Lincoln Electric SVM161-A User Manual

SVM161-A

V205-TV205-T AC/DCAC/DC

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January, 2011

INVERTEC®V205-T AC/DC

Safety Depends on You

Lincoln arc welding and cutting
equipment is designed and built
with safety in mind. However,
your overall safety can be
increased by proper installation
. . . and thoughtful operation on
your part. DO NOT INSTALL,

OPERATE OR REPAIR THIS
EQUIPMENT WITHOUT READ­ING THIS MANUAL AND THE
SAFETY PRECAUTIONS CON­TAINED THROUGHOUT. And,

most importantly, think before you
act and be careful.

™

For use with machine code number: 10860

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Cleveland, Ohio 44117-1199 U.S.A. TEL: [phone] FAX: [phone] WEB SITE: www.lincolnelectric.com

SERVICE MANUAL

Copyright © Lincoln Global Inc.

• World's Leader in Welding and Cutting Products •

• Sales and Service through Subsidiaries and Distributors Worldwide •

i i

SAFETY

WARNING

CALIFORNIA PROPOSITION 65 WARNINGS

Diesel engine exhaust and some of its constituents
are known to the State of California to cause can­cer, birth defects, and other reproductive harm.

The Above For Diesel Engines

ARC WELDING can be hazardous. PROTECT YOURSELF AND OTHERS FROM POSSIBLE SERIOUS INJURY OR DEATH.

KEEP CHILDREN AWAY. PACEMAKER WEARERS SHOULD CONSULT WITH THEIR DOCTOR BEFORE OPERATING.

Read and understand the following safety highlights. For additional safety information, it is strongly recommended that you
purchase a copy of “Safety in Welding & Cutting - ANSI Standard Z49.1” from the American Welding Society, P.O. Box 351040,
Miami, Florida 33135 or CSA Standard W117.2-1974. A Free copy of “Arc Welding Safety” booklet E205 is available from the
Lincoln Electric Company, 22801 St. Clair Avenue, Cleveland, Ohio 44117-1199.

BE SURE THAT ALL INSTALLATION, OPERATION, MAINTENANCE AND REPAIR PROCEDURES ARE
PERFORMED ONLY BY QUALIFIED INDIVIDUALS.

The engine exhaust from this product contains
chemicals known to the State of California to cause
cancer, birth defects, or other reproductive harm.

The Above For Gasoline Engines

FOR ENGINE
powered equipment.

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

____________________________________________________

1.b.Operate engines in open, well-ventilated
areas or vent the engine exhaust fumes
outdoors.

____________________________________________________

1.c. Do not add the fuel near an open flame weld­ing arc or when the engine is running. Stop
the engine and allow it to cool before refuel­ing to prevent spilled fuel from vaporizing on
contact with hot engine parts and igniting. Do
not spill fuel when filling tank. If fuel is spilled,
wipe it up and do not start engine until fumes
have been eliminated.

____________________________________________________

1.d. Keep all equipment safety guards, covers and devices in posi­tion and in good repair.Keep hands, hair, clothing and tools
away from V-belts, gears, fans and all other moving parts
when starting, operating or repairing equipment.

____________________________________________________

1.e. In some cases it may be necessary to remove safety

guards to perform required maintenance. Remove
guards only when necessary and replace them when the
maintenance requiring their removal is complete.
Always use the greatest care when working near moving
parts.

___________________________________________________

1.h. To avoid scalding, do not remove the
radiator pressure cap when the engine is
hot.

ELECTRIC AND
MAGNETIC FIELDS
may be dangerous

2.a. Electric current flowing through any conductor causes
localized Electric and Magnetic Fields (EMF). Welding
current creates EMF fields around welding cables and
welding machines

2.b. EMF fields may interfere with some pacemakers, and
welders having a pacemaker should consult their physician
before welding.

2.c. Exposure to EMF fields in welding may have other health
effects which are now not known.

2.d. All welders should use the following procedures in order to
minimize exposure to EMF fields from the welding circuit:

2.d.1.

Route the electrode and work cables together - Secure
them with tape when possible.

2.d.2. Never coil the electrode lead around your body.

1.f. Do not put your hands near the engine fan.
Do not attempt to override the governor or
idler by pushing on the throttle control rods
while the engine is running.

___________________________________________________

1.g. To prevent accidentally starting gasoline engines while
turning the engine or welding generator during maintenance
work, disconnect the spark plug wires, distributor cap or
magneto wire as appropriate.

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2.d.3. Do not place your body between the electrode and
work cables. If the electrode cable is on your right
side, the work cable should also be on your right side.

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

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

INVERTEC® V205-T AC/DC™

ii ii

SAFETY

ELECTRIC SHOCK can kill.

3.a. The electrode and work (or ground) circuits
are electrically “hot” when the welder is on.
Do not touch these “hot” parts with your bare
skin or wet clothing. Wear dry, hole-free
gloves to insulate hands.

3.b. Insulate yourself from work and ground using dry insulation.
Make certain the insulation is large enough to cover your full
area of physical contact with work and ground.

In addition to the normal safety precautions, if welding
must be performed under electrically hazardous
conditions (in damp locations or while wearing wet
clothing; on metal structures such as floors, gratings or
scaffolds; when in cramped positions such as sitting,
kneeling or lying, if there is a high risk of unavoidable or
accidental contact with the workpiece or ground) use
the following equipment:

• Semiautomatic DC Constant Voltage (Wire) Welder.

• DC Manual (Stick) Welder.

• AC Welder with Reduced Voltage Control.

3.c. In semiautomatic or automatic wire welding, the electrode,
electrode reel, welding head, nozzle or semiautomatic
welding gun are also electrically “hot”.

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.

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.

3.i. When working above floor level, use a safety belt to protect
yourself from a fall should you get a shock.

3.j. Also see Items 6.c. and 8.

ARC RAYS can burn.

4.a. Use a shield with the proper filter and cover
plates to protect your eyes from sparks and
the rays of the arc when welding or observing
open arc welding. Headshield and filter lens
should conform to ANSI Z87. I standards.

4.b. Use suitable clothing made from durable flame-resistant
material to protect your skin and that of your helpers from
the arc rays.

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.

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
your head out of the fume. Use enough
ventilation and/or exhaust at the arc to keep

fumes and gases away from the breathing zone. When

welding with electrodes which require special
ventilation such as stainless or hard facing (see
instructions on container or MSDS) or on lead or
cadmium plated steel and other metals or coatings
which produce highly toxic fumes, keep exposure as
low as possible and within applicable OSHA PEL and
ACGIH TLV limits using local exhaust or mechanical ven­tilation. In confined spaces or in some circumstances,
outdoors, a respirator may be required. Additional pre­cautions are also required when welding on galvanized
steel.

5. b. The operation of welding fume control equipment is affected
by various factors including proper use and positioning of the
equipment, maintenance of the equipment and the specific
welding procedure and application involved. Worker expo­sure level should be checked upon installation and periodi­cally thereafter to be certain it is within applicable OSHA PEL
and ACGIH TLV limits.

5.c.

Do not weld in locations near chlorinated hydrocarbon
coming from degreasing, cleaning or spraying operations.
The heat and rays of the arc can react with solvent vapors
form phosgene, a highly toxic gas, and other irritating prod­ucts.

vapors

to

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5.d. 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.

5.e. 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.

5.f. Also see item 1.b.

INVERTEC® V205-T AC/DC™

iii iii

SAFETY

WELDING and CUTTING
SPARKS can cause fire or
explosion.

6.a.
this is not possible, cover them to prevent the welding sparks
from starting a fire. Remember that welding sparks and hot
materials from welding can easily go through small cracks
and openings to adjacent areas. Avoid welding near hydraulic
lines. Have a fire extinguisher readily available.

6.b. 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.

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.

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
been “cleaned”. For information, purchase “Recommended
Safe Practices for the
Containers and Piping That Have Held Hazardous
Substances”, AWS F4.1 from the American Welding Society

(see address above).

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

Sparks and spatter are thrown from the welding arc. Wear oil

6.f.
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.

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.

6.h. Also see item 1.c.

Remove fire hazards from the welding area.

though

they have

Preparation

for Welding and Cutting of

CYLINDER may explode
if damaged.

7.a. Use only compressed gas cylinders

If

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

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

7.c. Cylinders should be located:

• Away from areas where they may be struck or subjected to

physical damage.

• 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.

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.

containing the correct shielding gas for the
process used and properly operating
regulators designed for the gas and

FOR ELECTRICALLY
powered equipment.

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.

8.c. Ground the equipment in accordance with the U.S. National
Electrical Code and the manufacturer’s recommendations.

6.I. Read and follow NFPA 51B “ Standard for Fire Prevention
During Welding, Cutting and Other Hot Work”, available from
NFPA, 1 Batterymarch Park,PO box 9101, Quincy, Ma
022690-9101.

6.j. Do not use a welding power source for pipe thawing.

Refer to http://www.lincolnelectric.com/safety for additional safety information.

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INVERTEC® V205-T AC/DC™

iv iv

SAFETY

PRÉCAUTIONS DE SÛRETÉ

Pour votre propre protection lire et observer toutes les instructions
et les précautions de sûreté specifiques qui parraissent dans ce
manuel aussi bien que les précautions de sûreté générales suiv­antes:

Sûreté Pour Soudage A L’Arc

1. Protegez-vous contre la secousse électrique:

a. Les circuits à l’électrode et à la piéce sont sous tension

quand la machine à souder est en marche. 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 met­allique 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 defonc­tionnement.

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.

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.

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:

6. Eloigner les matériaux inflammables ou les recouvrir afin de
prévenir tout risque d’incendie dû aux étincelles.

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.

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.

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.

PRÉCAUTIONS DE SÛRETÉ POUR
LES MACHINES À SOUDER À
TRANSFORMATEUR ET À
REDRESSEUR

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a. Utiliser un bon masque avec un verre filtrant approprié ainsi

qu’un verre blanc afin de se protéger les yeux du rayon­nement de l’arc et des projections quand on soude ou
quand on regarde l’arc.

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.

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, pan­talons sans revers, et chaussures montantes.

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.

INVERTEC® V205-T AC/DC™

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.

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 debranch­er à l’interrupteur à la boite de fusibles.

4. Garder tous les couvercles et dispositifs de sûreté à leur place.

v v

SAFETY

Electromagnetic Compatibility (EMC)

Conformance

Products displaying the CE mark are in conformity with European Community Council Directive of 15 Dec
2004 on the approximation of the laws of the Member States relating to electromagnetic compatibility,
2004/108/EC. It was manufactured in conformity with a national standard that implements a harmonized
standard: EN 60974-10 Electromagnetic Compatibility (EMC) Product Standard for Arc Welding Equipment.
It is for use with other Lincoln Electric equipment. It is designed for industrial and professional use.

Introduction

All electrical equipment generates small amounts of electromagnetic emission. Electrical emission may be
transmitted through power lines or radiated through space, similar to a radio transmitter. When emissions
are received by other equipment, electrical interference may result. Electrical emissions may affect many
kinds of electrical equipment; other nearby welding equipment, radio and TV reception, numerical controlled
machines, telephone systems, computers, etc. Be aware that interference may result and extra precautions
may be required when a welding power source is used in a domestic establishment.

Installation and Use

The user is responsible for installing and using the welding equipment according to the manufacturer’s
instructions. If electromagnetic disturbances are detected then it shall be the responsibility of the user of the
welding equipment to resolve the situation with the technical assistance of the manufacturer. In some cases
this remedial action may be as simple as earthing (grounding) the welding circuit, see Note. In other cases
it could involve construction of an electromagnetic screen enclosing the power source and the work com­plete with associated input filters. In all cases electromagnetic disturbances must be reduced to the point
where they are no longer troublesome.

Note: The welding circuit may or may not be earthed for safety reasons according to national

codes. Changing the earthing arrangements should only be authorized by a person who is
competent to access whether the changes will increase the risk of injury, e.g., by allowing
parallel welding current return paths which may damage the earth circuits of other equip­ment.

Assessment of Area

Before installing welding equipment the user shall make an assessment of potential electromagnetic prob­lems in the surrounding area. The following shall be taken into account:

a) other supply cables, control cables, signaling and telephone cables; above, below and adjacent to the

welding equipment;

b) radio and television transmitters and receivers;

c) computer and other control equipment;

d) safety critical equipment, e.g., guarding of industrial equipment;

e) the health of the people around, e.g., the use of pacemakers and hearing aids;

f) equipment used for calibration or measurement

g) the immunity of other equipment in the environment. The user shall ensure that other equipment being

used in the environment is compatible. This may require additional protection measures;

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h) the time of day that welding or other activities are to be carried out.

INVERTEC® V205-T AC/DC™

vi vi

SAFETY

Electromagnetic Compatibility (EMC)

The size of the surrounding area to be considered will depend on the structure of the building and other
activities that are taking place. The surrounding area may extend beyond the boundaries of the premises.

Methods of Reducing Emissions

Mains Supply

Welding equipment should be connected to the mains supply according to the manufacturer’s recommenda­tions. If interference occurs, it may be necessary to take additional precautions such as filtering of the mains
supply. Consideration should be given to shielding the supply cable of permanently installed welding equip­ment, in metallic conduit or equivalent. Shielding should be electrically continuous throughout its length. The
shielding should be connected to the welding power source so that good electrical contact is maintained
between the conduit and the welding power source enclosure.

Maintenance of the Welding Equipment

The welding equipment should be routinely maintained according to the manufacturer’s recommendations.
All access and service doors and covers should be closed and properly fastened when the welding equip­ment is in operation. The welding equipment should not be modified in any way except for those changes
and adjustments covered in the manufacturers instructions. In particular, the spark gaps of arc striking and
stabilizing devices should be adjusted and maintained according to the manufacturer’s recommendations.

Welding Cables

The welding cables should be kept as short as possible and should be positioned close together, running at
or close to floor level.

Equipotential Bonding

Bonding of all metallic components in the welding installation and adjacent to it should be considered.
However, metallic components bonded to the work piece will increase the risk that the operator could
receive a shock by touching these metallic components and the electrode at the same time. The operator
should be insulated from all such bonded metallic components.

