Invertec 200 260 400t
Invertec 200 260 400t
Invertec 200 260 400t
INSTRUCTION MANUAL:
V200T SINGLEPHASE
V260T THREEPHASE
V400T THREEPHASE
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INDEX
INSTRUCTION NOTES. 7
WARNING!
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INSTRUCTIONS FOR ELECTROMAGNETIC COMPATIBILITY
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 the welding circuit. In other cases it could involve constructing 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. Changing the earthing arrangements should
only be authorized by a person who is competent to assess whether the changes 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) critical safety 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;
h) the time of the day that welding or other activities are to be carried out.
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.
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INTRODUCTION
The welding machine you have purchased has been designed, manufactured and tested to comply with the latest
European Community regulations.
The working frequency (30 kHz) eliminates the characteristic noise of older electronic power modules.
Variations of mains supplies within the working limits set forth in this manual will not cause any variation in the welding
current.
As well as using tested quality components, LINCOLN ELECTRIC bench tests every power module, simulating
particularly heavy working conditions. In this way it is possible to spot any potentially defective component.
LINCOLN ELECTRIC has compiled this manual with the intention to furnish the instructions for operation of the arc
welding machines V200-T 2V, V260-T, V400-T.
The arc welding machine, if used correctly, can be operated in very safe conditions but if the prescribed safety norms are
not observed it could cause serious damage to people and objects.
PREVENTION OF BURNS
The electric arc is a source of intense visible light and heat emissions as well as very damaging invisible ultra red and
ultraviolet radiation.
To avoid any possible damage, the operator must use adequate protective garments such as:
1) insulating gloves,
2) leather apron,
3) gaiters,
4) protective shoes,
5) welding mask provided with safety lenses of adequate DIN grade selected, capable of filtering the radiation and
reducing the bright light intensity.
The safety lenses must always be kept clean and must be quickly replaced in case of damage.
Since incandescent spray products generated during the cutting or welding operations may be deposited on the safety
lenses thus reducing the visual field, the use of a protective transparent lens in front of the safety lens is strongly
recommended.
Never look at the electric arc without adequate protections for the eyes.
Protect the working area in order that other working people in the vicinity are not affected by the radiation from the
electric arc.
Pay attention in handling the pieces being worked on, use adequate tools to avoid burns that can be caused by the
overheating of the piece during the operations of welding and/or cutting.
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PREVENTION OF TOXIC FUMES
These precautions must be adopted in order to prevent exposure of the operator or other people to the toxic fumes
generated during the welding process.
Avoid to perform welding operations on painted or oily or greasy surfaces.
Some chlorinated solvents can break down during welding and generate harmful gases such as phosgene gas.
It is therefore important to make sure that such solvents are not present on the parts being worked on and if they are
present it is necessary to remove them before the operating the welding machine.
It is furthermore necessary to make sure that such solvents or other degrading agents are not in the immediate proximity
of the working area.
Metal parts coated with or containing lead, graphite, cadmium, zinc, mercury beryllium and chrome could cause harmful
concentrations of toxic fumes and must not be subjected to welding operations unless:
1) the coating is removed before starting to weld,
2) the working area is adequately ventilated.
3) the operator uses an adequate fume filtering system.
Don't work in a space without adequate ventilation.
PREVENTING FIRE.
During the welding process metal gets overheated and sparks and slag may fly around. Adequate precautions must be
taken in order to prevent fires and/or explosions.
Avoid operating in areas where there are containers of flammable substances.
All fuels and/or combustible products must be kept away from the working area.
Fireproof devices must be in the immediate proximity..
Particular precautions must be taken when welding on barrels that have contained inflammable substances or inside
metallic containers or places with poor ventilation.
These operations must always be performed in the presence of qualified personnel that could lend necessary assistance if
required.
DO NOT ever operate in an environment whose atmosphere is filled with flammable gases, vapors or combustible
liquids (such as. gasoline or its vapors).
Pressure regulators
All pressure regulators used in the equipment must be in good working conditions.
These devices, if not kept in optimal conditions, could cause damages to the welding machine or to the operator. In case
of damage replace the device immediately.
