Lincoln Electric SVM161-A Main Transformer, Output Module Transistor Board, Superimposition Board

Page 38

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E-4

THEORY OF OPERATION

E-4

 

FIGURE E.4 - MAIN TRANSFORMER, OUTPUT DIODE MODULE & CLAMPING BOARD,

OUTPUT TRANSISTOR MODULE & SUPERIMPOSITION BOARD

Fan

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Superimposition

 

 

 

 

 

 

 

 

 

 

 

 

board

 

 

 

 

 

 

 

 

 

 

 

24 VDC

Bus board

 

 

 

 

 

 

 

 

 

AC DC Gate drive signals

 

 

 

Input

 

 

 

 

 

 

 

 

 

HF

 

 

 

 

 

 

 

 

 

 

 

 

 

 

board

 

 

 

 

 

board

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Voltage Feedback

 

 

 

 

 

15,+5-+24,+15,48,-

.inforeconnect

ckt.AConturn

supplyvolthigh

feedbackvoltage

feedbackcurrent

 

 

 

 

Current Feedback

 

 

 

 

 

 

 

 

 

Output

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

IGBT

 

Diode

 

 

 

 

 

 

 

 

 

 

 

 

 

Thermostat

 

 

 

Output

 

 

 

 

 

 

 

Thermostats

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Filter bd.

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

(bypass)

 

Main IGBT

 

 

 

 

 

 

 

 

 

 

 

 

 

& Power board

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

4

 

 

 

 

 

 

_

 

 

 

 

 

 

 

 

IGBT's

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Output

RF coil

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Choke

+

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

infothermostat

metervoltinput

metercurrentinput

 

DC blocking

 

 

Current

 

 

 

 

 

.cktAConturn

+515,+15,-

infoset

PWMonturn

capacitor board

 

 

 

 

 

Input

 

 

 

Hall

 

 

 

 

 

 

 

 

 

 

 

Main

 

Output

 

 

 

Choke

 

 

 

 

 

 

 

Output

Device

 

 

 

 

 

 

 

 

 

 

 

 

Transformer

board

Transistor

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Module

 

 

 

 

 

 

 

 

 

 

 

 

 

24 VDC Remote 2/4 path (D + E)

 

 

 

 

HF control signal

 

 

 

 

 

 

 

888

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

+48, +24

 

 

 

 

 

Control board

Display & LED

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

board

 

 

 

 

Control

(D + E)

Remote 2/4

Knob

 

Remote

48 VDC75, 76, 77 A, B, C

Gas

Solenoid

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MAIN TRANSFORMER

The 100KHZ output of the Main IGBT Inverter Board is coupled, through a DC Blocking Capacitor Board, to the primary of the Main Transformer. The transformer reduces the high voltage (low current) input applied to the primary winding and through transformer action develops a lower secondary voltage capable of high output currents.

OUTPUT MODULE TRANSISTOR BOARD

This module produces the AC waveforms and frequen- cies. It receives command signals from the Superimposition Board. Depending on which of the two IGBTs is active at any given moment the welding output of the machine can be either positive or nega- tive AC or DC.

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Master TOC

OUTPUT MODULE AND CLAMPING BOARD

The AC output of the Main Transformer is applied to the Output Modules for full wave rectification. The Clamping Diodes function as a filter eliminating any pulsed over-voltages that may be present at the Output Modules. The Clamping Board protects the Output Modules from damage due to higher than normal volt- age spikes.

SUPERIMPOSITION BOARD

The Super Imposition Board receives signals from the Control/Display Board to control the status of the sec- ondary inverter portion of the V205T machine. This board also generates voltage pulses at about +/- 200VDC that facilitate the re-striking of the arc when the TIG AC welding current is being utilized. The Superimposition Board internally generates the auxil- iary power supply for the isolated piloting of the power elements (IGBTs) for the Output Module Transistor Board. The Superimposition Board plugs directly into the Bus Board.

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NOTE: Unshaded areas of Block Logic Diagram are the subject of discussion

INVERTEC® V205-T AC/DC™

Page 37 Page 39
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Page 37 Page 39
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
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