Earthing of the Workpiece

Where the workpiece is not bonded to earth for electrical safety, not connected to earth because of its size
and position, e.g., ships hull or building steelwork, a connection bonding the workpiece to earth may reduce
emissions in some, but not all instances. Care should be taken to prevent the earthing of the workpiece
increasing the risk of injury to users, or damage to other electrical equipment. Where necessary, the con­nection of the workpiece to earth should be made by a direct connection to the workpiece, but in some
countries where direct connection is not permitted, the bonding should be achieved by suitable capacitance,
selected according to national regulations.

Screening and Shielding

Selective screening and shielding of other cables and equipment in the surrounding area may alleviate
problems of interference. Screening of the entire welding installation may be considered for special applica-

1

tions.

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_________________________

1

Portions of the preceding text are contained in EN 60974-10: “Electromagnetic Compatibility (EMC) prod­uct standard for arc welding equipment.”

INVERTEC® V205-T AC/DC™

I I

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- MASTER TABLE OF CONTENTS FOR ALL SECTIONS -

Page

Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .i-vi

Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Section A

Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Section B

Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Section C

Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Section D

Theory of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Section E

Troubleshooting and Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Section F

Electrical Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Section G

Parts Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .P-400

INVERTEC® V205-T AC/DC™

A-1 A-1

Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-1

Technical Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-2

Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-3

Select Suitable Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-3

Stacking, Tilting, Environmental Area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-3

Machine Grounding / High Frequency Interference Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-3

Input Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-4

Reconnect Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-4

230V Input, 115V Input . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-5

TABLE OF CONTENTS - INSTALLATION SECTION

Engine Driven Generator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-5

Output Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-6

Output and Gas Connection For Tig Welding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-6

Output Connection For Stick Welding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-6

Quick Disconnect Plug (For Stick Electrode Cable and Work Cable) . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-7

Shielding Gas Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-7

Remote Control Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-7

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INVERTEC® V205-T AC/DC™

A-2 A-2

INSTALLATION

TECHNICAL SPECIFICATIONS - V205-T AC/DC™ TIG K1855-1 (Code Number 10860)

INPUT - SINGLE PHASE ONLY

Input Voltages / 50 /60 Hz.

115

230

Duty Cycle

RATED OUTPUT

Output Amps Volts at Rated Amperes

Max. Input Current

34A at Rated Output
30A at Rated Output

Input Amps

(115V) 35%

60%
100%

(115V) 40%

60%
100%

(230V) 35%

60%
100%

(230V) 40%

60%
100%

(Stick) 110 24.4V

90 23.6V
70 22.8V

(TIG) 150 16V

120 14.8V
100 14V

(Stick) 180 27.2V

150 26V
130 25.2V

(TIG) 200 18V

170 16V
140 15.6V

34A
28A
20A

34A
25A
20A

30A
23A
19A

30A
18A
15A

OUTPUT

Output Current

Range

6-200 Amps

Maximum Open

Circuit Voltage

54 Volts Max.

Type of Output

AC/DC

RECOMMENDED INPUT WIRE AND FUSE SIZES FOR MAXIMUM RATED OUTPUT

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INPUT

VOLTAGE /

FREQUENCY

(HZ)

115/50/60
230/50/60

TYPE S, SO ST, STO, OR EXTRA

HARD USAGE INPUT CORD AWG

#12

TIME-DELAY CIRCUIT BREAKER

OR FUSE SIZE (AMPS)

PHYSICAL DIMENSIONS

Height Width Depth Weight

15 in. 8.5 in. 19 in. Approx. 38 lbs.
381 mm 216 mm 483 mm 17 kgs.

TEMPERATURE RANGES

OPERATING TEMPERATURE RANGE

-20°C to +40°C

INVERTEC® V205-T AC/DC™

STORAGE TEMPERATURE RANGE

-50°C to +85°C

30A

A-3 A-3

Read entire installation section before starting
installation.

INSTALLATION

MACHINE GROUNDING AND HIGH FRE­QUENCY INTERFERENCE PROTECTION

Safety Precautions

WARNING

ELECTRIC SHOCK can kill.

• Only qualified personnel should
perform this installation.

• 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
capacitors to discharge before
working inside this equipment.

• Insulate yourself from the work and ground.

• Always wear dry insulating gloves.

• Always connect the V205-T to a power supply
grounded according to the National Electrical
Code and local codes.

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

SELECT SUITABLE LOCATION

The Invertec® will operate in harsh environments.
Even so, it is important that simple preventative mea­sures are followed in order to assure long life and reli­able operation.

The Capacitor Discharge Circuit used in the high fre­quency generator, may cause many radio, TV and
electronic equipment interference problems. These
problems may be the result of radiated interference.
Proper grounding methods can reduce or eliminate
radiated interference.

The Invertec® V205-T AC/DC™ has been field tested
under recommended installation conditions. It com­plies with FCC allowable limits for radiation.

Radiated interference can develop in the following four
ways:

1. Direct interference radiated from the welder.

2. Direct interference radiated from the welding leads.

3. Direct interference radiated from feedback into the
power lines.

4. Interference from re-radiation of “pickup” by
ungrounded metallic objects.

Keeping these contributing factors in mind, installing
equipment per the following instructions should mini­mize problems.

• The machine must be located where there is free cir­culation of clean air such that air movement in the
back and out the front will not be restricted.

• Dirt and dust that can be drawn into the machine
should be kept to a minimum. Failure to observe
these precautions can result in excessive operating
temperatures and nuisance shutdown.

STACKING

The Invertec® V205-T AC/DC™ can

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.

not be stacked.

1. Keep the welder power supply lines as short as pos­sible and enclose as much of them as possible in
rigid metallic conduit or equivalent shielding for a
distance of 50 feet (15.2m). There should be good
electrical contact between this conduit and the
welder case ground. Both ends of the conduit
should be connected to a driven ground and the
entire length should be continuous.

2. Keep the work and electrode leads as short as pos­sible 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 prac­tical.

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INVERTEC® V205-T AC/DC™

A-4 A-4

INSTALLATION

3. Be sure the torch and work cable rubber coverings
are free of cuts and cracks that allow high fre­quency leakage. Cables with high natural rubber

®

content, such as Lincoln Stable-Arc

better resist
high frequency leakage than neoprene and other
synthetic rubber insulated cables.

4. Keep the torch in good repair and all connections
tight to reduce high frequency leakage.

5. The work terminal must be connected to a ground
within ten feet of the welder, using one of the fol­lowing methods.

a) A metal underground water pipe in direct con-

tact with the earth for ten feet or more.

b) A 3/4” (19mm) galvanized pipe or a 5/8”

(16mm) solid galvanized iron, steel or copper
rod driven at least eight feet into the ground.

The ground should be securely made and the
grounding cable should be as short as possible
using cable of the same size as the work cable, or
larger. Grounding to the building frame electrical
conduit or a long pipe system can result in re-radi­ation, effectively making these members radiating
antennas.

6. Keep all panels securely in place.

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 build­ing are recommended.

Failure to observe these recommended installation
procedures can cause radio or TV interference prob­lems.

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.

WARNING

ELECTRIC SHOCK can kill.

• Have a qualified electrician install
and service this equipment.

• Turn the input power OFF and
unplug the machine from the recep­tacle before working on this equip­ment.

• Allow machine to sit for 5 minutes minimum to
allow the power capacitors to discharge before
working inside this equipment.

• Do not touch electrically hot parts.

• Machine must be plugged into a receptacle that
is grounded according to the National Electrical
Code and local codes.

• Do not remove or defeat the purpose of the
power cord ground pin.

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

RECONNECT PROCEDURE

The Invertec® V205-T AC/DC™ auto reconnects to
either 115V or 230V supply.

Fuse the input circuit with time delay fuses or delay

1

circuit breakers. Using fuses or circuit breakers

type
smaller than recommended may result in “nuisance”
shut-offs from welder inrush currents even if not weld­ing at high currents.

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The Invertec® V205-T AC/DC™ is recommended for
use on an individual branch circuit.

1

Also called “inverse time” or “thermal/magnetic” circuit breakers.
These circuit breakers have a delay in tripping action that decreases
as the magnitude of the current increases.

INVERTEC® V205-T AC/DC™

A-5 A-5

230V INPUT

The equipment is provided with a 230/115V cable,

6.6ft.(2m) in length with a 230V 6-50P attachment plug.

The Invertec® V205-T AC/DC™ performs best when
connected to 230VAC inputs. This input allows full out­put of the machine (200 amps).

115V INPUT

INSTALLATION

In all cases, the green or green/yellow grounding wire
must be connected to the grounding pin of the plug,
usually identified by a green screw.

Attachment plugs must comply with the Standard for
Attachment Plugs and Receptacles, UL498.

The product is considered acceptable for use only
when an attachment plug as specified is properly
attached to the supply cord.

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 characteristics will affect
the available output. Do not exceed these welding con­ditions:

15A branch circuit

10% duty cycle
Stick: 75A
TIG: 105A

20A branch circuit

10% duty cycle
Stick: 90A
TIG: 130A

ATTACHMENT PLUG INSTALLATION

For use on engine drives, keep in mind the above input
draw restrictions and the following precaution.

ENGINE DRIVEN GENERATOR

The Invertec® V205-T AC/DC™ can be operated on
engine driven generators as long as the 230 volt auxil­iary 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 condi­tions when run in the high idle mode:

• Ranger 250,305

• Commander 300, 400, & 500

Some engine drives do not meet these conditions (e.g.
Miller Bobcats, etc). Operation of the Invertec® V205­T AC/DC™ is not recommended on engine drives not
conforming to these conditions. Such drives may deliv­er unacceptably high voltage levels to the Invertec®
V205-T AC/DC™ power source.

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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 ter­minal 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.

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

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INVERTEC® V205-T AC/DC™

A-6 A-6

+

-

TI G AD APT ER

RE TA IN ING C OM P OU ND

ST RA IN RE LI EF BO OT

TI G TO RCH P OW E R CA BL E WI TH GA S FI T IN G

+

-

INSTALLATION

OUTPUT CONNECTIONS

WARNING

ELECTRIC SHOCK can kill.

• Keep the electrode holder, TIG
torch and cable insulation in good
condition and in place.

• Do not touch electrically live parts
or electrode with skin or wet cloth­ing.

• Insulate yourself from work and ground.

• Turn the input line Switch on the Invertec® V205­T AC/DC™ “off” before connecting or discon­necting output cables or other equipment.

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

OUTPUT AND GAS CONNECTION FOR
TIG WELDING (FIGURE A.1)

The TIG Torch Twist-Mate and work cable Twist-Mate
Connectors are supplied with the welder. To connect
the cables, turn the Power Switch “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 connection for the shielding gas to the
torch.

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 fit­ting on the torch cable into the brass connector snugly

and slide the boot back over the brass connector.

OUTPUT CONNECTION FOR STICK
WELDING (FIGURE A.2)

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 key­way, and rotate clockwise; until the connection is snug.
Do not over tighten.

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WARNING

To avoid receiving a high frequency shock, keep
the TIG torch and cable insulation in good condi­tion.

___________________________________________

WORK CABLE CONNECTION

Next, connect the work cable to the “+” output terminal
in the same way. To minimize high frequency interfer­ence, refer to Machine Grounding and High
Frequency Interference Protection section of this
manual for the proper procedure on grounding the
work clamp and work piece.

FIGURE A.1

TIG TORCH

WORK CABLE

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FIGURE A.2

WORK CABLE

WORK CABLE

STICK ELECTRODE
HOLDER

WORK CLAMP

INVERTEC® V205-T AC/DC™

A-7 A-7

25 mm

1.00 in.

WELDING CABLE

BOOT

TRIM, IF REQ'D
TO FIT OVER CABLE

WELDING CABLE

COPPER FERRULE

SET SCREW

BRASS PLUG

COPPER TUBE

QUICK DISCONNECT PLUG (FOR STICK
ELECTRODE CABLE and WORK CABLE)

A quick disconnect system is used for the welding
cable connections. The stick electrode cable will need
to have a plug attached.

1. Cut off welding cable lug, if present.

INSTALLATION

SHIELDING GAS CONNECTION

Obtain the necessary inert shielding gas. Connect the
cylinder of gas with a pressure regulator and flow
gage. Install a gas hose between the regulator and gas
inlet (located on the rear of the welder). The gas inlet
has a 5/16-18 right hand female thread; CGA #032.

2. Remove 1.00 in. (25mm) of welding cable insula­tion.

3. Slide rubber boot onto cable end. The boot end
may be trimmed to match the cable diameter. Use

WARNING

CYLINDER could explode
if damaged.

soap or other nonpetroleum-based lubricant to help
slide the boot over the cable, if needed.

• Keep cylinder upright and
chained to a support.

• Keep cylinder away from areas where it
could be damaged.

• Never allow the torch or welding electrode to
touch the cylinder.

4. Insert copper strands into ferrule.

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.

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.

• Keep cylinder away from live electrical cir­cuits.

___________________________________________

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.

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INVERTEC® V205-T AC/DC™

A-8 A-8

NOTES

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INVERTEC® V205-T AC/DC™

B-1 B-1

Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-1

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

TABLE OF CONTENTS - OPERATION SECTION

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

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INVERTEC® V205-T AC/DC™

B-2 B-2

OPERATION

Read and understand this entire section before
operating your machine.

SAFETY INSTRUCTIONS

WARNING

ELECTRIC SHOCK can kill.

• Do not touch electrically live parts
such as output terminals, electrode or
internal wiring.

• Insulate yourself from the work and
ground.

• Always wear dry insulating gloves.

FUMES AND GASES
can be dangerous.

• Keep your head out of fumes.

• Use ventilation or exhaust to
remove fumes from breathing
zone.

GENERAL DESCRIPTION

The Invertec® V205-T AC/DC™ is an industrial 200
amp arc welding power source which utilizes single
phase input power, to produce constant current output.
The welding response of this Invertec® has been 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:

TIG (with high frequency or Touch Start Tig Starting).

• TIG AC with square, sinusoidal and triangular wave­forms

• Tig DC

The following items can be connected to the 6 pin
socket on the front panel:

• Remote control potentiometer for Stick welding.

• Remote Foot Amptrol or Hand Amptrol

• Arc Start Switch

NOTE: See Accessories section of this manual for

product numbers and complete description.

WELDING CAPABILITY

WELDING, CUTTING and
GOUGING SPARKS
can cause fire or explosion

• Keep flammable material away.

• Do not weld, cut or gouge on
containers that have held com-

bustibles.

ARC RAYS
can burn.

• Wear eye, ear and body

protection.

