Lincoln Electric V205-T service manual Table of Contents Theory of Operation Section

Page 31

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Section E-1

Section E-1

TABLE OF CONTENTS

-THEORY OF OPERATION SECTION-

Theory of Operation	Section E
General Description	E-2
Input Board and Bus Board	E-2
Main IGBT Inverter Board	E-3
Main Transformer	E-4
Output Module and Clamping Board	E-4
Output Module Transistor Board	E-4
Superimposition Board	E-4
Control/Display Board	E-5
High Frequency Board	E-5
Output Filter Board	E-5
Insulated Gate Bipolar Transistor (IGBT) Operation	E-6

FIGURE E.1 – V205-T BLOCK LOGIC DIAGRAM

Fan

Superimposition

board

24 VDC

Bus board

AC DC Gate drive signals

Input

HF

board

board

Voltage Feedback

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

info.reconnect

ckt.AConturn

supplyvolthigh

feedbackvoltage

feedbackcurrent

Current Feedback

Output

IGBT

Diode

Thermostat

Output

Thermostats

Filter bd.

(bypass)

Main IGBT

& Power board

4

_

IGBT’s

Output

RF coil

Choke

+

infothermostat

metervoltinput

metercurrentinput

DC blocking

Current

ckt.AConturn

+515,-+15,

infoset

PWMonturn

capacitor board

Input

Hall

Main

Output

Choke

Output

Device

Transformer

board

Transistor

Module

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

HF control signal

888

+48, +24	Control board	Display & LED
		board

Control		(D + E)
		Remote 2/4
Knob

Remote

48 VDC75, 76, 77 A, B, C

Gas

Solenoid

V205-T AC/DC

Image 31

Contents Invertec V205-T AC/DC Safety Electric Shock can kill Cylinder may explode if damaged Sûreté Pour Soudage a L’Arc Précautions DE SûretéMaster Table of Contents for ALL Sections Table of Contents Installation Section Operating Temperature Range Storage Temperature Range InstallationEnvironmental Area Select Suitable LocationStacking TiltingInput Connections Reconnect ProcedureEngine Driven Generator Attachment Plug Installation230V Input 115V InputOutput and GAS Connection for TIG Welding Figure A.1 Output Connection for StickWork Cable Connection Shielding GAS Connection Remote Control ConnectionV205-T AC/DC Table of Contents Operation Section Limitations Safety InstructionsGeneral Description Welding CapabilityFigure B.1 Rear Control Panel Figure B.1Figure B.2 Controls and SettingsLocal/Remote push button Selects the welding Step DiagramTIG DC TIG AC Indicator Parameter Default SET UP MenuWelding Polarity Output LimitationsFigure B.5 Filler Material Steel TIG WeldingCopper TIG Welding Tips for AC TIG WeldingProtective GAS AC TIG Welding Quick Start UPDC TIG Welding Quick Start UP Accessories Table of ContentsTIG Torch Kits Optional AccessoriesCompatible Equipment Cable PlugsTable of Contents Maintenance Input Filter Capacitor Discharge Procedure Safety PrecautionsRoutine Maintenance Table of Contents Theory of Operation Section General Description Theory of OperationInput Board and BUS Board Figure E.3 Main Igbt Inverter Board Main Igbt Inverter BoardSuperimposition Board Main TransformerOutput Module Transistor Board Output Module and Clamping BoardOutput Filter Board CONTROL/DISPLAY Board High Frequency HF BoardFigure E.6 Igbt Insulated Gate Bipolar Transistor Igbt OperationTable of Contents Troubleshooting & Repair Section HOW to USE Troubleshooting Guide Troubleshooting & RepairElectric Shock can kill PC Board Troubleshooting ProceduresOutput Problems Function Problems Function Problems Secondary Power Board Test Welding Problems Figure F.1 External Diagnostics Troubleshooting & Repair External DiagnosticsFigure F.2 Troubleshooting & Repair Internal DiagnosticsLED Internal DiagnosticsV205-T AC/DC Description Input Filter Capacitor Discharge ProcedureDischarge Procedure Input Filter Capacitor Discharge ProcedureInput Filter Board Test Input Filter Board Figure F.5 Input Filter Board V205-T AC/DC Main Igbt Inverter Board LOW Voltage Test Main Board Table F.1 Test Points LEDFigure F.7 Main Igbt Inverter Board Location TP2 MF2CONTROL/DISPLAY Board Test Control/Display Board Figure F.9 CONTROL/DISPLAY Board Location CN2 CN7 CN1Table F.4 Plug CN7 Test Points CN1Table F.2 Plug CN1 Test Points Table F.3 Plug CN2 Test PointsBUS Board Test BUS Board Table F.8 Plug CN7 Test Points Table F.5 Plug CN2 Test PointsTable F.6 Plug CN3 Test Points Table F.7 Plug CN4 Test PointsCN4 CN2Main Inverter Board Upfr Section Test Table F.10 Voltage Checks with 115 VAC Applied to Machine Figure F.14 Upfr Location on Main BoardDD1 MF9 TP9 Gndpwr RL1V205-T AC/DC Output Filter Board Test Troubleshooting and RepairOutput Filter Board Figure F.18 Output Filter Board Plug CN1 Figure F.17 Output Filter Board Plug LocationV205-T AC/DC Secondary Power Board Test Secondary Power Board Table F.13 Voltage Checks with 115 VAC Applied to Machine Figure F.20 Secondary Power Board Test Point LocationsV205-T AC/DC Main Inverter Board Welding Logic and Inverter Section Test Figure F.21 Main Board Location Main Inverter BoardTable F.16 Voltage Checks with 115 VAC Applied to Machine Table F.15 Feedback Voltage SignalsTable F.17 LED Check in Stick Mode Table F.14 LED FunctionsTP14 TP15 TP16 TP19 TP31 CN4/1-2 Short Circuit Ohms CN5/1-2 MF15 VDS MF12 MF16 VDS Figure F.23 Main Board Lower Left TP9 Ground PowerV205-T AC/DC Input Filter Board Removal and Replacement Input Filter Board Removal and Replacement RV1 V205-T AC/DC Main Igbt Board Removal and Replacement Main Igbt Board Removal & Replacement CN2 CN1 V205-T AC/DC CONTROL/DISPLAY Board Removal and Replacement CONTROL/DISPLAY Board Removal & Replacement CN3 CN7V205-T AC/DC Output Filter Board Removal and Replacement Removal and Replacement Casefront Mounting Screws Phillips Head Screws CN1 CN2 Output Diodes Removal and Replacement Figure F.35 Output Diode Location Output DiodesOutput Transistor Removal and Replacement Output Transistor Removal and Replacement Plug CN1 5mm V205-T AC/DC Table of Contents Electrical Diagrams Section Electrical DiagramsWiring Diagram V205-T AC/DC Standard Diagram SVM Error Reporting Form