NEVER use regulators intended for a gas different from the one used with the welding machine.
NEVER use regulators that are visibly damaged.
Do not lubricate the regulators with oil or grease.
Gas cylinders
Cylinders containing compressed gas are to be used according to the relevant regulations.
Never use a cylinder that is broken or visibly damaged..
Do not use cylinders that are not firmly fixed.
Do not move or transport a cylinder without the prescribed protection.
Do not use the gas if the cylinders for applications differ from that originally intended.
Do not lubricate the valves of the cylinders with oil or grease.
Do not allow electric contact between the cylinders and the welding machine.
NEVER expose the cylinders to excessive heat, sparks, slag or flames ever.
NEVER try to repair a defective cylinder but send it back to the gas supplier.
Pipelines
The pipelines used for the various gases have the following colour codes:
Blue = Oxygen
Black = Inert gas and Air
NEVER use green pipes for gases other than oxygen.
REPLACE any pipe that is damaged by cuts or that shows scorch marks.
Do not allow any creases or folds that could reduce the pressure on the delivery of the line.
Examine periodically the pipelines looking for possible leaks, wearing or defective connections.
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PROTECTION FROM NOISE
On the subject of noise the prescriptions of the directive n86/ 188/ C.E.E. are to be applied.
In normal conditions the electronic apparatuses used in electric arc welding do not cause noise levels above 80 db.
In connection with the working procedure being used (TIG welding in continuous or pulsed conditions) and with the
relative conditions of use (values of the welding parameters or distance between piece to be welded and torch, closed or
open environment) could be verified noise levels higher than this limit.
It is therefore necessary for the operator to apply the precautions prescribed by the relevant regulations..
SAFETY DEVICES
The power supplies are equipped with appropriate safety devices to prevent damage to the welding machine and the
operator.
Never tamper with the safety devices by short circuiting or opening the connecting terminals. Never try to use the power
supply without the protection circuits and/or devices installed and in perfect working conditions as this could be
extremely risky for the operator and any person nearby.
All electric connections must be shielded by the appropriate insulating material.
WARNING: The safety devices must be checked periodically and whenever found defective must be replaced
immediately.
DANGER SIGNALS
Inside or outside the power supply are danger warning signs against possible risks.
This are described as follows:
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INSTRUCTION NOTES
This part of the manual is important for a correct use of the of the arc welding power supply; it does not contain
particular instructions for maintenance as these power supply do not require any maintenance.
The unique precautions to be taken are those typical for any electric welding machine with metallic frame and cover.
It is recommended to avoid hitting, banging and in any way exposing the welding machine to dropping, sources of
excessive heat, or other such situations.
In case of transportation and/ or storage the welding machine should not be exposed to a temperature outside the range
of: -25 to + 55 °C
If extraordinary maintenance is required, and only if the necessary technical expertise and tools are available, it is
possible to follow the instructions provided by the relevant technical service manual, otherwise it is recommended to
approach the nearest technical service centre or directly the manufacturer.
Maintenance or repairs performed by technical service centres not authorized by LINCOLN ELECTRIC will
immediately render null and void manufacturer warranty.
START-UP PROCEDURE
CAREFULLY READ THE INSTRUCTION MANUAL BEFORE ATTEMPTING TO CONNECT THE POWER
UNIT TO THE LINE AND TO USE IT.
By following these instructions you will avoid damage due to incorrect installation.
The damage caused by incorrect use of the power unit is not covered by manufacturer warranty.
This arc welding machine is a power unit designed for professional applications and must only be used by trained
personnel.
The power unit can perform in environments where conditions are particularly harsh and with outside temperature
between - 20 and +40 °C with a humidity level:
max 50% up to +40° C
max 90% up to +20° C
1. Do not place the unit close to walls or in positions where the flow of air through the cooling air slots is obstructed or
limited in any way do not cover the power supply with rags, sheets of paper, plastic covers, etc.
