encapsulated and are therefore considered to be unservice-
able.
V205-T AC/DC
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G-2
G-2
ELECTRICAL DIAGRAMS
WIRING DIAGRAM - V205-T AC/DC STANDARD DIAGRAM
*
*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.
V205-T AC/DC
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SVM ERROR REPORTING FORM
We need to know if there are errors in our manuals. We also value any suggestions as to
additional tests or procedures that would make this SVM a better tool for you.
If you discover new or different “Problems or Symptoms” that are not covered in the three col-
umn troubleshooting chart, please share this information with us. Please include the
machine’s code number and how the problem was resolved.
Thank You,
Technical Services Group
Lincoln Electric Co.
22801 ST. Clair Ave.
Cleveland, Ohio 44117-1199
FAX 216-481-2309
SVM Number ___________________________
Page Number if necessary__________________
Your Company__________________________
Your Name_____________________________
Please give detailed description below:
___________________________________________________________________________
___________________________________________________________________________
___________________________________________________________________________
___________________________________________________________________________
___________________________________________________________________________
___________________________________________________________________________
___________________________________________________________________________
___________________________________________________________________________
___________________________________________________________________________
___________________________________________________________________________
___________________________________________________________________________
___________________________________________________________________________
___________________________________________________________________________
SD287 01/99
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