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

The Invertec® V205-T AC/DC™ is rated at 200 amps,
18 volts, at 40% duty cycle on a ten minute basis. It is
capable of higher duty cycles at lower output currents.
It is capable of 140 amps, 15.6 volts at 100% duty
cycle. If the duty cycle is exceeded, a thermal protec­tor will shut off the output until the machine cools. See
Technical Specifications in A-1 for other rated outputs.

The Invertec® V205-T is recommended for stick weld­ing with such popular electrodes as Fleetweld 35,
Fleetweld 37, Fleetweld 180 and Excalibur 7018.

LIMITATIONS

The V205-T is not recommended for pipe thawing.

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INVERTEC® V205-T AC/DC™

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 posi­tive (+) 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 there­fore there are electrically live parts inside the power
source. Carefully follow the instructions given in this
manual.

* 1 : Supply cable
* 2 : Gas attachment

l1 : Power Switch

FIGURE B.1

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INVERTEC® V205-T AC/DC™

B-4 B-4

2. Thermal / Device Warning Light Yellow LED

6. Digital Display

1. Input Voltage warning Light Green LED

5. Output/Parameter Adjust Knob

4. Setup/Parameter Select Button

9. Welding Process (MODE) Button

7. Local/Remote Button

3. Pulse On/Off Button

8.Trigger Selection Button

10. Electrode Connection (Negative)

11. Remote Control Connector

12. Electrode Connection (Positive)

13. Welding Parameter Drawing

sec

sec

LOCAL

1

9

10

11

12

13

8

7

6

5

4

3

2

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

1. Input Voltage warning light green LED - Indicates

that the machine is on and input voltage is within
acceptable range.

2. Thermal Shutdown Light (yellow LED) - Indicates

thermal over load or output disabled for incorrect
supply voltage.

• With the "Yellow LED" on, and an alarm code blink­ing on "Digital Display Item 6" (see Troubleshooting
Section E, "Possible electrical problems"), the
machine will not supply power at the output.

• If over-heating occurs, the "Yellow LED" will stay on
until the machine has sufficiently cooled. Leave the
power source on to allow the fan to cool the unit.

3. Pulse On/OFF push button - CONSTANT current

- PULSED current

4. Setup/Parameter Select push button -

“Setup/Parameter" push button has three (3) differ­ent functions:

• Accesses Welding Parameter. Repeatedly pressing

the Parameter button will step through the Welding
Parameter waveform lights on the front panel.
Parameters which can be changed.

Start Current
Upslope
Weld Current (Peak Current)
Pulse Frequency
% on Time
Background Current
Downslope
Finish Current

Postflow sec.
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.

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INVERTEC® V205-T AC/DC™

B-5 B-5

5. Output / Parameter Adjust Knob- Allows you to

continuously adjust the current both in TIG and in Stick

OPERATION

2 STEP DIAGRAM 1

(1)

welding. Allows you to change the value, shown on
"Digital Display Item 6", of the parameter selected with
"Setup/Parameter select button Item 4".

6. Digital Display - displays currently set values for

each mode or welding parameter.

7. Local/Remote push button - Selects the welding

current adjusting system:

• from front panel

• from remote control

The LED beside the symbol confirms the selection.

8. Tig Trigger 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.

Possible variations of this standard sequence is shown
in (2 step diagram 2). It is possible to press and hold
the TIG torch trigger a second time during downslope
to restart. After the trigger is pressed the output current
will increase to the welding current. This operation is
shown in (2 step diagram 2).

2 STEP DIAGRAM 2

(1)

(2)

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)

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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 cur­rent. Both the start current and increase, or upslope
time are presettable. The default start current is 15
amps and the default upslope time is 0.2 seconds.

2. Release the Arc Start Switch to stop welding.

The machine will now decrease the output current at
a controlled rate, or downslope time, until the Finish
current, (also commonly referred to as Crater
Current) is reached and the output of the machine is
turned OFF. Both the Downslope Time and the Finish
Current are can be preset.

After the arc is turned OFF, the gas valve will remain
open to continue the flow of the shielding gas to the
hot electrode and work piece. The duration of this
postflow shielding gas is adjusted by the Postflow
Parameter.

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INVERTEC® V205-T AC/DC™

4-Step Sequence

With the 4-step Selected, the following welding
sequence will occur.

1. Press and hold the Arc Start Switch to start the
sequence.

The machine will open the gas valve to start the flow
of the shielding gas. After a 0.5 second preflow time,
to purge air from the torch hose, the output of the
machine is turned ON. At this time the arc is started.

After the arc is started the output current will be at
the Start current. This condition can be maintained
as long or as short as necessary.

If the Start current is not necessary, do not hold the
TIG torch trigger as described at the beginning of this
step. Instead, quickly press and release the trigger.
In this condition, the machine will automatically pass
from Step 1 to Step 2 when the arc is started.

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 ups­lope time is 0.2 seconds.

B-6 B-6

3. Press and hold the TIG torch trigger when the main
part of the weld is complete.

The machine will now decrease the output current at
a controlled rate, or downslope time, until the Finish
current is reached. Both the Downslope Time and
the Finish Current are presettable. This Finish cur­rent can be maintained as long or as short as nec­essary.

OPERATION

9. Welding selection button - Permits selection of the

welding mode. The LED beside the symbol confirm
the selection:

10. Electrode Connection (Negative) - For quick dis-

connect system using Twist-Mate

• Stick

• TIG DC

• TIG AC

TM

cable plugs

with gas pass through for TIG Torches.

4. Release the TIG torch trigger.

The output current of the machine will turn OFF and
the gas valve will remain open to continue the flow
of the shielding gas. The duration of this postflow
time is adjusted by the Postflow parameter. This

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.

operation is shown in (4 step diagram 1).

12. Electrode Connection (Positive) - For quick dis-

4 STEP DIAGRAM 1

(3)

(4)

connect system using Twist-Mate

TM

cable plugs

13. Welding Parameter Display - LED’s show which

mode or welding parameter is activated for adjust­ment.

• 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.

Possible variations of this standard sequence are
shown below.
By releasing and re-pressing the TIG torch trigger dur­ing 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

- Press the SETUP/Parameter push button
"Item 4"; every time the push button is
pressed, one of the LED’s in the diagram
“Item 13” comes on (in clockwise sequence)
and the value of the parameter appears on
the Digital display "Item 6". Stop at the
desired parameter.

- Rotate the Output/Parameter Adjust
Knob"Item 5" and modify the parameter
value.

- Press the SETUP/Parameter "Item 4" push
button again to pass to another parameter, or
wait five seconds and the Weld Current LED
will come on again.

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WELDING PARAMETER DEFAULTS AND RANGES

PARAMETER VALUE MIN MAX DEFAULT

START CURRENT AMPS 6 MAX 15

UPSLOPE SEC. 0 10 0.2
WELD CURRENT* AMPS 6 MAX 100
DOWNSLOPE SEC. 0 10 1.0
FINISH CURRENT AMPS 6 MAX 8
POSTFLOW SEC. 0.2 60 5.0
PULSE FREQUENCY HZ 0.1 500 0.5
% ON TIME %595 50

BACKGROUND CURRENT

AC FREQUENCY HZ 20 150 100
AC BALANCE % EN 35 85 65

MODE DC TIG
TRIGGER 2 STEP
LOCAL / REMOTE LOCAL

% OF WELD CURRENT

(EN = Electrode Negative)

1 100 20

* Maximum Weld Current can be limited by input voltage, Welding Mode, AC TIG waveform and AC TIG frequency.

INVERTEC® V205-T AC/DC™

B-7 B-7

SET UP MENU

Many additional parameters can be modified via the
Set Up Menu. To access the Set Up Menu:

• Position the ON/OFF switch to OFF “0”.

• Depress and hold the Parameter select Push Button.

• Position the On/Off switch to on "I" at the back of the
machine; the input voltage light "Item 1" (green LED)
confirms normal operation.

• The SETUP mode is confirmed by a center "0" on the
Digital display “Item 6”.

INDICATOR PARAMETER DEFAULT

OPERATION

- Rotate the Output / Parameter Adjust Knob,
the Digital Display shows the numbers corre­sponding to the parameters in sequence;
stop at the desired parameter and push the
"Setup/Parameter Push Button".

- The number on the Digital display "Item 6" is
replaced by the value of the parameter that
can be modified through the Output /
Parameter adjust knob "Item 5".

- 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.

- To exit the Set Up Menu, return to “0” and
press the Setup/Parameter Push Button

0 Exit From Set Up
1 Not Used
2 Pre Flow Time (0 - 25 seconds) 0.5 sec.
3 Arc Force, percent above Peak Current for Stick only (0 - 100%) 30%
4 Hot Start, percent above Peak Current for Stick only (0 - 100%) 80%
5 Setting of AC wave Form 2 (Square)

0 = Sinusoidal
1 = Triangular
2 = Square

NOTE: This parameter limits maximum weld current, see "OUTPUT LIMITATIONS" section of the manual.

6 Min. Weld Current Value with Remote Control,for TIG only. 10 Amps

(6 Amps - Value set for Indicator 7)

7 Max. Weld Current Value with Remote Control,for TIG only. Peak Current

(Value set for Indicator 6 - Peak Current)

NOTE: Peak Current (Max Weld Current) can be limited by input voltage, welding mode, AC TIG waveform and AC TIG frequency.

8 Touch Start or H.F. Start in DC TIG (0 = H.F. Start, 1 = touch Start) 0

This parameter is ignored in AC TIG Mode

9 Reset all Parameters, (including control panel settings)
10 Not Used
11 Not Used
12 2 Step Trigger Selection 1

0 = Restart Disabled
1 = Restart Enabled

13 4 Step Trigger Selection 0

0 = Restart Disabled
1 = Restart Enabled

14 Start Power , for TIG only 2.0

This function sets the initial start energy limit.

(1.0 = min., 5.0 = max.)

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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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INVERTEC® V205-T AC/DC™

B-8 B-8

1

e-

+

–

1) Workpiece 5) Flowmeter

2) Filler material 6) Pressure reducer

3) Non-consumable electrode 7

) l

nert gas (typically argon)

4) Torch 8)

Power source

1

2

3

4

5

6

7

8

H2O

H.F.

OPERATION

OUTPUT LIMITATIONS

The maximum output current as specified in the instal­lation section of this manual is derated in two situa­tions; alternate AC Wave Forms and elevated AC
Frequencies.

• Alternate AC Wave Forms (See Set Up Menu)
Square 200 amps max. output
Sinusoidal 150 amps max. output
Triangular 120 amps max output

• Elevated AC Frequencies
Above 85Hz (AC output) the square wave out­put is limited to 170 amps. Elevated AC
Frequencies do not effect the output of
Sinusoidal and Triangular Waveforms.

These derated values have been programmed into the
Invertec® V205-T AC/DC™ to ensure reliable 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.

WELDING POLARITY

DC Electrode Negative Polarity (Direct Current
Straight Polarity)

(see FIGURE B.4)
While Welding, there is a continuous flow of electrons
from the electrode to the workpiece.

This is the most used polarity, ensuring limited wear of
the electrode, since the majority of the heat concen­trates on the anode (workpiece). Narrow and deep
welds are obtained with high travel speeds.

Most materials, with the exception of aluminum and
magnesium, are welded with this polarity.

FIGURE B.4

To avoid inclusions of tungsten in the joint, the elec­trode 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 cur­rent and ensure proper gas coverage over the weld.

FIGURE B.3

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INVERTEC® V205-T AC/DC™

B-9 B-9

AC TIG - NOT PULSED

Ip
Im
Ib

O

O

t

t

T

f = 1 to 10Hz
T= 1/ f

I

AC - PULSED TIG

1

e-

+

–

T

Is

O

t

T

Is

O

t

m

Ib

T

DC TIG - NOT PULSED

DC - PULSED TIG

+

+

+

---

30% MAX. PENETRATION

50%

70% MAX. CLEANING

OPERATION

DC Electrode Positive Polarity. (Direct Current
Reverse Polarity) (see Figure B.5)

In this case, there is a continuous flow of electrons
from the workpiece to the electrode. The reverse polar­ity is used for welding alloys covered with a layer of
refractory oxide.

With this polarity the electrode functions as anode and
is subjected to a high degree of heat; the workpiece is
bombardment by positive ions sent from the electrode
which break the surface oxide.

In Electrode Positive Polarity, high currents cannot be
used, since they would cause an excessive wear of the
electrode.

NOTE: (The Invertec® V205-T AC/DC™ cannot be

used for Electrode Positive TIG welding without
special adapters.)

FIGURE B.5

A.C. (Alternating Current)

(see Figure B.7)

Alternating Current welding is typically used for Tig
welding aluminum (and its alloys) or magnesium. The
polarity alternates between Electrode Positive and
Electrode Negative (EN). During the positive half-wave
the oxide is broken. During the negative half-wave, the
electrode cools, the workpiece melts and penetration
occurs.

FIGURE B.7

Greater % EN = MORE PENETRATION

50% (EN)

Lesser % EN = more CLEANING

Changing the wave balance alters the ratio between
the cleaning and the penetrating current.

A.C.-Pulsed TIG

When AC welding, a pulsed current can be used, with
similar effects to those described in pulsed direct cur-

rent welding.

D.C.-Pulsed TIG

(see Figure B-6)

The use of pulsed direct current allows better control of
the weld pool during certain operating conditions.

When compared with traditional TIG welding per­formed 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.

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FIGURE B.6

FIGURE B.8

INVERTEC® V205-T AC/DC™

B-10 B-10

OPERATION

STEEL TIG WELDING

The TIG process is very effective for welding both car­bon steel and alloy steel, especially in applications
requiring precision results. DC Electrode Negative
Polarity is required. Since this process does not
include the removal of impurities, proper cleaning and
preparation of the edges is required.

FILLER MATERIAL:

The filler rods must deposit welds with mechanical
characteristics appropriate for the application.

COPPER TIG WELDING

Since the TIG welding is a process characterized by
high heat concentration, it is particularly suitable for
welding materials with high thermal conductivity, like
copper. As with steel, the DC Electrode Negative
Polarity is employed, with argon as protective gas.
Considering the fluidity of molten copper, the use of
backup support may prove useful.

FILLER MATERIAL:

In order to avoid the oxidation of the molten material,
filler materials containing phosphorus, silicon or other
deoxidating materials are typically used. The mechan­ical properties can also be improved through the use of
silver.