2. Make sure that the room temperature is lower than 40° C and that the working area is not subject to any damaging
pollution, such as:
a) damp air with dust mixed with acids or salts.
b) air with high concentrations of iron or metallic dust.
3. Verify that the value of the main line voltage conforms to the value indicated for the power supply
4. Verify that the value of the available main line power is adequate for the requirements of the power unit. If in doubt,
consult the table under the heading TECHNICAL DATA.
5. The protection class for the machine is IP 23, which means that the cover of the power unit protects it from external
bodies having a diameter larger than 12 mm and from water spray up to 60 degrees from the vertical. Therefore do
not:
• dip the power unit in liquid of any kind.
• place it on muddy and damp surfaces.
• Insert foreign bodies in or around the cooling air slots.
6. Don't use the power unit without its cover; this could prove to be harmful for the welding machine and for the
operator.
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• M5: To adjust the time of post-gas flow during the T.I.G. process.
• M6-M7-M8 : To adjust the parameters of the pulsed T.I.G. process (with S2 in position "PULSER"), PERIOD,
DUTY CYCLE, AMPLITUDE; with S2 in position "TIG SPOT," M6 regulates the time interval for spot welding
while the other two controls, M6-M7, are disabled.
• CN1: Connector for the remote control.
PIN Function Description Value Note
1 INPUT Weld. Current Reg. 0..5Vdc (0..10Vdc) active connecting pin5 to GND
2 OUTPUT Supply 12Vdc @20mA
3 GND Ground 0V
4 INPUT Start welding active connecting to GND active connecting pin5 to GND
5 INPUT Remote active connecting to GND
3
4
1 5
pin 1: torch switch.
pin 2: torch switch.
pin 3,4,5 : n.c.
PROTECTION
The power unit has a range of internal protection that always assures correct operation:
• Protection for the maximum value of the mains voltage,
• Protections against overheating,
• Internal fuse.
Maximum value of main supply voltage.
The power unit is protected against irregularities of voltage that could be caused by anomalies in the mains supply; in
this case the power unit will turn into “blocked conditions” and this situation will be indicated by LED2, on the front
panel.
It will remain in this state until the mains supply voltage goes back within the pre-set values after which the unlocking
will be automatic.
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Overheating protection.
If the temperature climbs above the pre-set value or if the duty cycle goes beyond the expected limits, appropriate heat
sensors, placed inside the power unit, would stop the operation with consequent lighting of LED 2 indicator; as soon as
the conditions return to those expected, the power unit will resume functioning.
Internal fuse
The power unit is provided with an internal fuse for the protection of some circuits.
Before replacing a broken fuse please seek LINCOLN ELECTRIC.
WARNING: If the power unit connected to the mains supply and in “ON” position is not used for a period of time
longer than 5 minutes, it will turn itself into "STANDBY" conditions and it will be turned “ON”, automatically, when
the electrode touches the work piece. In the TIG process, the restoration will occur upon pressing of the torch switch.
This feature reduces the power consumption of the welding equipment with low frequency of use.
OPERATING INSTRUCTIONS
Start-up
Rotate the mains supply switch on the back of the power unit to the position "I" or on the value of the mains supply
voltage selected, depending upon the power unit being used; the LED indicator "POWER" (LED 1) placed on the front
panel will turn on.
One second after the switching on of the power unit a “click” from the starter relay will be heard, after which the unit
will be ready to operate.
Regulation and reading of the welding current
The regulation of the welding current is effected with the knob M1 having a range of 0-200 Amp for V200-T, of 260
Amp for V260-T or 0-400 Amp for V400-T. The set welding current is directly legible on the scale on the front panel.
Hot start
A system of "HOT START" has been built within the welding current control in order to have, when striking the arc,
an higher current to help the ignition of the arc.
OPERATING INSTRUCTIONS
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During this phase, the welding current falls from the nominal value to the value of CRATER-CURRENT (M2). The
speed at which the welding current decreases is determined by the setting of the knob "DOWN-SLOPE" (M4).
The power supply comes equipped with RESTART. The pre-setting without RESTART must be performed by
specialized personnel or by authorized service centers.
