Lincoln Electric SVM161-A service manual RV1 RV2 CN4 RV3 RV4 CN5 RV5 RV7 RV6

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F-55	TROUBLESHOOTING AND REPAIR	F-55

MAIN IGBT BOARD REMOVAL AND REPLACEMENT (continued)

FIGURE F.28 – MAIN BOARD PLUG AND MOUNTING SCREW LOCATION

CN2

CN1

CN3

RV1
RV2	CN4
	CN4
RV3
RV4
	CN5

RV5

RV7 RV6

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10.Reconnect previously removed leads RV1 thru RV7 to the P.C. board. See Wiring Diagram if necessary.

11.Reconnect previously removed plugs CN1 thru CN5 to the P.C. board.

NOTE: All ribbon cable connections have an “indexing location slot” to assure proper replacement.

12.Replace the case wraparound cover previous- ly removed.

INVERTEC® V205-T AC/DC™

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Contents Invertec V205-T AC/DC Invertec V205-T AC/DC SafetyCan be dangerous Electric Shock can kill ARC Rays can burnSparks can cause fire or If damaged Explosion Powered equipmentWelding Cutting Cylinder may explodeSûreté Pour Soudage a L’Arc Précautions DE SûretéSafety Methods of Reducing Emissions Mains Supply Master Table of Contents for ALL Sections Table of Contents Installation Section Operating Temperature Range Storage Temperature Range InstallationEnvironmental Area Select Suitable LocationStacking TiltingInput Connections Reconnect ProcedureEngine Driven Generator Attachment Plug Installation230V Input 115V InputWork Cable Connection Output ConnectionsOutput and GAS Connection for TIG Welding Figure A.1 Shielding GAS Connection Remote Control ConnectionInvertec V205-T AC/DC Table of Contents Operation Section Welding Capability Safety InstructionsOperation General DescriptionRear Control Panel Figure B.1 OPERATIONB-3Figure 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.7 Filler Material Steel TIG WeldingCopper TIG Welding Tips for AC TIG WeldingProtective GAS AC TIG Welding Quick Start UPDC TIG Welding Quick Start UP Table of Contents Accessories Section Cable Plugs AccessoriesOptional Accessories Compatible EquipmentTable of Contents Maintenance Section Routine Maintenance MaintenanceSafety Precautions Input Filter Capacitor Discharge ProcedureFigure D.1 Major Component Locations 3MAINTENANCEInvertec V205-T AC/DC 1TABLE of CONTENTS-THEORY of Operation Section E-1 Input Board and BUS Board Theory of OperationFigure E.3 Main Igbt Inverter Board Main Igbt Inverter BoardSuperimposition Board Main TransformerOutput Module Transistor Board Output Module and Clamping BoardOutput Filter Board CONTROL/DISPLAY BoardHigh Frequency HF Board Passive Active Insulated Gate Bipolar Transistor Igbt Operation1TABLE of Contents Troubleshooting and Repair F-1 HOW to USE Troubleshooting Guide Troubleshooting and RepairElectric Shock can kill PC Board Troubleshooting ProceduresIgbt Perform the Input Filter Board Igbt Inverter Board Test Secondary Output Board Assembly Test See the Output Filter Display Troubleshooting and Repair External DiagnosticsFigure F.2 Troubleshooting and Repair Internal DiagnosticsLED Internal DiagnosticsInvertec V205-T AC/DC Materials Needed Test DescriptionCapacitor Solder Resistor Pads Input Filter Capacitor Discharge ProcedureInput 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 Figure F.6 Main Igbt Inverter Board Location Main Igbt Inverter Board LOW Voltage TestLED Main Igbt Inverter Board LOW Voltage TestFigure F.7 Main Igbt Inverter Board Location TP2 MF2CONTROL/DISPLAY Board Test Figure F.8 CONTROL/DISPLAY Board Location CONTROL/DISPLAY Board TestFigure F.9 CONTROL/DISPLAY Board Location CN2Figure F.10 Plugs CN1, CN2 & CN7 CN1BUS Board Test Figure F.11 BUS Board Location BUS Board TestTable F.8 Plug CN7 Test Points Table F.5 Plug CN2 Test PointsTable F.6 Plug CN3 Test Points Table F.7 Plug CN4 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 Figure F.16 Output Filter Board Location Output Filter Board TestFigure F.18 Output Filter Board Plug CN1 Figure F.17 Output Filter Board Plug LocationInvertec V205-T AC/DC Secondary Output Board Assembly Test Figure F.19 Secondary Power Board Location Secondary Output Board Assembly TestOFF GA-SA Table F.14 Output Diode Resistance Check Mode Positive Meter Negative Meter Expected Reading ProbeMain Inverter Board Welding Logic and Inverter Section Test Welding Logic and Inverter Section Test Main Inverter BoardTable F.17 Voltage Checks with 115 VAC Applied to Machine Table F.16 Feedback Voltage SignalsTable F.18 LED Check in Stick Mode Table F.15 LED FunctionFigure F.22 Main Board Inverter Section TP9 Ground Power Invertec V205-T AC/DC Input Filter Board Removal and Replacement Figure F.24 Input Filter Board Location Input Filter Board Removal and ReplacementRV1 RV2 Invertec V205-T AC/DC Main Igbt Board Removal and Replacement Figure F.27 Main Igbt Board Location Main Igbt Board Removal and ReplacementRV1 RV2 CN4 RV3 RV4 CN5 RV5 RV7 RV6 Invertec V205-T AC/DC CONTROL/DISPLAY Board Removal and Replacement Figure F.29 CONTROL/DISPLAY Board Location CONTROL/DISPLAY Board Removal and ReplacementCN2 Invertec V205-T AC/DC Output Filter Board Removal and Replacement Figure F.32 Output Filter Board Location Removal and ReplacementPhillips Head Screws CN1 Output Diodes Removal and Replacement To Replace ANY of the Output Diodes D1, D2, D3 or D4 Output Diodes Removal and ReplacementOutput Transistor Removal and Replacement Figure F.36 Output Transistor Location Output Transistor Removal and ReplacementPlug CN1 5mm Allen Bolts Invertec V205-T AC/DC Table of Contents Diagram Section ELECTriCaL DiaGramS