Lincoln Electric SVM161-A service manual Safety Precautions, Routine Maintenance

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D-2	MAINTENANCE	D-2

SAFETY PRECAUTIONS

WARNING

ELECTRIC SHOCK can kill.

•Have an electrician install and service this equipment.

•Turn the input power off at the fuse box, disconnect or unplug supply lines and allow machine to sit for five minutes minimum to allow the power capacitors to discharge before working inside this equipment.

•Do not touch electrically hot parts.

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INPUT FILTER CAPACITOR

DISCHARGE PROCEDURE

The machine has internal capacitors which are charged to a high voltage during power-on condi- tions. This voltage is dangerous and must be dis- charged before the machine can be serviced. Discharging is done automatically by the machine each time the power is switched off. However, you must allow the machine to sit for at least 5 minutes to allow time for the process to take place.

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ROUTINE MAINTENANCE

Prevent metal powder from accumulating near the aer- ation fins and over them.

Carry out the following periodic controls on the power source:

•Clean the power source inside by means of low- pressure compressed air.

•Check the electric connections and all the connec- tion cables.

•Always use gloves in compliance with the safety standards.

INVERTEC® V205-T AC/DC™

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Contents Invertec V205-T AC/DC Safety Invertec V205-T AC/DCElectric Shock can kill ARC Rays can burn Can be dangerousPowered equipment Welding CuttingCylinder may explode 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 RangeSelect Suitable Location StackingTilting Environmental AreaReconnect Procedure Input ConnectionsAttachment Plug Installation 230V Input115V 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 Safety Instructions OperationGeneral Description 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 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 Accessories Section Accessories Optional AccessoriesCompatible Equipment Cable PlugsTable of Contents Maintenance Section Maintenance Safety PrecautionsInput Filter Capacitor Discharge Procedure 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 BoardMain Transformer Output Module Transistor BoardOutput Module and Clamping 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.5 Plug CN2 Test Points Table F.6 Plug CN3 Test PointsTable F.7 Plug CN4 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.16 Feedback Voltage Signals Table F.18 LED Check in Stick ModeTable F.15 LED Function 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