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Lincoln Electric Invertec V205-T User's Manual

1. E 5 High Frequency Board E 5 Output Filter Board E 5 Insulated Gate Bipolar Transistor IGBT Operation E 6 TABLE OF CONTENTS THEORY OF OPERATION SECTION Superimposition board Bus board Fan Input board HF board Main IGBT amp Power board 4 IGBT s Control board Display amp LED board 888 Control Knob Gas Solenoid DC blocking capacitor board Main Transformer Output board Output Transistor Module Current Hall Device Output Filter bd bypass D E Remote 2 4 Remote 75 76 77 A B C 24 VDC Remote 2 4 path D E turn on AC ckt 15 15 5 input volt meter thermostat info set info input current meter turn on PWM HF control signal 48 24 Input Choke _ RF coil 48 24 15 15 5 reconnect info voltage feedback high volt supply turn on AC ckt current feedback IGBT Thermostats Output Diode Thermostat Voltage Feedback Current Feedback AC DC Gate drive signals 24 VDC 48 VDC Output Choke FIGURE E 1
2. B 10 AC TIG Welding Quick Start Up B 11 DC TIG Welding Quick Start Up B 12 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 OPERATION 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 qualified personnel should operate this equipment Observe all safety information throughout this manual GENERAL DESCRIPTION The Invertec V205 T AC DC is an industrial 200 amp arc welding power source which utilizes single phase input power to produce constant current output The welding response of this Invertec has been optimized for stick SMAW and TIG GTAW The unit is ideal for industrial applicat
3. Section E Troubleshooting and Repair Section F Safety Precautions F 2 How to Use Troubleshooting Guide F 2 Troubleshooting Guide F 4 Test Procedures F 9 Replacement Procedures F 49 Electrical Diagrams Section G Parts Manual P400 Series RETURN TO MAIN MENU A 1 A 1 V205 T AC DC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC TABLE OF CONTENTS INSTALLATION SECTION INSTALLATION
4. Section A Technical Specifications A 2 Select Suitable Location A 3 Machine Grounding High Frequency Interference Protection A 3 Reconnect Procedures A 4 Output Connections A 6 TIME DELAY 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 INSTALLATION Input Amps 34A 28A 20A 34A 25A 20A 30A 23A 19A 30A 18A 15A Type of Output AC DC Output Amps Volts at Rated Amperes Stick 110 24 4V 90 23 6V 70 22 8V TIG 150 16V 120 14 8V 100 14V Stick 180 27 2V 150 26V 130 25 2V TIG 200 18V 170 16V 140 15 6V Maximum Open Circuit Voltage 54 Volts Max Input Voltages 50 60 Hz 115 230 Duty Cycle 115V 35 60 100 115V 40 60 100 230V 35 60
5. B 2 Welding Capability B 2 Limitations B 2 Rear Control Panel B 3 Controls and Settings B 4 Set Up Menu B 7 Output Limitations B 8 DC TIG Welding B 8 Welding Polarity B 8 Steel TIG Welding B 10 Copper TIG Welding B 10 Tips for AC TIG Welding
6. Connect up the shielding gas typically argon using an appropriate regulator Connect foot amptrol torch and work lead to power source With the Work cable connected to a properly grounded work piece turn the power source on To change to DC TIG Welding Press Mode button to select DC TIG Press Trigger Mode button and set to 2 step Press Local Remote Mode button and set for Remote Pulsing parameters selected by Parameter button and changed using Output Control Set the maximum output current desired using the Output Control Initiate the arc by closing the Foot Amptrol s arc start switch The Amptrol will control the output current from 10 amps to current level set by output control To change the Post Flow time repeatedly push the Parameter button until the Post Flow indicator light is on Adjust the Output control to the desired Post Flow time as indicated on digital display To change from High Frequency to Lift Start turn power source off Press and hold the Parameter button while the power source is turned on A 0 in the center of the digital display indicates the Set Up Menu is now active Rotate the Output Control until 8 is displayed Press the Parameter button again and rotate the Output Control until 1 is displayed Press the Parameter button to accept this setting Rotate the Output Control until 0 is displayed Press the para meter button to exit the Set
7. WORK CLAMP WORK CABLE TIG TORCH WARNING FIGURE A 1 This unit does not include a TIG torch but one may be purchased separately The accessories section of this manual lists a number of Lincoln Electric TIG torches and TIG Torch Starter Packs that are recommended for use with this machine however any similar TIG torch can be used To attach the Twist Mate Plug to a Lincoln Torch slide the rubber boot onto the torch cable enlarge the boot opening if necessary screw the fit ting on the torch cable into the brass connector snugly and slide the boot back over the brass connector OUTPUT CONNECTION FOR STICK WELDING FIGURE A 2 First determine the proper electrode polarity for the electrode to be used Consult the electrode data for this information Then connect the output cables to the output terminals corresponding to this polarity For instance for DC welding connect the electrode cable which is connected to the electrode holder to the output terminal and the work cable which is connected to the work clamp to the output terminal Insert the connector with the key lining up with the key way and rotate clockwise until the connection is snug Do not over tighten TIG ADAPTER RETAINING COMPOUND STRAIN RELIEF BOOT TIG TORCH POWER CABLE WITH GAS FITING FIGURE A 2 WORK CABLE WORK CABLE STICK ELECTRODE HOLDER A 7 A 7 V205 T AC DC Return to Section TOC R
8. V205 T BLOCK LOGIC DIAGRAM Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC FIGURE E 2 GENERAL DESCRIPTION INPUT BOARD amp BUS BOARD Superimposition board Bus board Fan Input board HF board Main IGBT amp Power board 4 IGBT s Control board Display amp LED board 888 Control Knob Gas Solenoid DC blocking capacitor board Main Transformer Output board Output Transistor Module Current Hall Device Output Filter bd bypass D E Remote 2 4 Remote 75 76 77 A B C 24 VDC Remote 2 4 path D E turn on AC ckt 15 15 5 input volt meter thermostat info set info input current meter turn on PWM HF control signal 48 24 Input Choke _ RF coil 48 24 15 15 5 reconnect info voltage feedback high volt supply turn on AC ckt current feedback IGBT Thermostats Output Diode Thermostat Voltage Feedback Current Feedback AC DC Gate drive signals 24 VDC 48 VDC Output Choke GENERAL DESCRIPTION The Invertec V205T AC DC is an inverter based indus trial welding power source that utilizes single phase input power to produce constant current AC or DC output for both Stick SMAW and TIG GTAW With 230VAC input applied the V205T is rated at 200 amps 18volts at a 40 duty cycle With 115VAC applied the machine is rated at 150 amps 16 volts at a 40 duty
9. OPERATION 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 maintained as long or as short as nec essary 4 Release the TIG torch trigger The output current of the machine will turn OFF and the gas valve will remain open to continue the flow of the shielding gas The duration of this postflow time is adjusted by the Postflow parameter This operation is shown in 4 step diagram 1 Possible variations of this standard sequence are shown below By releasing and re pressing the TIG torch trigger dur ing the downslope step the output will immediately drop to and hold at the Finish Current Releasing the trigger will turn off the output and begin postflow This operation shown in 4 step diagram 2 9 Welding selection button Permits selection of the welding mode The LED beside the symbol confirm the selection Stick TIG DC TIG AC 10 Electrode Connection Negative For quick dis connect system using Twist MateTM cable plugs with gas pass through for TIG Torches 11 Remote Control Connector For the connection of a Lincoln Foot Amptrol Hand Amptrol or Arc Start Switch See the ACCESSORIES section for available options 12 Electrode Connection Positive
10. 48 VDC Output Choke 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 Transformer The transformer reduces the high voltage low current input applied to the primary winding and through transformer action develops a lower secondary voltage capable of high output currents OUTPUT MODULE AND CLAMPING BOARD The AC output of the Main Transformer is applied to the Output Modules for full wave rectification The Clamping Diodes function as a filter eliminating any pulsed over voltages that may be present at the Output Modules The Clamping Board protects the Output Modules from damage due to higher than nor mal voltage spikes OUTPUT MODULE TRANSISTOR BOARD This module produces the AC waveforms and fre quencies It receives command signals from the Superimposition Board Depending on which of the two IGBTs is active at any given moment the welding output of the machine can be either positive or nega tive AC or DC SUPERIMPOSITION BOARD The Super Imposition Board receives signals from the Control Display Board to control the status of the sec ondary inverter portion of the V205T machine This board also generates voltage pulses at about 200VDC that facilitate the re striking of the arc when the TIG AC welding current is being utilized The Superimposition Board internally generates the auxil iary power supply for the isolated pilot
11. 100 230V 40 60 100 Output Current Range 6 200 Amps INPUT SINGLE PHASE ONLY RATED OUTPUT OUTPUT Height Width Depth Weight 15 in 8 5 in 19 in Approx 38 lbs 381 mm 216 mm 483 mm 17 kgs PHYSICAL DIMENSIONS TECHNICAL SPECIFICATIONS V205 T AC DC TIG K1855 1 Code Number 10860 TEMPERATURE RANGES OPERATING TEMPERATURE RANGE 20 C to 40 C STORAGE TEMPERATURE RANGE 50 C to 85 C INPUT VOLTAGE FREQUENCY HZ 115 50 60 230 50 60 TYPE S SO ST STO OR EXTRA HARD USAGE INPUT CORD AWG 12 Max Input Current 34A at Rated Output 30A at Rated Output RECOMMENDED INPUT WIRE AND FUSE SIZES FOR MAXIMUM RATED OUTPUT 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 INSTALLATION 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 reduce or eliminate radiated interference The Invertec V205 T AC DC has been field tested under recommended installation conditions It com plies with FCC allowable limits for radiation Radiated interference can develop in the following four wa
12. CAUTIONS DE S RET POUR LES MACHINES SOUDER TRANSFORMATEUR ET REDRESSEUR 1 Relier la terre le chassis du poste conformement au code de l lectricit et aux recommendations du fabricant Le dispositif de montage ou la piece souder doit tre branch une bonne mise la terre 2 Autant que possible I installation et l entretien du poste seront effectu s par un lectricien qualifi 3 Avant de faires des travaux l interieur de poste la debranch er l interrupteur la boite de fusibles 4 Garder tous les couvercles et dispositifs de s ret leur place vi vi V205 T AC DC MASTER TABLE OF CONTENTS FOR ALL SECTIONS Page Safety i iv Installation Section A Operation Section B Accessories Section C Maintenance Section D Theory of Operation
13. FIGURE B 8 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 varied to focus the arc Increasing the AC frequency above 60Hz will narrow the cone shape arc from the tungsten s tip Decreasing the AC frequency below 60Hz will broaden the cone shape arc from the tungsten s tip The two above benefits can be used to maintain a tight focus of the arc for precise heat control and tight joint access Because of the AC inverters abilities in these areas the following recommendations are made as a starting point A 2 Thoriated tungsten is recommended instead of the Pure tungsten that is normally recommended for AC welding Thoriated tungstens emit electrons eas ier and therefore will improve starting Sharpen the tungsten to a point Normally it is rec ommended to pre ball a pure tungsten when AC welding with a conventional power source However the AC inverter with it s extended AC bal ance control minimized tungsten heating thus allow ing for a pointed tungsten to be used Set the AC Balance control to maximum 85 elec trode negative This can be reduced if the material welded is heavily oxidized however s
14. For quick dis connect system using Twist MateTM cable plugs 13 Welding Parameter Display LED s show which mode or welding parameter is activated for adjust ment If it is necessary to modify the welding parameters Item 13 Wait four seconds after the LED s on the panel have gone out the welding current LED will be lit Press the SETUP Parameter push button Item 4 every time the push button is pressed one of the LED s in the diagram Item 13 comes on in clockwise sequence and the value of the parameter appears on the Digital display Item 6 Stop at the desired parameter Rotate the Output Parameter Adjust Knob Item 5 and modify the parameter value Press the SETUP Parameter Item 4 push button again to pass to another parameter or wait five seconds and the Weld Current LED will come on again 4 STEP DIAGRAM 1 4 STEP DIAGRAM 2 WELDING PARAMETER DEFAULTS AND RANGES PARAMETER VALUE MIN MAX DEFAULT START CURRENT AMPS 6 MAX 15 UPSLOPE SEC 0 10 0 2 WELD CURRENT AMPS 6 MAX 100 DOWNSLOPE SEC 0 10 1 0 FINISH CURRENT AMPS 6 MAX 8 POSTFLOW SEC 0 2 60 5 0 PULSE FREQUENCY HZ 0 1 500 0 5 ON TIME 5 95 50 BACKGROUND CURRENT OF WELD CURRENT 1 100 20 AC FREQUENCY HZ 20 150 100 AC BALANCE EN 35 85 65 EN Electrode Negative MODE DC TIG TRIGGER 2 STEP LOCAL REMOTE LOCAL 3 4 Maximum Weld Current can be limited by input vo
15. In Electrode Positive Polarity high currents cannot be used since they would cause an excessive wear of the electrode NOTE The Invertec V205 T AC DC cannot be used for Electrode Positive TIG welding without special adapters FIGURE B 5 D C Pulsed TIG see Figure B 6 The use of pulsed direct current allows better control of the weld pool during certain operating conditions When compared with traditional TIG welding per formed at the same average current pulsed welding results in a smaller heat affected zone which results in fewer deformations and reduced chance of cracking and gas entrapment Increasing the frequency constricts the arc increases stability and improves weld quality FIGURE B 6 A C Alternating Current see Figure B 7 Alternating Current welding is typically used for Tig welding aluminum and its alloys or magnesium The polarity alternates between Electrode Positive and Electrode Negative EN During the positive half wave the oxide is broken During the negative half wave the electrode cools the workpiece melts and penetration occurs FIGURE B 7 Changing the wave balance alters the ratio between the cleaning and the penetrating current DC PULSED TIG DC TIG NOT PULSED Greater EN MORE PENETRATION 50 EN Lesser EN more CLEANING A C Pulsed TIG When AC welding a pulsed current can be used with similar effects to those described in pulsed direct cur rent welding
