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Lincoln Electric SVM161-A manual

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Table of contents for the manual

  • Page 1

    SVM161-A January , 201 1 Safety Depends on Y ou 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 INST ALL, OPERA TE OR REP AIR THIS EQUIPMENT WITHOUT READ- ING THIS MANUAL AND THE SAFETY PRE[...]

  • Page 2

    INVERTEC® V205-T AC/DC™ SAFETY i i FOR ENGINE powered equipment. 1.a. T urn the engine off before troubleshooting and maintenance work unless the maintenance work requires it to be running. ____________________________________________________ 1.b.Operate engines in open, well-ventilated areas or vent the engine exhaust fumes outdoors. __________[...]

  • Page 3

    SAFETY ii ii INVERTEC® V205-T AC/DC™ FUMES AND GASES can be dangerous. 5.a. Welding may produce fumes and gases hazardous to health. Avoid breathing these fumes and gases.When welding, keep your head out of the fume. Use enough ventilation and/or exhaust at the arc to keep fumes and gases away from the breathing zone. When welding with electrode[...]

  • Page 4

    INVERTEC® V205-T AC/DC™ SAFETY iii iii FOR ELECTRICALL Y powered equipment. 8.a. Turn off input power using the disconnect switch at the fuse box before working on the equipment. 8.b. Install equipment in accordance with the U.S. National Electrical Code, all local codes and the manufacturer ’s recommendations. 8.c. Ground the equipment in acc[...]

  • Page 5

    SAFETY iv iv INVERTEC® V205-T AC/DC™ PRÉCAUTIONS DE SÛRETÉ Pour votre propre protection lire et observer toutes les instructions et les précautions de sûreté specifiques qui parraissent dans ce manuel aussi bien que les précautions de sûreté générales suiv- antes: Sûreté Pour Soudage A L’Arc 1. Protegez-vous contre la secousse él[...]

  • Page 6

    SAFETY Electromagnetic Compatibility (EMC) Confor mance P roducts displaying the CE mark are in conformity with European Community Council Directive of 1 5 Dec 2004 on the appro ximation of the laws of the Member Stat es relating to electromagnetic compatibilit y , 2004/1 08/EC . It was manuf actured in conformit y with a national standar d that im[...]

  • Page 7

    SAFETY Electromagnetic Compatibility (EMC) The size of the surrounding area to be considered will depend on the structure of the building and other activities that are taking place. The surrounding area may ext end bey ond the boundar ies of the premises. Methods of Reducing Emissions Mains Supply W elding equipment should be connected to the mains[...]

  • Page 8

    Page Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .i-vi Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Section A Operation . . . . . . . . . . [...]

  • Page 9

    T ABLE OF CONTENTS - INST ALLA TION SECTION A-1 A-1 INVERTEC® V205-T AC/DC™ Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-1 T echnical Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .[...]

  • Page 10

    TIME-DELA Y CIRCUIT BREAKER OR FUSE SIZE (AMPS) 30A Height Width Depth Weight 15 in. 8.5 in. 19 in. Approx. 38 lbs. 381 mm 216 mm 483 mm 17 kgs. INST ALLA TION A-2 A-2 INVERTEC® V205-T AC/DC™ Input Amps 34A 28A 20A 34A 25A 20A 30A 23A 19A 30A 18A 15A T ype of Output AC/DC Output Amps V olts at Rated Amperes (Stick) 1 10 24.4V 90 23.6V 70 22.8V ([...]

  • Page 11

    INST ALLA TION A-3 A-3 INVERTEC® V205-T AC/DC™ MACHINE GROUNDING AND HIGH FRE- QUENCY INTERFERENCE PROTECTION The Capacitor Discharge Circuit used in the high fre- quency generator , may cause many radio, TV and electronic equipment interference problems. These problems may be the result of radiated interference. Proper grounding methods can red[...]

  • Page 12

    INST ALLA TION A-4 A-4 INVERTEC® V205-T AC/DC™ 3. Be sure the torch and work cable rubber coverings are free of cuts and cracks that allow high fre- quency leakage. Cables with high natural rubber content, such as Lincoln Stable-Arc ® better resist high frequency leakage than neoprene and other synthetic rubber insulated cables. 4. Keep the tor[...]

  • Page 13

    INST ALLA TION A-5 A-5 INVERTEC® V205-T AC/DC™ In all cases, the green or green/yellow grounding wire must be connected to the grounding pin of the plug, usually identified by a green screw . Attachment plugs must comply with the Standard for Attachment Plugs and Receptacles, UL498. The product is considered acceptable for use only when an attac[...]

