Lincoln Electric SVM161-A service manual Safety, Invertec V205-T AC/DC

Page 2

Return to Master TOC

TOC

i

SAFETY

i

 

WARNING

CALIFORNIA PROPOSITION 65 WARNINGS

Diesel engine exhaust and some of its constituents

 

The engine exhaust from this product contains

are known to the State of California to cause can-

 

chemicals known to the State of California to cause

cer, birth defects, and other reproductive harm.

 

cancer, birth defects, or other reproductive harm.

 

 

 

The Above For Diesel Engines

 

The Above For Gasoline Engines

ARC WELDING can be hazardous. PROTECT YOURSELF AND OTHERS FROM POSSIBLE SERIOUS INJURY OR DEATH. KEEP CHILDREN AWAY. PACEMAKER WEARERS SHOULD CONSULT WITH THEIR DOCTOR BEFORE OPERATING.

Read and understand the following safety highlights. For additional safety information, it is strongly recommended that you purchase a copy of “Safety in Welding & Cutting - ANSI Standard Z49.1” from the American Welding Society, P.O. Box 351040, Miami, Florida 33135 or CSA Standard W117.2-1974. A Free copy of “Arc Welding Safety” booklet E205 is available from the Lincoln Electric Company, 22801 St. Clair Avenue, Cleveland, Ohio 44117-1199.

BE SURE THAT ALL INSTALLATION, OPERATION, MAINTENANCE AND REPAIR PROCEDURES ARE PERFORMED ONLY BY QUALIFIED INDIVIDUALS.

Return to Master

Return to Master TOC

Return to Master TOC

FOR ENGINE powered equipment.

1.a. Turn the engine off before troubleshooting and maintenance work unless the maintenance work requires it to be running.

____________________________________________________

1.b.Operate engines in open, well-ventilated areas or vent the engine exhaust fumes

outdoors.

____________________________________________________

1.c. Do not add the fuel near an open flame weld- ing arc or when the engine is running. Stop the engine and allow it to cool before refuel- ing to prevent spilled fuel from vaporizing on contact with hot engine parts and igniting. Do not spill fuel when filling tank. If fuel is spilled, wipe it up and do not start engine until fumes

have been eliminated.

____________________________________________________

1.d. Keep all equipment safety guards, covers and devices in posi- tion and in good repair.Keep hands, hair, clothing and tools away from V-belts, gears, fans and all other moving parts when starting, operating or repairing equipment.

____________________________________________________

1.e. In some cases it may be necessary to remove safety guards to perform required maintenance. Remove guards only when necessary and replace them when the maintenance requiring their removal is complete. Always use the greatest care when working near moving parts.

___________________________________________________

1.f. Do not put your hands near the engine fan. Do not attempt to override the governor or idler by pushing on the throttle control rods while the engine is running.

___________________________________________________

1.g. To prevent accidentally starting gasoline engines while turning the engine or welding generator during maintenance work, disconnect the spark plug wires, distributor cap or magneto wire as appropriate.

1.h. To avoid scalding, do not remove the radiator pressure cap when the engine is hot.

ELECTRIC AND MAGNETIC FIELDS may be dangerous

2.a. Electric current flowing through any conductor causes localized Electric and Magnetic Fields (EMF). Welding current creates EMF fields around welding cables and welding machines

2.b. EMF fields may interfere with some pacemakers, and welders having a pacemaker should consult their physician before welding.

2.c. Exposure to EMF fields in welding may have other health effects which are now not known.

2.d. All welders should use the following procedures in order to minimize exposure to EMF fields from the welding circuit:

2.d.1. Route the electrode and work cables together - Secure them with tape when possible.

2.d.2. Never coil the electrode lead around your body.

2.d.3. Do not place your body between the electrode and work cables. If the electrode cable is on your right side, the work cable should also be on your right side.

2.d.4. Connect the work cable to the workpiece as close as possible to the area being welded.

2.d.5. Do not work next to welding power source.

