Lincoln Electric V205-T Theory of Operation, General Description, Input Board and BUS Board

Page 32

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E-2

E-2

THEORY OF OPERATION

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

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

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GENERAL DESCRIPTION

The Invertec V205T AC/DC is an inverter based indus- trial welding power source that utilizes single-phase input power to produce constant current AC or DC output for both Stick (SMAW) and TIG (GTAW). With 230VAC input applied the V205T is rated at 200 amps, 18volts at a 40% duty cycle. With 115VAC applied the machine is rated at 150 amps, 16 volts at a 40% duty cycle. The machine has the capabilities to produce several varieties of AC waveforms (square, sinusoidal and triangular). The unit also employs an auto recon- nect feature that does not require manual intervention when the input power is changed from 115VAC to 230VAC or 230VAC to 115VAC. When in the TIG mode the operator may select to use either the high frequen- cy or touch start function.

INPUT BOARD AND BUS BOARD

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

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

The Bus Board performs several functions within the V205T. It accepts and distributes power and informa- tion to other circuitry. This interfacing is accomplished through harness and ribbon connectors and also via other PC boards that are plugged directly into the Bus Board. The Input Board, the High Frequency Board and the AC Super-Imposition Board plug into the Bus Board. Circuitry located on the Main IGBT Inverter Board, the Control Board, the Output Module Board, the Output Filter Board and the Hall Effect Device interface with the Bus Board. Some circuits are also incorporated within the Bus Board. They are the fan circuit (24VDC) and an input voltage sensing circuit that is utilized by the auto reconnect circuitry located on the Main Inverter Board.

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

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NOTE: Unshaded areas of Block Logic Diagram are the subject of discussion.

V205-T AC/DC

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Contents Invertec V205-T AC/DC Safety Electric Shock can kill Cylinder may explode if damaged Précautions DE Sûreté Sûreté Pour Soudage a L’ArcMaster Table of Contents for ALL Sections Table of Contents Installation Section Installation Operating Temperature Range Storage Temperature RangeSelect Suitable Location StackingTilting Environmental AreaReconnect Procedure Input ConnectionsAttachment Plug Installation 230V Input115V Input Engine Driven GeneratorWork Cable Connection Output Connection for StickOutput and GAS Connection for TIG Welding Figure A.1 Remote Control Connection Shielding GAS ConnectionV205-T AC/DC Table of Contents Operation Section Safety Instructions General DescriptionWelding Capability LimitationsRear Control Panel Figure B.1 Figure B.1Controls and Settings Figure B.2Step Diagram Local/Remote push button Selects the weldingTIG DC TIG AC SET UP Menu Indicator Parameter DefaultOutput Limitations Welding PolarityFigure B.5 Steel TIG Welding Copper TIG WeldingTips for AC TIG Welding Filler MaterialAC TIG Welding Quick Start UP Protective GASDC TIG Welding Quick Start UP Table of Contents AccessoriesOptional Accessories Compatible EquipmentCable Plugs TIG Torch KitsTable of Contents Maintenance Routine Maintenance Safety PrecautionsInput Filter Capacitor Discharge Procedure Table of Contents Theory of Operation Section Input Board and BUS Board Theory of OperationGeneral Description Main Igbt Inverter Board Figure E.3 Main Igbt Inverter BoardMain Transformer Output Module Transistor BoardOutput Module and Clamping Board Superimposition BoardCONTROL/DISPLAY Board High Frequency HF Board Output Filter BoardInsulated Gate Bipolar Transistor Igbt Operation Figure E.6 IgbtTable of Contents Troubleshooting & Repair Section Troubleshooting & Repair HOW to USE Troubleshooting GuidePC Board Troubleshooting Procedures Electric Shock can killOutput Problems Function Problems Function Problems Secondary Power Board Test Welding Problems Troubleshooting & Repair External Diagnostics Figure F.1 External DiagnosticsTroubleshooting & Repair Internal Diagnostics Figure F.2Internal Diagnostics LEDV205-T AC/DC Input Filter Capacitor Discharge Procedure DescriptionInput Filter Capacitor Discharge Procedure 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 LED Table F.1 Test PointsTP2 MF2 Figure F.7 Main Igbt Inverter Board LocationCONTROL/DISPLAY Board Test Control/Display Board CN2 CN7 CN1 Figure F.9 CONTROL/DISPLAY Board LocationCN1 Table F.2 Plug CN1 Test PointsTable F.3 Plug CN2 Test Points Table F.4 Plug CN7 Test PointsBUS Board Test BUS Board Table F.5 Plug CN2 Test Points Table F.6 Plug CN3 Test PointsTable F.7 Plug CN4 Test Points Table F.8 Plug CN7 Test PointsCN2 CN4Main Inverter Board Upfr Section Test Figure F.14 Upfr Location on Main Board Table F.10 Voltage Checks with 115 VAC Applied to MachineTP9 Gndpwr RL1 DD1 MF9V205-T AC/DC Troubleshooting and Repair Output Filter Board TestOutput Filter Board Figure F.17 Output Filter Board Plug Location Figure F.18 Output Filter Board Plug CN1V205-T AC/DC Secondary Power Board Test Secondary Power Board Figure F.20 Secondary Power Board Test Point Locations Table F.13 Voltage Checks with 115 VAC Applied to MachineV205-T AC/DC Main Inverter Board Welding Logic and Inverter Section Test Main Inverter Board Figure F.21 Main Board LocationTable F.15 Feedback Voltage Signals Table F.17 LED Check in Stick ModeTable F.14 LED Functions Table F.16 Voltage Checks with 115 VAC Applied to MachineTP14 TP15 TP16 TP19 TP31 CN4/1-2 Short Circuit Ohms CN5/1-2 Figure F.23 Main Board Lower Left TP9 Ground Power MF15 VDS MF12 MF16 VDSV205-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 CN7 CN3V205-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 Output Diodes Figure F.35 Output Diode LocationOutput Transistor Removal and Replacement Output Transistor Removal and Replacement Plug CN1 5mm V205-T AC/DC Electrical Diagrams Table of Contents Electrical Diagrams SectionWiring Diagram V205-T AC/DC Standard Diagram SVM Error Reporting Form
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