  • Page 14

    INST ALLA TION A-6 A-6 INVERTEC® V205-T AC/DC™ OUTPUT AND GAS CONNECTION FOR TIG WELDING (FIGURE A.1) The TIG T orch T wist-Mate and work cable T wist-Mate Connectors are supplied with the welder . T o connect the cables, turn the Power Switch “OFF”. Connect the torch cable T wist-Mate plug into the DC(-) Electrode/Gas Output Receptacle on t[...]

  • Page 15

    INST ALLA TION A-7 A-7 INVERTEC® V205-T AC/DC™ REMOTE CONTROL CONNECTION A remote control receptacle is provided on the lower center case front of the welder for connecting a remote control to the machine. Refer to the Optional Accessories section of this manual for available remote controls. CYLINDER could explode if damaged. • Keep cylinder [...]

  • Page 16

    NOTES A-8 A-8 INVERTEC® V205-T AC/DC™ Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC[...]

  • Page 17

    T ABLE OF CONTENTS - OPERA TION SECTION B-1 B-1 INVERTEC® V205-T AC/DC™ Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-1 Safety Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . [...]

  • Page 18

    OPERA TION B-2 B-2 INVERTEC® V205-T AC/DC™ Read and understand this entire section before operating your machine. SAFETY INSTRUCTIONS ELECTRIC SHOCK can kill. • Do not touch electrically live parts such as output terminals, electrode or internal wiring. • Insulate yourself from the work and ground. • Always wear dry insulating gloves. Only[...]

  • Page 19

    OPERA TION B-3 B-3 INVERTEC® V205-T AC/DC™ REAR CONTROL P ANEL (FIGURE B.1) • I1: Off/On switch turns on the electric power to the welder . It has two positions, "O" off, and "I" on. ------------------------------------------------------------------------ * With "l1" in the "I" (ON) position, the welding[...]

  • Page 20

    OPERA TION B-4 B-4 INVERTEC® V205-T AC/DC™ 1. Input V oltage warning light green LED - Indicates that the machine is on and input voltage is within acceptable range. 2. Thermal Shutdown Light (yellow LED) - Indicates thermal over load or output disabled for incorrect supply voltage. • With the "Y ellow LED" on, and an alarm code blin[...]

  • Page 21

    OPERA TION B-5 B-5 INVERTEC® V205-T AC/DC™ 5. Output / Parameter Adjust Knob - Allows you to continuously adjust the current both in TIG and in Stick welding. Allows you to change the value, shown on "Digital Display Item 6", of the parameter selected with "Setup/Parameter select button Item 4". 6. Digital Display - displays [...]

  • Page 22

    OPERA TION B-6 B-6 INVERTEC® V205-T AC/DC™ 3. Press and hold the TIG torch trigger when the main part of the weld is complete. The machine will now decrease the output current at a controlled rate, or downslope time, until the Finish current is reached. Both the Downslope Time and the Finish Current are presettable. This Finish cur- rent can be [...]

  • Page 23

    OPERA TION B-7 B-7 INVERTEC® V205-T AC/DC™ SET UP MENU Many additional parameters can be modified via the Set Up Menu. T o access the Set Up Menu: • Position the ON/OFF switch to OFF “0”. • Depress and hold the Parameter select Push Button. • Position the On/Off switch to on "I" at the back of the machine; the input voltage l[...]

  • Page 24

    OPERA TION B-8 B-8 INVERTEC® V205-T AC/DC™ WELDING POLARITY DC Electrode Negative Polarity (Direct Current Straight Polarity) (see FIGURE B.4) While Welding, there is a continuous flow of electrons from the electrode to the workpiece. This is the most used polarity , ensuring limited wear of the electrode, since the majority of the heat concen- [...]

  • Page 25

    OPERA TION B-9 B-9 INVERTEC® V205-T AC/DC™ AC TIG - NOT PULSED Ip Im Ib O O t t T f = 1 to 10Hz T= 1/ f I AC - PULSED TIG DC Electrode Positive Polarity . (Direct Current Reverse Polarity) (see Figure B.5) In this case, there is a continuous flow of electrons from the workpiece to the electrode. The reverse polar- ity is used for welding alloys [...]

  • Page 26

    OPERA TION B-10 B-10 INVERTEC® V205-T AC/DC™ 1. The AC wave balance can be set to a higher per- centage electrode negative which minimizes tung- sten heating and erosion. 2. The AC frequency can be varied to "focus" the arc. Increasing the AC frequency above 60Hz will narrow the cone shape arc from the tungsten’s tip. Decreasing the [...]

  • Page 27

    OPERA TION B-11 B-11 INVERTEC® V205-T AC/DC™ PROTECTIVE GAS Both argon and helium work when welding aluminum. Argon is preferred, due to its lower cost and consump- tion rate. This gas also tends to stabilize the arc, thus making it easy to operate. For some applications, how- ever , the use of helium, or argon-helium blends, is rec- ommended du[...]

