Lincoln Electric V205-T CONTROL/DISPLAY Board High Frequency HF Board, Output Filter Board

Page 35

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E-5

E-5

THEORY OF OPERATION

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

Fan

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Superimposition

 

 

 

 

 

 

 

 

 

 

 

 

board

 

 

 

 

 

 

 

 

 

 

 

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

 

 

 

 

 

 

 

 

 

48 VDC

 

 

 

 

 

Remote

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

75, 76, 77

 

 

 

 

 

 

 

 

A, B, C

Gas

Solenoid

CONTROL/DISPLAY BOARD

HIGH FREQUENCY (HF) BOARD

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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 sup- plies signals for the Display Board to show set and actual current values, error codes and pre-set values. It also accepts signals via the Output Filter Board (Pins D and E- 24VDC) to initiate welding output. Upon clo- sure of D and E a 24VDC relay is activated to indicate that welding output is required. The Control Board CPU sends a command to the Main IGBT Inverter Board to activate the welding IGBTs. The remote con- trol signals (Pins A, B&C) are also fed into the Control/Display Board from the 6 pin connector locat- ed on the front of the machine. Based upon current and voltage feedback information the Control Board regulates the welding output to coincide with the pre- set welding commands. The Control/Display Board also activates and controls the High Frequency Board, the gas solenoid and the Super Imposition Board.

The HF Board generates a set of pulses of about 900V, which are amplified through the high voltage trans- former to about 8 to 10KV. These pulses that are repeated at a frequency of about 80HZ are applied to the high frequency transformer that is located in the negative welding output leg of the machine. This high frequency pulse is transferred to the TIG torch via the high frequency transformer. This allows the remote starting of the TIG arc without the need for the tung- sten electrode to touch the work. This high frequency pulse is removed when the welding arc is established. The command signals are received from the micro- processor on the Control Board and last for about 1 second maximum. The HF Board receives it’s power from the + 385 VDC derived from the electrolytic capacitors on the Main IGBT Inverter Board.

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.

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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 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 InputWork Cable Connection Output Connection for StickOutput and GAS Connection for TIG Welding Figure A.1 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 Routine Maintenance Safety PrecautionsInput Filter Capacitor Discharge Procedure Table of Contents Theory of Operation Section Input Board and BUS Board Theory of Operation General Description 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
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