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Lincoln Electric V205-T manual

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Table of contents for the manual

  • Page 1

    SVM161-A February , 200 6 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 pr oper 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

    ii V205-T AC/DC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC 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-ventila[...]

  • Page 3

    iii iii V205-T AC/DC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC SAFETY ARC RA YS can burn. 4.a. Use a shield with the proper filter and cover plates to protect your eyes from sparks and the rays of the arc when welding or observing open arc welding. Headshield and filter lens should conform to ANSI Z87. I st[...]

  • Page 4

    iv iv V205-T AC/DC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC FOR ELECTRICALL Y powered equipment. 8.a. T urn 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 manuf[...]

  • Page 5

    v v V205-T AC/DC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC SAFETY 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: Sû[...]

  • Page 6

    vi vi V205-T AC/DC MASTER T ABLE OF CONTENTS FOR ALL SECTIONS Page Safety .................................................................................................................................................i-iv Installation .................................................................................................................[...]

  • Page 7

    A-1 A-1 V205-T AC/DC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC T ABLE OF CONTENTS - INST ALLA TION SECTION - INST ALLA TION ...................................................................................................................... Section A T echnical Specifications .............................[...]

  • Page 8

    TIME-DELA Y CIRCUIT BREAKER OR FUSE SIZE (AMPS) 30A A-2 A-2 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 INST ALLA TION Input Amps 34A 28A 20A 34A 25A 20A 30A 23A 19A 30A 18A 15A T ype of Output AC/DC Output Am[...]

  • Page 9

    A-3 A-3 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 INST ALLA TION MACHINE GROUNDING AND HIGH FRE- QUENCY INTERFERENCE PROTECTION The Capacitor Discharge Circuit used in the high fre- quency generator , may ca[...]

  • Page 10

    A-4 A-4 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 INST ALLA TION 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[...]

  • Page 11

    A-5 A-5 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 In all cases, the green or green/yellow grounding wire must be connected to the grounding pin of the plug, usu- ally identified by a green screw . Attachment[...]

  • Page 12

    A-6 A-6 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 INST ALLA TION 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 [...]

  • Page 13

    A-7 A-7 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 INST ALLA TION REMOTE CONTROL CONNECTION A remote control receptacle is provided on the lower center case front of the welder for connecting a remote control[...]

  • Page 14

    NOTES A-8 A-8 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 15

    B-1 B-1 V205-T AC/DC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC T ABLE OF CONTENTS - OPERA TION SECTION - Operation ............................................................................................................................... Section B Safety Instructions ...................................[...]

  • Page 16

    B-2 B-2 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 OPERA TION Read and understand this entire section before operating your machine. SAFETY INSTRUCTIONS ELECTRIC SHOCK can kill. • Do not touch electrically [...]

  • Page 17

    B-3 B-3 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 OPERA TION 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 &q[...]

  • Page 18

    B-4 B-4 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 OPERA TION 1. Input V oltage warning light green LED - Indicates that the machine is on and input voltage is within acceptable range. 2. Thermal Shutdown Lig[...]

  • Page 19

    B-5 B-5 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 OPERA TION 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[...]

  • Page 20

    B-6 B-6 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 OPERA TION 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 controll[...]

  • Page 21

    B-7 B-7 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 OPERA TION 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[...]

  • Page 22

    B-8 B-8 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 OPERA TION WELDING POLARITY DC Electrode Negative Polarity (Direct Current Straight Polarity) (see FIGURE B.4) While Welding, there is a continuous flow of e[...]

  • Page 23

    B-9 B-9 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 A.C.- PULSED TIG OPERA TION DC Electrode Positive Polarity . (Direct Current Reverse Polarity) (see Figure B.5) In this case, there is a continuous flow of e[...]

  • Page 24

    B-10 B-10 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 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 va[...]

  • Page 25

    B-11 B-11 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 OPERA TION 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[...]