  • Page 28

    OPERA TION B-12 B-12 INVERTEC® V205-T AC/DC™ DC TIG WELDING QUICK ST ART UP ELECTRIC SHOCK can kill. • Have an electrician install and service this equipment. • T urn the input power off at the fuse box, dis- connect or unplug supply lines and allow machine to sit for five minutes minimum to allow the power capacitors to discharge before[...]

  • Page 29

    T ABLE OF CONTENTS - ACCESSORIES SECTION C-1 C-1 INVERTEC® V205-T AC/DC™ Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .C-1 Options/Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .[...]

  • Page 30

    ACCESSORIES C-2 C-2 INVERTEC® V205-T AC/DC™ OPTIONAL ACCESSORIES AND COMP A TIBLE EQUIPMENT Factory Installed T wist-Mate Cable Connectors 1 – standard for Ground Clamp 1 – Gas Pass through for T ig T orch Strap Packet Instruction Manual Field Installed K857 - Remote Output Control - For Stick welding. When the V205-T’ s Output Control is [...]

  • Page 31

    T ABLE OF CONTENTS - MAINTENANCE SECTION D-1 D-1 INVERTEC® V205-T AC/DC™ Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-1 Input Filter Capacitor Discharge Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . [...]

  • Page 32

    MAINTENANCE D-2 D-2 INVERTEC® V205-T AC/DC™ SAFETY PRECAUTIONS ELECTRIC SHOCK can kill. • Have an electrician install and service this equipment. • T urn 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 discharge before working inside[...]

  • Page 33

    MAINTENANCE D-3 D-3 INVERTEC® V205-T AC/DC™ FIGURE D.1 - MAJOR COMPONENT LOCA TIONS 1. Cradle T ube Assembly and Roof 2. Control Panel Assembly 3. Stator & Rotor Assembly and Battery 4. Rear Control Panel, Fuel T ank Assembly , and Engine 1 1 4 4 2 2 3 3 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC [...]

  • Page 34

    NOTES D-4 D-4 INVERTEC® V205-T AC/DC™ Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC[...]

  • Page 35

    T ABLE OF CONTENTS-THEOR Y OF OPERA TION SECTION E-1 E-1 INVERTEC® V205-T AC/DC™ Theory of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .E-1 General Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .[...]

  • Page 36

    THEOR Y OF OPERA TION E-2 E-2 INVERTEC® V205-T AC/DC™ GENERAL DESCRIPTION The Invertec® V205T AC/DC is an inverter based industrial welding power source that utilizes single- phase input power to produce constant current AC or DC output for both Stick (SMA W) and TIG (GT A W). With 230V AC input applied the V205T is rated at 200 amps, 18volts a[...]

  • Page 37

    THEOR Y OF OPERA TION E-3 E-3 INVERTEC® V205-T AC/DC™ MAIN IGBT INVERTER BOARD The filtered input voltage, from the Input Board, is applied through an input choke to the Main IGBT Inverter Board. This input voltage is rectified, regulat- ed and a unity power factor output is developed for the main welding IGBT s. This unity power factor circuit [...]

  • Page 38

    THEOR Y OF OPERA TION E-4 E-4 INVERTEC® V205-T AC/DC™ MAIN TRANSFORMER The 100KHZ output of the Main IGBT Inverter Board is coupled, through a DC Blocking Capacitor Board, to the primary of the Main T ransformer . The transformer reduces the high voltage (low current) input applied to the primary winding and through transformer action develops a[...]

  • Page 39

    THEOR Y OF OPERA TION E-5 E-5 INVERTEC® V205-T AC/DC™ CONTROL/DISPLA Y BOARD The Control/Display Board assembly is actually two boards mounted together . They should be replaced together . The Display portion houses the control panel, LEDs, push buttons and output encoders. The Display Boards functions as the interface between the user and the V[...]

  • Page 40

    THEOR Y OF OPERA TION E-6 E-6 INVERTEC® V205-T AC/DC™ INSULA TED GA TE BIPOLAR TRANSIST OR (IGBT) OPERA TION An IGBT is a type of transistor . IGBT are semiconduc- tors well suited for high frequency switching and high current applications. Example A in Figure E.6 shows an IGBT in passive mode. There is no gate signal, zero volts relative to the[...]

  • Page 41

    T ABLE OF CONTENTS - TROUBLESHOOTING AND REP AIR F-1 F-1 INVERTEC® V205-T AC/DC™ T roubleshooting and Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .F-1 How to Use T roubleshooting Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .[...]

