Lincoln Electric V205-T service manual Output Problems

Page 40

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F-4

 

 

 

F-4

 

TROUBLESHOOTING & REPAIR

 

 

 

Observe Safety Guidelines

 

 

TROUBLESHOOTING GUIDE

 

detailed in the beginning of this manual.

 

 

 

 

 

 

 

 

 

 

 

OUTPUT PROBLEMS

POSSIBLE AREAS OF

RECOMMENDED

 

 

 

(SYMPTOMS)

MISADJUSTMENT(S)

 

COURSE OF ACTION

 

 

 

 

 

 

 

 

 

OUTPUT PROBLEMS

 

 

 

 

 

 

 

Major physical or electrical damage

1. Contact your local authorized

1. Contact the Lincoln Electric

 

is evident when the sheet metal

Lincoln Electric Field

Service

Service Department 1-800-833-

 

cover(s) are removed.

Facility for assistance.

 

9353.

 

 

 

 

 

 

 

The machine is dead—no fan –no

1. Make sure the input

power

1. Check the input power switch for

 

output—no LEDs.

switch is in the ON position.

proper operation. Also check the

 

 

 

2. Check the main input fuses. If

associated leads

for loose or

 

 

 

faulty connections.

See wiring

 

 

 

open replace.

 

 

 

 

 

diagram.

 

 

 

 

 

 

 

 

 

 

3. Make sure the correct input volt-

2. Perform the Input Filter Board

 

 

 

age is applied to the machine.

 

 

 

Test.

 

 

 

 

 

 

 

 

 

 

 

 

The main input fuses or breakers

1. Make certain the fuses or break-

1. The Input Filter Board may be

 

repeatedly fail.

ers are properly sized for the

faulty. Perform the Input Filter

 

 

 

input draw of the machine.

Board Test.

 

 

 

 

2. The welding procedure may be

2. The Main IGBT Inverter Board

 

 

 

drawing too much input current

may be faulty.

Perform the

 

 

 

or the duty cycle may be too

Main IGBT Inverter Board Low

 

 

 

high. Reduce the welding cur-

Voltage Supply Test.

 

 

 

rent and/or reduce the duty

 

 

 

 

 

cycle.

 

 

 

 

 

 

 

 

 

 

 

CAUTION

If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, con- tact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call 1-800-833-9353(WELD).

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 GeneratorOutput and GAS Connection for TIG Welding Figure A.1 Output Connection for StickWork Cable Connection 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 Input Filter Capacitor Discharge Procedure Safety PrecautionsRoutine Maintenance Table of Contents Theory of Operation Section General Description Theory of OperationInput Board and BUS Board 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 Igbt Table 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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