  • Page 26

    B-12 B-12 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 OPERA TION DC TIG WELDING QUICK ST ART UP ELECTRIC SHOCK can kill. • Have an electrician install and service this equipment. • T urn the input power of[...]

  • Page 27

    C-1 C-1 V205-T AC/DC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC T ABLE OF CONTENTS - ACCESSORIES - Accessories ........................................................................................................................... Section C Options/Accessories.............................................[...]

  • Page 28

    C-2 C-2 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 ACCESSORIES OPTIONAL ACCESSORIES AND COMP A TIBLE EQUIPMENT Factory Installed T wist-Mate Cable Connectors 1 – standard for Ground Clamp 1 – Gas Pass thr[...]

  • Page 29

    D-1 D-1 V205-T AC/DC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC T ABLE OF CONTENTS -MAINTENANCE- Maintenance ......................................................................................................................... Section D Input Filter Capacitor Dischar ge Procedur e .......................[...]

  • Page 30

    D-2 D-2 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 MAINTENANCE SAFETY PRECAUTIONS ELECTRIC SHOCK can kill. • Have an electrician install and service this equipment. • T urn the input power off at the fuse[...]

  • Page 31

    Section E-1 Section E-1 V205-T AC/DC Theory of Operation ............................................................................................................. Section E General Description ............................................................................................................ ........E-2 Input Board and Bus Boar d .....[...]

  • Page 32

    FIGURE E.2 – GENERAL DESCRIPTION, INPUT BOARD & BUS BOARD Superimposition board Bus board Fan Input board HF board Main IGBT & Power board 4 IGBT’s Control board Display & LED board 888 Control Knob Gas Solenoid DC blocking capacitor board Main Transformer Output board Output Transistor Module Current Hall Device Output Filter bd. ([...]

  • Page 33

    MAIN IGBT INVER TER BOARD The filtered input voltage, fr om the Input Board, is applied through an input choke to the Main IGBT Inverter Board. This input voltage is r ectified, regulat- ed and a unity power factor output is developed for the main welding IGBT s. This unity power factor cir- cuit provides several advantages over a traditional bridg[...]

  • Page 34

    THEOR Y OF OPERA TION E-4 E-4 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 FIGURE E.4 – MAIN TRANSFORMER, OUTPUT DIODE MODULE & CLAMPING BOARD, OUTPUT TRANSISTOR MODULE & SUPERIMPOSITION BOARD Superim[...]

  • Page 35

    CONTROL/DISPLA Y BOARD The Control/Display Boar d 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 V205-T machine. The Control Boar d functions as the suppo[...]

  • Page 36

    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, zer o volts relative to the source, and ther efore, no curr ent flow . The drain te[...]

  • Page 37

    V205-T AC/DC Section F-1 Section F-1 Tr oubleshooting & Repair Section ................................................................................. Section F How to Use T roubleshooting Guide ....................................................................................F-2 PC Board T roubleshooting Pr ocedures and Replacement .......[...]

  • Page 38

    HOW TO USE TROUBLESHOOTING GUIDE Service and repair should be performed by only Lincoln Electric Factory T rained Personnel. Unauthorized repairs performed on this equipment may r esult in danger to the technician and machine operator and will invalidate your factory warranty . For your safety and to avoid Electrical Shock, please observe all safet[...]

  • Page 39

    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 TROUBLESHOOTING & REP AIR F-3 F-3 Sometimes machine failures appear to be due to PC board failures. These problems can sometimes be traced to poor electrical con[...]

  • Page 40

    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 V205-T AC/DC TROUBLESHOOTING & REP AIR F-4 F-4 Observe Safety Guidelines TROUBLESHOOTING GUIDE detailed in the beginning of this manual. CAUTION If for any reason you do not [...]

  • Page 41

    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 V205-T AC/DC TROUBLESHOOTING & REP AIR F-5 F-5 TROUBLESHOOTING GUIDE Observe Safety Guidelines detailed in the beginning of this manual. CAUTION If for any reason you do not [...]