16. Return to Master TOC V205 T AC DC TROUBLESHOOTING amp REPAIR F 2 F 2 CAUTION CAUTION This Troubleshooting Guide is provided to help you locate and repair possible machine malfunctions Simply follow the three step procedure listed below Step 1 LOCATE PROBLEM SYMPTOM Look under the column labeled PROBLEM SYMPTOMS This column describes possible symptoms that the machine may exhibit Find the listing that best describes the symptom that the machine is exhibiting Symptoms are grouped into three main categories Output Problems Function Problems and Welding Problems Step 2 PERFORM EXTERNAL TESTS The second column labeled POSSIBLE AREAS OF MISADJUSTMENT S lists the obvious external possibilities that may contribute to the machine symptom Perform these tests checks in the order listed In general these tests can be conducted without removing the case wrap around cover Step 3 PERFORM COMPONENT TESTS The last column labeled Recommended Course of Action lists the most likely components that may have failed in your machine It also specifies the appropriate test procedure to verify that the subject component is either good or bad If there are a number of possible components check the components in the order listed to eliminate one possibility at a time until you locate the cause of your problem All of the referenced test procedures referred to in the Troubleshooting Guide ar
17. 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 WARNING Section E 1 Section E 1 V205 T AC DC Theory of Operation Section E General Description E 2 Input Board and Bus Board E 2 Main IGBT Inverter Board E 3 Main Transformer E 4 Output Module and Clamping Board E 4 Output Module Transistor Board E 4 Superimposition Board E 4 Control Display Board
18. cycle The machine has the capabilities to produce several varieties of AC waveforms square sinusoidal and triangular The unit also employs an auto recon nect feature that does not require manual intervention when the input power is changed from 115VAC to 230VAC or 230VAC to 115VAC When in the TIG mode the operator may select to use either the high frequen cy or touch start function INPUT BOARD AND BUS BOARD The single phase input voltage is applied to the V205T through a line switch located on the back of the machine The AC input voltage is filtered and condi tioned by a network of inductors capacitors and a varistor that are all located on the Input Board This fil tered input voltage is applied to the Main IGBT Inverter Board Another function of the Input Board is to pre vent high frequency inverter generated noise from being induced back into the supply lines The Bus Board performs several functions within the V205T It accepts and distributes power and informa tion to other circuitry This interfacing is accomplished through harness and ribbon connectors and also via other PC boards that are plugged directly into the Bus Board The Input Board the High Frequency Board and the AC Super Imposition Board plug into the Bus Board Circuitry located on the Main IGBT Inverter Board the Control Board the Output Module Board the Output Filter Board and the Hall Effect Device interface with the Bus Board Some circuit
19. special precautions should be used to prevent hazardous situations Refer to Safety in Welding and Cutting ANSI Standard Z49 1 and the operating information for the equipment being used 6 c When not welding make certain no part of the electrode circuit is touching the work or ground Accidental contact can cause overheating and create a fire hazard 6 d Do not heat cut or weld tanks drums or containers until the proper steps have been taken to insure that such procedures will not cause flammable or toxic vapors from substances inside They can cause an explosion even though they have been cleaned For information purchase Recommended Safe Practices for the Preparation for Welding and Cutting of Containers and Piping That Have Held Hazardous Substances AWS F4 1 from the American Welding Society see address above 6 e Vent hollow castings or containers before heating cutting or welding They may explode 6 f Sparks and spatter are thrown from the welding arc Wear oil free protective garments such as leather gloves heavy shirt cuffless trousers high shoes and a cap over your hair Wear ear plugs when welding out of position or in confined places Always wear safety glasses with side shields when in a welding area 6 g Connect the work cable to the work as close to the welding area as practical Work cables connected to the building framework or other locations away from the welding area increase the pos
20. 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 SECONDARY POWER BOARD TEST 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 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 troubleshooting assistance before you proceed Call 1 800 833 9353 WELD DESCRIPTION This test will help determine if the Secondary Power Board has shorted or damaged compo nents MATERIALS NEEDED Volt Ohmeter Phillips Head Screwdriver Wiring Diagram WARNING TROUBLESHOOTING AND REPAIR SECONDARY 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 screwdriver remove the case wraparound cover 3 Perform t
21. DISPLAY BOARD TEST CONTINUED FIGURE F 8 CONTROL DISPLAY BOARD LOCATION Control Display Board TROUBLESHOOTING amp REPAIR 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 DISPLAY BOARD TEST CONTINUED CN1 CN7 CN2 FIGURE F 9 CONTROL DISPLAY BOARD LOCATION TROUBLESHOOTING amp REPAIR CONTROL DISPLAY 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 amp CN7 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 TABLE F 2 PLUG CN1 TEST POINTS TABLE F 3 PLUG CN2 TEST POINTS TABLE F 4 PLUG CN7 TEST POINTS Wire 52 53 54 44 48 58 Description Solenoid Valve Ground Trigger Trigger Start High Frequency High Frequency Ground Start Solenoid Valve Expected Voltage 48 VDC Wire 71 72 73 74 75 76 Description Ext Ext Ext Ground Ext Trigger Ext Ground Ext Ground Expected Voltage 5 VDC Wire 41 42 45 Description Supply S
22. F 32 OUTPUT FILTER BOARD LOCATION Output Filter Board OUTPUT FILTER BOARD REMOVAL 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 phillips head screwdriver remove the four screws at the corners of the nameplate keypad See Figure F 33 5 Gently pull the Control Display board assembly forward and up to gain access to the two case front mounting screws located beneath See Figure F 33 NOTE There is no need to disconnect any leads from the P C boards located behind the nameplate keypad 6 Remove the two phillips head casefront mounting screws located behind the metal dis play plate See Figure F 33 7 Remove the four phillips head screws located around the output terminals on the lower front of the machine See Figure F 33 8 Carefully manipulate the casefront off of the machine TROUBLESHOOTING amp REPAIR 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 REMOVAL Phillips Head Screws PARAMETER SELECT HOLD PULSE ON UPSLOPE ON TIME DOWNSLOPE FINISH CURRENT BACKGROUND CURRENT POSTFL
23. IGBT Inverter Board May be Faulty Perform the Main IGBT Inverter Board Low Voltage Supply Test 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 amp REPAIR F 7 F 7 Observe Safety Guidelines TROUBLESHOOTING GUIDE detailed in the beginning of this manual CAUTION If for any reason you do not understand the test procedures or are unable to perform the test repairs safely con tact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed Call 1 800 833 9353 WELD FUNCTION PROBLEMS SYMPTOMS POSSIBLE AREAS OF MISADJUSTMENT S RECOMMENDED COURSE OF ACTION FUNCTION PROBLEMS No current regulation in the Stick mode Low open circuit voltage 1 Make sure the machine is set up and configured correctly for the Stick mode 1 The Superimposition Board may be faulty 2 The Output Module Transistor Board may be faulty See the Secondary Power Board Test and Wiring Diagram There is no response to changes to the output control settings No cur rent regulation in all modes 1 Make sure the correct input voltage is applied to the machine 230 or 115VAC 1 The Control Display board may be faulty Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master T
24. L13 Under Small PCB L12 L10 L9 L8 L4 L1 L5 L2 L3 L6 L7 FIGURE F 2 TROUBLESHOOTING amp REPAIR 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 L11 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 power front panel 48VDC supply by 15 14 316 for power front panel 15VDC supply by 15 14 316 for 15 14 316 UPFR part 15VDC supply by 15 14 316 for 15 14 316 UPFR part Output power enabled See pot signal amp LED Output Thermal Alarm UPFR on Gate MOS 11 active output power enabled Gate MOS 12 active output power enabled Gate MOS 16 active output power enabled Gate MOS 15 active output power enabled Normal Status Conditions ON Green ON Green ON Green ON Green ON Green ON Green ON Green STICK ON Green TIG ON torch trigger pulled OFF OK ON ALARM Red Brightness proportional with actual output current STICK ON Green TIG ON torch trigger pulled STICK ON Green TIG ON torch trigger pulled S
25. Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC TROUBLESHOOTING amp REPAIR F 15 F 15 V205 T AC DC WARNING 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 amp REPAIR F 16 F 16 V205 T AC DC INPUT FILTER BOARD TEST continued FIGURE F 4 INPUT FILTER BOARD TEST 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 Figure F 4 5 See Note 1 and Note 2 INPUT FILTER BOARD 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 amp REPAIR F 17 F 17 V205 T AC DC INPUT FILTER BOARD TEST continued FIGURE F 5 INPUT FILTER BOARD Note 1 A varistor ZN1 is placed between the two power supply phases so if an instantaneous voltage in excess of 275VAC appears on ter minals RV1 amp RV2 the varistor very rapidly becomes conductive and thus absorbing a current peak sufficient to limit the above said overvoltage this way the varistor ZN1 pro tects the other parts of the machine from energy limi
26. Up Menu WARNING C 1 C 1 V205 T AC DC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC TABLE OF CONTENTS ACCESSORIES Accessories Section C Options Accessories C 2 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 COMPATIBLE EQUIPMENT Factory Installed Twist Mate Cable Connectors 1 standard for Ground Clamp 1 Gas Pass through for Tig Torch Strap Packet Instruction Manual Field Installed K857 Remote Output Control For Stick welding When the V205 T s Output Control is in the REMOTE position this portable current control provides the same range as the current control on the welder Consists of a 6 pin Amphenol connector which plugs into the remote control Amphenol 25 foot cable length K870 Foot Amptroltm for TIG welding When the V205 T s Output Control is in the REMOTE position the foot Amptrol energizes the output and controls the output remotely The Foot Amptrol connects directly to the 6 pin Amphenol K963 3 Han
27. and the corresponding explanations 2 Thermal Device Warning Light Yellow LED 6 Digital Display 1 Input Voltage warning Light Green LED 5 Output Parameter Adjust Knob 4 Setup Parameter Select Button 9 Welding Process MODE Button 7 Local Remote Button 3 Pulse On Off Button 8 Trigger Selection Button 10 Electrode Connection Negative 11 Remote Control Connector 12 Electrode Connection Positive 13 Welding Parameter Drawing sec sec LOCAL 1 9 10 11 12 13 8 7 6 5 4 3 2 FIGURE B 2 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 OPERATION 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 currently set values for each mode or welding parameter 7 Local Remote push button Selects the welding current adjusting system from front panel from remote control The LED beside the symbol confirms the selection 8 Tig Trigger Sequences For the V205 T AC DC TIG welding can be done in either the 2 step or 4 step mode which is selected with the Trigger Mode Push Butto
28. are unable to perform the test repairs safely contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed Call 1 800 833 9353 WELD DESCRIPTION The following procedure will aid the technician in removing the control display board for replacement MATERIALS NEEDED Phillips Head Screwdriver Wiring Diagram 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 amp REPAIR F 57 F 57 WARNING 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 precautions detailed in PC Board Troubleshooting Procedures at the beginning of this section Failure to do so can result in perma nent damage to equipment 3 Tilt display plate forward and carefully label and disconnect leads CN1 CN2 CN3 amp CN7 See Figure F 31 4 Disconnect the ground lead running from the P C board to the machine frame See Figure F 31 5 Carefully remove the board assembly NOTE The board assembly is attached to the nameplate keypad and is to be replaced as one unit 6 Replace the board assembly 7 Connect previously removed ground lead 8 Connect previously removed
29. i SAFETY ARC WELDING CAN BE HAZARDOUS PROTECT YOURSELF AND OTHERS FROM POSSIBLE SERIOUS INJURY OR DEATH KEEP CHILDREN AWAY PACEMAKER WEARERS SHOULD CONSULT WITH THEIR DOCTOR BEFORE OPERATING Read and understand the following safety highlights For additional safety information it is strongly recommended that you purchase a copy of Safety in Welding amp Cutting ANSI Standard Z49 1 from the American Welding Society P O Box 351040 Miami Florida 33135 or CSA Standard W117 2 1974 A Free copy of Arc Welding Safety booklet E205 is available from the Lincoln Electric Company 22801 St Clair Avenue Cleveland Ohio 44117 1199 BE SURE THAT ALL INSTALLATION OPERATION MAINTENANCE AND REPAIR PROCEDURES ARE PERFORMED ONLY BY QUALIFIED INDIVIDUALS WARNING Mar 95 ELECTRIC AND MAGNETIC FIELDS may be dangerous 2 a Electric current flowing through any conductor causes localized Electric and Magnetic Fields EMF Welding current creates EMF fields around welding cables and welding machines 2 b EMF fields may interfere with some pacemakers and welders having a pacemaker should consult their physician before welding 2 c Exposure to EMF fields in welding may have other health effects which are now not known 2 d All welders should use the following procedures in order to minimize exposure to EMF fields from the welding circuit 2 d 1 Route the electrode and work cables together Secure them with tape when p
30. les zones o l on pique le laitier 6 Eloigner les mat riaux inflammables ou les recouvrir afin de pr venir tout risque d incendie d aux tincelles 7 Quand on ne soude pas poser la pince une endroit isol de la masse Un court circuit accidental peut provoquer un chauffement et un risque d incendie 8 S assurer que la masse est connect e le plus pr s possible de la zone de travail qu il est pratique de le faire Si on place la masse sur la charpente de la construction ou d autres endroits loign s de la zone de travail on augmente le risque de voir passer le courant de soudage par les chaines de levage c bles de grue ou autres circuits Cela peut provoquer des risques d incendie ou d echauffement des chaines et des c bles jusqu ce qu ils se rompent 9 Assurer une ventilation suffisante dans la zone de soudage Ceci est particuli rement important pour le soudage de t les galvanis es plomb es ou cadmi es ou tout autre m tal qui produit des fume s toxiques 10 Ne pas souder en pr sence de vapeurs de chlore provenant d op rations de d graissage nettoyage ou pistolage La chaleur ou les rayons de l arc peuvent r agir avec les vapeurs du solvant pour produire du phosg ne gas fortement toxique ou autres produits irritants 11 Pour obtenir de plus amples renseignements sur la s ret voir le code Code for safety in welding and cutting CSA Standard W 117 2 1974 PR