  • Page 42

    TROUBLESHOOTING AND REP AIR F-2 F-2 INVERTEC® V205-T AC/DC™ This T roubleshooting Guide is provided to help you locate and repair possible machine malfunctions. Simply follow the three-step procedure listed below . Step 1. LOCA TE PROBLEM (SYMPTOM). Look under the column labeled “PROBLEM (SYMPTOMS)”. This column describes pos- sible sympto[...]

  • Page 43

    TROUBLESHOOTING AND REP AIR F-3 F-3 INVERTEC® V205-T AC/DC™ Sometimes machine failures appear to be due to PC board failures. These problems can sometimes be traced to poor electrical connections. T o avoid prob- lems when troubleshooting and replacing PC boards, please use the following procedure: 1. Determine to the best of your technical abil[...]

  • Page 44

    OUTPUT PROBLEMS Observe Safety Guidelines detailed in the beginning of this manual. PROBLEMS (SYMPTOMS) POSSIBLE AREAS OF MISADJUSTMENT(S) RECOMMENDED COURSE OF ACTION 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 troubles[...]

  • Page 45

    FUNCTION PROBLEMS Observe Safety Guidelines detailed in the beginning of this manual. PROBLEMS (SYMPTOMS) POSSIBLE AREAS OF MISADJUSTMENT(S) RECOMMENDED COURSE OF ACTION 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 troubl[...]

  • Page 46

    FUNCTION PROBLEMS Observe Safety Guidelines detailed in the beginning of this manual. PROBLEMS (SYMPTOMS) POSSIBLE AREAS OF MISADJUSTMENT(S) RECOMMENDED COURSE OF ACTION 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 troubl[...]

  • Page 47

    FUNCTION PROBLEMS Observe Safety Guidelines detailed in the beginning of this manual. PROBLEMS (SYMPTOMS) POSSIBLE AREAS OF MISADJUSTMENT(S) RECOMMENDED COURSE OF ACTION 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 troubl[...]

  • Page 48

    WELDING PROBLEMS Observe Safety Guidelines detailed in the beginning of this manual. PROBLEMS (SYMPTOMS) POSSIBLE AREAS OF MISADJUSTMENT(S) RECOMMENDED COURSE OF ACTION 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 trouble[...]

  • Page 49

    TROUBLESHOOTING AND REP AIR F-9 F-9 INVERTEC® V205-T AC/DC™ EXTERNAL DIAGNOSTICS ® P ARAMETER SELECT / HOLD PULSE ON UPSLOPE % ON TIME DOWNSLOPE FINISH CURRENT BACKGRO UND CURRENT POSTFLOW WELD CURRENT sec sec sec MODE STICK D C TI G AC TIG WARNING TRIGGER 4-STEP 2-STEP LOCAL REMOTE OUTPUT A PULSE FREQUENCY Hz V AC FREQUENCY Hz AC BALANCE % EN [...]

  • Page 50

    TROUBLESHOOTING AND REP AIR F-10 F-10 INVERTEC® V205-T AC/DC™ INTERNAL DIAGNOSTICS L11 Under Small PCB L14 L13 Under Small PCB L12 L10 L9 L8 L4 L1 L5 L2 L3 L6 L7 FIGURE F .2 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC[...]

  • Page 51

    TROUBLESHOOTING AND REP AIR F-11 F-11 INVERTEC® V205-T AC/DC™ INTERNAL DIAGNOSTICS (Continued) LED L1 L2 L3 L4 L5 L6 L7 L8 L9 L10 L1 1 L12 L13 L14 Definition -15VDC supply by 15.14.316 for 15.14.316 logic part +15VDC supply by 15.14.316 for 15.14.316 logic part +5VDC supply by 15.14.316 for 15.14.316 logic part +24VDC supply by 15.14.316 for pow[...]

  • Page 52

    NOTES F-12 F-12 INVERTEC® V205-T AC/DC™ Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC[...]

  • Page 53

    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 thr[...]

  • Page 54

    ELECTRIC SHOCK can kill. • Have an electrician install and ser- vice 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 proce- dure to avoid electric shock. DISCHARGE PROCEDU[...]

  • Page 55

    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 thr[...]

  • Page 56

    INPUT FIL TER BO ARD FIGURE F .4 – INPUT FIL TER BOARD LOCA TION INPUT FIL TER BOARD TEST (continued) PROCEDURE 1. Remove input power to the V205-T . 2. Using a phillips head screwdriver , remove the case wraparound. 3. Perform the Input Filter Capacitor Discharge Procedure detailed earlier in this section. 4. Locate the Input Filter board. See F[...]