TIPS FOR AC TIG WELDING

AC Inverter TIG power sources offer two significant
advantages over conventional Silicon Controlled
Rectifier (SCR) / transformer power sources:

1. The AC wave balance can be set to a higher per­centage electrode negative which minimizes tung­sten heating and erosion.

2. The AC frequency can be varied to "focus" the arc.
Increasing the AC frequency above 60Hz will narrow
the cone shape arc from the tungsten’s tip.
Decreasing the AC frequency below 60Hz will
broaden the cone shape arc from the tungsten’s tip.

The two above benefits can be used to maintain a tight
focus of the arc for precise heat control and tight joint
access. Because of the AC inverters abilities in these
areas the following recommendations are made as a
starting point:

• A 2% Thoriated tungsten is recommended instead of
the Pure tungsten that is normally recommended for
AC welding. Thoriated tungstens emit electrons eas­ier and therefore will improve starting.

• Sharpen the tungsten to a point. Normally it is rec­ommended to pre-ball a pure tungsten when AC
welding with a conventional power source.
However, the AC inverter with it’s extended AC bal­ance control minimized tungsten heating thus allow­ing for a pointed tungsten to be used.

• Set the AC Balance control to maximum 85% elec­trode negative. This can be reduced if the material
welded is heavily oxidized, however starting at max­imum and adjusting to less is desired.

• Set the AC Frequency in the 100 to 120 Hz range.
This is a "Sweet Spot" for most aluminum applica­tions.

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GTAW Process

Electrode Polarity DC- AC Approximate Argon

Electrode Tip Preparation Sharpened Sharpened Gas Flow Rate

Electrode Type

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

Electrode Size-in. (mm) Aluminum Steel

.010 (0.25) Up to 15 A. Up to 15 A. 3-8 (2-4) 3-8 (2-4)
.020 (0.50) Up to 15 A. Up to 20 A. 5-10 (3-5) 5-10 (3-5)
.040 (1.0) Up to 80 A. Up to 60 A. 5-10 (3-5) 5-10 (3-5)
1/16 (1.6) Up to 150 A. Up to 130 A. 5-10 (3-5) 9-13 (4-6)
3/32 (2.4) Up to MAX. A. Up to MAX. A. 13-17 (6-8) 11-15 (5-7)

1/8 (3.2) XX15-23 (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

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INVERTEC® V205-T AC/DC™

C.F.H. (l/min.)

B-11 B-11

Current (A)

50
100
150
200
250
300

Helium cfh-(l/min)

29 - (14)
29 - (14)
42 - (20)
42 - (20)
53 - (25)
53 - (25)

OPERATION

PROTECTIVE GAS

Both argon and helium work when welding aluminum.
Argon is preferred, due to its lower cost and consump-

The Invertec® V205 T AC/DC TIG is ready to AC TIG

weld with the following features:
tion rate. This gas also tends to stabilize the arc, thus
making it easy to operate. For some applications, how­ever, the use of helium, or argon-helium blends, is rec­ommended due to better weld penetration and faster
travel speed. Helium is especially suitable for welding
thick workpieces. The recommended gas flow rates
are shown in table 5.

• AC TIG

• Trigger Mode in 2 step mode

• Local control

• Pulser off

• AC Square Wave

• AC Balance 65% EN

• AC Frequency 100HZ

TABLE 5

• Pre Flow .5sec.

• Post Flow 5 sec.

• High Freq Start

Change from Local to Remote control by pushing front

panel push button.

Set the maximum output current desired using the

Output Control. Initiate the arc by closing the arc start

AC TIG WELDING QUICK START UP

switch. The Amptrol will control the output current from

10 amps to current level set by Output Control.

WARNING

ELECTRIC SHOCK can kill.

• Have an electrician install and
service this equipment.

• Turn the input power off at the fuse box, dis­connect or unplug supply lines and allow
machine to sit for five minutes minimum to
allow the power capacitors to discharge
before working inside this equipment.

• Do not touch electrically hot parts.

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

Connect the shielding gas – typically argon – using a
appropriate regulator. Connect the foot amptrol, torch
and work lead to the power source.

With the work cable connected to a properly grounded
work piece, turn the power source on.

To change the AC Frequency, press and hold the
Parameter button for 3 seconds. The AC Frequency is
now selected and can be varied by the Output Control.
The frequency is displayed on the digital meter. After
about 5 seconds, the power source will switch back to
the welding mode ready to weld with the new selected
AC Frequency.

To change the AC Balance, press and hold the
Parameter button for 3 seconds, AC Frequency is
selected, press the Parameter button again and AC
Balance is selected. Adjust the Output Control for the
desired AC Balance. After about 5 seconds, the power
source will switch back to the welding mode ready to
weld with the new selected AC Balance.

To change the Post Flow time, repeatedly push the
Parameter button until the Post Flow indicator light is
on. Adjust the Output control to the desired Post Flow
time as indicated on digital display.

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INVERTEC® V205-T AC/DC™

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, dis­connect or unplug supply lines and allow
machine to sit for five minutes minimum to
allow the power capacitors to discharge before
working inside this equipment.

• Do not touch electrically hot parts.

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

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 para­meter button to exit the Set Up Menu.

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INVERTEC® V205-T AC/DC™

C-1 C-1

Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .C-1

Options/Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .C-2

Factory Installed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .C-2

Field Installed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .C-2

Tig Torch Kits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .C-2

Cable Plugs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .C-2

TABLE OF CONTENTS - ACCESSORIES SECTION

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INVERTEC® V205-T AC/DC™

C-2 C-2

ACCESSORIES

OPTIONAL ACCESSORIES

AND COMPATIBLE EQUIPMENT

Factory Installed

Twist-Mate Cable Connectors

1 – standard for Ground Clamp
1 – Gas Pass through for Tig Torch
Strap Packet
Instruction Manual

Field Installed

K857 - Remote Output Control - For Stick welding.

When the V205-T’s Output Control is in the "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.

tm

K870 - Foot Amptrol

V205-T’s Output Control is in the “REMOTE” position,
the foot Amptrol energizes the output and controls the
output remotely. The Foot Amptrol connects directly to
the 6 pin Amphenol.

K963-3 - Hand Amptrol

V205-T’s Output Control is in the “Remote” position,
the hand Amptrol energizes the output and controls the
output remotely. The Hand Amptrol connects directly to
the 6 pin Amphenol.

K814 - Arc Start Switch - 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.

for TIG welding. When the

tm

for TIG welding. When the

TIG TORCH KITS

K2266-1 – TIG-Mate 17 Air Cooled TIG Torch Starter
Pack. One complete easy-to-order kit packaged in its

own portable carrying case. Includes: PTA-17 torch,
parts kit, Harris flowmeter/regulator, 10 ft. gas hose,
Twist-mate™ adapter, work clamp and cable.

K2267-1 – TIG-Mate 20 Water-Cooled TIG Torch
Starter Pack. One complete easy-to-order kit pack-

aged in its own portable carrying case. Includes: PTW­20 torch, parts kit, Harris flowmeter/regulator, 10 ft. gas
hose, Twist-Mate™ adapter, work clamp and cable,
and 10 ft. water hose.

CABLE PLUGS

K852-70 - Cable Plug Kit for 1/0-2/0 cable. Attaches to

welding cable to provide quick disconnect from
machine.

Twist-Mate Torch 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.

K1622-4 – Twist-Mate adapter for Water-Cooled TIG
torches. Adapter for PTW-18 and -20 Torches.

TIG Torch Parts Kits - Parts kits are available for the

PTA-9 and PTA-17 TIG torches. These kits include
back cap, collets, collet bodies, nozzles and tungstens.

Order KP507 for PTA-9 torches
Order KP508 for PTA-17 torches

See publication E12.150 for parts kits breakdown.
Cut Length Consumables - TIG welding filler metals
are available for welding stainless steel, mild steel, alu­minum and copper alloys. See publication C9.10.

Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC

Magnum® PTA-9 and PTA-17 TIG Torches - The fol­lowing standard Magnum® TIG torches with one-piece
cable may be used with the Invertec® V205-T.

• K1781-1 PTA-9 12.5 ft medium back cap

• K1781-3 PTA-9 25 ft medium back cap

• K1782-1 PTA-17 12.5 ft long back cap

• K1782-3 PTA-17 25 ft long back cap

NOTE: Each torch requires a Twist-Mate adapter, (one

is included with the machine). Collets, collet
bodies, and nozzles are not included and must
be ordered separately.

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INVERTEC® V205-T AC/DC™

D-1 D-1

Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-1

Input Filter Capacitor Discharge Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-2

Routine Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-2

Major Component Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-3

TABLE OF CONTENTS - MAINTENANCE SECTION

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INVERTEC® V205-T AC/DC™

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 discharge 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 condi­tions. This voltage is dangerous and must be dis­charged before the machine can be serviced.
Discharging is done automatically by the machine
each time the power is switched off. However, you
must allow the machine to sit for at least 5 minutes
to allow time for the process to take place.

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

ROUTINE MAINTENANCE

Prevent metal powder from accumulating near the aer­ation fins and over them.

Carry out the following periodic controls on the power
source:

• Clean the power source inside by means of low­pressure compressed air.

• Check the electric connections and all the connec­tion cables.

• Always use gloves in compliance with the safety
standards.

Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC

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INVERTEC® V205-T AC/DC™

D-3 D-3

11

44

22

33

FIGURE D.1 - MAJOR COMPONENT LOCATIONS

1. Cradle Tube Assembly and Roof

2. Control Panel Assembly

3. Stator & Rotor Assembly and Battery

4. Rear Control Panel, Fuel Tank Assembly, and Engine

MAINTENANCE

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INVERTEC® V205-T AC/DC™

D-4 D-4

NOTES

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INVERTEC® V205-T AC/DC™

E-1 E-1

Superimposition
board

Bus board

Fan

Input
board

HF
board

Main IGBT
& Power board

4
IGBT's

Control board

Display & LED
board

888

Control
Knob

Gas
Solenoid

DC blocking
capacitor board

Main
Trans former

Output
board

Output
Trans istor
Module

Current
Hall
Device

Output
Filter bd.
(bypass)

(D + E)
Remote 2/4

Remote
75, 76, 77
A, B, C

24 VDC Remote 2/4 path (D + E)

turn on AC ckt.

+15, -15, +5

input volt meter

thermostat info

set info

input current meter

turn on PWM

HF control signal

+48, +24

Input
Choke

_

+

RF coil

-48, +24,+15,-15,+5

reconnect info.

voltage feedback

high volt supply

turn on AC ckt.

current feedback

IGBT
Thermostats

Output
Diode
Thermostat

Voltage Feedback

Current Feedback

AC DC Gate drive signals

24 VDC

48 VDC

Output
Choke

TABLE OF CONTENTS-THEORY OF OPERATION SECTION

Theory of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .E-1

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

Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC

Output Filter Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .E-5

Insulated Gate Bipolar Transistor (IGBT) Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .E-6

FIGURE E.1 - V205-T BLOCK LOGIC DIAGRAM

INVERTEC® V205-T AC/DC™

E-2 E-2

Superimposition
board

Bus board

Fan

Input
board

HF
board

Main IGBT
& Power board

4
IGBT's

Control board

Display & LED
board

888

Control
Knob

Gas
Solenoid

DC blocking
capacitor board

Main
Trans former

Output
board

Output
Trans istor
Module

Current
Hall
Device

Output
Filter bd.
(bypass)

(D + E)
Remote 2/4

Remote
75, 76, 77
A, B, C

24 VDC Remote 2/4 path (D + E)

turn on AC ckt.

+15, -15, +5

input volt meter

thermostat info

set info

input current meter

turn on PWM

HF control signal

+48, +24

Input
Choke

_

+

RF coil

-48, +24,+15,-15,+5

reconnect info.

voltage feedback

high volt supply

turn on AC ckt.

current feedback

IGBT
Thermostats

Output
Diode
Thermostat

Voltage Feedback

Current Feedback

AC DC Gate drive signals

24 VDC

48 VDC

Output
Choke

THEORY OF OPERATION

FIGURE E.2 - GENERAL DESCRIPTION, INPUT BOARD & BUS BOARD

Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC

GENERAL DESCRIPTION

The Invertec® V205T AC/DC is an inverter based
industrial welding power source that utilizes single­phase 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 reconnect feature that does not require manual
intervention when the input power is changed from
115VAC to 230VAC or 230VAC to 115VAC. When in
the TIG mode the operator may select to use either the
high frequency or touch start function.

INPUT BOARD AND BUS BOARD

The single phase input voltage is applied to the V205T
through a line switch located on the back of the
machine. The AC input voltage is filtered and condi­tioned by a network of inductors, capacitors and a
varistor that are all located on the Input Board. This fil-

Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC

NOTE: Unshaded areas of Block Logic

Diagram are the subject of discussion

INVERTEC® V205-T AC/DC™

tered input voltage is applied to the Main IGBT Inverter
Board. Another function of the Input Board is to pre­vent high frequency inverter generated “noise” from
being induced back into the supply lines.

The Bus Board performs several functions within the
V205T. It accepts and distributes power and informa­tion 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.

The fan fuse F3, the 400VDC fuse F2 and the water
cooler F1 (not used) are also located on the Bus
Board.

E-3 E-3

Superimposition
board

Bus board

Fan

Input
board

HF
board

Main IGBT
& Power board

4
IGBT's

Control board

Display & LED
board

888

Control
Knob

Gas
Solenoid

DC blocking
capacitor board

Main
Trans former

Output
board

Output
Trans istor
Module

Current
Hall
Device

Output
Filter bd.
(bypass)

(D + E)
Remote 2/4

Remote
75, 76, 77
A, B, C

24 VDC Remote 2/4 path (D + E)

turn on AC ckt.

+15, -15, +5

input volt meter

thermostat info

set info

input current meter

turn on PWM

HF control signal

+48, +24

Input
Choke

_

+

RF coil

-48, +24,+15,-15,+5

reconnect info.

voltage feedback

high volt supply

turn on AC ckt.

current feedback

IGBT
Thermostats

Output
Diode
Thermostat

Voltage Feedback

Current Feedback

AC DC Gate drive signals

24 VDC

48 VDC

Output
Choke

THEORY OF OPERATION

FIGURE E.3 - MAIN IGBT INVERTER BOARD

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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, regulat­ed and a unity power factor output is developed for the
main welding IGBTs. This unity power factor circuit
provides several advantages over a traditional bridge
rectifier circuit. Among these advantages are that the
UPFR operates over a wide range of voltages, there is
no need for any manual circuit changes when the input
voltages are changed from 115VAC to 230VAC and
there is absolute voltage stability maintained on the
IGBT electrolytic capacitors. The four main welding
IGBTs are located on a large center mounted heat sink
assembly.

