Test Description, Materials Needed | Lincoln Electric SVM161-A

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F-13	TROUBLESHOOTING AND REPAIR	F-13

INPUT FILTER CAPACITOR DISCHARGE PROCEDURE

WARNING

Service and repair should be performed only by Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty. For your safety and to avoid electrical shock, please observe all safety notes and precautions detailed throughout this manual.

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

TEST DESCRIPTION

This procedure will drain off any charge stored in the four Capacitors that are part of the Main IGBT Inverter Board Assembly. This procedure MUST be performed, as a safety precaution, before conducting any test or repair procedure that requires you to touch inter- nal components of the machine.

MATERIALS NEEDED

Phillips Screwdriver

Insulated Pliers

Insulated Gloves

High Wattage Resistor (25-1000 ohms and 25 watts minimum)

Volt Meter

INVERTEC® V205-T AC/DC™

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Lincoln Electric SVM161-A service manual Test Description, Materials Needed

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 Work Cable Connection Output ConnectionsOutput and GAS Connection for TIG Welding Figure A.1 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 Output Filter Board CONTROL/DISPLAY BoardHigh Frequency HF 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 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 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.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 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