31. 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 troubleshooting assistance before you proceed Call 1 800 833 9353 WELD DESCRIPTION This test will help determine if all of the auxiliary voltages on the main IGBT inverter board are correct MATERIALS NEEDED Voltmeter Phillips Head Screwdriver Wiring Diagram Voltmeter WARNING TEST 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 Main IGBT Inverter board See Figure F 6 5 Use the voltmeter to perform the tests detailed in Table F 1 See the wiring dia gram TROUBLESHOOTING amp REPAIR F 20 F 20 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 INVERTER BOARD LOW VOLTAGE TEST CONTINUED BACK SIDE MAIN BOARD FIGURE F 6 MAIN IGBT INVERTER BOARD LOCATION TROUBLESHOOTING amp RE
32. 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 troubleshooting assistance before you proceed Call 1 800 833 9353 WELD DESCRIPTION This procedure will help determine if the UPFR section on the main board is functioning prop erly MATERIALS NEEDED Volt Ohmmeter Phillips Head Screwdriver Wiring Diagram 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 amp REPAIR F 31 F 31 V205 T AC DC WARNING 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 amp REPAIR F 32 F 32 V205 T AC DC MAIN INVERTER BOARD UPFR SECTION TEST continued TEST 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 UPFR section on the main board and associated plugs Do not remove plugs from the board See Figure F 14 5 Car
33. 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 Yellow LED on and an alarm code blink ing on Digital Display Item 6 see Troubleshooting Section E Possible electrical problems the machine will not supply power at the output If over heating occurs the Yellow LED will stay on until the machine has sufficiently cooled Leave the power source on to allow the fan to cool the unit 3 Pulse On OFF push button CONSTANT current PULSED current 4 Setup Parameter Select push button Setup Parameter push button has three 3 differ ent functions Accesses Welding Parameter Repeatedly pressing the Parameter button will step through the Welding Parameter waveform lights on the front panel Parameters which can be changed Start Current Upslope Weld Current Peak Current Pulse Frequency on Time Background Current Downslope Finish Current Postflow sec There is a LED for each welding parameter When lit it has confirmed the mode or selection chosen Accesses the AC Frequency and AC Balance by pressing and holding the Parameter button for three 3 seconds Accesses the Set Up Menu See Set Up Menu section CONTROLS AND SETTINGS All operator controls and adjustments are located on the case front of the V205 T machine Refer to Figure B 2
34. the digital dis play 1 E12 is an indication that the input voltage being applied is too low Check for the correct input voltage 230VAC or 115VAC 1 If the correct input voltage 230VAC or 115VAC is being applied to the machine the Input Filter Board may be faulty Perform the Input Filter Board Test 2 The Main IGBT Inverter Board May be Faulty Perform the Main IGBT Inverter Board Low Voltage Supply Test No output Error code E10 is flashing on the digital display The thermal indicator light is on 1 The welding application may be exceeding the recommended duty cycle 2 Dirt and dust may have clogged the cooling channels inside the machine Refer to the Maintenance Section in this manual 3 The air intake and exhaust lou vers may be blocked due in inadequate clearance around the machine 4 Make sure the cooling fan is operating correctly 1 One of the thermal devices may be faulty Check and replace if necessary See the Wiring Diagram 2 The Main IGBT Inverter Board may be faulty 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 amp REPAIR F 6 F 6 Observe Safety Guidelines TROUBLESHOOTING GUIDE detailed in the beginning of this manual CAUTION If for any reason you do not understand the test procedures
35. to Master TOC INSTALLATION OUTPUT AND GAS CONNECTION FOR TIG WELDING FIGURE A 1 The TIG Torch Twist Mate and work cable Twist Mate Connectors are supplied with the welder To connect the cables turn the Power Switch OFF Connect the torch cable Twist Mate plug into the DC Electrode Gas Output Receptacle on the front of the welder and turn it clockwise until snug Do not Overtighten This is a quick connect terminal and also provides the gas con nection for the shielding gas to the torch To avoid receiving a high frequency shock keep the TIG torch and cable insulation in good condi tion ___________________________________________ WORK CABLE CONNECTION Next connect the work cable to the output terminal in the same way To minimize high frequency interfer ence refer to Machine Grounding and High Frequency Interference Protection section of this manual for the proper procedure on grounding the work clamp and work piece OUTPUT CONNECTIONS ELECTRIC SHOCK can kill Keep the electrode holder TIG torch and cable insulation in good condition and in place Do not touch electrically live parts or electrode with skin or wet cloth ing Insulate yourself from work and ground Turn the input line Switch on the Invertec V205 T AC DC off before connecting or disconnect ing output cables or other equipment WARNING
36. 5 VDC 3 75 VDC 3 75 VDC 3 75 VDC D S 178 VDC 260 VDC 260 VDC 34 VDC TABLE F 17 LED CHECK IN STICK MODE Generator Mode ON STICK ON STICK ON STICK ON STICK Component L11 L12 L13 L14 Value ON ON ON ON TROUBLESHOOTING AND REPAIR MAIN INVERTER BOARD WELDING LOGIC AND INVERTER 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 Short Circuit 0 3 Ohms L9 L8 CN5 1 2 Short Circuit 0 3 Ohms FIGURE F 22 MAIN BOARD INVERTER SECTION TROUBLESHOOTING AND REPAIR MAIN INVERTER BOARD WELDING LOGIC AND INVERTER 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 POWER MF11 MF15 VDS MF16 MF12 VDS L13 L12 D S S G S S S S S S G G G D D D FIGURE F 23 MAIN BOARD LOWER LEFT 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 INPUT FILTER BOAR
37. BLESHOOTING amp REPAIR F 4 F 4 Observe Safety Guidelines TROUBLESHOOTING GUIDE detailed in the beginning of this manual CAUTION If for any reason you do not understand the test procedures or are unable to perform the test repairs safely con tact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed Call 1 800 833 9353 WELD OUTPUT PROBLEMS SYMPTOMS POSSIBLE AREAS OF MISADJUSTMENT S RECOMMENDED COURSE OF ACTION OUTPUT PROBLEMS Major physical or electrical damage is evident when the sheet metal cover s are removed 1 Contact your local authorized Lincoln Electric Field Service Facility for assistance 1 Contact the Lincoln Electric Service Department 1 800 833 9353 The machine is dead no fan no output no LEDs 1 Make sure the input power switch is in the ON position 2 Check the main input fuses If open replace 3 Make sure the correct input volt age is applied to the machine 1 Check the input power switch for proper operation Also check the associated leads for loose or faulty connections See wiring diagram 2 Perform the Input Filter Board Test The main input fuses or breakers repeatedly fail 1 Make certain the fuses or break ers are properly sized for the input draw of the machine 2 The welding procedure may be drawing too much input current or the duty cycle may be too high Reduce the welding cur rent and or r
38. C 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 plugs must comply with the Standard for Attachment Plugs and Receptacles UL498 The product is considered acceptable for use only when an attachment plug as specified is properly attached to the supply cord For use on engine drives keep in mind the above input draw restrictions and the following precaution ENGINE DRIVEN GENERATOR The Invertec V205 T AC DC can be operated on engine driven generators as long as the 230 volt auxil iary meets the following conditions The AC waveform peak voltage is below 400 volts The AC waveform frequency is between 45 and 65Hz The following Lincoln engine drives meet these condi tions when run in the high idle mode Ranger 250 305 Commander 300 400 amp 500 Some engine drives do not meet these conditions e g Miller Bobcats etc Operation of the Invertec V205 T AC DC is not recommended on engine drives not con forming to these conditions Such drives may deliver unacceptably high voltage levels to the Invertec V205 T AC DC power source 230V INPUT The equipment is provided with a 230 115V cable 6 6ft 2m in length with a 230V 6 50P attachment plug The Invertec V205 T AC DC performs best when con nected to 230VAC
39. D REMOVAL 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 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 troubleshooting assistance before you proceed Call 1 800 833 9353 WELD DESCRIPTION The following procedure will aid the technician in removing the Input Filter board for replace ment MATERIALS NEEDED 7mm Nut Driver Phillips Head Screwdriver 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 amp REPAIR F 49 F 49 WARNING 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 amp REPAIR F 50 F 50 PROCEDURE 1 Remove input power to the V205 T 2 Using a phillips head screwdriver remove the case wraparound cover 3 Perform the Input Filt
40. Discharge Procedure detailed earlier in this section 4 Locate the Welding Logic and Inverter section of the Main Inverter board and associated plugs Do not remove plugs from the board See Figure F 21 See Figures F 22 amp F 23 5 Carefully apply the correct input voltage to the V205 T and check for the correct secondary voltages per Tables F 14 F 15 F 16 amp F17 FIGURE F 21 MAIN BOARD LOCATION BACK SIDE MAIN BOARD TROUBLESHOOTING AND REPAIR MAIN INVERTER BOARD WELDING LOGIC AND INVERTER 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 TABLE F 14 LED FUNCTIONS TABLE F 15 FEEDBACK VOLTAGE SIGNALS Machine Mode ON STICK ON ON Component L8 L9 TP31 TP9 Value 2 56 VDC Condition ON OFF Note POT SIGNAL THERMAL ALWAYS Machine Mode ON TIG Component TP15 TP14 Value 2 VDC 100A 4 VDC 200A Condition WELDING ON CURRENT FEEDBACK ON STICK TP16 TP14 4 3 VDC O C V WELDING ON VOLTAGE FEEDBACK ON TIG TP19 TP14 2 VDC 100A 4 VDC 200A WELDING ON CURRENT REFERENCE TABLE F 16 VOLTAGE CHECKS WITH 115 VAC APPLIED TO MACHINE Generator Mode ON STICK ON STICK ON STICK ON STICK Component MF11 MF12 MF15 MF16 G S 3 7
41. 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 troubleshooting assistance before you proceed Call 1 800 833 9353 WELD DESCRIPTION This test will help determine if the front panel boards work properly MATERIALS NEEDED Volt Ohmmeter Phillips Head Screwdriver Wiring Diagram WARNING TEST 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 board and asso ciated plugs Do not remove plugs from the board See Figure F 8 5 Carefully apply the correct input voltage to the V205 T and check for the correct sec ondary voltages per Tables F 2 F3 amp F 4 TROUBLESHOOTING amp REPAIR F 24 F 24 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
42. K START UP ELECTRIC SHOCK can kill Have an electrician install and service this equipment Turn 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 working inside this equipment Do not touch electrically hot parts Connect the shielding gas typically argon using a appropriate regulator Connect the foot amptrol torch and work lead to the power source With the work cable connected to a properly grounded work piece turn the power source on The Invertec V205 T AC DC TIG is ready to AC TIG weld with the following features AC TIG Trigger Mode in 2 step mode Local control Pulser off AC Square Wave AC Balance 65 EN AC Frequency 100HZ Pre Flow 5sec Post Flow 5 sec High Freq Start Change from Local to Remote control by pushing front panel push button Set the maximum output current desired using the Output Control Initiate the arc by closing the arc start switch The Amptrol will control the output current from 10 amps to current level set by Output Control To change the AC Frequency press and hold the Parameter button for 3 seconds The AC Frequency is now selected and can be varied by the Output Control The frequency is displayed on the digital meter After abou
43. LESHOOTING amp REPAIR MAIN IGBT BOARD REMOVAL amp 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 LOCATIONS RV1 RV2 RV4 RV3 CN1 CN2 CN3 CN4 CN5 RV6 RV7 RV5 10 Reconnect previously removed leads RV1 thru RV7 to the P C board See Wiring Diagram if necessary 11 Reconnect previously removed plugs CN1 thru CN5 to the P C board NOTE All ribbon cable connections have an indexing location slot to assure proper replacement 12 Replace the case wraparound cover previ ously removed 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 CONTROL DISPLAY BOARD REMOVAL 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 all safety notes and precautions detailed throughout this manual If for any reason you do not understand the test procedures or
44. Master TOC Return to Master TOC Return to Master TOC OUTPUT FILTER BOARD REMOVAL 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 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 troubleshooting assistance before you proceed Call 1 800 833 9353 WELD DESCRIPTION The following procedure will aid the technician in removing the output filter board for replace ment MATERIALS NEEDED 17mm Wrench 13mm Wrench Large Crescent Wrench Phillips Head Screwdriver 90o Phillips Head Screwdriver 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 amp REPAIR F 61 F 61 WARNING 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 amp REPAIR F 62 F 62 FIGURE
45. OC Return to Master TOC Return to Master TOC V205 T AC DC TROUBLESHOOTING amp REPAIR F 53 F 53 WARNING 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 amp REPAIR F 54 F 54 FIGURE F 27 MAIN IGBT BOARD LOCATION BACK SIDE MAIN BOARD MAIN IGBT BOARD REMOVAL amp 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 IGBT board See Figure F 27 5 VERY CAREFULLY label and disconnect plugs CN1 CN2 CN3 CN4 amp CN5 See Figure F 28 NOTE All ribbon cable connections are secured by a small amount of RTV on the outside surface to keep the connections secure 6 Using a 7mm nut driver label and disconnect leads RV1 RV2 RV3 RV4 RV5 RV6 amp RV7 See Figure F 28 7 Using a phillips head screwdriver remove the thirty two 32 phillips head screws from the main board Note washer positions for replacement See Figure F 28 8 Carefully maneuver the main board out of the machine Replace 9 Maneuver new board into its proper location and secure to machine using the thirty two phillips head screws previously removed TROUB