The pre-charge and auto reconnect circuits are posi­tioned on the Main IGBT Inverter Board. When power
is first applied to the V205T the rectified DC input volt­age is applied to the input capacitors through a current
limiting circuit. The capacitors are charged slowly and
current limited for approximately five seconds. After
five seconds a relay closes and the pre-charge circuit
is bypassed and a controlled DC input voltage is
applied to the weld capacitors and IGBTs making them
ready for welding 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 adjust for the

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NOTE: Unshaded areas of Block Logic

Diagram are the subject of discussion

INVERTEC® V205-T AC/DC™

different voltage requirements needed by the weld
IGBT circuits. A signal is also sent to the Control Board
so that when the input voltage is reduced the output of
the machine will be limited accordingly.

The Auxiliary power portion of the board generates
several voltages through flyback topology and a
50KHZ switching frequency. These various voltages
(+24, +15, +5, +48 and –15) are utilized to operate the
control and protection electronics, the gas solenoid,
the trigger circuit and the fan motor.

The Main IGBT Inverter Board receives command and
pre-set signals from the Control/Display board. It also
receives feedback information, both voltage and cur­rent, from the Output Filter Board and Hall Effect
Device via the Bus Board. It processes this informa­tion and generates the correct pulse width modulation
signal (PWM) that is applied to the gates of the weld
IGBTs. This controls and regulates the output of the
machine. The thermostats signals are connected to the
Main IGBT Inverter Board. This status information is
passed on to the Control Board. In the case of an over
temperature condition the Control Board will prevent
output until the machine cools and the thermostats
reset.

Low-level analog signals are generated on the Main
IGBT Inverter Board and sent to the Control/Display
Board for meter set and actual display values.

E-4 E-4

Superimposition
board

Bus board

Fan

Input
board

HF
board

Main IGBT
& Power board

4
IGBT's

Control board

Display & LED
board

888

Control
Knob

Gas
Solenoid

DC blocking
capacitor board

Main
Trans former

Output
board

Output
Trans istor
Module

Current
Hall
Device

Output
Filter bd.
(bypass)

(D + E)
Remote 2/4

Remote
75, 76, 77
A, B, C

24 VDC Remote 2/4 path (D + E)

turn on AC ckt.

+15, -15, +5

input volt meter

thermostat info

set info

input current meter

turn on PWM

HF control signal

+48, +24

Input
Choke

_

+

RF coil

-48, +24,+15,-15,+5

reconnect info.

voltage feedback

high volt supply

turn on AC ckt.

current feedback

IGBT
Thermostats

Output
Diode
Thermostat

Voltage Feedback

Current Feedback

AC DC Gate drive signals

24 VDC

48 VDC

Output
Choke

THEORY OF OPERATION

FIGURE E.4 - MAIN TRANSFORMER, OUTPUT DIODE MODULE & CLAMPING BOARD,

OUTPUT TRANSISTOR MODULE & SUPERIMPOSITION BOARD

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MAIN TRANSFORMER

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 normal volt­age spikes.

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NOTE: Unshaded areas of Block Logic

Diagram are the subject of discussion

INVERTEC® V205-T AC/DC™

OUTPUT MODULE TRANSISTOR
BOARD

This module produces the AC waveforms and frequen­cies. 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 nega­tive AC or DC.

SUPERIMPOSITION BOARD

The Super Imposition Board receives signals from the
Control/Display Board to control the status of the sec­ondary 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 auxil­iary 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.

E-5 E-5

Superimposition
board

Bus board

Fan

Input
board

HF
board

Main IGBT
& Power board

4
IGBT's

Control board

Display & LED
board

888

Control
Knob

Gas
Solenoid

DC blocking
capacitor board

Main
Trans former

Output
board

Output
Trans istor
Module

Current
Hall
Device

Output
Filter bd.
(bypass)

(D + E)
Remote 2/4

Remote
75, 76, 77
A, B, C

24 VDC Remote 2/4 path (D + E)

turn on AC ckt.

+15, -15, +5

input volt meter

thermostat info

set info

input current meter

turn on PWM

HF control signal

+48, +24

Input
Choke

_

+

RF coil

-48, +24,+15,-15,+5

reconnect info.

voltage feedback

high volt supply

turn on AC ckt.

current feedback

IGBT
Thermostats

Output
Diode
Thermostat

Voltage Feedback

Current Feedback

AC DC Gate drive signals

24 VDC

48 VDC

Output
Choke

THEORY OF OPERATION

FIGURE E.5 - CONTROL/DISPLAY BOARD, HF BOARD & OUTPUT FILTER BOARD

Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC

CONTROL/DISPLAY BOARD

The Control/Display Board assembly is actually two
boards mounted together. They should be replaced
together. The Display portion houses the control
panel, LEDs, push buttons and output encoders. The
Display Boards functions as the interface between the
user and the V205-T machine.

The Control Board functions as the support circuitry for
the on board CPU (micro-processor). The Control
Board receives information and power from the Bus
Board, and Main IGBT Inverter Board. The Control
Board supplies power for the Display Board and sup­plies 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 clo­sure 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 con­trol signals (Pins A, B&C) are also fed into the
Control/Display Board from the 6 pin connector located
on the front of the machine. Based upon current and
voltage feedback information the Control Board 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.

Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC

INVERTEC® V205-T AC/DC™

HIGH FREQUENCY (HF) BOARD

The HF Board generates a set of pulses of about 900V,
which are amplified through the high voltage trans­former 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 tungsten
electrode to touch the work. This high frequency pulse
is removed when the welding arc is established.

The command signals are received from the micro­processor on the Control Board and last for about 1
second maximum. The HF Board receives it’s power
from the + 385 VDC derived from the electrolytic
capacitors on the Main IGBT Inverter Board.

OUTPUT FILTER BOARD

This PC board, located at the welding output terminals
protects the internal circuitry of the machine from high
voltage and high frequency pulses that may be fed
back into the unit via the welding cables, torch cable or
remote control equipment. This unwanted “noise” is
shunted to case ground.

NOTE: Unshaded areas of Block Logic

Diagram are the subject of discussion

E-6 E-6

DRAIN

SOURCE

GATE

INJECTING LAYER

BUFFER LAYER

DRAIN DRIFT REGION

BODY REGION

p +

n +

n -

p

n + n +

DRAIN

SOURCE

GATE

INJECTING LAYER

BUFFER LAYER

DRAIN DRIFT REGION

BODY REGION

p +

n +

n -

p

n + n +

POSITIVE
VOLTAGE
APPLIED

B. ACTIVE

A. PASSIVE

THEORY OF OPERATION

FIGURE E.6 - IGBT

INSULATED GATE BIPOLAR
TRANSISTOR (IGBT)
OPERATION

An IGBT is a type of transistor. IGBT are semiconduc­tors 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 termi­nal of the IGBT may be connected to a voltage supply;
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
capable of conducting current. A voltage supply con­nected to the drain terminal will allow the IGBT to con­duct 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.

Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC

Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC

NOTE: Unshaded areas of Block Logic

Diagram are the subject of discussion

INVERTEC® V205-T AC/DC™

F-1 F-1

TABLE OF CONTENTS - TROUBLESHOOTING AND REPAIR

Troubleshooting and Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .F-1

How to Use Troubleshooting Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .F-2

PC Board Troubleshooting Procedures and Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .F-3

Troubleshooting Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .F-4/F-8

Test Procedures

External and Internal diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .F-9/F-11

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 Power Factor Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .F-31

Output Filter Board Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .F-35

Secondary Output Board Assembly Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .F-39

Main Inverter Board “Welding Logic And Inverter” 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

Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC

INVERTEC® V205-T AC/DC™

F-2 F-2

TROUBLESHOOTING AND REPAIR

HOW TO USE TROUBLESHOOTING GUIDE

WARNING

Service and Repair should only be performed by Lincoln Electric Factory Trained
Personnel. Unauthorized repairs performed on this equipment may result in danger to
the technician and machine operator and will invalidate your factory warranty. For your
safety and to avoid Electrical Shock, please observe all safety notes and precautions
detailed throughout this manual.

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

This Troubleshooting Guide is provided to
help you locate and repair possible machine
malfunctions. Simply follow the three-step
procedure listed below.

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 the following
categories: output problems, function prob­lems, and welding problems.

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.

Step 3. RECOMMENDED
COURSE OF ACTION

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
one possibility at a time until you locate the
cause of your problem.

All of the referenced test procedures
referred to in the Troubleshooting Guide are
described in detail at the end of this chapter.
Refer to the Troubleshooting and Repair
Table of Contents to locate each specific
Test Procedure. All of the specified test
points, components, terminal 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.

to eliminate

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CAUTION

If for any reason you do not understand the test procedures or are unable to perform the
tests/repairs safely, contact the Lincoln Electric Service Department for technical troubleshooting
assistance before you proceed. Call 1-888-935-3877.

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

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INVERTEC® V205-T AC/DC™

F-3 F-3

TROUBLESHOOTING AND REPAIR

PC BOARD TROUBLESHOOTING PROCEDURES

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 electricall y hot par ts.

CAUTION

Sometimes machine failures appear to be due to PC
board failures. These problems can sometimes be
traced to poor electrical connections. To avoid prob­lems when troubleshooting and replacing PC boards,
please use the following procedure:

1. Determine to the best of your technical ability
that the PC board is the most likely component
causing the failure symptom.

2. Check for loose connections at the PC board
to a ss ur e th a t the PC b oa rd is p ro pe rl y
connected.

3. If the problem persists, replace the suspect PC
board using standard practices to avoid static
electrical damage and electrical shock. Read
the warning inside the static resistant bag and
perform the following procedures:

PC board can be damaged by static electricity.

- Rem o ve y o ur b o dy ’s s t at ic
charge before opening the static­shielding bag. Wear an anti-static
wris t strap. For sa f e t y, use a 1
Meg ohm resistive cord connected

ATTENTION
Static-Sensitive
Devices
Handle only at
Static-Safe
Workstations

to a g ro un de d p ar t of th e
equipment frame.

- If you don’t have a wrist strap,
touch an un-painted, grounded,
part of the equipment frame. Keep
touc h in g t h e fram e to pr ev en t
stat i c bui l d- up . Be su r e not to
touch any electrically live parts at
the same time.

- 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-shield­ing bag.

- If the PC board uses protective shorting jumpers,
don’t remove them until installation is complete.

- If you return a PC board to The Lincoln Electric
Company for credit, it must be in the static-shielding
bag. This will prevent further damage and allow prop­er failure analysis.

4. Test the machine to determ ine if the failure

symp t om has b een c o rrect e d by t he
replacement PC board.

NOTE: It is desirable to have a spare (known good)
PC board available for PC board troubleshooting.

NOTE: Allow the machine to heat up so that all
electrica l components can reach their operating
temperature.

5. Rem o ve t he r ep lacem e nt P C boar d a nd

subs t it ute it wi t h the ori g in al PC boa r d to
recreate the original problem.

a. If the original problem does not reappear by

substituting the original board, then the PC
board was not the problem. Continue to look
fo r bad connect ions in the control wiring
harness, junction blocks, and terminal strips.

b. If the original problem is recreated by the

substitution of the original board, then the PC
boar d wa s the pr ob le m. Rei n st all the
replacement PC board and test the machine.

6. Alw a ys in d ic at e th a t thi s pro c edure wa s

foll o we d whe n warra n ty re p or ts are to b e
submitted.

NOTE: Following this procedure and writing on the
warranty report, “INSTALLED AND SWITCHED PC
BOARDS TO VERIFY PROBLEM,” will help avoid
denial of legitimate PC board warranty claims.

Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC

- Tools which come in contact with the PC board must
be either conductive, anti-static or static-dissipative.

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INVERTEC® V205-T AC/DC™

F-4 F-4

Observe Safety Guidelines detailed in the beginning of this manual.

TROUBLESHOOTING AND REPAIR

PROBLEMS

(SYMPTOMS)

Major physical or electrical damage is evident when the sheet metal cover(s) are removed.

The machine is dead—no fan –no output—no LEDs.

The main input fuses or breakers repeatedly fail.

POSSIBLE AREAS OF

MISADJUSTMENT(S)

OUTPUT PROBLEMS

1. Contact your local authorized
Lincoln Electric Field Service
Facility for assistance.

1. Make sure the input power switch

is in the ON position.

2. Check the main input fuses. If

open replace.

3. Make sure the correct input volt-

age is applied to the machine.

1. Make certain the fuses or break-

ers are properly sized for the
input draw of the machine.

2. The welding procedure may be

drawing too much input current or
the duty cycle may be too high.
Reduce the welding current
and/or reduce the duty cycle.

RECOMMENDED

COURSE OF ACTION

1. Contact the Lincoln Electric
Service Department 1-800-833-

9353.

1. Check the input power switch for

proper operation. Also check the
associated leads for loose or
faulty connections. See Wiring
Diagram.

2. Perform the Input Filter Board

Test.

1. 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.

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CAUTION

If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely,
contact the Lincoln Electric Service Department for technical troubleshooting assistance before you proceed.
Call 1-888-935-3877.

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INVERTEC® V205-T AC/DC™

F-5 F-5

Observe Safety Guidelines detailed in the beginning of this manual.

TROUBLESHOOTING AND REPAIR

PROBLEMS

(SYMPTOMS)

No or low output. Error code “E11” is flashing on the digital display.

No or low output. Error code “E12” is flashing on the digital display.

POSSIBLE AREAS OF

MISADJUSTMENT(S)

FUNCTION PROBLEMS

1. “E11” is an indication that the
input voltage being applied is too
high. Check for the correct input
voltage. 230VAC or 115VAC.

1. “E12” is an indication that the
input voltage being applied is too
low. Check for the correct input
voltage. 230VAC or 115VAC.

RECOMMENDED

COURSE OF ACTION

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.

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.

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No output. Error code “E10” is flashing on the digital display. The thermal indicator light is on.

1. The welding application may be
exceeding the recommended
duty cycle.

2. Dirt and dust may have clogged
the cooling channels inside the
machine. Refer to the
Maintenance Section in this
manual.

