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Lincoln Electric V205-T DISCHARGE PROCEDURE, INPUT FILTER CAPACITOR DISCHARGE PROCEDURE (continued)

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TROUBLESHOOTING & REPAIR

F-14 F-14

V205-T AC/DC

ELECTRIC SHOCK can kill.

• Have an electrician install and service

this equipment.

• Turn the input power off at the fuse box

before working on equipment.

• Do not touch electrically hot parts.

• Prior to performing preventative maintenance,

perform the following capacitor discharge procedure

to avoid electric shock.

DISCHARGE PROCEDURE

1. Remove the input power to the machine.

2. Using the phillips head screwdriver remove the

screws securing the case wraparound cover.

3. Be careful not to make contact with the capacitor

solder pads located at the top of the IGBT power

board.

4. Obtain a high resistance and high wattage resistor

(25-1000 ohms and 25 watts minimum). This

resistor is not with the machine. NEVER USE A

SHORTING STRAP FOR THIS PROCEDURE.

5. Locate the eight capacitor solder pads shown in

Figure F.3.

6. Using electrically insulated gloves and pliers, hold

the body of the resistor with the pliers and con-

nect the resistor leads across the two capacitor

solder pads. Hold the resistor in place for 10 sec-

onds. DO NOT TOUCH CAPACITOR SOLDER

PADS WITH YOUR BARE HANDS.

7. Repeat the discharge procedure for the other

three capacitors.

8. Check the voltage across the terminals of all

capacitors with a DC voltmeter. Voltage should be

zero. If any voltage remains, repeat this capacitor

discharge procedure.

WARNING

Capacitor Solder

Pads

Resistor

FIGURE F.3 – LOCATION OF INPUT FILTER CAPACITOR TERMINALS ON MAIN IGBT INVERTER BOARD

INPUT FILTER CAPACITOR DISCHARGE PROCEDURE (continued)