46. OC Return to Master TOC Return to Master TOC Return to Master TOC V205 T AC DC TROUBLESHOOTING amp REPAIR F 8 F 8 Observe Safety Guidelines TROUBLESHOOTING GUIDE detailed in the beginning of this manual CAUTION If for any reason you do not understand the test procedures or are unable to perform the test repairs safely con tact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed Call 1 800 833 9353 WELD WELDING PROBLEMS SYMPTOMS POSSIBLE AREAS OF MISADJUSTMENT S RECOMMENDED COURSE OF ACTION WELDING PROBLEMS The machine does not have weld ing output in the Stick mode Zero volts open circuit voltage The Output LED on the control panel is blinking The machine operates correctly in the TIG mode 1 Make sure the machine is prop erly set up and configured for Stick mode 1 Check for output voltage feed back from the Output Filter Board See the Output Filter Board Test 2 Check for output voltage feed back through the Bus Board See the Bus Board Test 3 The Control Display Board may be faulty The machine does not have weld ing output in either the Stick or TIG modes Zero volts open circuit The Output LED on the control panel is blinking 1 Make sure the correct input volt age is applied to the machine 230 or 115VAC 1 The output rectifier may be faulty Check and replace if nec essary See the Secondary Power Board Test and
47. ON 1 2 3 Plug CN1 5mm Allen Bolts 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 G 1 ELECTRICAL DIAGRAMS G 1 TABLE OF CONTENTS ELECTRICAL DIAGRAMS SECTION ELECTRICAL DIAGRAMS SECTION G WIRING DIAGRAM CODE 10860 ONLY G 2 NOTE Many PC Board Assemblies are now totally encapsulated and are therefore considered to be unservice able Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC V205 T AC DC ELECTRICAL DIAGRAMS G 2 V205 T AC DC WIRING DIAGRAM V205 T AC DC STANDARD DIAGRAM To 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 machine 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 SVM ERROR REPORTING FORM We need to know if there are errors in our manuals We also val
48. OW 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 OUTPUT FILTER BOARD REMOVAL AND REPLACEMENT continued 9 Using a 17mm wrench remove the heavy lead from the positive output terminal 10 Using a 13mm wrench remove the heavy lead from the high frequency transformer 11 Disconnect plugs CN1 and CN2 from the out put filter board See Figure F 34 12 Using a 90o phillips head screwdriver remove the output filter board mounting screws NOTE The output terminal assembly may have to be removed to gain access to the out put filter board mounting screws 13 Remove the large nut holding the output filter board to the positive terminal See Figure F 34 14 Disconnect plug CN7 from the control display board assembly See Control Display Board Removal Procedure for plug CN7 location 15 Carefully remove the output filter board by sliding it by the the plug and lead assembly 16 Replace the output filter board 17 Maneuver the new board into its proper loca tion from which it was previously removed TROUBLESHOOTING amp REPAIR 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 Ma
49. PAIR 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 INVERTER BOARD LOW VOLTAGE TEST CONTINUED TABLE F 1 TEST POINTS ON ON ON ON ON ON ON ON TP13 TP14 TP11 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 Mode Test Point LED Value TROUBLESHOOTING amp REPAIR 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 INVERTER BOARD LOW VOLTAGE TEST CONTINUED FIGURE F 7 MAIN IGBT INVERTER BOARD LOCATION TP2 TP5 TP4 TP3 L4 MF2 L1 L5 L3 L2 TP14 TP13 TP12 TP11 L6 TP17 TP18 TP21 L10 L7 This is an illustration of the upper right corner of the P C board 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 amp REPAIR CONTROL DISPLAY BOARD TEST Service and repair should be performed by only Lincoln
50. Peak Current for Stick only 0 100 30 4 Hot Start percent above Peak Current for Stick only 0 100 80 5 Setting of AC wave Form 2 Square 0 Sinusoidal 1 Triangular 2 Square NOTE This parameter limits maximum weld current see OUTPUT LIMITATIONS section of the manual 6 Min Weld Current Value with Remote Control for TIG only 10 Amps 6 Amps Value set for Indicator 7 7 Max Weld Current Value with Remote Control for TIG only Peak Current Value set for Indicator 6 Peak Current NOTE Peak Current Max Weld Current can be limited by input voltage welding mode AC TIG waveform and AC TIG frequency 8 Touch Start or H F Start in DC TIG 0 H F Start 1 touch Start 0 This parameter is ignored in AC TIG Mode 9 Reset all Parameters including control panel settings 10 Not Used 11 Not Used 12 2 Step Trigger Selection 1 0 Restart Disabled 1 Restart Enabled 13 4 Step Trigger Selection 0 0 Restart Disabled 1 Restart Enabled 14 Start Power for TIG only 2 0 This function sets the initial start energy limit 1 0 min 5 0 max Note If the machine does not initiate a welding arc it will repeat the starting sequence with an increased start energy up to this limit Set this number to a higher setting than the factory default if needed to improve starting of large diameter tungstens electrodes B 8 B 8 V205 T AC DC Return to Section TOC Return to Section TOC Return to Sec
51. STICS The front panel controls the status of the equipment and shows it to the operator via the LED s and the display Immediately after switch on of the equipment the front panel executes an autotest operation all LED s will light up and the display shows 200 as a check Power supply LED GREEN Indicates the machine switch on status Always present if the panel and therefor the machine is correctly powered Alarm LED YELLOW Indicates a protection status of the equipment Comes on to indicate the presence of a problem The type of alarm is indi cated in the display by an error code see below Display Immediately after the autotest operations above the display briefly shows the software version of control panel e g 01 It indicates the welding parameters requested by the operator with the help of the other keys and immediately after striking of the arc sets to reading mode providing the real value of the current delivered by generator It indicates a protection status via codes with simultaneous switch on of the yellow LED Indic E10 E11 E12 E13 E14 Type of Error Internal Heatsink Overtemp Power Supply Overvoltage Power Supply Undervoltage Front Panel Memory Error Front Panel Secondary Memory Error Action Remove upper cover check internal temperature check thermal device status N C See machine layout Remove upper cover check that the power supply voltage is within the establ
52. SVM161 A February 2006 Safety Depends on You 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 INSTALL OPERATE OR REPAIR THIS EQUIPMENT WITHOUT READ ING THIS MANUAL AND THE SAFETY PRECAUTIONS CON TAINED THROUGHOUT And most importantly think before you act and be careful SERVICE MANUAL For use with machine code number 10860 INVERTEC V205 T AC DC V205 T AC DC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC View Safety Info View Safety Info View Safety Info View Safety Info Sales and Service through Subsidiaries and Distributors Worldwide Cleveland Ohio 44117 1199 U S A TEL 216 481 8100 FAX 216 486 1751 WEB SITE www lincolnelectric com World s Leader in Welding and Cutting Products Copyright 2006 Lincoln Global Inc RETURN TO MAIN MENU 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 Turn 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 ______________________________________________
53. Supply Ground HF Start Front Panel Supply HF Start Ground Expected Voltage 24 VDC 48 VDC TABLE F 8 PLUG CN7 TEST POINTS TABLE F 9 PLUG CN1 TEST POINTS Wire 11 Earth Cable 12 Earth Cable Description Water Cooling Supply Water Cooling Supply Water Cooling Supply Expected Voltage Wire 5 6 Description Fan Expected Voltage 24 VDC 1 In TIG mode only when Remote is pushed comes on for two sec then goes to zero In STICK mode is present all the time TROUBLESHOOTING amp REPAIR 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 LOCATIONS 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 F1 F2 F3 CN7 CN3 CN4 CN2 CN1 MAIN INVERTER BOARD UPFR SECTION TEST 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
54. TICK ON Green TIG ON torch trigger pulled STICK ON Green TIG ON torch trigger pulled 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 WARNING 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 amp REPAIR F 13 F 13 V205 T AC DC INPUT FILTER CAPACITOR DISCHARGE PROCEDURE 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 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 troubleshooting assistance before you proceed Call 1 800 833 9353 WELD 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 proced
55. TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC TROUBLESHOOTING AND REPAIR 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 FILTER BOARD TEST 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 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 troubleshooting assistance before you proceed Call 1 800 833 9353 WELD DESCRIPTION This test will help determine if output voltages and external trigger signals are being processed through the output board MATERIALS NEEDED Volt Ohmmeter Phillips Head Screwdriver External DC Ammeter WARNING TROUBLESHOOTING AND REPAIR OUTPUT FILTER 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 R
56. Test the machine to determine if the failure symptom has been corrected by the replacement PC board NOTE It is desirable to have a spare known good PC board available for PC board troubleshooting NOTE Allow the machine to heat up so that all electrical components can reach their operating temperature 5 Remove the replacement PC board and substitute it with the original PC board to recreate the original problem a If the original problem does not reappear by substituting the original board then the PC board was not the problem Continue to look for bad connections in the control wiring harness junction blocks and terminal strips b If the original problem is recreated by the substitution of the original board then the PC board was the problem Reinstall the replacement PC board and test the machine 6 Always indicate that this procedure was followed when warranty reports are to be submitted NOTE Following this procedure and writing on the warranty report INSTALLED AND SWITCHED PC BOARDS TO VERIFY PROBLEM will help avoid denial of legitimate PC board warranty claims PC BOARD TROUBLESHOOTING PROCEDURES ATTENTION Static Sensitive Devices Handle only at Static Safe Workstations WARNING CAUTION 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 TROU
57. Wiring Diagram 2 The Output Clamp Board may be faulty 3 The Output Module Transistor Board may be faulty See the Secondary Power Board Test and Wiring Diagram 4 Perform the Main IGBT Inverter Board Welding Logic and Inverter Test 5 The Superimposition Board may be faulty 6 The Hall Effect device may be faulty 7 The Control Display Board may be faulty The machine operates properly in the Stick and DC TIG modes AC TIG mode does not function prop erly 1 Make sure the machine is set up and configured correctly for the AC TIG mode 1 The Output Module Transistor Board may be faulty See the Secondary Power Board Test and Wiring Diagram 2 The Superimposition Board may be faulty TROUBLESHOOTING amp REPAIR 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 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 Power Supply Alarm Display Output Current Control Output Set up Parameter Select Button FIGURE F 1 EXTERNAL DIAGNO
58. ______ 1 c Do not add the fuel near an open flame weld ing arc or when the engine is running Stop the engine and allow it to cool before refuel ing to prevent spilled fuel from vaporizing on contact with hot engine parts and igniting Do not spill fuel when filling tank If fuel is spilled wipe it up and do not start engine until fumes have been eliminated ____________________________________________________ 1 d Keep all equipment safety guards covers and devices in posi tion and in good repair Keep hands hair clothing and tools away from V belts gears fans and all other moving parts when starting operating or repairing equipment ____________________________________________________ 1 e In some cases it may be necessary to remove safety guards to perform required maintenance Remove guards only when necessary and replace them when the maintenance requiring their removal is complete Always use the greatest care when working near moving parts ___________________________________________________ 1 f Do not put your hands near the engine fan Do not attempt to override the governor or idler by pushing on the throttle control rods while the engine is running ___________________________________________________ 1 g To prevent accidentally starting gasoline engines while turning the engine or welding generator during maintenance work disconnect the spark plug wires distributor cap or magneto wire as appropriate
59. _______________________________________________ ___________________________________________________________________________ ___________________________________________________________________________ SD287 01 99 Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC
60. ain ter minal of the IGBT may be connected to a voltage sup ply but since there is no conduction the circuit will not supply current to components connected to the source The circuit is turned OFF like a light switch Example B shows the IGBT in an active mode When the gate signal a positive DC voltage relative to the source is applied to the gate terminal of the IGBT it is capable of conducting current A voltage supply con nected to the drain terminal will allow the IGBT to con duct and supply current to the circuit components coupled to the source Current will flow through the conducting IGBT to downstream components as long as the positive gate signal is present This is similar to turning ON a light switch THEORY OF OPERATION E 6 E 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 FIGURE E 6 IGBT DRAIN SOURCE GATE INJECTING LAYER BUFFER LAYER DRAIN DRIFT REGION BODY REGION p n n p n n DRAIN SOURCE GATE INJECTING LAYER BUFFER LAYER DRAIN DRIFT REGION BODY REGION p n n p n n POSITIVE VOLTAGE APPLIED B ACTIVE A PASSIVE V205 T AC DC Section F 1 Section F 1 Troubleshooting amp Repair Section Se
61. approximate melting temperature of 3370 C and the workpiece An inert gas typically argon atmosphere protects the weld pool To avoid inclusions of tungsten in the joint the elec trode should not contact the workpiece For this reason the arc is started through a Hi Freq generator For situations requiring no Hi Freq Touch Start Tig reduces the short circuit current to keep tungsten inclusions to the minimum To improve weld bead quality at the end of the weld it is important to carefully control the downslope of cur rent and ensure proper gas coverage over the weld 1 Workpiece 5 Flowmeter 2 Filler material 6 Pressure reducer 3 Non consumable electrode 7 lnert gas typically argon 4 Torch 8 Power source FIGURE B 3 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 OPERATION 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 covered with a layer of refractory oxide With this polarity the electrode functions as anode and is subjected to a high degree of heat the workpiece is bombardment by positive ions sent from the electrode which break the surface oxide
