Lincoln Electric V205-T service manual Welding Problems

Page 44

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F-8

TROUBLESHOOTING & REPAIR

 

 

 

F-8

 

 

 

 

 

Observe Safety Guidelines

 

TROUBLESHOOTING GUIDE

detailed in the beginning of this manual.

 

 

 

 

 

 

 

 

 

 

 

WELDING PROBLEMS

POSSIBLE AREAS OF

RECOMMENDED

 

 

 

(SYMPTOMS)

MISADJUSTMENT(S)

COURSE OF ACTION

 

 

 

 

 

 

 

 

 

 

 

WELDING PROBLEMS

 

 

 

 

 

The machine does not have weld-

1. Make sure the machine is prop-

1. Check for output voltage feed-

ing output in the Stick mode. Zero

erly set-up and configured for

back from the Output Filter

volts open circuit voltage. The

Stick mode.

Board.

See the Output Filter

Output LED on the control panel is

 

Board Test.

 

 

 

blinking.

The machine operates

 

2. Check for output voltage feed-

correctly in the TIG mode

 

 

back through the Bus Board.

 

 

 

 

 

 

See the Bus Board Test.

 

 

 

 

3. The Control/Display Board may

 

 

 

be faulty.

 

 

 

 

 

 

 

 

 

The machine does not have weld-

1. Make sure the correct input volt-

1. The output rectifier

may

be

ing output in either the Stick or TIG

age is applied to the machine.

faulty. Check and replace if nec-

modes.

Zero volts open circuit.

230 or 115VAC.

essary.

See the

Secondary

The Output LED on the control

 

Power Board Test and Wiring

panel is blinking.

 

Diagram.

 

 

 

 

 

 

2. The Output Clamp Board may be

 

 

 

faulty.

 

 

 

 

 

 

 

3. The Output Module Transistor

 

 

 

Board may be faulty. See the

 

 

 

Secondary Power Board Test

 

 

 

and Wiring Diagram.

 

 

 

 

 

4. Perform the Main IGBT Inverter

 

 

 

Board

Welding

Logic

and

 

 

 

Inverter Test.

 

 

 

 

 

 

5. The Superimposition Board may

 

 

 

be faulty.

 

 

 

 

 

 

6. The Hall Effect device may be

 

 

 

faulty.

 

 

 

 

 

 

 

7. The Control/Display Board may

 

 

 

be faulty.

 

 

 

 

 

 

 

The machine operates properly in

1. Make sure the machine is set-up

1. The Output Module

Transistor

the Stick and DC TIG modes. AC

and configured correctly for the

Board may be faulty.

See the

TIG mode does not function prop-

AC TIG mode.

Secondary Power Board Test

erly.

 

 

and Wiring Diagram.

 

 

 

 

 

 

2. The Superimposition Board may

 

 

 

be faulty.

 

 

 

 

 

 

 

 

 

 

 

 

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 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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