Contents

Main SVM161-A February, 2006 SERVICE MANUAL INVERTEC V205-T AC/DC ii V205-T AC/DC FOR ENGINE powered equipment. i WARNING ELECTRIC AND MAGNETIC FIELDS may be dangerous iii iii ARC RAYS can burn. ELECTRIC SHOCK can kill. FUMES AND GASES can be dangerous. iv iv FOR ELECTRICALLY powered equipment. CYLINDER may explode if damaged. WELDING SPARKS can cause fire or explosion. v v V205-T AC/DC PRCAUTIONS DE SRET PRCAUTIONS DE SRET POUR LES MACHINES SOUDER TRANSFORMATEUR ET REDRESSEUR MASTER TABLE OF CONTENTS FOR ALL SECTIONS Page INPUT - SINGLE PHASE ONLY RATED OUTPUT OUTPUT RECOMMENDED INPUT WIRE AND FUSE SIZES FOR MAXIMUM RATED OUTPUT PHYSICAL DIMENSIONS TECHNICAL SPECIFICATIONS - V205-T AC/DC TIG K1855-1 (Code Number 10860) TEMPERATURE RANGES MACHINE GROUNDING AND HIGH FRE- QUENCY INTERFERENCE PROTECTION Safety Precautions ------------------------------------------------------------ SELECT SUITABLE LOCATION INPUT CONNECTIONS RECONNECT PROCEDURE 230V INPUT OUTPUT AND GAS CONNECTION FOR TIG WELDING (FIGURE A.1) OUTPUT CONNECTIONS OUTPUT CONNECTION FOR STICK WELDING (FIGURE A.2) QUICK DISCONNECT PLUG (FOR STICK ELEC- TRODE CABLE and WORK CABLE) Page - OPERATION SECTION - SAFETY INSTRUCTIONS GENERAL DESCRIPTION WELDING CAPABILITY LIMITATIONS REAR CONTROL PANEL CONTROLS AND SETTINGS Page Page SET UP MENU WELDING POLARITY OUTPUT LIMITATIONS DC TIG WELDING Page STEEL TIG WELDING COPPER TIG WELDING TIPS FOR AC TIG WELDING AC TIG WELDING QUICK START UP DC TIG WELDING QUICK START UP Page ACCESSORIES OPTIONAL ACCESSORIES AND COMPATIBLE EQUIPMENT Factory Installed Field Installed CABLE PLUGS Page MAINTENANCE SAFETY PRECAUTIONS ELECTRIC SHOCK INPUT FILTER CAPACITOR DISCHARGE PROCEDURE ROUTINE MAINTENANCE -THEORY OF OPERATION SECTION- set info turn on PWM _ + reconnect info. voltage feedback high volt supply GENERAL DESCRIPTION INPUT BOARD AND BUS BOARD MAIN IGBT INVERTER BOARD MAIN TRANSFORMER OUTPUT MODULE AND CLAMPING BOARD OUTPUT MODULE TRANSISTOR BOARD SUPERIMPOSITION BOARD CONTROL/DISPLAY BOARD HIGH FREQUENCY (HF) BOARD INSULATED GATE BIPOLAR TRANSISTOR (IGBT) OPERATION TROUBLESHOOTING & REPAIR SECTION HOW TO USE TROUBLESHOOTING GUIDE PC BOARD TROUBLESHOOTING PROCEDURES OUTPUT PROBLEMS TROUBLESHOOTING GUIDE Page Page WELDING PROBLEMS EXTERNAL DIAGNOSTICS Power Supply Alarm Display Output Current Control Output Set-up Parameter Select Button INTERNAL DIAGNOSTICS INTERNAL DIAGNOSTICS (Continued) Page INPUT FILTER CAPACITOR DISCHARGE PROCEDURE ELECTRIC SHOCK DISCHARGE PROCEDURE INPUT FILTER CAPACITOR DISCHARGE PROCEDURE (continued) Capacitor Solder Pads Resistor INPUT FILTER BOARD TEST INPUT FILTER BOARD TEST INPUT FILTER BOARD INPUT FILTER BOARD TEST Page MAIN IGBT INVERTER BOARD LOW VOLTAGE TEST MAIN IGBT INVERTER BOARD LOW VOLTAGE TEST (CONTINUED) MAIN BOARD BACK SIDE MAIN IGBT INVERTER BOARD LOW VOLTAGE TEST (CONTINUED) Page CONTROL/DISPLAY BOARD TEST Control/Display Board Page CN2 41 CN7 42 45 CN1 44 BUS BOARD TEST BUS BOARD Page CN3 MAIN INVERTER BOARD UPFR SECTION TEST Page MAIN INVERTER BOARD UPFR SECTION TEST (continued) Page OUTPUT FILTER BOARD TEST OUTPUT FILTER BOARD TEST (continued) Output Filter Board OUTPUT FILTER BOARD TEST (continued) - + CN1 64 CN1 66 53 Page SECONDARY POWER BOARD TEST SECONDARY POWER BOARD TEST (continued) SECONDARY POWER BOARD SECONDARY POWER BOARD TEST (continued) Page WELDING LOGIC AND INVERTER SECTION TEST MAIN BOARD BACK SIDE Page Page Page Page INPUT FILTER BOARD REMOVAL AND REPLACEMENT INPUT FILTER BOARD REMOVAL AND REPLACEMENT (continued) S/L1 R/L1 RV1 RV2 INPUT FILTER BOARD REMOVAL AND REPLACEMENT (continued) Page MAIN IGBT BOARD REMOVAL AND REPLACEMENT MAIN BOARD MAIN IGBT BOARD REMOVAL & REPLACEMENT (continued) Page CONTROL/DISPLAY BOARD REMOVAL AND REPLACEMENT CONTROL/DISPLAY BOARD REMOVAL & REPLACEMENT (continued) Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC F-59 F-59 FIGURE F.30 METALDISPLAY PLATE CN1 FIGURE F.31 CONTROL/DISPLAY BOARD REMOVAL & REPLACEMENT (continued) 4 Phillips Head Screws WARNING Page REMOVAL AND REPLACEMENT Output Filter Board Phillips Head Screws Casefront Mounting Screws - + OUTPUT DIODES REMOVAL AND REPLACEMENT OUTPUT DIODES OUTPUT DIODES REMOVAL AND REPLACEMENT (continued) TO REPLACE ANY OF THE OUTPUT DIODES (D1, D2, D3 or D4) OUTPUT TRANSISTOR REMOVAL AND REPLACEMENT OUTPUT TRANSISTOR REMOVAL AND REPLACEMENT (continued) Output Transistor Page Page ELECTRICAL DIAGRAMS ELECTRICAL DIAGRAMS SVM ERROR REPORTING FORM