62. ard Welding Logic Test F 43 Replacement Procedures Input Filter Board Removal and Replacement F 49 Main IGBT Board Removal and Replacement F 53 Control Display Board Removal and Replacement F 57 Output Filter Board Removal and Replacement F 61 Output Diodes Removal and Replacement F 65 Output Transistor Removal and Replacement F 67 TABLE OF CONTENTS TROUBLESHOOTING amp REPAIR SECTION Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC HOW TO USE TROUBLESHOOTING GUIDE 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 and 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 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
63. 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 from the output transistor See Figure F 37 6 Using a phillips head screwdriver disconnect leads 1 2 amp 3 See Figure F 37 7 Using a 5mm allen wrench remove the output tran sistor mounting bolts 8 Remove and replace the output transistor NOTE Be careful not to bend the copper bus bars 9 Apply a thin layer of heatsink compound to all con tact surfaces 10 Replace the output transistor mounting bolts pre viously removed 11 Reconnect leads 1 2 amp 3 previously removed 12 Reconnect lead CN1 13 Replace the case wraparound cover TROUBLESHOOTING amp REPAIR F 68 F 68 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 REMOVAL AND REPLACEMENT continued Output Transistor FIGURE F 36 OUTPUT TRANSISTOR LOCATION TROUBLESHOOTING amp REPAIR 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 REMOVAL AND REPLACEMENT continued FIGURE F 37 OUTPUT TRANSISTOR LEAD LOCATI
64. ction F How to Use Troubleshooting Guide F 2 PC Board Troubleshooting Procedures and Replacement F 3 Troubleshooting Guide F 4 Test Procedures External and Internal diagnostics F 9 Input Filter Capacitor Discharge Procedure F 13 Input Filter Board Test F 15 Main IGBT Inverter Board Low Voltage Test F 19 Control Display Board Test F 23 Bus Board Test F 27 Main Inverter Board UPFR Section Test F 31 Output Filter Board Test F 35 Secondary Power Board Test F 39 Main Inverter Bo
65. d Amptroltm for TIG welding When the V205 T s Output Control is in the Remote position the hand Amptrol energizes the output and controls the output remotely The Hand Amptrol connects directly to the 6 pin Amphenol K814 Arc Start Switch Energizes the output for TIG welding if remote output control of the amperage is not desired It allows on off TIG welding at the current set by the Current Control on the control panel When using the Arc Start Switch set the Output Control to the LOCAL position Magnum PTA 9 and PTA 17 TIG Torches The fol lowing standard Magnum TIG torches with one piece cable may be used with the Invertec V205 T K1781 1 PTA 9 12 5 ft medium back cap K1781 3 PTA 9 25 ft medium back cap K1782 1 PTA 17 12 5 ft long back cap K1782 3 PTA 17 25 ft long back cap NOTE Each torch requires a Twist Mate adapter one is included with the machine Collets collet bodies and nozzles are not included and must be ordered sep arately TIG TORCH KITS K2266 1 TIG Mate 17 Air Cooled TIG Torch Starter Pack One complete easy to order kit packaged in its own portable carrying case Includes PTA 17 torch parts kit Harris flowmeter regulator 10 ft gas hose Twist mate adapter work clamp and cable K2267 1 TIG Mate 20 Water Cooled TIG Torch Starter Pack One complete easy to order kit pack aged in its own portable carrying case Includes PTW 20 torch par
66. e described in detail at the end of this chapter Refer to the Troubleshooting and Repair Table of Contents to locate each specific Test Procedure All of the referred to test points components terminal strips etc can be found on the referenced electrical wiring diagrams and schematics Refer to the Electrical Diagrams Section Table of Contents to locate the appropriate diagram 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 troubleshooting assistance before you proceed Call 1 800 833 9353 WELD 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 amp REPAIR F 3 F 3 Sometimes machine failures appear to be due to PC board failures These problems can sometimes be traced to poor electrical connections To avoid prob lems when troubleshooting and replacing PC boards please use the following procedure 1 Determine to the best of your technical ability that the PC board is the most likely component causing the failure symptom 2 Check for loose connections at the PC board to assure that the PC board is properly connected 3 If the problem persists replace the suspect PC board using standard practices to avoid static electrical damage and electr
67. e technician in removing the output diodes for replace ment MATERIALS NEEDED Phillips Head Screwdriver 7mm Nut Driver Heatsink Compound 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 amp REPAIR F 65 F 65 WARNING 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 amp REPAIR F 66 F 66 FIGURE F 35 OUTPUT DIODE LOCATION OUTPUT DIODES OUTPUT DIODES REMOVAL 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 this section 4 Locate the output diodes See Figure F 35 5 Using a phillips head screwdriver remove the P C board mounting screws 6 Using a phillips head screwdriver and or a 7mm wrench remove the copper bus bars from the diode module that is to be replaced 7 Using a phillips head screwdriver remove the two mounting screws from the output diode 8 Remove and replace the output diode 9 Apply a thin layer of heatsink compound to the areas of con
68. econnect info voltage feedback high volt supply turn on AC ckt current feedback IGBT Thermostats Output Diode Thermostat Voltage Feedback Current Feedback AC DC Gate drive signals 24 VDC 48 VDC Output Choke THEORY OF OPERATION 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 amp CLAMPING BOARD OUTPUT TRANSISTOR MODULE amp SUPERIMPOSITION BOARD Superimposition board Bus board Fan Input board HF board Main IGBT amp Power board 4 IGBT s Control board Display amp LED board 888 Control Knob Gas Solenoid DC blocking capacitor board Main Transformer Output board Output Transistor Module Current Hall Device Output Filter bd bypass D E Remote 2 4 Remote 75 76 77 A B C 24 VDC Remote 2 4 path D E turn on AC ckt 15 15 5 input volt meter thermostat info set info input current meter turn on PWM HF control signal 48 24 Input Choke _ RF coil 48 24 15 15 5 reconnect info voltage feedback high volt supply turn on AC ckt current feedback IGBT Thermostats Output Diode Thermostat Voltage Feedback Current Feedback AC DC Gate drive signals 24 VDC
69. educe the duty cycle 1 The Input Filter Board may be faulty Perform the Input Filter Board Test 2 The Main IGBT Inverter Board may be faulty Perform the Main IGBT Inverter Board Low Voltage Supply Test 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 amp REPAIR F 5 F 5 TROUBLESHOOTING GUIDE Observe Safety Guidelines detailed in the beginning of this manual CAUTION If for any reason you do not understand the test procedures or are unable to perform the test repairs safely con tact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed Call 1 800 833 9353 WELD FUNCTION PROBLEMS SYMPTOMS POSSIBLE AREAS OF MISADJUSTMENT S RECOMMENDED COURSE OF ACTION FUNCTION PROBLEMS No or low output Error code E11 is flashing on the digital display 1 E11 is an indication that the input voltage being applied is too high Check for the correct input voltage 230VAC or 115VAC 1 If the correct input voltage 230VAC or 115VAC is being applied to the machine the Input Filter Board may be faulty Perform the Input Filter Board Test 2 The Main IGBT Inverter Board May be Faulty Perform the Main IGBT Inverter Board Low Voltage Supply Test No or low output Error code E12 is flashing on
70. efully apply the correct input voltage to the V205 T and check for the correct sec ondary voltages per tables F 10 amp F11 Voltage readings were taken with a Fluke RMS meter See Figure F 15 for joint loca tions FIGURE F 14 UPFR LOCATION ON MAIN BOARD BACK SIDE MAIN BOARD TABLE F 10 VOLTAGE CHECKS WITH 115 VAC APPLIED TO MACHINE Generator Mode ON STICK ON STICK ON STICK ON STICK ON STICK ON STICK ON STICK Component DD1 MF8 MF8 MF9 MF9 TP20 TP9 Ref Joint A K S D S G S D S G L10 LED Value 250 260 VDC 125 VDC 2 2 VDC 120 VDC 2 2 VDC ON 385 VDC 5V Generator Mode OFF OFF Component F1 R82 Ref Joint Value lt 1 OHM 46 OHM TABLE F 11 RESISTANCE CHECKS TROUBLESHOOTING amp REPAIR 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 POWER INPUT 230 VAC 115 DD1 MF9 L10 G G S S S S D K K A A D MAIN INVERTER BOARD UPFR SECTION TEST continued NOTE UPFR Section is located at the upper left section of Main board NOTES F 34 F 34 V205 T AC DC Return to Section TOC Return to Section TOC Return to Section
71. elding commands The Control Display Board also activates and controls the High Frequency Board the gas solenoid and the Super Imposition Board HIGH FREQUENCY HF BOARD The HF Board generates a set of pulses of about 900V which are amplified through the high voltage trans former to about 8 to 10KV These pulses that are repeated at a frequency of about 80HZ are applied to the high frequency transformer that is located in the negative welding output leg of the machine This high frequency pulse is transferred to the TIG torch via the high frequency transformer This allows the remote starting of the TIG arc without the need for the tung sten electrode to touch the work This high frequency pulse is removed when the welding arc is established The command signals are received from the micro processor on the Control Board and last for about 1 second maximum The HF Board receives it s power from the 385 VDC derived from the electrolytic capacitors on the Main IGBT Inverter Board OUTPUT FILTER BOARD This PC board located at the welding output terminals protects the internal circuitry of the machine from high voltage and high frequency pulses that may be fed back into the unit via the welding cables torch cable or remote control equipment This unwanted noise is shunted to case ground THEORY OF OPERATION E 5 E 5 V205 T AC DC Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Re
72. er Capacitor Discharge Procedure detailed earlier in this section 4 Locate the input filter board See Figure F 24 5 Using a 7mm nut driver label and remove leads R L1 and S L2 from the upper right corner of the input filter board See Figure F 25 6 Using a 7mm nut driver label and remove leads RV1 and RV2 from the left side of the main IGBT board See Figure F 26 See Wiring Diagram INPUT FILTER BOARD REMOVAL AND REPLACEMENT continued S L1 R L1 FIGURE F 24 INPUT FILTER BOARD LOCATION FIGURE F 25 INPUT FILTER BOARD LEADS INPUT FILTER BOARD 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 buttons at the ends of the board with your thumbs Depressing these buttons will free the plastic lock pins that prevent the P C board from sliding upward 9 Remove and replace the input filter board 10 Slide the new input filter board into its proper posi tion on the mounting slides 11 Push on backside of mounting pins to ensure that the P C board is secured in its proper position 12 Reconnect all previously removed leads to their proper locations See Wiring Diagram if neces sary 13 Replace case wraparound assembly CAUTION V205 T AC DC Return to Section TOC Return to Section TOC Return to Section TOC Return
73. et screw will be well below the surface of the brass plug after tightening 7 Slide rubber boot over brass plug The rubber boot must be positioned to completely cover all electrical surfaces after the plug is locked into the receptacle 25 mm 1 00 in WELDING CABLE BOOT TRIM IF REQ D TO FIT OVER CABLE WELDING CABLE COPPER FERRULE SET SCREW BRASS PLUG COPPER TUBE SHIELDING GAS CONNECTION Obtain the necessary inert shielding gas Connect the cylinder of gas with a pressure regulator and flow gage Install a gas hose between the regulator and gas inlet located on the rear of the welder The gas inlet has a 5 16 18 right hand female thread CGA 032 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 B 1 B 1 V205 T AC DC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC TABLE OF CONTENTS OPERATION SECTION Operation Section B Safety Instructions B 2 General Description
74. eturn to Master TOC Return to Master TOC TEST 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 and associated plugs Do not remove plugs from the board See Figure F 16 5 Carefully apply the correct input voltage to the V205 T and check for the correct secondary voltages per Table F 12 FIGURE F 16 OUTPUT FILTER BOARD LOCATION Output Filter Board TROUBLESHOOTING AND REPAIR OUTPUT FILTER 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 FILTER BOARD PLUG LOCATION FIGURE F 18 OUTPUT FILTER BOARD PLUG CN1 CN1 TABLE F 12 PLUG CN1 TEST POINTS Wire 53 54 64 66 65 Description Trigger Trigger Output Voltage Superimposition Common Expected Voltage 52 6 VDC CN1 2 3 5 6 1 4 66 53 65 54 64 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 TROUBLESHOOTING AND REPAIR F 39 F 39 V205 T AC
75. eturn 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 INSTALLATION 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 upright and chained to a support Keep cylinder away from areas where it could be damaged Never allow the torch or welding electrode to touch the cylinder Keep cylinder away from live electrical cir cuits ___________________________________________ WARNING QUICK DISCONNECT PLUG FOR STICK ELEC TRODE CABLE and WORK CABLE A quick disconnect system is used for the welding cable connections The stick electrode cable will need to have a plug attached 1 Cut off welding cable lug if present 2 Remove 1 00 in 25mm of welding cable insula tion 3 Slide rubber boot onto cable end The boot end may be trimmed to match the cable diameter Use soap or other nonpetroleum based lubricant to help slide the boot over the cable if needed 4 Insert copper strands into ferrule 5 Slide the copper ferrule into the brass plug 6 Tighten set screw to collapse copper tube Screw must apply pressure against welding cable The top of the s
76. explosion Keep flammable material away Do not weld cut or gouge on containers that have held com bustibles 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 OPERATION REAR CONTROL PANEL 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 machine is operational and there is voltage between the posi tive and negative Terminals in stick welding In TIG the welding process needs a trigger closure command at the remote control connection Usually via an Arc Start Switch or Foot Amptrol The welder is connected to the supply even if the l1 Power Switch is in the O Off position and there fore there are electrically live parts inside the power source Carefully follow the instructions given in this manual FIGURE B 1 1 Supply cable 2 Gas attachment l1 Power Switch WARNING 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 OPERATION 1 Input Voltage warning light green LED Indicates