  • Page 57

    INPUT FILTER BOARD - Checks the correct voltages as indicated on the above drawing CN 1/1-2 CN 1/3-4 V AC 2.3V (1.2V) “PE” EARTH CONNECTION POWER SUPPL Y “OUT” 230V (115V) 230V (115V) POWER SUPPL Y “IN” 230V (115V) RV1 RV2 PZ1 PZ2 FIGURE F .5 – INPUT FIL TER BOARD INPUT FIL TER BOARD TEST (continued) NOTE 1: A varistor ZN1 is placed b[...]

  • Page 58

    NOTES F-18 F-18 INVERTEC® V205-T AC/DC™ Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC[...]

  • Page 59

    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 thr[...]

  • Page 60

    BACK SIDE MAIN BOARD FIGURE F .6 – MAIN IGBT INVERTER BOARD LOCA TION MAIN IGBT INVERTER BOARD LOW VOL T AGE TEST (continued) PROCEDURE 1. Remove input power to the V205-T machine. 2. Using a phillips head screwdriver , remove the case wraparound cover . 3. Perform the Capacitor Discharge Procedure detailed earlier in this section. 4. Locate the [...]

  • Page 61

    MAIN IGBT INVERTER BOARD LOW VOL T AGE TEST (continued) TROUBLESHOOTING AND REP AIR F-21 F-21 INVERTEC® V205-T AC/DC™ T able F .1 T est Points ON ON ON ON ON ON ON ON TP13-TP14 TP1 1-TP14 TP12-TP14 TP3-TP5 TP4-TP5 TP17-TP18 TP21-TP18 TP2[+],TP18[-] L2 L3 L1 L4 L5 L6 L7 --- +15 VDC +5 VDC +15 VDC +24 VDC +48 VDC +15 VDC +15 VDC +14.5 VDC Machine [...]

  • Page 62

    TP2 TP5 TP4 TP3 L4 MF2 L1 L5 L3 L2 TP14 TP13 TP12 TP11 L6 TP17 TP18 TP21 L10 L7 FIGURE F .7 – MAIN IGBT INVERTER BOARD LOCA TION This is an illustration of the upper right corner of the P .C. board MAIN IGBT INVERTER BOARD LOW VOL T AGE TEST (continued) TROUBLESHOOTING AND REP AIR F-22 F-22 INVERTEC® V205-T AC/DC™ Return to Section TOC Return [...]

  • Page 63

    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 thr[...]

  • Page 64

    Control/Display Board FIGURE F .8 – CONTROL/DISPLA Y BOARD LOCA TION CONTROL/DISPLA Y BOARD TEST (continued) PROCEDURE 1. Remove input power to the V205-T machine. 2. Using a phillips head screwdriver , remove the case wraparound cover . 3. Perform the Capacitor Discharge Procedure detailed earlier in this section. 4. Locate the control/display b[...]

  • Page 65

    CN1 CN7 CN2 FIGURE F .9 – CONTROL/DISPLA Y BOARD LOCA TION CONTROL/DISPLA Y BOARD TEST (continued) TROUBLESHOOTING AND REP AIR F-25 F-25 INVERTEC® V205-T AC/DC™ Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC[...]

  • Page 66

    CN2 41 1 2 3 4 42 45 CN1 44 1 2 3 4 7 8 6 5 48 52 53 54 CN7 2 3 5 6 73 76 1 4 72 71 58 FIGURE F .10 – PLUGS CN1, CN2 & CN7 CONTROL/DISPLA Y BOARD TEST (continued) TROUBLESHOOTING AND REP AIR F-26 F-26 INVERTEC® V205-T AC/DC™ T able F .2 Plug CN1 T est Points T able F .3 Plug CN2 T est Points T able F .4 Plug CN7 T est Points Wire # 52 53 5[...]

  • Page 67

    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 thr[...]

  • Page 68

    BUS BOARD FIGURE F .1 1 – BUS BOARD LOCA TION BUS BOARD TEST (continued) PROCEDURE 1. Remove input power to the V205-T machine. 2. Using a phillips head screwdriver , remove the case wraparound cover . 3. Perform the Capacitor Discharge Procedure detailed earlier in this section. 4. Locate the Bus board and associated plugs. Do not remove plugs f[...]

  • Page 69

    BUS BOARD TEST (continued) TROUBLESHOOTING AND REP AIR F-29 F-29 INVERTEC® V205-T AC/DC™ T ABLE F .5 PLUG CN2 TEST POINTS T ABLE F .6 PLUG CN3 TEST POINTS Wire # 21 22 23 24 26 27 28 29 30 32 Description Thermal T rigger Output Hall Probe Hall Probe Ground Gate Switch B Ground Gate Switch A Thermal T rigger (AC Unit) Ground Hall Probe Hall Probe[...]