3. The air intake and exhaust lou­vers may be blocked due in inad­equate clearance around the
machine.

4. Make sure the cooling fan is
operating correctly.

1. One of the thermal devices may
be faulty. Check and replace if
necessary. See the Wiring
Diagram.

2. The Main IGBT Inverter Board
may be faulty.

CAUTION

If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely,
contact the Lincoln Electric Service Department for technical troubleshooting assistance before you proceed.
Call 1-888-935-3877.

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INVERTEC® V205-T AC/DC™

F-6 F-6

Observe Safety Guidelines detailed in the beginning of this manual.

TROUBLESHOOTING AND REPAIR

PROBLEMS

(SYMPTOMS)

Error code “E20”, “E24”, or “E25” is flashing on the digital display.

The machine functions normally except the cooling fan does not operate.

No High Frequency when the torch trigger is pulled and the machine is in the TIG mode.

POSSIBLE AREAS OF

MISADJUSTMENT(S)

FUNCTION PROBLEMS

1. Any one of these codes indicates
a memory error.

1. Check for obstructions that could

prevent the fan from turning.

1. Make sure the HF is in the active

mode. See the Set-up Menu in
this manual.

RECOMMENDED

COURSE OF ACTION

1. The Control/Display Board is
faulty. Replace.

1. Check the fan fuse F3 located on

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.

1. Check fuse F2 on the Bus Board.

2. Check for 385VDC at Test
Points 9 and 20. See the Main

IGBT Inverter Board Test.

Error code “E14” is flashing of the digital display

1. This is an indication that the out­put inductance is too high.

3. Perform the Control/Display

Board Test.

4. The HF board may be faulty.
Replace.

1. Check for excessive welding
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.

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CAUTION

If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely,
contact the Lincoln Electric Service Department for technical troubleshooting assistance before you proceed.
Call 1-888-935-3877.

Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC

INVERTEC® V205-T AC/DC™

F-7 F-7

Observe Safety Guidelines detailed in the beginning of this manual.

TROUBLESHOOTING AND REPAIR

PROBLEMS

(SYMPTOMS)

No current regulation in the Stick mode. Low open circuit voltage.

There is no response to changes to
the output control settings. No cur­rent regulation in all modes.

POSSIBLE AREAS OF

MISADJUSTMENT(S)

FUNCTION PROBLEMS

1. Make sure the machine is set-up
and configured correctly for the
Stick mode,

1. Make sure the correct input volt­age is applied to the machine.
230 or 115VAC.

RECOMMENDED

COURSE OF ACTION

1. The Superimposition Board may
be faulty

2. The Output Module Transistor
Board may be faulty. See the

Secondary Output Board
Assembly Test and Wiring

Diagram.

1. The Control/Display board may
be faulty.

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CAUTION

If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely,
contact the Lincoln Electric Service Department for technical troubleshooting assistance before you proceed.
Call 1-888-935-3877.

Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC

INVERTEC® V205-T AC/DC™

F-8 F-8

Observe Safety Guidelines detailed in the beginning of this manual.

TROUBLESHOOTING AND REPAIR

PROBLEMS

(SYMPTOMS)

The machine does not have weld­ing 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

The machine does not have welding output in either the Stick or TIG modes. Zero volts open circuit. The Output LED on the control panel is blinking.

POSSIBLE AREAS OF

MISADJUSTMENT(S)

WELDING PROBLEMS

1. Make sure the machine is prop­erly set-up and configured for
Stick mode.

1. Make sure the correct input volt­age is applied to the machine.
230 or 115VAC.

RECOMMENDED

COURSE OF ACTION

1. Check for output voltage feed­back from the Output Filter
Board. See the Output Filter

Board Test.

2. Check for output voltage feed­back through the Bus Board.
See the Bus Board Test.

3. The Control/Display Board may
be faulty.

1. The output rectifier may be
faulty. Check and replace if nec­essary. See the Secondary

Output Board Assembly Test

and Wiring Diagram.

2. The Output Clamp Board may be
faulty.

3. The Output Module Transistor
Board may be faulty. See the

Secondary Output Board
Assembly Test and Wiring

Diagram.

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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
the Stick and DC TIG modes. AC
TIG mode does not function prop­erly.

1. Make sure the machine is set-up
and configured correctly for the
AC TIG mode.

1. The Output Module Transistor
Board may be faulty. See the

Secondary Output Board
Assembly 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 tests/repairs safely,
contact the Lincoln Electric Service Department for technical troubleshooting assistance before you proceed.
Call 1-888-935-3877.

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INVERTEC® V205-T AC/DC™

F-9 F-9

®

PARAMETER

SELECT / HOLD

PULSE ON

UPSLOPE

% ON TIME

DOWNSLOPE

FINISH

CURRENT

BACKGROUND

CURRENT

POSTFLOW

WELD

CURRENT

sec

sec

sec

MODE

STICK

DC TI G

AC TIG

WARNING

TRIGGER

4-STEP

2-STEP

LOCAL

REMOTE

OUTPUT

A

PULSE FREQUENCY

Hz

V

AC FREQUENCY Hz

AC BALANCE % EN

Power Supply

Alarm

Display

Output Current Control

Output

Set-up Parameter
Select Button

TROUBLESHOOTING AND REPAIR

EXTERNAL DIAGNOSTICS

Figure F.1 External Diagnostics

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 indi­cated 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.

*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.

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Indic.

E10

E11

E12

E13

E14

Type of Error

Internal Heatsink Overtemp.

Power Supply Overvoltage

Power Supply Undervoltage

Front Panel Memory Error

Front Panel Secondary

Memory Error

Power supply rated

Under/Overvoltage alarm thresholds

voltage

115 VAC

230 VAC

Action

Remove upper cover, check internal temperature, check thermal device status

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)

Remove upper cover, check front panel power supplies. Perform front panel reset*

Remove upper cover, check front panel power supplies. Perform front panel reset*

Undervoltage

92 VAC

184 VAC

INVERTEC® V205-T AC/DC™

(N.C.). See machine layout.

test and replace if necessary.

test and replace if necessary.

Overvoltage

138 VAC
276 VAC

F-10 F-10

L11
Under
Small
PCB

L14

L13
Under
Small
PCB

L12

L10

L9

L8

L4

L1

L5

L2

L3

L6

L7

TROUBLESHOOTING AND REPAIR

INTERNAL DIAGNOSTICS

FIGURE F.2

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INVERTEC® V205-T AC/DC™

F-11 F-11

TROUBLESHOOTING AND REPAIR

INTERNAL DIAGNOSTICS (Continued)

LED

L1

L2

L3

L4

L5

L6

L7

L8

L9

L10

L11

L12

L13

L14

Definition

-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

-15VDC supply by 15.14.316 for 15.14.316 UPFR
part

+15VDC supply by 15.14.316 for 15.14.316 UPFR
part

Output power enabled (See “pot signal” & LED
“Output”)

Thermal Alarm

UPFR on

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)

Normal Status Conditions

ON [Green]

ON [Green]

ON [Green]

ON [Green]

ON [Green]

ON [Green]

ON [Green]

STICK: ON [Green]
TIG: ON (torch trigger pulled)

OFF = OK
ON = ALARM [Red]

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)

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INVERTEC® V205-T AC/DC™

F-12 F-12

NOTES

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INVERTEC® V205-T AC/DC™

F-13 F-13

TROUBLESHOOTING AND REPAIR

INPUT FILTER CAPACITOR DISCHARGE PROCEDURE

WARNING

Service and repair should be performed only by Lincoln Electric factory trained personnel.
Unauthorized repairs performed on this equipment may result in danger to the technician
or machine operator and will invalidate your factory warranty. For your safety and to avoid
electrical shock, please observe all safety notes and precautions detailed throughout this
manual.

If for any reason you do not understand the test procedures or are unable to perform the
test/repairs safely, contact the Lincoln Electric Service Department for electrical trou­bleshooting assistance before you proceed. Call 1-888-935-3877.

TEST DESCRIPTION

This procedure will drain off any charge stored in the four Capacitors that are part of the
Main IGBT Inverter Board Assembly. This procedure MUST be performed, as a safety
precaution, before conducting any test or repair procedure that requires you to touch 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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INVERTEC® V205-T AC/DC™

Capacitor Solder
Pads

Resistor

F-14 F-14

TROUBLESHOOTING AND REPAIR

INPUT FILTER CAPACITOR DISCHARGE PROCEDURE (continued)

FIGURE F.3 – LOCATION OF INPUT FILTER CAPACITOR TERMINALS ON MAIN IGBT INVERTER BOARD

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WARNING

ELECTRIC SHOCK can kill.

• Have an electrician install and ser-

• Do not touch electrically hot parts.

• Prior to performing preventative maintenance,
perform the following capacitor discharge proce­dure to avoid electric shock.

vice this equipment.

• Turn the input power off at the fuse
box before working on equipment.

DISCHARGE PROCEDURE

1. Remove the input power to the machine.

2. Using the phillips head screwdriver remove the
screws securing the case wraparound cover.

3. Be careful not to make contact with the capac­itor solder pads located at the top of the IGBT
power board.

INVERTEC® V205-T AC/DC™

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.

5. Locate the eight capacitor solder pads shown
in Figure F.3.

6. Using electrically insulated gloves and pliers,
hold the body of the resistor with the pliers and
connect the resistor leads across the two
capacitor solder pads. Hold the resistor in
place for 10 seconds. DO NOT TOUCH
CAPACITOR SOLDER PADS WITH YOUR
BARE HANDS.

7. Repeat the discharge procedure for the other
three capacitors.

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 discharge procedure.

F-15 F-15

TROUBLESHOOTING AND REPAIR

INPUT FILTER BOARD TEST

WARNING

Service and repair should be performed only by Lincoln Electric factory trained personnel.
Unauthorized repairs performed on this equipment may result in danger to the technician
or machine operator and will invalidate your factory warranty. For your safety and to avoid
electrical shock, please observe all safety notes and precautions detailed throughout this
manual.

If for any reason you do not understand the test procedures or are unable to perform the
test/repairs safely, contact the Lincoln Electric Service Department for electrical trou­bleshooting assistance before you proceed. Call 1-888-935-3877.

TEST DESCRIPTION

This test will help determine if the Input Filter Board is functioning properly.

MATERIALS NEEDED

Analog Volt/Ohmmeter

Phillips Head Screwdriver

Wiring Diagram

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INVERTEC® V205-T AC/DC™

INPUT FILTER BOARD

F-16 F-16

TROUBLESHOOTING AND REPAIR

INPUT FILTER BOARD TEST (continued)

FIGURE F.4 – INPUT FILTER BOARD LOCATION

PROCEDURE

1. Remove input power to the V205-T.

2. Using a phillips head screwdriver, remove the
case wraparound.

3. Perform the Input Filter Capacitor Discharge
Procedure detailed earlier in this section.

4. Locate the Input Filter board. See Figure F.4.

5. See Note 1 and Note 2..

6. See Figure F.5 for voltage checks.

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INVERTEC® V205-T AC/DC™

INPUT FILTER BOARD

-

Checks

the

correct

voltagesasindicatedonthe

above

drawing

CN 1/1-2 CN 1/3-4

VAC 2.3V (1.2V)

“PE”

EARTH CONNECTION

POWER SUPPLY “OUT” 230V (115V)

230V (115V)

POWER SUPPLY “IN” 230V (115V)

RV1 RV2

PZ1 PZ2

F-17 F-17

TROUBLESHOOTING AND 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 terminals 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 protects the
other parts of the machine from energy­limited 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 over­voltage 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.

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NOTE 2: The radio noise suppression circuit has

two purposes: to keep the machine’s
radio frequency emissions within limits
specified by standards and to ensure the
machine’s immunity against the same
type of problems caused any electronic
devices connected to the same power
supply source. The filter consists of a
network of capacitors, some of which are
grounded, and a toroidal inductor.

INVERTEC® V205-T AC/DC™

F-18 F-18

NOTES

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INVERTEC® V205-T AC/DC™

F-19 F-19

TROUBLESHOOTING AND REPAIR

MAIN IGBT INVERTER BOARD LOW VOLTAGE TEST

WARNING

Service and repair should be performed only by Lincoln Electric factory trained personnel.
Unauthorized repairs performed on this equipment may result in danger to the technician
or machine operator and will invalidate your factory warranty. For your safety and to avoid
electrical shock, please observe all safety notes and precautions detailed throughout this
manual.

If for any reason you do not understand the test procedures or are unable to perform the
test/repairs safely, contact the Lincoln Electric Service Department for electrical trou­bleshooting assistance before you proceed. Call 1-888-935-3877.

TEST DESCRIPTION

This test will help determine if all of the auxiliary voltages on the Main IGBT Inverter
Board are correct.

MATERIALS NEEDED

Voltmeter

Phillips Head Screwdriver

Wiring Diagram

Voltmeter

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INVERTEC® V205-T AC/DC™

BACK SIDE

MAIN BOARD

F-20 F-20

TROUBLESHOOTING AND REPAIR

MAIN IGBT INVERTER BOARD LOW VOLTAGE TEST (continued)

FIGURE F.6 – MAIN IGBT INVERTER BOARD LOCATION

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PROCEDURE

1. Remove input power to the V205-T machine.

2. Using a phillips head screwdriver, remove the
case wraparound cover.

3. Perform the Capacitor Discharge Procedure
detailed earlier in this section.

INVERTEC® V205-T AC/DC™

4. Locate the Main IGBT Inverter board. See
Figure F.6.

5. Use the voltmeter to perform the tests detailed
in Table F.1. See the Wiring Diagram.

F-21 F-21

TROUBLESHOOTING AND REPAIR

MAIN IGBT INVERTER BOARD LOW VOLTAGE TEST (continued)

Table F.1 Test Points

Machine Mode

ON

ON

ON

ON

ON

ON

ON

ON

Test Point

TP13-TP14

TP11-TP14

TP12-TP14

TP3-TP5

TP4-TP5

TP17-TP18

TP21-TP18

TP2[+],TP18[-]

LED Value

L2

L3

L1

L4

L5

L6

L7

---

+15 VDC

+5 VDC

+15 VDC

+24 VDC

+48 VDC

+15 VDC

+15 VDC

+14.5 VDC

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INVERTEC® V205-T AC/DC™

TP2

TP5TP4TP3L4MF2 L1L5

L3

L2

TP14

TP13

TP12

TP11

L6

TP17

TP18

TP21

L10

L7

F-22 F-22

TROUBLESHOOTING AND REPAIR

MAIN IGBT INVERTER BOARD LOW VOLTAGE TEST (continued)

FIGURE F.7 – MAIN IGBT INVERTER BOARD LOCATION

This is an illustration of the upper right corner of the P.C. board

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INVERTEC® V205-T AC/DC™

F-23 F-23

TROUBLESHOOTING AND REPAIR

CONTROL/DISPLAY BOARD TEST

WARNING

Service and repair should be performed only by Lincoln Electric factory trained personnel.
Unauthorized repairs performed on this equipment may result in danger to the technician
or machine operator and will invalidate your factory warranty. For your safety and to avoid
electrical shock, please observe all safety notes and precautions detailed throughout this
manual.