  • Page 42

    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 V205-T AC/DC TROUBLESHOOTING & REP AIR F-6 F-6 Observe Safety Guidelines TROUBLESHOOTING GUIDE detailed in the beginning of this manual. CAUTION If for any reason you do not [...]

  • Page 43

    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 V205-T AC/DC TROUBLESHOOTING & REP AIR F-7 F-7 Observe Safety Guidelines TROUBLESHOOTING GUIDE detailed in the beginning of this manual. CAUTION If for any reason you do not [...]

  • Page 44

    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 V205-T AC/DC TROUBLESHOOTING & REP AIR F-8 F-8 Observe Safety Guidelines TROUBLESHOOTING GUIDE detailed in the beginning of this manual. CAUTION If for any reason you do not [...]

  • Page 45

    TROUBLESHOOTING & REP AIR F-9 F-9 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 EXTERNAL DIAGNOSTICS ® P ARAMETER SELECT / HOLD PULSE ON UPSLOPE % ON TIME DOWNSLOPE FINISH CURRENT BA CKGROUND CURRENT POSTFL[...]

  • Page 46

    TROUBLESHOOTING & REP AIR F-10 F-10 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 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[...]

  • Page 47

    TROUBLESHOOTING & REP AIR INTERNAL DIAGNOSTICS (Continued) F-11 F-11 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 LED L1 L2 L3 L4 L5 L6 L7 L8 L9 L10 L1 1 L12 L13 L14 Definition -15VDC supply by 15.14.316 fo[...]

  • Page 48

    NOTES F-12 F-12 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 49

    W ARNING 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 TROUBLESHOOTING & REP AIR F-13 F-13 V205-T AC/DC INPUT FIL TER CAP ACITOR DISCHARGE PROCEDURE Service and repair should be performed by only Lincoln Electric factory[...]

  • Page 50

    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 TROUBLESHOOTING & REP AIR F-14 F-14 V205-T AC/DC ELECTRIC SHOCK can kill. • Have an electrician install and service this equipment. • T urn the input power off at the fus[...]

  • Page 51

    INPUT FIL TER BOARD TEST Service and repair should be performed by only Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may r esult 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 an[...]

  • Page 52

    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 TROUBLESHOOTING & REP AIR F-16 F-16 V205-T AC/DC INPUT FIL TER BOARD TEST (continued) FIGURE F .4 INPUT FIL TER BOARD TEST PROCEDURE 1. Remove input power to the V205-T . 2. [...]

  • Page 53

    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 TROUBLESHOOTING & REP AIR F-17 F-17 V205-T AC/DC INPUT FIL TER BOARD TEST (continued) FIGURE F .5 INPUT FIL TER BOARD Note 1: A varistor ZN1 is placed between the two power s[...]

  • Page 54

    NOTES F-18 F-18 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 55

    TROUBLESHOOTING & REP AIR F-19 F-19 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 MAIN IGBT INVER TER BOARD LOW VOL T AGE TEST Service and repair should be performed by only Lincoln Electric factory trained [...]

  • Page 56

    TEST PROCEDURE 1. Remove input power to the V205-T machine. 2. Using a phillips head scr ewdriver , remove the case wraparound cover . 3. Perform the Capacitor Discharge P r ocedu r e detailed earlier in this section. 4. Locate the Main IGBT Inverter board. See Figure F .6. 5. Use the voltmeter to perform the tests detailed in T able F .1. See the [...]

  • Page 57

    TROUBLESHOOTING & REP AIR F-21 F-21 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 MAIN IGBT INVER TER BOARD LOW VOL T AGE TEST (CONTINUED) T ABLE F .1 TEST POINTS ON ON ON ON ON ON ON ON TP13-TP14 TP1 1-TP14[...]

  • Page 58

    TROUBLESHOOTING & REP AIR F-22 F-22 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 MAIN IGBT INVER TER BOARD LOW VOL T AGE TEST (CONTINUED) FIGURE F .7 MAIN IGBT INVERTER BOARD LOCA TION TP2 TP5 TP4 TP3 L4 MF[...]

