Page 2 - ii; SAFETY; WARNING; CALIFORNIA PROPOSITION 65 WARNINGS; The Above For Diesel Engines
ii V205-T AC/DC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC FOR ENGINEpowered equipment. 1.a. Turn the engine off before troubleshooting and maintenance work unless the maintenance work requires it to be running. ___________________________________________...
Page 3 - ELECTRIC SHOCK can kill.
iii iii V205-T AC/DC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Retur n 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 andthe rays of the arc when welding or observingopen arc welding. Headshie...
Page 5 - PRÉCAUTIONS DE SÛRETÉ
v v V205-T AC/DC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC SAFETY PRÉCAUTIONS DE SÛRETÉ Pour votre propre protection lire et observer toutes les instructionset les précautions de sûreté specifiques qui parraissent dans cemanuel aussi bien que les précaut...
Page 6 - MASTER TABLE OF CONTENTS FOR ALL SECTIONS; Page
vi vi V205-T AC/DC MASTER TABLE OF CONTENTS FOR ALL SECTIONS Page Safety .................................................................................................................................................i-iv Installation ...................................................................
Page 7 - TABLE OF CONTENTS; INSTALLATION
A-1 A-1 V205-T AC/DC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC TABLE OF CONTENTS - INSTALLATION SECTION - INSTALLATION ...................................................................................................................... Section A Techni...
Page 9 - Safety Precautions; Insulate yourself from the work and ground.
A-3 A-3 V205-T AC/DC Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC INSTALLATION MACHINE GROUNDING AND HIGH FRE-QUENCY INTERFERENCE PROTECTION The Capacitor Discharge ...
Page 10 - INPUT CONNECTIONS; RECONNECT PROCEDURE
A-4 A-4 V205-T AC/DC Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC INSTALLATION 3. Be sure the torch and work cable rubber coverings are free of cuts and cracks that ...
Page 12 - WORK CABLE CONNECTION; Machine Grounding and High; OUTPUT CONNECTIONS; OUTPUT CONNECTION FOR STICK
A-6 A-6 V205-T AC/DC Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC INSTALLATION OUTPUT AND GAS CONNECTION FORTIG WELDING (FIGURE A.1) The TIG Torch Twist-Mate and wor...
Page 13 - REMOTE CONTROL CONNECTION; Optional; • Keep cylinder upright and; Slide rubber boot onto cable end. The boot end; SHIELDING GAS CONNECTION
A-7 A-7 V205-T AC/DC Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC INSTALLATION REMOTE CONTROL CONNECTION A remote control receptacle is provided on the lowercenter c...
Page 14 - NOTES
NOTES A-8 A-8 V205-T AC/DC Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC
Page 15 - Operation
B-1 B-1 V205-T AC/DC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC TABLE OF CONTENTS - OPERATION SECTION - Operation ............................................................................................................................... Section B Saf...
Page 16 - OPERATION; SAFETY INSTRUCTIONS; Accessories; WELDING CAPABILITY
B-2 B-2 V205-T AC/DC Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC OPERATION Read and understand this entire section beforeoperating your machine. SAFETY INSTRUCTIONS...
Page 17 - REAR CONTROL PANEL; I1: Off/On switch turns on the electric power to; * The welder is connected to the supply even if the “l1”
B-3 B-3 V205-T AC/DC Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC OPERATION REAR CONTROL PANEL (FIGURE B.1) • I1: Off/On switch turns on the electric power to the we...
Page 18 - Input Voltage warning light green LED -; Indicates; CONTROLS AND SETTINGS
B-4 B-4 V205-T AC/DC Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC OPERATION 1. Input Voltage warning light green LED - Indicates that the machine is on and input vol...
Page 19 - Tig Trigger Sequences -
B-5 B-5 V205-T AC/DC Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC OPERATION 5. Output / Parameter Adjust Knob - Allows you to continuously adjust the current both in...
Page 20 - Remote Control Connector; STEP DIAGRAM 1
B-6 B-6 V205-T AC/DC Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC OPERATION 3. Press and hold the TIG torch trigger when the main part of the weld is complete. The m...
Page 21 - SET UP MENU; INDICATOR
B-7 B-7 V205-T AC/DC Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC OPERATION SET UP MENU Many additional parameters can be modified via theSet Up Menu. To access the ...
Page 22 - WELDING POLARITY; • Alternate AC Wave Forms (See Set Up Menu); DC TIG WELDING
B-8 B-8 V205-T AC/DC Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC OPERATION WELDING POLARITY DC Electrode Negative Polarity (Direct CurrentStraight Polarity) (see FI...