  • Page 70

    F1 F2 F3 CN7 CN3 CN4 CN2 CN1 FIGURE F .12 – BUS BOARD PLUG LOCA TIONS CN4 45 1 2 3 4 7 8 6 5 48 41 42 44 CN2 27 1 2 3 4 9 10 8 7 28 22 23 24 5 6 11 12 26 21 29 30 32 CN3 2 3 5 6 1 4 65 61 63 64 66 FIGURE F .13 – PLUGS CN2, CN3, CN4 BUS BOARD TEST (continued) TROUBLESHOOTING AND REP AIR F-30 F-30 INVERTEC® V205-T AC/DC™ Return to Section TOC [...]

  • Page 71

    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 thr[...]

  • Page 72

    BACK SIDE MAIN BOARD FIGURE F .14 – LOCA TION ON MAIN BOARD T ABLE F .10 – VOL T AGE CHECKS WITH 1 15 V AC APPLIED TO MACHINE T ABLE F .1 1 – RESIST ANCE CHECKS MAIN INVERTER BOARD POWER F ACTOR SECTION TEST (continued) PROCEDURE 1. Remove input power to the V205-T machine. 2. Using a phillips head screwdriver , remove the case wraparound cov[...]

  • Page 73

    TP9 GNDPWR R82 F1 TP20 MF8 RL1 PO WER INPUT 2 3 0 VA C ( 1 1 5 ) DD1 MF9 L10 G G S S S S D K K A A D FIGURE F .15 – POWER F ACTOR AREA ON MAIN BOARD NOTE: Power Factor Section is located at the upper left section of main board MAIN INVERTER BOARD POWER F ACTOR SECTION TEST (continued) TROUBLESHOOTING AND REP AIR F-33 F-33 INVERTEC® V205-T AC/DC?[...]

  • Page 74

    NOTES F-34 F-34 INVERTEC® V205-T AC/DC™ Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC[...]

  • Page 75

    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 thr[...]

  • Page 76

    Output Filter Board FIGURE F .16 – OUTPUT FIL TER BOARD LOCA TION OUTPUT FIL TER BOARD TEST (continued) PROCEDURE 1. Remove input power to the V205-T machine. 2. Using a phillips head screwdriver , remove the case wraparound cover . 3. Perform the Capacitor Discharge Procedure detailed earlier in this section. 4. Locate the Output Filter board an[...]

  • Page 77

    - + CN1 CN1 2 3 5 6 1 4 66 53 65 54 64 FIGURE F .17 – OUTPUT FIL TER BOARD PLUG LOCA TION FIGURE F .18 – OUTPUT FIL TER BOARD PLUG CN1 T ABLE F .12 – PLUG CN1 TEST POINTS OUTPUT FIL TER BOARD TEST (continued) TROUBLESHOOTING AND REP AIR F-37 F-37 INVERTEC® V205-T AC/DC™ Wire # 53 54 64[-],66[+] 65 Description T rigger T rigger Output V olt[...]

  • Page 78

    NOTES F-38 F-38 INVERTEC® V205-T AC/DC™ Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC[...]

  • Page 79

    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 thr[...]

  • Page 80

    OUTPUT TRANSIST OR OUTPUT DIODES FIGURE F .19 – SECONDAR Y POWER BOARD LOCA TION SECONDAR Y OUTPUT BOARD ASSEMBL Y TEST (continued) PROCEDURE 1. Remove input power to the V205-T machine. 2. Using a phillips head screwdriver , remove the case wraparound cover . 3. Perform the Capacitor Discharge Procedure detailed earlier in this section. 4. Locat[...]

  • Page 81

    GA SA SB GB I I I I 10K Ohms 10K Ohms 1 2 3 A B FIGURE F .20 – SECONDAR Y POWER BOARD TEST POINT LOCA TIONS SECONDAR Y OUTPUT BOARD ASSEMBL Y TEST (continued) TROUBLESHOOTING AND REP AIR F-41 F-41 INVERTEC® V205-T AC/DC™ T ABLE F .13 – VOL T AGE CHECKS WITH 1 15 V AC APPLIED TO MACHINE Generator/Mode ON/STICK ON/STICK ON/STICK ON/STICK ON/ST[...]

  • Page 82

    MODE POSITIVE METER PROBE NEGA TIVE METER PROBE EXPECTED READING MACHINE OFF TEST POINT A TEST POINT 3 LOW - LESS THAN 200 OHMS MACHINE OFF TEST POINT 3 TEST POINT A HIGH - MORE THAN 1000 OHMS MACHINE OFF TEST POINT B TEST POINT 3 LOW - LESS THAN 200 OHMS MACHINE OFF TEST POINT 3 TEST POINT B HIGH - MORE THAN 1000 OHMS MACHINE OFF TEST POINT 2 TEST[...]

  • Page 83

    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 thr[...]