  • Page 59

    F-23 F-23 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 TROUBLESHOOTING & REP AIR CONTROL/DISPLA Y BOARD TEST Service and repair should be performed by only Lincoln Electric factory trained personnel. Unauth[...]

  • Page 60

    TEST PROCEDURE 1. Remove input power to the V205-T machine. 2. Using a phillips head scr ewdriver , remove the case wraparound cover . 3. Perform the Capacitor Discharge Procedure detailed earlier in this section. 4. Locate the control/display boar d and asso- ciated plugs . Do not remove plugs fr om the board. See Figur e F .8. 5. Carefully apply [...]

  • Page 61

    TROUBLESHOOTING & REP AIR F-25 F-25 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 CONTROL/DISPLA Y BOARD TEST (CONTINUED) CN1 CN7 CN2 FIGURE F .9 CONTROL/DISPLA Y BOARD LOCA TION[...]

  • Page 62

    TROUBLESHOOTING & REP AIR CONTROL/DISPLA Y BOARD TEST (CONTINUED) F-26 F-26 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 FIGURE F .10 PLUGS CN1, CN2 & CN7 CN2 41 1 2 3 4 42 45 CN1 44 1 2 3 4 7 8 6 5 48 [...]

  • Page 63

    BUS BOARD TEST Service and repair should be performed by only Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may r esult 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 precauti[...]

  • Page 64

    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 TROUBLESHOOTING & REP AIR F-28 F-28 V205-T AC/DC BUS BOARD TEST (continued) TEST PROCEDURE 1. Remove input power to the V205-T machine. 2. Using a phillips head screwdriver ,[...]

  • Page 65

    TROUBLESHOOTING & REP AIR F-29 F-29 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 BUS BOARD TEST (continued) T ABLE F .5 PLUG CN2 TEST POINTS T ABLE F .6 PLUG CN3 TEST POINTS W ire # 21 22 23 24 26 27 28 29 [...]

  • Page 66

    TROUBLESHOOTING & REP AIR BUS BOARD TEST (continued) F-30 F-30 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 FIGURE F .13 PLUGS CN2, CN3, CN4 FIGURE F .12 BUS BOARD PLUG LOCA TIONS CN4 45 1 2 3 4 7 8 6 5 48 [...]

  • Page 67

    MAIN INVER TER BOARD “UPFR” SECTION TEST Service and repair should be performed by only Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may r esult in danger to the technician or machine operator and will invalidate your factory warranty . For your safety and to avoid electrical shock, please observe[...]

  • Page 68

    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 TROUBLESHOOTING & REP AIR F-32 F-32 V205-T AC/DC MAIN INVER TER BOARD “UPFR” SECTION TEST (continued) TEST PROCEDURE 1. Remove input power to the V205-T machine. 2. Using[...]

  • Page 69

    TROUBLESHOOTING & REP AIR F-33 F-33 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 FIGURE F .15 UPFR AREA ON MAIN BOARD TP9 GNDPWR R82 F1 TP20 MF8 RL1 PO WER INPUT 230 V A C (115) DD1 MF9 L10 G G S S S S D K [...]

  • Page 70

    NOTES F-34 F-34 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 71

    TROUBLESHOOTING AND REP AIR F-35 F-35 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 OUTPUT FIL TER BOARD TEST Service and repair should be performed by only Lincoln Electric factory trained personnel. Unauthoriz[...]

  • Page 72

    TROUBLESHOOTING AND REP AIR OUTPUT FIL TER BOARD TEST (continued) F-36 F-36 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 TEST PROCEDURE 1. Remove input power to the V205-T machine. 2. Using a phillips head scr [...]

  • Page 73

    TROUBLESHOOTING AND REP AIR OUTPUT FIL TER BOARD TEST (continued) F-37 F-37 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 FIGURE F .17 OUTPUT FIL TER BOARD PLUG LOCA TION FIGURE F .18 OUTPUT FIL TER BOARD PLUG C[...]