Page 23 - rent welding
B-9 B-9 V205-T AC/DC Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC A.C.- PULSED TIG OPERATION DC Electrode Positive Polarity. (Direct CurrentReverse Polarity) (see Fi...
Page 24 - STEEL TIG WELDING; GTAW Process
B-10 B-10 V205-T AC/DC Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC 1. The AC wave balance can be set to a higher per- centage electrode negative which minimizes tun...
Page 25 - AC TIG WELDING QUICK START UP; , repeatedly push the
B-11 B-11 V205-T AC/DC Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC OPERATION PROTECTIVE GAS Both argon and helium work when welding aluminum.Argon is preferred, due...
Page 26 - DC TIG WELDING QUICK START UP; service this equipment.; To change to DC TIG Welding:; To change the Post Flow time; To change from High Frequency to Lift Start
B-12 B-12 V205-T AC/DC Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC OPERATION DC TIG WELDING QUICK START UP ELECTRIC SHOCK can kill.• Have an electrician install and...
Page 28 - ACCESSORIES; OPTIONAL ACCESSORIES; AND COMPATIBLE EQUIPMENT; TIG TORCH KITS; CABLE PLUGS; TIG Torch Parts Kits -
C-2 C-2 V205-T AC/DC Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC ACCESSORIES OPTIONAL ACCESSORIES AND COMPATIBLE EQUIPMENT Factory Installed Twist-Mate Cable Connec...
Page 29 - Maintenance
D-1 D-1 V205-T AC/DC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC TABLE OF CONTENTS -MAINTENANCE- Maintenance ......................................................................................................................... Section D Input Filter Ca...
Page 30 - MAINTENANCE; SAFETY PRECAUTIONS; ELECTRIC SHOCK; INPUT FILTER CAPACITOR; ROUTINE MAINTENANCE; • Clean the power source inside by means of low-
D-2 D-2 V205-T AC/DC Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC MAINTENANCE SAFETY PRECAUTIONS ELECTRIC SHOCK can kill. • Have an electrician install and service t...
Page 32 - GENERAL DESCRIPTION; THEORY OF OPERATION
FIGURE E.2 – GENERAL DESCRIPTION, INPUT BOARD & BUS BOARD Superimposition board Bus board Fan Inputboard HFboard Main IGBT& Power board 4IGBT’s Control board Display & LED board 888 Control Knob GasSolenoid DC blockingcapacitor board MainTransformer Output board OutputTransistor Module C...
Page 33 - MAIN IGBT INVERTER BOARD; FIGURE E.3 – MAIN IGBT INVERTER BOARD
MAIN IGBT INVERTER BOARD The filtered input voltage, from the Input Board, isapplied through an input choke to the Main IGBTInverter Board. This input voltage is rectified, regulat-ed and a unity power factor output is developed forthe main welding IGBTs. This unity power factor cir-cuit provides se...
Page 34 - OUTPUT TRANSISTOR MODULE & SUPERIMPOSITION BOARD; MAIN TRANSFORMER
THEORY OF OPERATION E-4 E-4 V205-T AC/DC Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC FIGURE E.4 – MAIN TRANSFORMER, OUTPUT DIODE MODULE & CLAMPING BOARD, OUTPUT...
Page 37 - Test Procedures
V205-T AC/DC Section F-1 Section F-1 Troubleshooting & Repair Section ................................................................................. Section F How to Use Troubleshooting Guide ....................................................................................F-2 PC Board Trou...
Page 38 - HOW TO USE TROUBLESHOOTING GUIDE; TROUBLESHOOTING & REPAIR; CAUTION; The; Step 3. PERFORM COMPONENT TESTS
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 machineoperator and will invalidate your factory warranty. For your safety and to avo...
Page 39 - PC board can be damaged by static electricity.; PC BOARD TROUBLESHOOTING PROCEDURES
V205-T AC/DC Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC TROUBLESHOOTING & REPAIR F-3 F-3 Sometimes machine failures appear to be due to PCboard failures. These...
Page 40 - Observe Safety Guidelines; TROUBLESHOOTING GUIDE; detailed in the beginning of this manual.; OUTPUT PROBLEMS; Input Filter Board
Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC V205-T AC/DC TROUBLESHOOTING & REPAIR F-4 F-4 Observe Safety Guidelines TROUBLESHOOTING GUIDE detailed in the beginn...
Page 41 - FUNCTION PROBLEMS
Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC V205-T AC/DC TROUBLESHOOTING & REPAIR F-5 F-5 TROUBLESHOOTING GUIDE Observe Safety Guidelines detailed in the beginn...