  • Page 84

    BACK SIDE MAIN BOARD FIGURE F .21 – MAIN BOARD LOCA TION MAIN INVERTER BOARD “WELDING LOGIC AND INVERTER” SECTION TEST (continued) PROCEDURE 1. Remove input power to the V205-T machine. 2. Using a phillips head screwdriver , remove the case wraparound cover . 3. Perform the Capacitor Discharge Procedure detailed earlier in this section. 4. Lo[...]

  • Page 85

    T ABLE F .15 – LED FUNCTION T ABLE F .16 – FEEDBACK VOL T AGE SIGNALS MAIN INVERTER BOARD “WELDING LOGIC AND INVERTER” SECTION TEST (continued) TROUBLESHOOTING AND REP AIR F-45 F-45 INVERTEC® V205-T AC/DC™ T ABLE F .18 – LED (CHECK IN STICK MODE) Generator/Mode ON/STICK ON/STICK ON/STICK ON/STICK Component L1 1 L12 L13 L14 V alue ON AN[...]

  • Page 86

    TP15 TP14 TP16 TP19 TP31 CN4/1-2 Shor t Cir cuit 0.3 Ohms L9 L8 CN5/1-2 Shor t Cir cuit 0.3 Ohms FIGURE F .22 – MAIN BOARD (INVERTER SECTION) MAIN INVERTER BOARD “WELDING LOGIC AND INVERTER” SECTION TEST (continued) TROUBLESHOOTING AND REP AIR F-46 F-46 INVERTEC® V205-T AC/DC™ Return to Section TOC Return to Section TOC Return to Section T[...]

  • Page 87

    L11 L14 TP9 GROUND PO WER MF11 MF15 MF16 MF12 L13 L12 D S S G SS SS S S G G G D D D FIGURE F .23 – MAIN BOARD (LOWER LEFT) MAIN INVERTER BOARD “WELDING LOGIC AND INVERTER” SECTION TEST (continued) TROUBLESHOOTING AND REP AIR F-47 F-47 INVERTEC® V205-T AC/DC™ Return to Section TOC Return to Section TOC Return to Section TOC Return to Sectio[...]

  • Page 88

    NOTES F-48 F-48 INVERTEC® V205-T AC/DC™ Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC[...]

  • Page 89

    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 thr[...]

  • Page 90

    INPUT FIL TER BO ARD FIGURE F .24 – INPUT FIL TER BOARD LOCA TION S/L1 R/L1 FIGURE F .25 – INPUT FIL TER BOARD LEADS INPUT FIL TER BOARD REMOV AL AND REPLACEMENT (continued) PROCEDURE 1. Remove input power to the V205-T . 2. Using a phillips head screwdriver remove the case wraparound cover . 3. Perform the Input Filter Capacitor Discharge Proc[...]

  • Page 91

    R V1 R V2 FIGURE F .26 – MAIN IGBT BOARD LEAD REMOV AL INPUT FIL TER BOARD REMOV AL AND REPLACEMENT (continued) Observe static precautions detailed in PC Board Troubleshooting Procedures at the beginning of this section. 7. Clean RTV off of the top of the input filter board mounting slides. 8. Release the board by simply pressing the two metal bu[...]

  • Page 92

    NOTES F-52 F-52 INVERTEC® V205-T AC/DC™ Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC[...]

  • Page 93

    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 thr[...]

  • Page 94

    BACK SIDE MAIN BOARD FIGURE F .27 – MAIN IGBT BOARD LOCA TION MAIN IGBT BOARD REMOV AL AND REPLACEMENT (continued) PROCEDURE 1. Remove input power to the V205-T . 2. Using a phillips head screwdriver remove the case wraparound cover . 3. Perform the Input Filter Capacitor Discharge Procedure detailed earlier in this section. 4. Locate the main IG[...]

  • Page 95

    R V1 R V2 R V4 R V3 CN1 CN2 CN3 CN4 CN5 R V6 R V7 R V5 FIGURE F .28 – MAIN BOARD PLUG AND MOUNTING SCREW LOCA TION MAIN IGBT BOARD REMOV AL AND REPLACEMENT (continued) 10. Reconnect previously removed leads RV1 thru RV7 to the P .C. board. See Wiring Diagram if necessary . 1 1. Reconnect previously removed plugs CN1 thru CN5 to the P .C. board. N[...]

  • Page 96

    NOTES F-56 F-56 INVERTEC® V205-T AC/DC™ Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC[...]

  • Page 97

    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 thr[...]

  • Page 98

    Control/Display Board FIGURE F .29 – CONTROL/DISPLA Y BOARD LOCA TION CONTROL/DISPLA Y BOARD REMOV AL AND REPLACEMENT (continued) PROCEDURE 1. Remove the input power to the V205-T . 2. Using a phillips head screwdriver remove the four screws from the corners of the name- plate/keypad on the front of the machine. See Figure F .30. Observe static p[...]

