Lincoln Electric V205-T service manual Function Problems

Page 41

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F-5

F-5

 

TROUBLESHOOTING & REPAIR

 

TROUBLESHOOTING GUIDE

Observe Safety Guidelines

 

 

detailed in the beginning of this manual.

FUNCTION PROBLEMS

POSSIBLE AREAS OF

 

RECOMMENDED

(SYMPTOMS)

MISADJUSTMENT(S)

 

COURSE OF ACTION

 

 

 

 

 

 

 

 

FUNCTION PROBLEMS

 

 

 

No or low output. Error code “E11”

1. “E11” is an indication that the

1. If the correct input voltage

is flashing on the digital display.

 

input voltage being applied is

 

230VAC or 115VAC is being

 

 

too high. Check for the correct

 

applied to the machine the Input

 

 

input voltage.

230VAC

or

 

Filter Board may be faulty.

 

 

115VAC.

 

 

 

 

 

Perform the Input Filter Board

 

 

 

 

 

 

 

 

Test.

 

 

 

 

 

 

 

 

2. The Main IGBT Inverter Board

 

 

 

 

 

 

 

 

May be Faulty. Perform the

 

 

 

 

 

 

 

 

Main IGBT Inverter Board Low

 

 

 

 

 

 

 

 

Voltage Supply Test.

 

 

 

 

 

No or low output. Error code

1.

“E12” is an indication that the

1.

If the correct input voltage

“E12” is flashing on the digital dis-

 

input voltage being applied is

 

230VAC or 115VAC is being

play.

 

too low. Check for the correct

 

applied to the machine, the

 

 

input voltage. 230VAC or

 

 

Input Filter Board may be

 

 

115VAC.

 

 

 

 

 

faulty. Perform the Input Filter

 

 

 

 

 

 

 

 

Board Test.

 

 

 

 

 

 

 

2. The Main IGBT Inverter Board

 

 

 

 

 

 

 

 

May be Faulty. Perform the

 

 

 

 

 

 

 

 

Main IGBT Inverter Board

 

 

 

 

 

 

 

 

Low Voltage Supply Test.

 

 

 

 

 

No output. Error code “E10” is

1.

The welding application may be

1.

One of the thermal devices may

flashing on the digital display. The

 

exceeding

the

recommended

 

be faulty.

Check and replace if

thermal indicator light is on.

 

duty cycle.

 

 

 

 

 

necessary.

See the Wiring

 

 

 

 

 

 

 

 

Diagram.

 

 

2. Dirt and dust may have clogged

 

 

 

 

 

the cooling channels inside the

2. The Main IGBT Inverter Board

 

 

machine.

Refer

to

the

 

may be faulty.

 

 

Maintenance Section

in

this

 

 

 

 

 

manual.

 

 

 

 

 

 

 

 

3. The air intake and exhaust lou-

 

 

 

 

 

vers may be blocked due in

 

 

 

 

 

inadequate

clearance

around

 

 

 

 

 

the machine.

 

 

 

 

 

 

 

4. Make sure the cooling fan is

 

 

 

 

 

operating correctly.

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

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

Image 41
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 InstallationStacking Select Suitable LocationTilting Environmental AreaInput Connections Reconnect Procedure230V Input Attachment Plug Installation115V Input Engine Driven GeneratorWork 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 General Description Safety InstructionsWelding Capability LimitationsFigure 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 Copper TIG Welding Steel TIG WeldingTips for AC TIG Welding Filler MaterialProtective GAS AC TIG Welding Quick Start UPDC TIG Welding Quick Start UP Accessories Table of ContentsCompatible Equipment Optional AccessoriesCable 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 Figure E.3 Main Igbt Inverter Board Main Igbt Inverter BoardOutput Module Transistor Board Main TransformerOutput Module and Clamping Board Superimposition 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.2 Plug CN1 Test Points CN1Table F.3 Plug CN2 Test Points Table F.4 Plug CN7 Test PointsBUS Board Test BUS Board Table F.6 Plug CN3 Test Points Table F.5 Plug CN2 Test PointsTable F.7 Plug CN4 Test Points Table F.8 Plug CN7 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.17 LED Check in Stick Mode Table F.15 Feedback Voltage SignalsTable 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 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