  • Page 74

    NOTES F-38 F-38 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

    TROUBLESHOOTING AND REP AIR F-39 F-39 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 SECONDAR Y POWER BOARD TEST Service and repair should be performed by only Lincoln Electric factory trained personnel. Unauthor[...]

  • Page 76

    TROUBLESHOOTING AND REP AIR SECONDAR Y POWER BOARD TEST (continued) F-40 F-40 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 TEST PROCEDURE 1. Remove input power to the V205-T machine. 2. Using a phillips head sc[...]

  • Page 77

    TROUBLESHOOTING AND REP AIR SECONDAR Y POWER BOARD TEST (continued) F-41 F-41 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 GA SA SB GB I I I I 10K Ohms 10K Ohms 1 2 3 FIGURE F .20 SECONDAR Y POWER BOARD TEST PO[...]

  • Page 78

    NOTES F-42 F-42 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

    TROUBLESHOOTING AND REP AIR F-43 F-43 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 MAIN INVER TER BOARD “WELDING LOGIC AND INVER TER” SECTION TEST Service and repair should be performed by only Lincoln Elec[...]

  • Page 80

    TROUBLESHOOTING AND REP AIR MAIN INVER TER BOARD “WELDING LOGIC AND INVER TER” SECTION TEST (continued) F-44 F-44 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 TEST PROCEDURE 1. Remove input power to the V20[...]

  • Page 81

    TROUBLESHOOTING AND REP AIR MAIN INVER TER BOARD “WELDING LOGIC AND INVER TER” SECTION TEST (continued) F-45 F-45 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 T ABLE F .14 LED FUNCTIONS T ABLE F .15 FEEDBAC[...]

  • Page 82

    TROUBLESHOOTING AND REP AIR MAIN INVER TER BOARD “WELDING LOGIC AND INVER TER” SECTION TEST (continued) F-46 F-46 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 TP15 TP14 TP16 TP19 TP31 CN4/1-2 Shor t Cir cui[...]

  • Page 83

    TROUBLESHOOTING AND REP AIR MAIN INVER TER BOARD “WELDING LOGIC AND INVER TER” SECTION TEST (continued) F-47 F-47 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 L11 L14 TP9 GROUND PO WER MF11 MF15 VDS MF16 MF[...]

  • Page 84

    NOTES F-48 F-48 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 85

    INPUT FIL TER BOARD REMOV AL AND REPLACEMENT Service and repair should be performed by only 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 [...]

  • Page 86

    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 V205-T AC/DC TROUBLESHOOTING & REP AIR F-50 F-50 PROCEDURE 1. Remove input power to the V205-T . 2. Using a phillips head screwdriver r emove the case wraparound cover . 3. P[...]

  • Page 87

    Observe static precautions detailed in PC Board Tr oubleshooting Procedures at the beginning of this section. 7. Clean RTV of f of the top of the input filter board mounting slides. 8. Release the board by simply pressing the two metal buttons at the ends of the board with your thumbs. Depressing these buttons will fr ee the plastic lock pins that [...]

  • Page 88

    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 NOTES F-52 F-52[...]

  • Page 89

    MAIN IGBT BOARD REMOV AL AND REPLACEMENT Service and repair should be performed by only Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may r esult 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[...]

  • Page 90

    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 V205-T AC/DC TROUBLESHOOTING & REP AIR F-54 F-54 FIGURE F .27 – MAIN IGBT BOARD LOCA TION BACK SIDE MAIN BOARD MAIN IGBT BOARD REMOV AL & REPLACEMENT (continued) PROCED[...]

  • Page 91

    TROUBLESHOOTING & REP AIR MAIN IGBT BOARD REMOV AL & REPLACEMENT (continued) F-55 F-55 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 FIGURE F .28 MAIN BOARD PLUG AND MOUNTING SCREW LOCA TIONS RV 1 RV 2 R[...]