77. he Capacitor Discharge Procedure detailed earlier in this section 4 Locate the Secondary Power board and asso ciated plugs Do not remove plugs from the board See Figure F 19 5 Carefully apply the correct input voltage to the V205 T and check for the correct secondary voltages per Table F 13 FIGURE F 19 SECONDARY POWER BOARD LOCATION SECONDARY POWER BOARD TROUBLESHOOTING AND REPAIR SECONDARY 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 SECONDARY POWER BOARD TEST POINT LOCATIONS TABLE F 13 VOLTAGE CHECKS WITH 115 VAC APPLIED TO MACHINE Generator Mode ON STICK ON STICK ON STICK ON STICK ON STICK OFF OFF Test Point GA SA GB SB 3 1 1 2 OCV R GA SA R GB SB Value 13 VDC 13 VDC 0 5 VDC 105 VDC 52 VDC 10 K Ohms 10 K Ohms 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 TROUBLESHOOTING AND REPAIR 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 Maste
78. hillips 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 from the board See Figure F 11 5 Carefully apply the correct input voltage to the V205 T and check for the correct volt ages per Tables F 5 F 6 F 7 F 8 amp F 9 6 Machine should be set to STICK mode FIGURE F 11 BUS BOARD LOCATION BUS BOARD TROUBLESHOOTING amp REPAIR 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 TABLE F 5 PLUG CN2 TEST POINTS TABLE F 6 PLUG CN3 TEST POINTS Wire 21 22 23 24 26 27 28 29 30 32 Description Thermal Trigger Output Hall Probe Hall Probe Ground Gate Switch B Ground Gate Switch A Thermal Trigger AC Unit Ground Hall Probe Hall Probe Gate Switch B Gate Switch A Expected Voltage 15 VDC 15 VDC Wire 61 65 63 64 66 Description Superimposition Ground Superimposition Superimposition Welding Voltage Expected Voltage 53 2 VDC 1 53 2 VDC 1 52 6 VDC TABLE F 7 PLUG CN4 TEST POINTS Wire 41 42 44 45 48 Description Front Panel Supply Front Panel
79. ical shock Read the warning inside the static resistant bag and perform the following procedures PC board can be damaged by static electricity Remove your body s static charge before opening the static shielding bag Wear an anti static wrist strap For safety use a 1 Meg ohm resistive cord connected to a grounded part of the equipment frame If you don t have a wrist strap touch an un painted grounded part of the equipment frame Keep touching the frame to prevent static build up Be sure not to touch any electrically live parts at the same time Tools which come in contact with the PC board must be either conductive anti static or static dissipative 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 Remove the PC board from the static shielding bag and place it directly into the equipment Don t set the PC board on or near paper plastic or cloth which could have a static charge If the PC board can t be installed immediately put it back in the static shield ing bag If the PC board uses protective shorting jumpers don t remove them until installation is complete If you return a PC board to The Lincoln Electric Company for credit it must be in the static shielding bag This will prevent further damage and allow prop er failure analysis 4
80. ing of the power elements IGBTs for the Output Module Transistor Board The Superimposition Board plugs directly into the Bus Board NOTE Unshaded areas of Block Logic Diagram are the subject of discussion CONTROL DISPLAY 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 V205 T machine The Control Board functions as the support circuitry for the on board CPU micro processor The Control Board receives information and power from the Bus Board and Main IGBT Inverter Board The Control Board supplies power for the Display Board and sup plies signals for the Display Board to show set and actual current values error codes and pre set values It also accepts signals via the Output Filter Board Pins D and E 24VDC to initiate welding output Upon clo sure of D and E a 24VDC relay is activated to indicate that welding output is required The Control Board CPU sends a command to the Main IGBT Inverter Board to activate the welding IGBTs The remote con trol signals Pins A B amp C are also fed into the Control Display Board from the 6 pin connector locat ed on the front of the machine Based upon current and voltage feedback information the Control Board regulates the welding output to coincide with the pre set w
81. inputs This input allows full output of the machine 200 amps 115V INPUT A suitable 115V attachment plug must be installed on the power cord to use the V205 T AC DC with a 115V input supply The rated output of the V205 T AC DC is available when connected to a 30A branch circuit When connected to a branch circuit with lower amp rating lower welding current and duty cycle must be used An output guide is provided below The values are approximate and must be adjusted downward if the fuse or circuit breaker trips off Other loads on the circuit and fuse circuit breaker charac teristics will affect the available output Do not exceed these welding conditions 15A branch circuit 10 duty cycle Stick 75A TIG 105A 20A branch circuit 10 duty cycle Stick 90A TIG 130A ATTACHMENT PLUG INSTALLATION Connect the white neutral wire under terminal clamp with silver screw and black hot wire under terminal clamp with brass screw Connect green wire under ter minal clamp with green screw Failure to wire as instructed may cause personal injury or damage to equipment To be installed or checked by an electrician or qualified person only WARNING INSTALLATION 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
82. ions where portability is important The Invertec V205 T AC DC is a power source that can perform the following types of welding with excellent results TIG with high frequency or Touch Start Tig Starting TIG AC with square sinusoidal and triangular wave forms Tig DC The following items can be connected to the 6 pin socket on the front panel Remote control potentiometer for Stick welding Remote Foot Amptrol or Hand Amptrol Arc Start Switch NOTE See Accessories section of this manual for product numbers and complete description WELDING CAPABILITY The Invertec V205 T AC DC is rated at 200 amps 18 volts at 40 duty cycle on a ten minute basis It is capable of higher duty cycles at lower output currents It is capable of 140 amps 15 6 volts at at 100 duty cycle If the duty cycle is exceeded a thermal protec tor will shut off the output until the machine cools See Technical Specifications in A 1 for other rated outputs The Invertec V205 T is recommended for stick welding with such popular electrodes as Fleetweld 35 Fleetweld 37 Fleetweld 180 and Excalibur 7018 LIMITATIONS The V205 T is not recommended for pipe thawing WARNING FUMES AND GASES can be dangerous Keep your head out of fumes Use ventilation or exhaust to remove fumes from breathing zone ARC RAYS can burn Wear eye ear and body protection WELDING CUTTING and GOUGING SPARKS can cause fire or
83. is controls and regulates the output of the machine The thermostats signals are connected to the Main IGBT Inverter Board This status information is passed on to the Control Board In the case of an over temperature condition the Control Board will pre vent output until the machine cools and the ther mostats reset Low level analog signals are generated on the Main IGBT Inverter Board and sent to the Control Display Board for meter set and actual display values THEORY OF OPERATION E 3 E 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 NOTE Unshaded areas of Block Logic Diagram are the subject of discussion FIGURE E 3 MAIN IGBT INVERTER BOARD Superimposition board Bus board Fan Input board HF board Main IGBT amp Power board 4 IGBT s Control board Display amp LED board 888 Control Knob Gas Solenoid DC blocking capacitor board Main Transformer Output board Output Transistor Module Current Hall Device Output Filter bd bypass D E Remote 2 4 Remote 75 76 77 A B C 24 VDC Remote 2 4 path D E turn on AC ckt 15 15 5 input volt meter thermostat info set info input current meter turn on PWM HF control signal 48 24 Input Choke _ RF coil 48 24 15 15 5 r
84. ished range 15 Check reading voltage on 15 14 314 CN1 See Fig 9 Remove upper cover check that the power supply voltage is within the established range 15 Check reading voltage on 15 14 315 CN1 See Fig 9 Remove upper cover check front panel power supplies Perform front panel reset test and replace if necessary Remove upper cover check front panel power supplies Perform front panel reset test and replace if necessary Note to reset front panel memory see procedure in Set up parameters chapter below Normally when cause s of alarm s is are removed press one of the keys to exit from alarm status or switch off and on the machine Thermal alarm will be automatically reset by letting go down internal temperature machine will execute a new autotest and then start as in normal operation In case of error code E10 see also the three thermal switches in fig below In case of error codes E11 E12 check input power supply voltage with reference to the following table Under Overvoltage alarm thresholds Power supply rated voltage 115 VAC 230 VAC 92 VAC 184 VAC 138 VAC 276 VAC Overvoltage Undervoltage TROUBLESHOOTING amp REPAIR 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
85. leads CN1 CN2 CN3 amp CN7 9 Replace the four phillips head screws previous ly removed from the corners of the name plate keypad CAUTION 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 amp REPAIR F 58 F 58 FIGURE F 29 CONTROL DISPLAY BOARD LOCATION CONTROL DISPLAY BOARD REMOVAL amp REPLACEMENT continued Control Display Board 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 amp REPAIR F 59 F 59 FIGURE F 30 METAL DISPLAY PLATE FIGURE F 31 CN1 CN2 CN7 CN3 Ground Wire 5 Mounting Nuts CONTROL DISPLAY BOARD REMOVAL amp REPLACEMENT continued 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 4 Phillips Head Screws 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
86. ltage Welding Mode AC TIG waveform and AC TIG frequency 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 OPERATION SET UP MENU Many additional parameters can be modified via the Set Up Menu To 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 light Item 1 green LED confirms normal operation The SETUP mode is confirmed by a center 0 on the Digital display Item 6 Rotate the Output Parameter Adjust Knob the Digital Display shows the numbers corre sponding to the parameters in sequence stop at the desired parameter and push the Setup Parameter Push Button The number on the Digital display Item 6 is replaced by the value of the parameter that can be modified through the Output Parameter adjust knob Item 5 With parameter 9 all the modifications made in the SETUP mode are cancelled and the standard values set by Invertec V205 T AC DC are restored To exit the Set Up Menu return to 0 and press the Setup Parameter Push Button INDICATOR PARAMETER DEFAULT 0 Exit From Set Up 1 Not Used 2 Pre Flow Time 0 25 seconds 0 5 sec 3 Arc Force percent above
87. n 2 Step Sequence With the Trigger Mode switch in the 2 step position the following welding sequence will occur This sequence is shown in 2 step diagram 1 1 Press and hold the Arc Start Switch to start the sequence The machine will open the gas valve to start the flow of the shielding gas After a 0 5 second preflow time to purge air from the torch hose the output of the machine is turned ON At this time the arc is started After the arc is started the output current will be increased from the start current to the welding cur rent Both the start current and increase or upslope time are presettable The default start current is 15 amps and the default upslope time is 0 2 seconds 2 Release the Arc Start Switch to stop welding The machine will now decrease the output current at a controlled rate or downslope time until the Finish current also commonly referred to as Crater Current is reached and the output of the machine is turned OFF Both the Downslope Time and the Finish Current are can be preset After the arc is turned OFF the gas valve will remain open to continue the flow of the shielding gas to the hot electrode and work piece The duration of this postflow shielding gas is adjusted by the Postflow Parameter Possible variations of this standard sequence is shown in 2 step diagram 2 It is possible to press and hold the TIG torch trigger a second time during downslope to restart After the trigger is
88. nt les parties sous tension des porte lectrodes connect s deux machines souder parce que la tension entre les deux pinces peut tre le total de la tension vide des deux machines f Si on utilise la machine souder comme une source de courant pour soudage semi automatique ces precautions pour le porte lectrode s applicuent aussi au pistolet de soudage 2 Dans le cas de travail au dessus du niveau du sol se prot ger contre les chutes dans le cas ou on recoit un choc Ne jamais enrouler le c ble lectrode autour de n importe quelle partie du corps 3 Un coup d arc peut tre plus s v re qu un coup de soliel donc a Utiliser un bon masque avec un verre filtrant appropri ainsi qu un verre blanc afin de se prot ger les yeux du rayon nement de l arc et des projections quand on soude ou quand on regarde l arc b Porter des v tements convenables afin de prot ger la peau de soudeur et des aides contre le rayonnement de l arc c Prot ger l autre personnel travaillant proximit au soudage l aide d crans appropri s et non inflammables 4 Des gouttes de laitier en fusion sont mises de l arc de soudage Se prot ger avec des v tements de protection libres de l huile tels que les gants en cuir chemise paisse pan talons sans revers et chaussures montantes 5 Toujours porter des lunettes de s curit dans la zone de soudage Utiliser des lunettes avec crans lateraux dans
89. ntained in good condition 7 b Always keep cylinders in an upright position securely chained to an undercarriage or fixed support 7 c Cylinders should be located Away from areas where they may be struck or subjected to physical damage A safe distance from arc welding or cutting operations and any other source of heat sparks or flame 7 d Never allow the electrode electrode holder or any other electrically hot parts to touch a cylinder 7 e Keep your head and face away from the cylinder valve outlet when opening the cylinder valve 7 f Valve protection caps should always be in place and hand tight except when the cylinder is in use or connected for use 7 g Read and follow the instructions on compressed gas cylinders associated equipment and CGA publication P l Precautions for Safe Handling of Compressed Gases in Cylinders available from the Compressed Gas Association 1235 Jefferson Davis Highway Arlington VA 22202 SAFETY Mar 95 WELDING SPARKS can cause fire or explosion 6 a Remove fire hazards from the welding area If this is not possible cover them to prevent the welding sparks from starting a fire Remember that welding sparks and hot materials from welding can easily go through small cracks and openings to adjacent areas Avoid welding near hydraulic lines Have a fire extinguisher readily available 6 b Where compressed gases are to be used at the job site