In the TIG-SPOT mode (S2) the UP/ DOWN-SLOPE controls and the possible function "PULSER." are disabled.
The welding cycle takes an "ON-OFF" type shape with the welding current jumping very rapidly from 0 to the nominal
value.
“PULSER” function.
It can be selected with S2 and enables the superimposition to the welding current of an impulsive current with
frequency, duty-cycle and varying amplitude adjusted by means of the respective knobs M6 M7 M8.
Remote control.
The remote is connected through the CN1 plug on the front panel. It is used for the control of the welding current from
a remote position through a foot operated or other external regulator. The setting of the power supply in remote control
mode happens automatically upon insertion of the remote control connector.
The insertion of the connector modifies the following functions:
- current control is moved from the front panel knob to the remote control knob
- the torch switch becomes inactive and it is replaced by the foot pedal
- the up-slope and down-slope functions control is transferred from the front panel to the foot pedal
- the 4 stroke mode is eliminated.
BLOCK DIAGRAM
Before describing the block diagram, we would like to introduce some general concepts upon which the construction of
our generator is based. The equipment “heart”, the most technically advanced part is the inverter, is built using top
quality electronic components, in order to obtain high reliability during heavy-duty operation.
The inverter is a particular oscillating circuit which, fed by a DC source, supplies an AC voltage at the desired
frequency. Advantages can be obtained by increasing the frequency, e.g.:
• It is possible to use smaller and lighter transformers and obtain the same transferred power.
• It is possible to have instantaneous output variation (welding current). This allows the current to be adjusted
continuously, thereby adapting it to the requirements of the process.
• The application of such frequencies eliminates well-known and troublesome noises that are generally met when using
electro-mechanical equipment.
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b) Dynamic current trimming.
f) The control panel (6)allows the “TC” equipment users to choose the type of welding process:
a) Stick electrode
b) TIG
The “TC” equipment is provided with an HF board to ignite the arc in TIG mode. This board ensures the arc striking
and avoids direct contact between electrode and the piece to be welded up to a distance of about 5 mm. This board
works automatically.
TECHNICAL DATA:
Welding:
V200-T 2V V260-T V400-T
Max. no-load Voltage 80 V 80 V 80 V
Welding current regulation 1/200 A 1/260 A 0/400 A
Current with Duty-Cycle 35% 200 A 250 A 400 A
Current with Duty-Cycle 60% 180 A 200 A 320 A
Current with Duty-Cycle 100% 150 A 150 A 250 A
Dimensions (d x l x h) 44 x 19 x 25.5 cm 44 x 19 x 25.5 cm. 55.5 x 23.5 x 33 cm
Weight 14/16Kg 14/16Kg 24/28 Kg
Protection class IP23 IP23 IP23
DUTY CYCLE:
Iout
400
350
300
250 V 2 0 0 -T
200 V 2 6 0 -T
150 V 4 0 0 -T
100
50
0
10% 35% 60% 100%
The graph shows the welding current (in Amps.) on the Y axis and the percentage of working time calculated on a total
time of ten minutes on X axis.
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BUTTON TORCH FUNCTIONS
TORCH TORCH
BUTTON BUTTON
GAS GAS
0,5 S AFTER-FLOW 0,5 S 0,5 S AFTER-FLOW
CURRENT CURRENT
UP-SLOPE DOWN-SLOPE UP-SLOPE STARTER CURRENT
STARTER CURRENT DOWN-SLOPE
TORCH
BUTTON
GAS
CURRENT
CRATER CURRENT
TORCH
BUTTON
GAS
0,5 S
CURRENT
CRATER CURRENT
t=> 1 sec
TORCH
BUTTON
GAS
CURRENT
CRATER CURRENT
Fig. 1
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WELDING
CURRENT
DISPLAY
M1
LED2
LED3
LED1
M3
M4
M2 M5
M6
CN1
M8
S1
M7
S2
NEGATIVE
OUTPUT
(TIG TORCH) POSITIVE
OUTPUT
(GROUND)
SWITCH
TORCH
CONNECTOR GAS
OUTPUT
photo 1
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