If for any reason you do not understand the test procedures or are unable to perform the
test/repairs safely, contact the Lincoln Electric Service Department for electrical trou­bleshooting assistance before you proceed. Call 1-888-935-3877.

TEST DESCRIPTION

This test will help determine if the Front Panel Boards work properly.

MATERIALS NEEDED

Volt-Ohmmeter

Phillips Head Screwdriver

Wiring Diagram

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INVERTEC® V205-T AC/DC™

Control/Display Board

F-24 F-24

TROUBLESHOOTING AND REPAIR

CONTROL/DISPLAY BOARD TEST (continued)

FIGURE F.8 – CONTROL/DISPLAY BOARD LOCATION

PROCEDURE

1. Remove input power to the V205-T machine.

2. Using a phillips head screwdriver, remove the
case wraparound cover.

3. Perform the Capacitor Discharge Procedure
detailed earlier in this section.

4. Locate the control/display board and associat-

ed plugs . Do not remove plugs from the
board. See Figure F.8.

5. Carefully apply the correct input voltage to the
V205-T and check for the correct secondary
voltages per Tables F.2, F3 & F.4.

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INVERTEC® V205-T AC/DC™

CN1

CN7

CN2

F-25 F-25

TROUBLESHOOTING AND REPAIR

CONTROL/DISPLAY BOARD TEST (continued)

FIGURE F.9 – CONTROL/DISPLAY BOARD LOCATION

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INVERTEC® V205-T AC/DC™

CN2

41

1

2

3

4

42

45

CN1

44

1

2

3

4

7

8

65

48

52

53

54

CN7

2

3

5

6

73

76

1

4

72

71

58

F-26 F-26

TROUBLESHOOTING AND REPAIR

CONTROL/DISPLAY BOARD TEST (continued)

Table F.2 Plug CN1 Test Points

Wire #

52

53

54

44

48

58

Wire #

41

42

45

Wire #

71

72

Description

Solenoid Valve Ground

Trigger

Trigger

Start High Frequency

High Frequency Ground

Start Solenoid Valve

Table F.3 Plug CN2 Test Points

Description

Supply

Supply

Ground for Supplies

Table F.4 Plug CN7 Test Points

Description

Ext

Ext

Expected Voltage

-------

-------

-------

-------

-------

48 VDC

Expected Voltage

24 VDC

48 VDC

-------

Expected Voltage

5 VDC

-------

73

74

75

76

Ext Ground

Ext Trigger

Ext Ground

Ext Ground

FIGURE F.10 – PLUGS CN1, CN2 & CN7

-------

-------

-------

-------

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INVERTEC® V205-T AC/DC™

F-27 F-27

TROUBLESHOOTING AND REPAIR

BUS BOARD TEST

WARNING

Service and repair should be performed only by Lincoln Electric factory trained personnel.
Unauthorized repairs performed on this equipment may result in danger to the technician
or machine operator and will invalidate your factory warranty. For your safety and to avoid
electrical shock, please observe all safety notes and precautions detailed throughout this
manual.

If for any reason you do not understand the test procedures or are unable to perform the
test/repairs safely, contact the Lincoln Electric Service Department for electrical trou­bleshooting assistance before you proceed. Call 1-888-935-3877.

TEST DESCRIPTION

This test will help determine if the BUS Board is functioning properly.

MATERIALS NEEDED

Volt/Ohmmeter
Phillips Head Screwdriver
Wiring Diagram

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INVERTEC® V205-T AC/DC™

BUS BOARD

F-28 F-28

TROUBLESHOOTING AND REPAIR

BUS BOARD TEST (continued)

FIGURE F.11 – BUS BOARD LOCATION

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PROCEDURE

1. Remove input power to the V205-T machine.

2. Using a phillips head screwdriver, remove the
case wraparound cover.

3. Perform the Capacitor Discharge Procedure
detailed earlier in this section.

INVERTEC® V205-T AC/DC™

4. Locate the Bus board and associated plugs.

Do not remove plugs from the board. See
Figure F.11.

5. Carefully apply the correct input voltage to the
V205-T and check for the correct voltages per

Tables F.5, F.6, F.7, F.8 & F.9

6. Machine should be set to “STICK” mode.

F-29 F-29

TROUBLESHOOTING AND REPAIR

BUS BOARD TEST (continued)

TABLE F.5 PLUG CN2 TEST POINTS

Wire #

21

22

23

24

26

27

28

29

30

32

Wire #

61

65

63

Description

Thermal Trigger

Output Hall Probe

Hall Probe

Ground Gate Switch B

Ground Gate Switch A

Thermal Trigger (AC Unit)

Ground Hall Probe

Hall Probe

Gate Switch B

Gate Switch A

TABLE F.6 PLUG CN3 TEST POINTS

Description

- Superimposition

Ground Superimposition

+ Superimposition

Expected Voltage

-------

-------

+15 VDC

-------

-------

-------

-------

-15 VDC

-------

-------

Expected Voltage

53.2 VDC

(1)

-------

53.2 VDC

(1)

64[-], 66[+]

(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

42

Front Panel Supply Ground

44

45

48

TABLE F.8 PLUG CN7 TEST POINTS

Wire #

11

Earth Cable

12

Earth Cable

TABLE F.9 PLUG CN1 TEST POINTS

Welding Voltage

Description

Front Panel Supply

HF Start

Front Panel Supply

HF Start Ground

Description

Water Cooling Supply

Water Cooling Supply

Water Cooling Supply

-------

52.6 VDC

Expected Voltage

24 VDC

-------

-------

48 VDC

-------

Expected Voltage

-------

-------

-------

-------

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Wire #

5[+], 6[-]

Description

Fan

INVERTEC® V205-T AC/DC™

Expected Voltage

24 VDC

F1

F2

F3

CN7

CN3

CN4

CN2

CN1

CN4

45

1

2

3

4

7

8

65

48

41

42

44

CN2

27

1

2

3

4

9

10

87

28

22

23

24

5

6

11

12

26

21

29

30

32

CN3

2

3

5

6

1

4

65

61

63

64

66

F-30 F-30

TROUBLESHOOTING AND REPAIR

BUS BOARD TEST (continued)

FIGURE F.12 – BUS BOARD PLUG LOCATIONS

FIGURE F.13 – PLUGS CN2, CN3, CN4

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INVERTEC® V205-T AC/DC™

F-31 F-31

TROUBLESHOOTING AND REPAIR

MAIN INVERTER BOARD POWER FACTOR SECTION TEST

WARNING

Service and repair should be performed only by Lincoln Electric factory trained personnel.
Unauthorized repairs performed on this equipment may result in danger to the technician
or machine operator and will invalidate your factory warranty. For your safety and to avoid
electrical shock, please observe all safety notes and precautions detailed throughout this
manual.

If for any reason you do not understand the test procedures or are unable to perform the
test/repairs safely, contact the Lincoln Electric Service Department for electrical trou­bleshooting assistance before you proceed. Call 1-888-935-3877.

TEST DESCRIPTION

This procedure will help determine if the Power Factor section on the Main Board is func­tioning properly.

MATERIALS NEEDED

Volt/Ohmmeter
Phillips Head Screwdriver
Wiring Diagram

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INVERTEC® V205-T AC/DC™

BACK SIDE

MAIN BOARD

F-32 F-32

TROUBLESHOOTING AND REPAIR

MAIN INVERTER BOARD POWER FACTOR SECTION TEST (continued)

FIGURE F.14 – LOCATION ON MAIN BOARD

PROCEDURE

1. Remove input power to the V205-T machine.

2. Using a phillips head screwdriver, remove the
case wraparound cover.

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

MF8

MF8

MF9

MF9

-------

TP20-TP9

TABLE F.11 – RESISTANCE CHECKS

4. Locate the power factor section on the main

board and associated plugs. Do not remove
plugs from the board. See Figure F.15.

5. Carefully apply the correct input voltage to the
V205-T and check for the correct secondary
voltages per tables F.10 & F11. Voltage read­ings were taken with a Fluke RMS meter. See
Figure F.15 for joint locations.

Ref. Point

A[-],K[+]

S[-],D[+]

S[-],G[+]

S[-],D[+]

S[-],G[+]

L10 (LED)

-------

Value

250-260 VDC

125 VDC

2.2 VDC

120 VDC

2.2 VDC

ON

385 VDC +/-5V

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Generator/Mode

OFF

OFF

Component

F1

R82

INVERTEC® V205-T AC/DC™

Ref. Point

-------

-------

Value

<1 OHM

46 OHM

TP9 GNDPWR

R82

F1

TP20

MF8

RL1

POWER INPUT

230 VAC (1 15)

DD1

MF9

L10

G

GSS

S

SD

K

K

A

A

D

F-33 F-33

TROUBLESHOOTING AND REPAIR

MAIN INVERTER BOARD POWER FACTOR SECTION TEST (continued)

FIGURE F.15 – POWER FACTOR AREA ON MAIN BOARD

NOTE: Power Factor Section is located at the upper left section of main board

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INVERTEC® V205-T AC/DC™

F-34 F-34

NOTES

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INVERTEC® V205-T AC/DC™

F-35 F-35

TROUBLESHOOTING AND REPAIR

OUTPUT FILTER BOARD TEST

WARNING

Service and repair should be performed only by Lincoln Electric factory trained personnel.
Unauthorized repairs performed on this equipment may result in danger to the technician
or machine operator and will invalidate your factory warranty. For your safety and to avoid
electrical shock, please observe all safety notes and precautions detailed throughout this
manual.

If for any reason you do not understand the test procedures or are unable to perform the
test/repairs safely, contact the Lincoln Electric Service Department for electrical trou­bleshooting assistance before you proceed. Call 1-888-935-3877.

TEST DESCRIPTION

This test will help determine if output voltages and external trigger signals are being
processed through the Output Board.

MATERIALS NEEDED

Volt/Ohmmeter
Phillips Head Screwdriver
External DC Ammeter

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INVERTEC® V205-T AC/DC™

Output Filter Board

F-36 F-36

TROUBLESHOOTING AND REPAIR

OUTPUT FILTER BOARD TEST (continued)

FIGURE F.16 – OUTPUT FILTER BOARD LOCATION

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PROCEDURE

1. Remove input power to the V205-T machine.

2. Using a phillips head screwdriver, remove the
case wraparound cover.

3. Perform the Capacitor Discharge Procedure
detailed earlier in this section.

INVERTEC® V205-T AC/DC™

4. Locate the Output Filter board and associated

plugs . Do not remove plugs from the board.
See Figure F.16.

5. Carefully apply the correct input voltage to the
V205-T and check for the correct secondary
voltages per Table F.12.

-

+

CN1

CN1

2

3

5

6

1

4

66

53

65

54

64

F-37 F-37

TROUBLESHOOTING AND REPAIR

OUTPUT FILTER BOARD TEST (continued)

FIGURE F.17 – OUTPUT FILTER BOARD PLUG LOCATION

Wire #

53

54

64[-],66[+]

65

FIGURE F.18 – OUTPUT FILTER BOARD PLUG CN1

TABLE F.12 – PLUG CN1 TEST POINTS

Description

Trigger

Trigger

Output Voltage

Superimposition Common

Expected Voltage

-------

-------

52.6 VDC

-------

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INVERTEC® V205-T AC/DC™

F-38 F-38

NOTES

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INVERTEC® V205-T AC/DC™

F-39 F-39

TROUBLESHOOTING AND REPAIR

SECONDARY OUTPUT BOARD ASSEMBLY TEST

WARNING

Service and repair should be performed only by Lincoln Electric factory trained personnel.
Unauthorized repairs performed on this equipment may result in danger to the technician
or machine operator and will invalidate your factory warranty. For your safety and to avoid
electrical shock, please observe all safety notes and precautions detailed throughout this
manual.

If for any reason you do not understand the test procedures or are unable to perform the
test/repairs safely, contact the Lincoln Electric Service Department for electrical trou­bleshooting assistance before you proceed. Call 1-888-935-3877.

TEST DESCRIPTION

This test will help determine if the Secondary Output Board Assembly has shorted or dam­aged components.

MATERIALS NEEDED

Volt/Ohmmeter
Phillips Head Screwdriver
Wiring Diagram

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INVERTEC® V205-T AC/DC™

OUTPUT TRANSISTOR

OUTPUT DIODES

F-40 F-40

TROUBLESHOOTING AND REPAIR

SECONDARY OUTPUT BOARD ASSEMBLY TEST (continued)

FIGURE F.19 – SECONDARY POWER BOARD LOCATION

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PROCEDURE

1. Remove input power to the V205-T machine.

2. Using a phillips head screwdriver, remove the
case wraparound cover.

3. Perform the Capacitor Discharge Procedure
detailed earlier in this section.

INVERTEC® V205-T AC/DC™

4. Locate the Secondary Power board and associ-

ated plugs. Do not remove plugs from the
board. See Figure F.19.

5. Perform the output diode resistance check per

Table F.13.