  • Page 92

    NOTES F-56 F-56 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

    CONTROL/DISPLA Y BOARD REMOV AL AND REPLACEMENT Service and repair should be performed by only Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may r esult in danger to the technician or machine operator and will invalidate your factory warranty . For your safety and to avoid electrical shock, please obse[...]

  • Page 94

    PROCEDURE 1. Remove the input power to the V205-T . 2. Using a phillips head screwdriver r emove the four screws fr om the corners of the name- plate/keypad on the front of the machine. See Figure F .30. Observe static precautions detailed in PC Board Tr oubleshooting Procedures at the beginning of this section. Failure to do so can r esult in perm[...]

  • Page 95

    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 TROUBLESHOOTING & REP AIR F-59 F-59 FIGURE F .30 MET AL DISPLA Y PLA TE FIGURE F .31 CN1 CN2 CN7 CN3 Ground Wire 5 Mounting Nuts CONTROL/DISPLA Y BOARD REMOV AL [...]

  • Page 96

    NOTES F-60 F-60 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

    OUTPUT FIL TER BOARD REMOV AL AND REPLACEMENT Service and repair should be performed by only Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may r esult in danger to the technician or machine operator and will invalidate your factory warranty . For your safety and to avoid electrical shock, please observ[...]

  • Page 98

    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 TROUBLESHOOTING & REP AIR F-62 F-62 FIGURE F .32 OUTPUT FIL TER BOARD LOCA TION Output Filter Board OUTPUT FIL TER BOARD REMOV AL AND REPLACEMENT (continued) PRO[...]

  • Page 99

    TROUBLESHOOTING & REP AIR F-63 F-63 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 FIGURE F .33 CASE FRONT SCREW REMOV AL Phillips Head Screws ® P ARAMETER SELECT / HOLD PULSE ON UPSLOPE % ON TIME DOWNSLOPE [...]

  • Page 100

    TROUBLESHOOTING & REP AIR F-64 F-64 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 OUTPUT FIL TER BOARD REMOV AL AND REPLACEMENT (continued) FIGURE F .34 OUTPUT FIL TER BOARD 18. Reconnect lead CN7 pr eviousl[...]

  • Page 101

    OUTPUT DIODES REMOV AL AND REPLACEMENT Service and repair should be performed by only Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may r esult 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 s[...]

  • Page 102

    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 TROUBLESHOOTING & REP AIR F-66 F-66 FIGURE F .35 OUTPUT DIODE LOCA TION OUTPUT DIODES OUTPUT DIODES REMOV AL AND REPLACEMENT (continued) TO REPLACE ANY OF THE OU[...]

  • Page 103

    OUTPUT TRANSISTOR REMOV AL AND REPLACEMENT Service and repair should be performed by only Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may r esult in danger to the technician or machine operator and will invalidate your factory warranty . For your safety and to avoid electrical shock, please observe a[...]

  • Page 104

    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 output transistor . See Figure F .36. 5. Disconnect plug CN1 fr om the output transistor . See Figure F .37. 6. Using a ph[...]

  • Page 105

    TROUBLESHOOTING & REP AIR F-69 F-69 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 OUTPUT TRANSISTOR REMOV AL AND REPLACEMENT (continued) FIGURE F .37 OUTPUT TRANSISTOR LEAD LOCA TION 1 2 3 Plug CN1 5mm Allen[...]

  • Page 106

    NOTES F-70 F-70 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 107

    G-1 ELECTRICAL DIAGRAMS G-1 T ABLE OF CONTENTS -ELECTRICAL DIAGRAMS SECTION- ELECTRICAL DIAGRAMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SECTION G WIRING DIAGRAM (CODE 10860 ONL Y) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . G-2 * NOT[...]

  • Page 108

    ELECTRICAL DIAGRAMS G-2 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 your mach[...]

  • Page 109

    SVM ERROR REPORTING FORM We need to know if there are errors in our manuals. We also value any suggestions as to additional tests or procedures that would make this SVM a better tool for you. If you discover new or different “Problems or Symptoms” that are not covered in the three col- umn troubleshooting chart, please share this information wi[...]