90. o the V205T the rectified DC input volt age is applied to the input capacitors through a cur rent limiting circuit The capacitors are charged slow ly and current limited for approximately five seconds After five seconds a relay closes and the pre charge circuit is bypassed and a controlled DC input voltage is applied to the weld capacitors and IGBTs making them ready for welding output demands when the IGBTs are gated on The auto reconnect circuit receives and processes a low level voltage signal from the Bus Board This low level signal is utilized to adjust for the different voltage requirements needed by the weld IGBT circuits A signal is also sent to the Control Board so that when the input voltage is reduced the output of the machine will be limited accordingly The Auxiliary power portion of the board generates several voltages through flyback topology and a 50KHZ switching frequency These various voltages 24 15 5 48 and 15 are utilized to operate the control and protection electronics the gas solenoid the trigger circuit and the fan motor The Main IGBT Inverter Board receives command and pre set signals from the Control Display board It also receives feedback information both voltage and cur rent from the Output Filter Board and Hall Effect Device via the Bus Board It processes this informa tion and generates the correct pulse width modulation signal PWM that is applied to the gates of the weld IGBTs Th
91. or are unable to perform the test repairs safely con tact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed Call 1 800 833 9353 WELD FUNCTION PROBLEMS SYMPTOMS POSSIBLE AREAS OF MISADJUSTMENT S RECOMMENDED COURSE OF ACTION FUNCTION PROBLEMS Error code E20 E24 or E25 is flashing on the digital display 1 Any one of these codes indi cates a memory error 1 The Control Display Board is faulty Replace No High Frequency when the torch trigger is pulled and the machine is in the TIG mode 1 Make sure the HF is in the active mode See the Set up Menu in this manual 1 Check fuse F2 on the Bus Board 2 Check for 385VDC at Test Points 9 and 20 See the Main IGBT Inverter Board UPFR Test 3 Perform the Control Display Board Test 4 The HF board may be faulty Replace Error code E14 is flashing of the digital display 1 This is an indication that the output inductance is too high 1 Check for excessive welding cable length 2 The Main IGBT Inverter Board may be faulty 3 The Superimposition Board may be faulty 4 The Control Display Board may be faulty The machine functions normally except the cooling fan does not operate 1 Check for obstructions that could prevent the fan from turn ing 1 Check the fan fuse F3 located on the Bus Board Replace if faulty 2 Perform the Bus Board Test 3 The Main
92. ossible 2 d 2 Never coil the electrode lead around your body 2 d 3 Do not place your body between the electrode and work cables If the electrode cable is on your right side the work cable should also be on your right side 2 d 4 Connect the work cable to the workpiece as close as possible to the area being welded 2 d 5 Do not work next to welding power source 1 h To avoid scalding do not remove the radiator pressure cap when the engine is hot CALIFORNIA PROPOSITION 65 WARNINGS Diesel engine exhaust and some of its constituents are known to the State of California to cause can cer birth defects and other reproductive harm The engine exhaust from this product contains chemicals known to the State of California to cause cancer birth defects or other reproductive harm The Above For Diesel Engines The Above For Gasoline Engines iii iii V205 T AC DC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC SAFETY ARC RAYS 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 standards 4 b Use suitable clothing made from durable flame resistant material to protect your skin and that of your helpers from the arc rays 4 c Protect other nearby personnel with suitable non flammable screening and o
93. pressed the output current will increase to the welding current This operation is shown in 2 step diagram 2 4 Step Sequence With the 4 step Selected the following welding sequence will occur 1 Press and hold the Arc Start Switch to start the sequence The machine will open the gas valve to start the flow of the shielding gas After a 0 5 second preflow time to purge air from the torch hose the output of the machine is turned ON At this time the arc is started After the arc is started the output current will be at the Start current This condition can be maintained as long or as short as necessary If the Start current is not necessary do not hold the TIG torch trigger as described at the beginning of this step Instead quickly press and release the trigger In this condition the machine will automatically pass from Step 1 to Step 2 when the arc is started 2 Release the TIG torch trigger to start the main part of the weld The output current will be increased from the start current to the welding current Both the start current and increase or upslope time are presettable The default start current is 15 amps and the default ups lope time is 0 2 seconds 2 STEP DIAGRAM 1 2 STEP DIAGRAM 2 1 2 1 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
94. r TOC Return to Master TOC Return to Master TOC Return to Master TOC MAIN INVERTER BOARD WELDING LOGIC AND INVERTER SECTION TEST 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 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 troubleshooting assistance before you proceed Call 1 800 833 9353 WELD DESCRIPTION This test will help determine if all functions of the Welding Logic Circuit and Inverter are func tioning properly MATERIALS NEEDED Volt Ohmmeter Phillips Head Screwdriver Wiring Diagram WARNING TROUBLESHOOTING AND REPAIR MAIN INVERTER BOARD WELDING LOGIC AND INVERTER 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 V205 T machine 2 Using a phillips head screwdriver remove the case wraparound cover 3 Perform the Capacitor
95. r resist high frequency leakage than neoprene and other synthetic rubber insulated cables 4 Keep the torch in good repair and all connections tight to reduce high frequency leakage 5 The work terminal must be connected to a ground within ten feet of the welder using one of the fol lowing methods a A metal underground water pipe in direct con tact with the earth for ten feet or more b A 3 4 19mm galvanized pipe or a 5 8 16mm solid galvanized iron steel or copper rod driven at least eight feet into the ground The ground should be securely made and the grounding cable should be as short as possible using cable of the same size as the work cable or larger Grounding to the building frame electrical conduit or a long pipe system can result in re radi ation effectively making these members radiating antennas 6 Keep all panels securely in place 7 All electrical conductors within 50 ft 15 2m of the welder should be enclosed in grounded rigid metallic conduit or equivalent shielding Flexible metallic conduit is generally not suitable 8 When the welder is enclosed in a metal building several earth driven electrical grounds connected as in 5b above around the periphery of the build ing are recommended Failure to observe these recommended installation procedures can cause radio or TV interference prob lems INPUT CONNECTIONS Be sure the voltage phase and frequency of the input power i
96. r warn them not to watch the arc nor expose themselves to the arc rays or to hot spatter or metal ELECTRIC SHOCK can kill 3 a The electrode and work or ground circuits are electrically hot when the welder is on Do not touch these hot parts with your bare skin or wet clothing Wear dry hole free gloves to insulate hands 3 b Insulate yourself from work and ground using dry insulation Make certain the insulation is large enough to cover your full area of physical contact with work and ground In addition to the normal safety precautions if welding must be performed under electrically hazardous conditions in damp locations or while wearing wet clothing on metal structures such as floors gratings or scaffolds when in cramped positions such as sitting kneeling or lying if there is a high risk of unavoidable or accidental contact with the workpiece or ground use the following equipment Semiautomatic DC Constant Voltage Wire Welder DC Manual Stick Welder AC Welder with Reduced Voltage Control 3 c In semiautomatic or automatic wire welding the electrode electrode reel welding head nozzle or semiautomatic welding gun are also electrically hot 3 d Always be sure the work cable makes a good electrical connection with the metal being welded The connection should be as close as possible to the area being welded 3 e Ground the work or metal to be welded to a good electrical ear
97. re D 2 Routine Maintenance D 2 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 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 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 ROUTINE MAINTENANCE Prevent metal powder from accumulating near the aer
98. roximate Argon Electrode Tip Preparation Sharpened Sharpened Gas Flow Rate Electrode Type C F H l min EWTh 2 EWLa 1 EWTh 2 EWLa 1 Stainless Electrode Size in mm Aluminum Steel 010 0 25 Up to 15 A Up to 15 A 3 8 2 4 3 8 2 4 020 0 50 Up to 15 A Up to 20 A 5 10 3 5 5 10 3 5 040 1 0 Up to 80 A Up to 60 A 5 10 3 5 5 10 3 5 1 16 1 6 Up to 150 A Up to 130 A 5 10 3 5 9 13 4 6 3 32 2 4 Up to MAX A Up to MAX A 13 17 6 8 11 15 5 7 1 8 3 2 X X 15 23 7 11 11 15 5 7 Tungsten electrodes are classified as follows by the American Welding Society AWS 2 Thoria EWTh 2 red 1 5 Lanthana EWLa 1 black 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 OPERATION 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 due to better weld penetration and faster travel speed Helium is especially suitable for welding thick workpieces The recommended gas flow rates are shown in table 5 TABLE 5 AC TIG WELDING QUIC
99. s are also incorporated within the Bus Board They are the fan circuit 24VDC and an input voltage sensing circuit that is utilized by the auto reconnect circuitry located on the Main Inverter Board The fan fuse F3 the 400VDC fuse F2 and the water cooler F1 not used are also located on the Bus Board THEORY OF OPERATION E 2 E 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 NOTE Unshaded areas of Block Logic Diagram are the subject of discussion 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 IGBTs This unity power factor cir cuit provides several advantages over a traditional bridge rectifier circuit Among these advantages are that the UPFR operates over a wide range of voltages there is no need for any manual circuit changes when the input voltages are changed from 115VAC to 230VAC and there is absolute voltage stability main tained on the IGBT electrolytic capacitors The four main welding IGBTs are located on a large center mounted heat sink assembly The pre charge and auto reconnect circuits are posi tioned on the Main IGBT Inverter Board When power is first applied t
100. s as specified on the rating plate located on the bottom of the machine ELECTRIC SHOCK can kill Have a qualified electrician install and service this equipment Turn the input power OFF and unplug the machine from the receptacle before working on this equipment Allow machine to sit for 5 minutes minimum to allow the power capacitors to discharge before working inside this equipment Do not touch electrically hot parts Machine must be plugged into a receptacle that is grounded according to the National Electrical Code and local codes Do not remove or defeat the purpose of the power cord ground pin RECONNECT PROCEDURE The Invertec V205 T AC DC auto reconnects to either 115V or 230V supply Fuse the input circuit with time delay fuses or delay type1 circuit breakers Using fuses or circuit breakers smaller than recommended may result in nuisance shut offs from welder inrush currents even if not weld ing at high currents The Invertec V205 T AC DC is recommended for use on an individual branch circuit 1Also called inverse time or thermal magnetic circuit breakers These circuit breakers have a delay in tripping action that decreases as the magnitude of the current increases WARNING A 5 A 5 V205 T AC DC Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TO
101. sibility of the welding current passing through lifting chains crane cables or other alternate circuits This can create fire hazards or overheat lifting chains or cables until they fail 6 h Also see item 1 c v v V205 T AC DC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC SAFETY PR CAUTIONS DE S RET Pour votre propre protection lire et observer toutes les instructions et les pr cautions de s ret specifiques qui parraissent dans ce manuel aussi bien que les pr cautions de s ret g n rales suiv antes S ret Pour Soudage A L Arc 1 Protegez vous contre la secousse lectrique a Les circuits l lectrode et la pi ce sont sous tension quand la machine souder est en marche Eviter toujours tout contact entre les parties sous tension et la peau nue ou les v tements mouill s Porter des gants secs et sans trous pour isoler les mains b Faire tr s attention de bien s isoler de la masse quand on soude dans des endroits humides ou sur un plancher met allique ou des grilles metalliques principalement dans les positions assis ou couch pour lesquelles une grande partie du corps peut tre en contact avec la masse c Maintenir le porte lectrode la pince de masse le c ble de soudage et la machine souder en bon et s r tat defonc tionnement d Ne jamais plonger le porte lectrode dans l eau pour le refroidir e Ne jamais toucher simultan me
102. sing cleaning or spraying operations The heat and rays of the arc can react with sol vent vapors to form phosgene a highly toxic gas and other irritating products 5 c Shielding gases used for arc welding can displace air and cause injury or death Always use enough ventilation especially in confined areas to insure breathing air is safe 5 d Read and understand the manufacturer s instructions for this equipment and the consumables to be used including the material safety data sheet MSDS and follow your employer s safety practices MSDS forms are available from your welding distributor or from the manufacturer 5 e Also see item 1 b iv iv V205 T AC DC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC FOR ELECTRICALLY 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 accordance with the U S National Electrical Code and the manufacturer s recommendations CYLINDER may explode if damaged 7 a Use only compressed gas cylinders containing the correct shielding gas for the process used and properly operating regulators designed for the gas and pressure used All hoses fittings etc should be suitable for the application and mai
103. 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 INPUT FILTER BOARD TEST 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 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 troubleshooting assistance before you proceed Call 1 800 833 9353 WELD DESCRIPTION This test will help determine if the input filter board is functioning properly MATERIALS NEEDED Analog Volt Ohmmeter Phillips Head Screwdriver Wiring Diagram Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC
104. ster TOC Return to Master TOC OUTPUT FILTER BOARD REMOVAL AND REPLACEMENT continued FIGURE F 34 OUTPUT FILTER BOARD 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 filter board mounting screws previously removed 21 Reconnect plugs CN1 and CN2 previously removed from the output filter board 22 Reconnect all heavy leads previously removed 23 Replace casefront 24 Replace all casefront mounting screws 25 Replace the four nameplate keypad mounting screws previously removed 26 Replace the case wraparound cover CN1 CN2 Positive Output Terminal Nut OUTPUT DIODES REMOVAL 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 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 troubleshooting assistance before you proceed Call 1 800 833 9353 WELD DESCRIPTION The following procedure will aid th
105. t 5 seconds the power source will switch back to the welding mode ready to weld with the new selected AC Frequency To change the AC Balance press and hold the Parameter button for 3 seconds AC Frequency is selected press the Parameter button again and AC Balance is selected Adjust the Output Control for the desired AC Balance After about 5 seconds the power source will switch back to the welding mode ready to weld with the new selected AC Balance To change the Post Flow time repeatedly push the Parameter button until the Post Flow indicator light is on Adjust the Output control to the desired Post Flow time as indicated on digital display Current A 50 100 150 200 250 300 Helium cfh l min 29 14 29 14 42 20 42 20 53 25 53 25 WARNING 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 OPERATION DC TIG WELDING QUICK START UP ELECTRIC SHOCK can kill Have an electrician install and service this equipment Turn 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 working inside this equipment Do not touch electrically hot parts
106. tact on the new diode s 10 Replace the two output diode mounting screws previously removed 11 Replace the copper bus bars to their proper loca tions 12 Mount the P C board previously removed 13 Replace the case wraparound cover OUTPUT TRANSISTOR REMOVAL 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 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 troubleshooting assistance before you proceed Call 1 800 833 9353 WELD DESCRIPTION The following procedure will aid the technician in removing the output transistor for replace ment MATERIALS NEEDED Phillips Head Screwdriver 5mm Allen Wrench Heatsink Compound F 67 F 67 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 WARNING TROUBLESHOOTING amp REPAIR PROCEDURE 1 Remove input power to the V205 T 2 Using a phillips head screwdriver remove the
107. tarting at max imum and adjusting to less is desired Set the AC Frequency in the 100 to 120 Hz range This is a Sweet Spot for most aluminum applica tions OPERATION STEEL TIG WELDING The TIG process is very effective for welding both car bon steel and alloy steel especially in applications requiring precision results DC Electrode Negative Polarity is required Since this process does not include the removal of impurities proper cleaning and preparation of the edges is required FILLER MATERIAL The filler rods must deposit welds with mechanical characteristics appropriate for the application COPPER TIG WELDING Since the TIG welding is a process characterized by high heat concentration it is particularly suitable for welding materials with high thermal conductivity like copper As with steel the DC Electrode Negative Polarity is employed with argon as protective gas Considering the fluidity of molten copper the use of backup support may prove useful FILLER MATERIAL In order to avoid the oxidation of the molten material filler materials containing phosphorus silicon or other deoxidating materials are typically used The mechan ical properties can also be improved through the use of silver TIPS FOR AC TIG WELDING AC Inverter TIG power sources offer two significant advantages over conventional Silicon Controlled Rectifier SCR transformer power sources GTAW Process Electrode Polarity DC AC App
108. ted overvoltages This process has no destructive effect on the component if the energy generated by the voltage peak is low as in the case of atmospheric lightening strikes However if over voltage is high and prolonged the varistor cannot dissipate this high energy and fails For example the machine is improperly connected to 275VAC or the over voltage is caused by non stabilized power units of inadequate capacity Note 2 The radio noise suppression circuit has two purposes to keep the machine s radio fre quency emisions within limits specified by standards and to ensure the machine s immu nity against the same type of problems caused any electronic devices connected to the same power supply source The filter con sists of a network of capacitors some of which are grounded and a toroidal inductor 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 TROUBLESHOOTING amp REPAIR 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 INVERTER BOARD LOW VOLTAGE TEST Service and repair should be performed by only Lincoln Electric factory trained personnel Unauthorized repairs performed on this equipment
109. th ground 3 f Maintain the electrode holder work clamp welding cable and welding machine in good safe operating condition Replace damaged insulation 3 g Never dip the electrode in water for cooling 3 h Never simultaneously touch electrically hot parts of electrode holders connected to two welders because voltage between the two can be the total of the open circuit voltage of both welders 3 i When working above floor level use a safety belt to protect yourself from a fall should you get a shock 3 j Also see Items 6 c and 8 Mar 95 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 electrodes which require special ventilation such as stainless or hard facing see instructions on container or MSDS or on lead or cadmium plated steel and other metals or coatings which produce highly toxic fumes keep exposure as low as possible and below Threshold Limit Values TLV using local exhaust or mechanical ventilation In confined spaces or in some circumstances outdoors a respirator may be required Additional precautions are also required when welding on galvanized steel 5 b Do not weld in locations near chlorinated hydrocarbon vapors coming from degrea
110. the front will not be restricted Dirt and dust that can be drawn into the machine should be kept to a minimum Failure to observe these precautions can result in excessive operating temperatures and nuisance shutdown STACKING The Invertec V205 T AC DC can not be stacked TILTING Place the machine directly on a secure level surface The machine may topple over if this procedure is not followed ENVIRONMENTAL AREA Keep the machine dry Do not place it on wet ground or in puddles ELECTRIC SHOCK can kill Only qualified personnel should per form this installation Turn the input power OFF and unplug the machine from the receptacle before working on this equipment Allow machine to sit for 5 minutes minimum to allow the power capac itors to discharge before working inside this equipment Insulate yourself from the work and ground Always wear dry insulating gloves Always connect the V205 T to a power supply grounded according to the National Electrical Code and local codes WARNING 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 INSTALLATION 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 bette
111. tion TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC OPERATION 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 trates on the anode workpiece Narrow and deep welds are obtained with high travel speeds Most materials with the exception of aluminum and magnesium are welded with this polarity FIGURE B 4 OUTPUT LIMITATIONS The maximum output current as specified in the instal lation section of this manual is derated in two situa tions alternate AC Wave Forms and elevated AC Frequencies Alternate AC Wave Forms See Set Up Menu Square 200 amps max output Sinusoidal 150 amps max output Triangular 120 amps max output Elevated AC Frequencies Above 85Hz AC output the square wave out put is limited to 170 amps Elevated AC Frequencies do not effect the output of Sinusoidal and Triangular Waveforms These derated values have been programmed into the Invertec V205 T AC DC to ensure reliable operation DC TIG WELDING see FIGURE B 3 The TIG Tungsten lnert Gas welding process is based on the presence of an electric arc between a non consumable electrode pure or alloyed tungsten with an
112. to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC TROUBLESHOOTING amp REPAIR F 51 F 51 RV1 RV2 FIGURE F 26 MAIN IGBT BOARD LEAD REMOVAL INPUT FILTER BOARD REMOVAL AND REPLACEMENT continued 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 MAIN IGBT BOARD REMOVAL 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 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 troubleshooting assistance before you proceed Call or 1 800 833 9353 WELD DESCRIPTION The following procedure will aid the technician in removing the main IGBT board for replace ment MATERIALS NEEDED 7mm Nut driver Phillips Head Screwdriver Wiring Diagram Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master T
113. ts kit Harris flowmeter regulator 10 ft gas hose Twist Mate adapter work clamp and cable and 10 ft water hose CABLE PLUGS K852 70 Cable Plug Kit for 1 0 2 0 cable Attaches to welding cable to provide quick disconnect from machine Twist Mate Torch Adapter K1622 1 One is shipped with the welder torch If you do not care to interchange this part between torches one is required to connect Magnum PTA 9 or PTA 17 TIG torches with one piece cable to the V205 T you may order an additional adapters The quick connect plug provides connection for both gas and welding current K1622 4 Twist Mate adapter for Water Cooled TIG torches Adapter for PTW 18 and 20 Torches TIG Torch Parts Kits Parts kits are available for the PTA 9 and PTA 17 TIG torches These kits include back cap collets collet bodies nozzles and tungstens Order KP507 for PTA 9 torches Order KP508 for PTA 17 torches See publication E12 150 for parts kits breakdown Cut Length Consumables TIG welding filler metals are available for welding stainless steel mild steel alu minum and copper alloys See publication C9 10 D 1 D 1 V205 T AC DC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC TABLE OF CONTENTS MAINTENANCE Maintenance Section D Input Filter Capacitor Discharge Procedu
114. turn to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC FIGURE E 5 CONTROL DISPLAY BOARD HF BOARD amp OUTPUT FILTER BOARD Superimposition board Bus board Fan Input board HF board Main IGBT amp Power board 4 IGBT s Control board Display amp LED board 888 Control Knob Gas Solenoid DC blocking capacitor board Main Transformer Output board Output Transistor Module Current Hall Device Output Filter bd bypass D E Remote 2 4 Remote 75 76 77 A B C 24 VDC Remote 2 4 path D E turn on AC ckt 15 15 5 input volt meter thermostat info set info input current meter turn on PWM HF control signal 48 24 Input Choke _ RF coil 48 24 15 15 5 reconnect info voltage feedback high volt supply turn on AC ckt current feedback IGBT Thermostats Output Diode Thermostat Voltage Feedback Current Feedback AC DC Gate drive signals 24 VDC 48 VDC Output Choke NOTE Unshaded areas of Block Logic Diagram are the subject of discussion INSULATED GATE BIPOLAR TRANSISTOR IGBT OPERATION 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 source and therefore no current flow The dr
115. ue 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 with us Please include the machine s code number and how the problem was resolved Thank You Technical Services Group Lincoln Electric Co 22801 ST Clair Ave Cleveland Ohio 44117 1199 FAX 216 481 2309 SVM Number ___________________________ Page Number if necessary__________________ Your Company__________________________ Your Name_____________________________ Please give detailed description below ___________________________________________________________________________ ___________________________________________________________________________ ___________________________________________________________________________ ___________________________________________________________________________ ___________________________________________________________________________ ___________________________________________________________________________ ___________________________________________________________________________ ___________________________________________________________________________ ___________________________________________________________________________ ___________________________________________________________________________ ____________________________
116. upply Ground for Supplies Expected Voltage 24 VDC 48 VDC BUS BOARD TEST 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 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 troubleshooting assistance before you proceed Call 1 800 833 9353 WELD DESCRIPTION This test will help determine if the BUS board is functioning properly MATERIALS NEEDED Volt Ohmmeter Phillips Head Screwdriver Wiring Diagram 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 amp REPAIR F 27 F 27 V205 T AC DC WARNING 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 amp REPAIR 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 p
117. ure that requires you to touch internal components of the machine MATERIALS NEEDED Phillips Screwdriver Insulated Pliers Insulated Gloves High Wattage Resistor 25 1000 ohms and 25 watts minimum Volt Meter 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 amp 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
118. ys 1 Direct interference radiated from the welder 2 Direct interference radiated from the welding leads 3 Direct interference radiated from feedback into the power lines 4 Interference from re radiation of pickup by ungrounded metallic objects Keeping these contributing factors in mind installing equipment per the following instructions should mini mize problems 1 Keep the welder power supply lines as short as pos sible and enclose as much of them as possible in rigid metallic conduit or equivalent shielding for a distance of 50 feet 15 2m There should be good electrical contact between this conduit and the welder case ground Both ends of the conduit should be connected to a driven ground and the entire length should be continuous 2 Keep the work and electrode leads as short as pos sible and as close together as possible Lengths should not exceed 25 ft 7 6m Tape the electrode and work leads together into one bundle when prac tical Read entire installation section before starting installation Safety Precautions SELECT SUITABLE LOCATION The Invertec will operate in harsh environments Even so it is important that simple preventative measures are followed in order to assure long life and reliable operation The machine must be located where there is free cir culation of clean air such that air movement in the back and out

Lincoln Electric Invertec V205-T User's Manual

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