INVERTEC® V205-T AC/DC™

Image 2
Contents Invertec V205-T AC/DC Safety Invertec V205-T AC/DCElectric Shock can kill ARC Rays can burn Can be dangerousCylinder may explode Powered equipmentWelding Cutting Sparks can cause fire or If damaged ExplosionPrécautions DE Sûreté Sûreté Pour Soudage a L’ArcSafety Methods of Reducing Emissions Mains Supply Master Table of Contents for ALL Sections Table of Contents Installation Section Installation Operating Temperature Range Storage Temperature RangeTilting Select Suitable LocationStacking Environmental AreaReconnect Procedure Input Connections115V Input Attachment Plug Installation230V Input Engine Driven GeneratorWork Cable Connection Output ConnectionsOutput and GAS Connection for TIG Welding Figure A.1 Remote Control Connection Shielding GAS ConnectionInvertec V205-T AC/DC Table of Contents Operation Section General Description Safety InstructionsOperation Welding CapabilityOPERATIONB-3 Rear Control Panel 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.7 Tips for AC TIG Welding Steel TIG WeldingCopper TIG Welding Filler MaterialAC TIG Welding Quick Start UP Protective GASDC TIG Welding Quick Start UP Table of Contents Accessories Section Compatible Equipment AccessoriesOptional Accessories Cable PlugsTable of Contents Maintenance Section Input Filter Capacitor Discharge Procedure MaintenanceSafety Precautions Routine Maintenance3MAINTENANCE Figure D.1 Major Component LocationsInvertec V205-T AC/DC 1TABLE of CONTENTS-THEORY of Operation Section E-1 Theory of Operation Input Board and BUS BoardMain Igbt Inverter Board Figure E.3 Main Igbt Inverter BoardOutput Module and Clamping Board Main TransformerOutput Module Transistor Board Superimposition BoardOutput Filter Board CONTROL/DISPLAY BoardHigh Frequency HF Board Insulated Gate Bipolar Transistor Igbt Operation Passive Active1TABLE of Contents Troubleshooting and Repair F-1 Troubleshooting and Repair HOW to USE Troubleshooting GuidePC Board Troubleshooting Procedures Electric Shock can killIgbt Perform the Input Filter Board Igbt Inverter Board Test Secondary Output Board Assembly Test See the Output Filter Troubleshooting and Repair External Diagnostics DisplayTroubleshooting and Repair Internal Diagnostics Figure F.2Internal Diagnostics LEDInvertec V205-T AC/DC Test Description Materials NeededInput Filter Capacitor Discharge Procedure Capacitor Solder Resistor PadsInput Filter Board Test Input Filter Board ProcedureInput Filter Board Test Input Filter Board Invertec V205-T AC/DC Main Igbt Inverter Board LOW Voltage Test Main Igbt Inverter Board LOW Voltage Test Figure F.6 Main Igbt Inverter Board LocationMain Igbt Inverter Board LOW Voltage Test LEDTP2 MF2 Figure F.7 Main Igbt Inverter Board LocationCONTROL/DISPLAY Board Test CONTROL/DISPLAY Board Test Figure F.8 CONTROL/DISPLAY Board LocationCN2 Figure F.9 CONTROL/DISPLAY Board LocationCN1 Figure F.10 Plugs CN1, CN2 & CN7BUS Board Test BUS Board Test Figure F.11 BUS Board LocationTable F.7 Plug CN4 Test Points Table F.5 Plug CN2 Test PointsTable F.6 Plug CN3 Test Points Table F.8 Plug CN7 Test PointsCN1 CN2 Main Inverter Board Power Factor Section Test Table F.11 Resistance Checks Main Inverter Board Power Factor Section TestTable F.10 Voltage Checks with 115 VAC Applied to Machine TP9 Gndpwr RL1 Invertec V205-T AC/DC Output Filter Board Test Output Filter Board Test Figure F.16 Output Filter Board LocationFigure F.17 Output Filter Board Plug Location Figure F.18 Output Filter Board Plug CN1Invertec V205-T AC/DC Secondary Output Board Assembly Test Secondary Output Board Assembly Test Figure F.19 Secondary Power Board LocationOFF GA-SA Mode Positive Meter Negative Meter Expected Reading Probe Table F.14 Output Diode Resistance CheckMain Inverter Board Welding Logic and Inverter Section Test Main Inverter Board Welding Logic and Inverter Section TestTable F.15 LED Function Table F.16 Feedback Voltage SignalsTable F.18 LED Check in Stick Mode Table F.17 Voltage Checks with 115 VAC Applied to MachineFigure F.22 Main Board Inverter Section TP9 Ground Power Invertec V205-T AC/DC Input Filter Board Removal and Replacement Input Filter Board Removal and Replacement Figure F.24 Input Filter Board LocationRV1 RV2 Invertec V205-T AC/DC Main Igbt Board Removal and Replacement Main Igbt Board Removal and Replacement Figure F.27 Main Igbt Board LocationRV1 RV2 CN4 RV3 RV4 CN5 RV5 RV7 RV6 Invertec V205-T AC/DC CONTROL/DISPLAY Board Removal and Replacement CONTROL/DISPLAY Board Removal and Replacement Figure F.29 CONTROL/DISPLAY Board LocationCN2 Invertec V205-T AC/DC Output Filter Board Removal and Replacement Removal and Replacement Figure F.32 Output Filter Board LocationPhillips Head Screws CN1 Output Diodes Removal and Replacement Output Diodes Removal and Replacement To Replace ANY of the Output Diodes D1, D2, D3 or D4Output Transistor Removal and Replacement Output Transistor Removal and Replacement Figure F.36 Output Transistor LocationPlug CN1 5mm Allen Bolts Invertec V205-T AC/DC Table of Contents Diagram Section ELECTriCaL DiaGramS