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Lincoln Electric SVM161-A service manual Igbt

Models: SVM161-A

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F-4	TROUBLESHOOTING AND REPAIR									F-4
F-4										F-4

Observe Safety Guidelines detailed in the beginning of this manual.

PROBLEMS			POSSIBLE AREAS OF				RECOMMENDED
(SYMPTOMS)			MISADJUSTMENT(S)				COURSE OF ACTION

			OUTPUT PROBLEMS
Major physical or electrical damage		1.	Contact	your	local authorized		1. Contact the Lincoln Electric
is evident when the sheet metal			Lincoln	Electric Field		Service	Service Department 1-800-833-
cover(s) are removed.			Facility for assistance.				9353.

The machine is dead—no fan –no		1.	Make sure the input power switch				1. Check the input power switch for
output—no LEDs.			is in the ON position.				proper operation. Also check the
		2.	Check the main input fuses. If				associated leads		for loose or
		2.	Check the main input fuses. If				faulty connections.		See	Wiring
			open replace.				faulty connections.		See	Wiring
			open replace.				Diagram.
							Diagram.
		3.	Make sure the correct input volt-				2. Perform	the Input	Filter	Board
			age is applied to the machine.				Test.
							Test.

The main input fuses or breakers		1.	Make certain the fuses or break-				1. The Input Filter Board may be
repeatedly fail.			ers are properly sized for the				faulty.	Perform the Input Filter
			input draw of the machine.				Board Test.
		2.	The welding procedure may be				2. The Main IGBT Inverter Board
			drawing too much input current or				may be faulty. Perform the Main
			the duty cycle may be too high.				IGBT	Inverter	Board	Low
			Reduce	the	welding	current	Voltage Supply Test.
			and/or reduce the duty cycle.

CAUTION

If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact the Lincoln Electric Service Department for technical troubleshooting assistance before you proceed. Call 1-888-935-3877.

INVERTEC® V205-T AC/DC™

Image 44

Lincoln Electric SVM161-A service manual Igbt

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