  • Page 99

    ® PARAMETER SELECT / HOLD PULSE ON UPSLOPE % ON TIME DOWNSLOPE FINISH CURRENT B ACKGRO UND CURRENT POSTFLOW WELD CURRENT sec sec sec MODE STICK DC T IG AC TIG WAR NI NG TRIGGER 4-STEP 2-STEP LOCAL REMOTE OUTPUT A PULSE FREQUENCY Hz V AC FREQUENCY Hz AC BALANCE % EN 4 Phillips Head Screws FIGURE F .30 – MET AL DISPLA Y PLA TE CN1 CN2 CN7 CN3 Gr o[...]

  • Page 100

    NOTES F-60 F-60 INVERTEC® V205-T AC/DC™ Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC[...]

  • Page 101

    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 thr[...]

  • Page 102

    Output Filter Board FIGURE F .32 – OUTPUT FIL TER BOARD LOCA TION OUTPUT FIL TER BOARD REMOV AL AND REPLACEMENT (continued) PROCEDURE 1. Remove input power to the V205-T . 2. Using a phillips head screwdriver , remove the case wraparound cover . 3. Perform the Input Filter Capacitor Discharge Procedure detailed earlier in this section. 4. Using a[...]

  • Page 103

    Phillips Head Screws ® PARAMETER SELECT / HOLD PULSE ON UPSLOPE % ON TIME DOWNSLOPE FINISH CURRENT BACKGROUND CURRENT POSTFLOW WELD CURRENT sec sec sec MODE STICK DC TIG AC TIG WARNING TRIGGER 4-STEP 2-STEP LOCAL REMOTE OUTPUT A PULSE FREQUENCY Hz V AC FREQUENCY Hz AC BALANCE % EN Phillips Head Screws Casefront Mounting Screws FIGURE F .33 – CAS[...]

  • Page 104

    - + CN1 CN2 Po s i t i v e Output Te r m i n a l Nut FIGURE F .34 – OUTPUT FIL TER BOARD OUTPUT FIL TER BOARD REMOV AL AND REPLACEMENT (continued) 18. Reconnect lead CN7 previously removed from the control/display board assembly . 19. Replace the large nut previously removed from around the positive output terminal. 20. Replace the two output fil[...]

  • Page 105

    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 thr[...]

  • Page 106

    OUTPUT DIODES FIGURE F .35 – OUTPUT DIODE LOCA TION OUTPUT DIODES REMOV AL AND REPLACEMENT (continued) TO REPLACE ANY OF THE OUTPUT DIODES (D1, D2, D3 OR D4) 1. Remove input power to the V205-T . 2. Using a phillips head screwdriver , remove the case wraparound cover . 3. Perform the Input Filter Capacitor Discharge Procedure detailed earlier in [...]

  • Page 107

    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 thr[...]

  • Page 108

    Output T ransistor FIGURE F .36 – OUTPUT TRANSISTOR LOCA TION OUTPUT TRANSISTOR REMOV AL AND REPLACEMENT (continued) PROCEDURE 1. Remove input power to the V205-T . 2. Using a phillips head screwdriver , remove the case wraparound cover . 3. Perform the Input Filter Capacitor Discharge Procedure detailed earlier in this section. 4. Locate the out[...]

  • Page 109

    1 2 3 Plug CN1 5mm Allen Bolts FIGURE F .37 – OUTPUT TRANSISTOR LEAD LOCA TION OUTPUT TRANSISTOR REMOV AL AND REPLACEMENT (continued) TROUBLESHOOTING AND REP AIR F-69 F-69 INVERTEC® V205-T AC/DC™ Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TO[...]

  • Page 110

    NOTES F-70 F-70 INVERTEC® V205-T AC/DC™ Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC[...]

  • Page 111

    T ABLE OF CONTENTS - DIAGRAM SECTION G-1 G-1 INVERTEC® V205-T AC/DC™ T ABLE OF CONTENTS -ELECTRICAL DIAGRAMS SECTION- ELECTRICAL DIAGRAMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SECTION G WIRING DIAGRAM (CODE 10860 ONL Y) . . . . . . . . . . . . . . . . . . . . . . . . .[...]

  • Page 112

    ELECTriCaL DiaGramS G-2 iNVErTEC® V205-T aC/DC™ WiriNG DiaGram - V205-T aC/DC ST aNDarD DiaGram * *T o Ground according to National Electrical Code G-2 NOTE: This diagram is for reference only . It may not be accurate for all machines covered by this manual. The wiring diagram specific to your code is pasted inside one of the enclosure panels of[...]