Safety Precautions, Routine Maintenance | Lincoln Electric V205-T

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D-2		MAINTENANCE	D-2

SAFETY PRECAUTIONS

WARNING

ELECTRIC SHOCK can kill.

•Have an electrician install and service this equipment.

•Turn the input power off at the fuse box, disconnect or unplug supply lines and allow machine to sit for five minutes minimum to allow the power capacitors to dis- charge before working inside this equipment.

•Do not touch electrically hot parts.

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INPUT FILTER CAPACITOR

DISCHARGE PROCEDURE

The machine has internal capacitors which are charged to a high voltage during power-on condi- tions. This voltage is dangerous and must be dis- charged before the machine can be serviced. Discharging is done automatically by the machine each time the power is switched off. However, you must allow the machine to sit for at least 5 minutes to allow time for the process to take place.

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ROUTINE MAINTENANCE

Prevent metal powder from accumulating near the aer- ation fins and over them.

Carry out the following periodic controls on the power source:

•Clean the power source inside by means of low- pressure compressed air.

•Check the electric connections and all the connec- tion cables.

•Always use gloves in compliance with the safety standards.

V205-T AC/DC

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Lincoln Electric V205-T service manual Safety Precautions, Input Filter Capacitor Discharge Procedure, Routine Maintenance

Contents

Invertec V205-T AC/DC Safety Electric Shock can kill Cylinder may explode if damaged Précautions DE Sûreté Sûreté Pour Soudage a L’Arc Master Table of Contents for ALL Sections Table of Contents Installation Section Installation Operating Temperature Range Storage Temperature Range Tilting Select Suitable LocationStacking Environmental Area Reconnect Procedure Input Connections 115V Input Attachment Plug Installation230V Input Engine Driven Generator Output Connection for Stick Output and GAS Connection for TIG Welding Figure A.1Work Cable Connection Remote Control Connection Shielding GAS Connection V205-T AC/DC Table of Contents Operation Section Welding Capability Safety InstructionsGeneral Description Limitations Rear Control Panel Figure B.1 Figure B.1 Controls and Settings Figure B.2 Step Diagram Local/Remote push button Selects the welding TIG DC TIG AC SET UP Menu Indicator Parameter Default Output Limitations Welding Polarity Figure B.5 Tips for AC TIG Welding Steel TIG WeldingCopper TIG Welding Filler Material AC TIG Welding Quick Start UP Protective GAS DC TIG Welding Quick Start UP Table of Contents Accessories Cable Plugs Optional AccessoriesCompatible Equipment TIG Torch Kits Table of Contents Maintenance Safety Precautions Input Filter Capacitor Discharge ProcedureRoutine Maintenance Table of Contents Theory of Operation Section Theory of Operation General DescriptionInput Board and BUS Board Main Igbt Inverter Board Figure E.3 Main Igbt Inverter Board Output Module and Clamping Board Main TransformerOutput Module Transistor Board Superimposition Board CONTROL/DISPLAY Board High Frequency HF Board Output Filter Board Insulated Gate Bipolar Transistor Igbt Operation Figure E.6 Igbt Table of Contents Troubleshooting & Repair Section Troubleshooting & Repair HOW to USE Troubleshooting Guide PC Board Troubleshooting Procedures Electric Shock can kill Output Problems Function Problems Function Problems Secondary Power Board Test Welding Problems Troubleshooting & Repair External Diagnostics Figure F.1 External Diagnostics Troubleshooting & Repair Internal Diagnostics Figure F.2 Internal Diagnostics LED V205-T AC/DC Input Filter Capacitor Discharge Procedure Description Input Filter Capacitor Discharge Procedure Discharge Procedure Input Filter Board Test Input Filter Board Figure F.5 Input Filter Board V205-T AC/DC Main Igbt Inverter Board LOW Voltage Test Main Board LED Table F.1 Test Points TP2 MF2 Figure F.7 Main Igbt Inverter Board Location CONTROL/DISPLAY Board Test Control/Display Board CN2 CN7 CN1 Figure F.9 CONTROL/DISPLAY Board Location Table F.3 Plug CN2 Test Points CN1Table F.2 Plug CN1 Test Points Table F.4 Plug CN7 Test Points BUS Board Test BUS Board Table 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 Points CN2 CN4 Main Inverter Board Upfr Section Test Figure F.14 Upfr Location on Main Board Table F.10 Voltage Checks with 115 VAC Applied to Machine TP9 Gndpwr RL1 DD1 MF9 V205-T AC/DC Troubleshooting and Repair Output Filter Board Test Output Filter Board Figure F.17 Output Filter Board Plug Location Figure F.18 Output Filter Board Plug CN1 V205-T AC/DC Secondary Power Board Test Secondary Power Board Figure F.20 Secondary Power Board Test Point Locations Table F.13 Voltage Checks with 115 VAC Applied to Machine V205-T AC/DC Main Inverter Board Welding Logic and Inverter Section Test Main Inverter Board Figure F.21 Main Board Location Table F.14 LED Functions Table F.15 Feedback Voltage SignalsTable F.17 LED Check in Stick Mode Table F.16 Voltage Checks with 115 VAC Applied to Machine TP14 TP15 TP16 TP19 TP31 CN4/1-2 Short Circuit Ohms CN5/1-2 Figure F.23 Main Board Lower Left TP9 Ground Power MF15 VDS MF12 MF16 VDS V205-T AC/DC Input Filter Board Removal and Replacement Input Filter Board Removal and Replacement RV1 V205-T AC/DC Main Igbt Board Removal and Replacement Main Igbt Board Removal & Replacement CN2 CN1 V205-T AC/DC CONTROL/DISPLAY Board Removal and Replacement CONTROL/DISPLAY Board Removal & Replacement CN7 CN3 V205-T AC/DC Output Filter Board Removal and Replacement Removal and Replacement Casefront Mounting Screws Phillips Head Screws CN1 CN2 Output Diodes Removal and Replacement Output Diodes Figure F.35 Output Diode Location Output Transistor Removal and Replacement Output Transistor Removal and Replacement Plug CN1 5mm V205-T AC/DC Electrical Diagrams Table of Contents Electrical Diagrams Section Wiring Diagram V205-T AC/DC Standard Diagram SVM Error Reporting Form