6. Carefully apply the correct input voltage to the
V205-T and check for the correct secondary
voltages per Table F.13.

GA SA SB GB

I I I I

10K Ohms

10K Ohms

1

2

3

A

B

F-41 F-41

TROUBLESHOOTING AND REPAIR

SECONDARY OUTPUT BOARD ASSEMBLY TEST (continued)

FIGURE F.20 – SECONDARY POWER BOARD TEST POINT LOCATIONS

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TABLE F.13 – VOLTAGE CHECKS WITH 115 VAC APPLIED TO MACHINE

Generator/Mode

ON/STICK

ON/STICK

ON/STICK

ON/STICK

ON/STICK

OCV @ Outpt Terminals

OFF/-

OFF/-

Test Point

GA[+],SA[-]

GB[+],SB[-]

3[+],1[-]

1[+]2[-]

R GA-SA

R GB-SB

Value

-13 VDC

+13 VDC

+ 0.5 VDC

+ 105 VDC

+ 52 VDC

10 K Ohms

10 K Ohms

INVERTEC® V205-T AC/DC™

MODE POSITIVE METER

PROBE

NEGATIVE METER

PROBE

EXPECTED READING

MACHINE OFF TEST POINT A TEST POINT 3 LOW - LESS THAN 200 OHMS

MACHINE OFF TEST POINT 3 TEST POINT A HIGH - MORE THAN 1000 OHMS

MACHINE OFF TEST POINT B TEST POINT 3 LOW - LESS THAN 200 OHMS

MACHINE OFF TEST POINT 3 TEST POINT B HIGH - MORE THAN 1000 OHMS

MACHINE OFF TEST POINT 2 TEST POINT A LOW - LESS THAN 200 OHMS

MACHINE OFF TEST POINT A TEST POINT 2 HIGH - MORE THAN 1000 OHMS

MACHINE OFF TEST POINT 2 TEST POINT B LOW - LESS THAN 200 OHMS

MACHINE OFF TEST POINT B TEST POINT 2 HIGH - MORE THAN 1000 OHMS

F-42 F-42

TROUBLESHOOTING AND REPAIR

SECONDARY OUTPUT BOARD ASSEMBLY TEST (continued)

TABLE F.14 – OUTPUT DIODE RESISTANCE CHECK

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INVERTEC® V205-T AC/DC™

F-43 F-43

TROUBLESHOOTING AND REPAIR

MAIN INVERTER BOARD

“WELDING LOGIC AND INVERTER” SECTION TEST

WARNING

Service and repair should be performed only by Lincoln Electric factory trained personnel.
Unauthorized repairs performed on this equipment may result in danger to the technician
or machine operator and will invalidate your factory warranty. For your safety and to avoid
electrical shock, please observe all safety notes and precautions detailed throughout this
manual.

If for any reason you do not understand the test procedures or are unable to perform the
test/repairs safely, contact the Lincoln Electric Service Department for electrical trou­bleshooting assistance before you proceed. Call 1-888-935-3877.

TEST DESCRIPTION

This test will help determine if all functions of the Welding Logic Circuit and Inverter are
functioning properly

MATERIALS NEEDED

Volt/Ohmmeter
Phillips Head Screwdriver
Wiring Diagram

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INVERTEC® V205-T AC/DC™

BACK SIDE

MAIN BOARD

F-44 F-44

TROUBLESHOOTING AND REPAIR

MAIN INVERTER BOARD

“WELDING LOGIC AND INVERTER” SECTION TEST (continued)

FIGURE F.21 – MAIN BOARD LOCATION

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PROCEDURE

1. Remove input power to the V205-T machine.

2. Using a phillips head screwdriver, remove the
case wraparound cover.

3. Perform the Capacitor Discharge Procedure
detailed earlier in this section.

INVERTEC® V205-T AC/DC™

4. Locate the Welding Logic and Inverter section
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.

5. Carefully apply the correct input voltage to the
V205-T and check for the correct secondary
voltages per Tables F.15, F.16, F.17 & F18.

F-45 F-45

TROUBLESHOOTING AND REPAIR

MAIN INVERTER BOARD

“WELDING LOGIC AND INVERTER” SECTION TEST (continued)

TABLE F.15 – LED FUNCTION

Machine/Mode

ON/STICK

ON

ON

Machine/Mode

ON/STICK TP16-TP14 4.3 VDC

Component

TP31-TP9

ON/TIG

L8

L9

TABLE F.16 – FEEDBACK VOLTAGE SIGNALS

Component

TP15-TP14

Value

-------

-------

2.56 VDC

-2 VDC @ 100A

Condition

ON AND FLASHING

-------

Value

-4 VDC @ 200A

OPEN CIRCUIT

VOLTAGE

CONDITION

ON/TIG TP19-TP14 2 VDC @ 100A

4 VDC @ 200A

OFF

Condition

WELDING ON:

CURRENT

FEEDBACK

WELDING ON:

VOLTAGE

FEEDBACK

WELDING ON:

CURRENT

REFERENCE

Note

POT SIGNAL

THERMAL

ALWAYS

TABLE F.17 – VOLTAGE CHECKS WITH 115 VAC APPLIED TO MACHINE

Generator/Mode

ON/STICK

ON/STICK

ON/STICK

ON/STICK

Generator/Mode

ON/STICK

ON/STICK

ON/STICK

ON/STICK

Component

MF11

MF12

MF15

MF16

TABLE F.18 – LED (CHECK IN STICK MODE)

Component

L11

L12

L13

L14

G[+],S[-]

3.75 VDC

3.75 VDC

3.75 VDC

3.75 VDC

Value

ON AND FLASHING

ON AND FLASHING

ON AND FLASHING

ON AND FLASHING

D[+],S[-]

178 VDC

260 VDC

260 VDC

34 VDC

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INVERTEC® V205-T AC/DC™

TP15

TP14

TP16

TP19

TP31

CN4/1-2
Short Circuit

0.3 Ohms

L9

L8

CN5/1-2
Short Circuit

0.3 Ohms

F-46 F-46

“WELDING LOGIC AND INVERTER” SECTION TEST (continued)

TROUBLESHOOTING AND REPAIR

MAIN INVERTER BOARD

FIGURE F.22 – MAIN BOARD (INVERTER SECTION)

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INVERTEC® V205-T AC/DC™

L11

L14

TP9 GROUND
POWER

MF11 MF15

MF16

MF12

L13

L12

D

SS

G

SS

SS

SS

G

G

G

D

D

D

F-47 F-47

TROUBLESHOOTING AND REPAIR

MAIN INVERTER BOARD

“WELDING LOGIC AND INVERTER” SECTION TEST (continued)

FIGURE F.23 – MAIN BOARD (LOWER LEFT)

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INVERTEC® V205-T AC/DC™

F-48 F-48

NOTES

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INVERTEC® V205-T AC/DC™

F-49 F-49

TROUBLESHOOTING AND REPAIR

INPUT FILTER BOARD REMOVAL AND REPLACEMENT

WARNING

Service and repair should be performed only by Lincoln Electric factory trained personnel.
Unauthorized repairs performed on this equipment may result in danger to the technician
or machine operator and will invalidate your factory warranty. For your safety and to avoid
electrical shock, please observe all safety notes and precautions detailed throughout this
manual.

If for any reason you do not understand the test procedures or are unable to perform the
test/repairs safely, contact the Lincoln Electric Service Department for electrical trou­bleshooting assistance before you proceed. Call 1-888-935-3877.

TEST DESCRIPTION

The following procedure will aid the technician in removing the Input Filter Board for
replacement.

MATERIALS NEEDED

7mm Nutdriver
Phillips Head Screwdriver

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INVERTEC® V205-T AC/DC™

INPUT FILTER BOARD

S/L1

R/L1

F-50 F-50

TROUBLESHOOTING AND REPAIR

INPUT FILTER BOARD REMOVAL AND REPLACEMENT (continued)

FIGURE F.24 – INPUT FILTER BOARD LOCATION

PROCEDURE

1. Remove input power to the V205-T.

2. Using a phillips head screwdriver remove the
case wraparound cover.

3. Perform the Input Filter Capacitor Discharge
Procedure detailed earlier in this section.

FIGURE F.25 – INPUT FILTER BOARD LEADS

4. Locate the input filter board. See Figure F.24.

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.

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

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INVERTEC® V205-T AC/DC™

RV1

RV2

F-51 F-51

TROUBLESHOOTING AND REPAIR

INPUT FILTER BOARD REMOVAL AND REPLACEMENT (continued)

FIGURE F.26 – MAIN IGBT BOARD LEAD REMOVAL

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CAUTION

Observe static precautions detailed in PC Board
Troubleshooting Procedures at the beginning of

this section.

7. Clean RTV off of the top of the input filter board
mounting slides.

8. Release the board by simply pressing the two
metal buttons at the ends of the board with your
thumbs. Depressing these buttons will free the
plastic lock pins that prevent the P.C. board
from sliding upward.

9. Remove and replace the input filter board.

INVERTEC® V205-T AC/DC™

10. Slide the new input filter board into its proper
position on the mounting slides.

11. Push on backside of mounting pins to ensure
that the P.C. board is secured in its proper posi­tion.

12. Reconnect all previously removed leads to
their proper locations. See Wiring Diagram if
necessary.

13. Replace case wraparound assembly.

F-52 F-52

NOTES

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INVERTEC® V205-T AC/DC™

F-53 F-53

TROUBLESHOOTING AND REPAIR

MAIN IGBT BOARD REMOVAL AND REPLACEMENT

WARNING

Service and repair should be performed only by Lincoln Electric factory trained personnel.
Unauthorized repairs performed on this equipment may result in danger to the technician
or machine operator and will invalidate your factory warranty. For your safety and to avoid
electrical shock, please observe all safety notes and precautions detailed throughout this
manual.

If for any reason you do not understand the test procedures or are unable to perform the
test/repairs safely, contact the Lincoln Electric Service Department for electrical trou­bleshooting assistance before you proceed. Call 1-888-935-3877.

TEST DESCRIPTION

The following procedure will aid the technician in removing the Main IGBT Board for
replacement.

MATERIALS NEEDED

7mm Nutdriver
Phillips Head Screwdriver
Wiring Diagram

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INVERTEC® V205-T AC/DC™

BACK SIDE

MAIN BOARD

F-54 F-54

TROUBLESHOOTING AND REPAIR

MAIN IGBT BOARD REMOVAL AND REPLACEMENT (continued)

FIGURE F.27 – MAIN IGBT BOARD LOCATION

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PROCEDURE

1. Remove input power to the V205-T.

2. Using a phillips head screwdriver remove the
case wraparound cover.

3. Perform the Input Filter Capacitor Discharge
Procedure detailed earlier in this section.

4. Locate the main IGBT board. See Figure F.27.

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.

INVERTEC® V205-T AC/DC™

6. Using a 7mm nut driver, label and disconnect
leads RV1, RV2, RV3, RV4, RV5, RV6 & RV7.
See Figure F.28.

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.

8. Carefully maneuver the main board out of the

machine. Replace.

9. Maneuver new board into its proper location

and secure to machine using the thirty-two
phillips head screws previously removed.

RV1

RV2

RV4

RV3

CN1

CN2

CN3

CN4

CN5

RV6

RV7

RV5

F-55 F-55

TROUBLESHOOTING AND REPAIR

MAIN IGBT BOARD REMOVAL AND REPLACEMENT (continued)

FIGURE F.28 – MAIN BOARD PLUG AND MOUNTING SCREW LOCATION

10. Reconnect previously removed leads RV1 thru
RV7 to the P.C. board. See Wiring Diagram if
necessary.

11. Reconnect previously removed plugs CN1 thru

CN5 to the P.C. board.

NOTE: All ribbon cable connections have an

“indexing location slot” to assure proper
replacement.

12. Replace the case wraparound cover previous­ly removed.

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INVERTEC® V205-T AC/DC™

F-56 F-56

NOTES

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INVERTEC® V205-T AC/DC™

F-57 F-57

TROUBLESHOOTING AND REPAIR

CONTROL/DISPLAY BOARD REMOVAL AND REPLACEMENT

WARNING

Service and repair should be performed only by Lincoln Electric factory trained personnel.
Unauthorized repairs performed on this equipment may result in danger to the technician
or machine operator and will invalidate your factory warranty. For your safety and to avoid
electrical shock, please observe all safety notes and precautions detailed throughout this
manual.

If for any reason you do not understand the test procedures or are unable to perform the
test/repairs safely, contact the Lincoln Electric Service Department for electrical trou­bleshooting assistance before you proceed. Call 1-888-935-3877.

TEST DESCRIPTION

The following procedure will aid the technician in removing the Control/Display Board for
replacement.

MATERIALS NEEDED

Phillips Head Screwdriver
Wiring Diagram

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INVERTEC® V205-T AC/DC™

Control/Display Board

F-58 F-58

TROUBLESHOOTING AND REPAIR

CONTROL/DISPLAY BOARD REMOVAL AND REPLACEMENT (continued)

FIGURE F.29 – CONTROL/DISPLAY BOARD LOCATION

PROCEDURE

1. Remove the input power to the V205-T.

2. Using a phillips head screwdriver remove the
four screws from the corners of the name­plate/keypad on the front of the machine. See

Figure F.30.

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.

3. Tilt display plate forward and carefully label and
disconnect leads CN1, CN2, CN3 & CN7. See

Figure F.31.

CAUTION

4. Disconnect the ground lead running from the

P.C. board to the machine frame. See Figure

F.31.

5. Carefully remove the board assembly.
NOTE: The board assembly is attached to the

nameplate/keypad and is to be replaced as
one unit.

6. Replace the board assembly.

7. Connect previously removed ground lead.

8. Connect previously removed leads CN1, CN2,
CN3, & CN7.

9. Replace the four phillips head screws previous­ly removed from the corners of the name­plate/keypad.

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INVERTEC® V205-T AC/DC™

®

PARAMETER

SELECT / HOLD

PULSE ON

UPSLOPE

% ON TIME

DOWNSLOPE

FINISH

CURRENT

BACKGROUND

CURRENT

POSTFLOW

WELD

CURRENT

sec

sec

sec

MODE

STICK

DC T IG

AC TIG

WARNIN G

TRIGGER

4-STEP

2-STEP

LOCAL

REMOTE

OUTPUT

A

PULSE FREQUENCY

Hz

V

AC FREQUENCY Hz

AC BALANCE % EN

4 Phillips Head Screws

CN1

CN2

CN7

CN3

Ground
Wire

5 Mounting
Nuts

F-59 F-59

TROUBLESHOOTING AND REPAIR

CONTROL/DISPLAY BOARD REMOVAL AND REPLACEMENT (continued)

FIGURE F.30 – METAL DISPLAY PLATE

FIGURE F.31 – PLUG AND MOUNTING NUT LOCATION

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INVERTEC® V205-T AC/DC™

F-60 F-60

NOTES

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INVERTEC® V205-T AC/DC™