Invertec V205-T AC/DC | Lincoln Electric SVM161-A instruction

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SVM161-A

January, 2011

INVERTEC® V205-T AC/DC™

For use with machine code number: 10860

Safety Depends on You

Lincoln arc welding and cutting equipment is designed and built with safety in mind. However, your overall safety can be increased by proper installation

. . . and thoughtful operation on your part. DO NOT INSTALL,

OPERATE OR REPAIR THIS EQUIPMENT WITHOUT READ- ING THIS MANUAL AND THE SAFETY PRECAUTIONS CON- TAINED THROUGHOUT. And, most importantly, think before you act and be careful.

SERVICE MANUAL

Copyright © Lincoln Global Inc.

• World's Leader in Welding and Cutting Products •

• Sales and Service through Subsidiaries and Distributors Worldwide •

Cleveland, Ohio 44117-1199 U.S.A. TEL: 216.481.8100 FAX: 216.486.1751 WEB SITE: www.lincolnelectric.com

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

Contents

Invertec V205-T AC/DC Invertec V205-T AC/DC Safety Can be dangerous Electric Shock can kill ARC Rays can burn Welding Cutting Powered equipmentCylinder may explode Sparks can cause fire or If damaged Explosion Sûreté Pour Soudage a L’Arc Précautions DE Sûreté Safety Methods of Reducing Emissions Mains Supply Master Table of Contents for ALL Sections Table of Contents Installation Section Operating Temperature Range Storage Temperature Range Installation Stacking Select Suitable LocationTilting Environmental Area Input Connections Reconnect Procedure 230V Input Attachment Plug Installation115V Input Engine Driven Generator Output and GAS Connection for TIG Welding Figure A.1 Output ConnectionsWork Cable Connection Shielding GAS Connection Remote Control Connection Invertec V205-T AC/DC Table of Contents Operation Section Operation Safety InstructionsGeneral Description Welding Capability Rear Control Panel Figure B.1 OPERATIONB-3 Figure B.2 Controls and Settings Local/Remote push button Selects the welding Step Diagram TIG DC TIG AC Indicator Parameter Default SET UP Menu Welding Polarity Output Limitations Figure B.7 Copper TIG Welding Steel TIG WeldingTips for AC TIG Welding Filler Material Protective GAS AC TIG Welding Quick Start UP DC TIG Welding Quick Start UP Table of Contents Accessories Section Optional Accessories AccessoriesCompatible Equipment Cable Plugs Table of Contents Maintenance Section Safety Precautions MaintenanceInput Filter Capacitor Discharge Procedure Routine Maintenance Figure D.1 Major Component Locations 3MAINTENANCE Invertec V205-T AC/DC 1TABLE of CONTENTS-THEORY of Operation Section E-1 Input Board and BUS Board Theory of Operation Figure E.3 Main Igbt Inverter Board Main Igbt Inverter Board Output Module Transistor Board Main TransformerOutput Module and Clamping Board Superimposition Board High Frequency HF Board CONTROL/DISPLAY BoardOutput Filter Board Passive Active Insulated Gate Bipolar Transistor Igbt Operation 1TABLE of Contents Troubleshooting and Repair F-1 HOW to USE Troubleshooting Guide Troubleshooting and Repair Electric Shock can kill PC Board Troubleshooting Procedures Igbt Perform the Input Filter Board Igbt Inverter Board Test Secondary Output Board Assembly Test See the Output Filter Display Troubleshooting and Repair External Diagnostics Figure F.2 Troubleshooting and Repair Internal Diagnostics LED Internal Diagnostics Invertec V205-T AC/DC Materials Needed Test Description Capacitor Solder Resistor Pads Input Filter Capacitor Discharge Procedure Input Filter Board Test Input Filter Board Test ProcedureInput Filter Board 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 Test LED Main Igbt Inverter Board LOW Voltage Test Figure F.7 Main Igbt Inverter Board Location TP2 MF2 CONTROL/DISPLAY Board Test Figure F.8 CONTROL/DISPLAY Board Location CONTROL/DISPLAY Board Test Figure F.9 CONTROL/DISPLAY Board Location CN2 Figure F.10 Plugs CN1, CN2 & CN7 CN1 BUS Board Test Figure F.11 BUS Board Location BUS Board Test Table F.6 Plug CN3 Test Points Table F.5 Plug CN2 Test PointsTable F.7 Plug CN4 Test Points Table F.8 Plug CN7 Test Points CN1 CN2 Main Inverter Board Power Factor Section Test Table F.10 Voltage Checks with 115 VAC Applied to Machine Main Inverter Board Power Factor Section TestTable F.11 Resistance Checks TP9 Gndpwr RL1 Invertec V205-T AC/DC Output Filter Board Test Figure F.16 Output Filter Board Location Output Filter Board Test Figure F.18 Output Filter Board Plug CN1 Figure F.17 Output Filter Board Plug Location Invertec V205-T AC/DC Secondary Output Board Assembly Test Figure F.19 Secondary Power Board Location Secondary Output Board Assembly Test OFF GA-SA Table F.14 Output Diode Resistance Check Mode Positive Meter Negative Meter Expected Reading Probe Main Inverter Board Welding Logic and Inverter Section Test Welding Logic and Inverter Section Test Main Inverter Board Table F.18 LED Check in Stick Mode Table F.16 Feedback Voltage SignalsTable F.15 LED Function Table F.17 Voltage Checks with 115 VAC Applied to Machine Figure 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 Replacement RV1 RV2 Invertec V205-T AC/DC Main Igbt Board Removal and Replacement Figure F.27 Main Igbt Board Location Main Igbt Board Removal and Replacement RV1 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 Replacement CN2 Invertec V205-T AC/DC Output Filter Board Removal and Replacement Figure F.32 Output Filter Board Location Removal and Replacement Phillips Head Screws CN1 Output Diodes Removal and Replacement To Replace ANY of the Output Diodes D1, D2, D3 or D4 Output Diodes Removal and Replacement Output Transistor Removal and Replacement Figure F.36 Output Transistor Location Output Transistor Removal and Replacement Plug CN1 5mm Allen Bolts Invertec V205-T AC/DC Table of Contents Diagram Section ELECTriCaL DiaGramS