Page 42 - Menu
Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC V205-T AC/DC TROUBLESHOOTING & REPAIR F-6 F-6 Observe Safety Guidelines TROUBLESHOOTING GUIDE detailed in the beginn...
Page 43 - Secondary Power Board Test
Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC V205-T AC/DC TROUBLESHOOTING & REPAIR F-7 F-7 Observe Safety Guidelines TROUBLESHOOTING GUIDE detailed in the beginn...
Page 44 - WELDING PROBLEMS
Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC V205-T AC/DC TROUBLESHOOTING & REPAIR F-8 F-8 Observe Safety Guidelines TROUBLESHOOTING GUIDE detailed in the beginn...
Page 45 - Power Supply; FIGURE F.1 EXTERNAL DIAGNOSTICS
TROUBLESHOOTING & REPAIR F-9 F-9 V205-T AC/DC Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC EXTERNAL DIAGNOSTICS ® PARAMETER SELECT / HOLD PULSE ON UPSLOPE % ON T...
Page 47 - LED; part; Normal Status Conditions
TROUBLESHOOTING & REPAIR INTERNAL DIAGNOSTICS (Continued) F-11 F-11 V205-T AC/DC Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC LED L1 L2 L3 L4 L5 L6 L7 L8 L9 L10 ...
Page 49 - INPUT FILTER CAPACITOR DISCHARGE PROCEDURE; DESCRIPTION; MUST; be performed, as a safety; MATERIALS NEEDED; Phillips Screwdriver
WARNING Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC TROUBLESHOOTING & REPAIR F-13 F-13 V205-T AC/DC INPUT FILTER CAPACITOR DISCHARGE PROCEDURE Service and repai...
Page 50 - DISCHARGE PROCEDURE; Resistor
Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC TROUBLESHOOTING & REPAIR F-14 F-14 V205-T AC/DC ELECTRIC SHOCK can kill. • Have an electrician install and service t...
Page 51 - INPUT FILTER BOARD TEST; Analog Volt/Ohmmeter
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 ormachine operator and will invalidate your factory warranty. For your safety and to avoidelectric...
Page 52 - FIGURE F.4 INPUT FILTER BOARD; TEST PROCEDURE; Using a phillips head screwdriver, remove the; INPUT FILTER BOARD
Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC TROUBLESHOOTING & REPAIR F-16 F-16 V205-T AC/DC INPUT FILTER BOARD TEST (continued) FIGURE F.4 INPUT FILTER BOARD TE...
Page 53 - FIGURE F.5 INPUT FILTER BOARD
Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC TROUBLESHOOTING & REPAIR F-17 F-17 V205-T AC/DC INPUT FILTER BOARD TEST (continued) FIGURE F.5 INPUT FILTER BOARD No...
Page 55 - MAIN IGBT INVERTER BOARD LOW VOLTAGE TEST; Voltmeter
TROUBLESHOOTING & REPAIR F-19 F-19 V205-T AC/DC Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC MAIN IGBT INVERTER BOARD LOW VOLTAGE TEST Service and repair should ...
Page 56 - Capacitor Discharge; MAIN IGBT INVERTER BOARD LOW VOLTAGE TEST (CONTINUED); BACK SIDE; MAIN BOARD; FIGURE F.6 MAIN IGBT INVERTER BOARD LOCATION
TEST PROCEDURE 1. Remove input power to the V205-Tmachine. 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 th...
Page 57 - TABLE F.1 TEST POINTS; Machine Mode
TROUBLESHOOTING & REPAIR F-21 F-21 V205-T AC/DC Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC MAIN IGBT INVERTER BOARD LOW VOLTAGE TEST (CONTINUED) TABLE F.1 TEST...
Page 58 - FIGURE F.7 MAIN IGBT INVERTER BOARD LOCATION
TROUBLESHOOTING & REPAIR F-22 F-22 V205-T AC/DC Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC MAIN IGBT INVERTER BOARD LOW VOLTAGE TEST (CONTINUED) FIGURE F.7 MAI...
Page 59 - CONTROL/DISPLAY BOARD TEST; Phillips Head Screwdriver
F-23 F-23 V205-T AC/DC Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC TROUBLESHOOTING & REPAIR CONTROL/DISPLAY BOARD TEST Service and repair should be performed by...
Page 60 - Using a phillips head screwdriver, remove; Do not remove plugs from; FIGURE F.8 CONTROL/DISPLAY BOARD LOCATION; Control/Display Board
TEST PROCEDURE 1. Remove input power to the V205-Tmachine. 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 b...
Page 61 - FIGURE F.9 CONTROL/DISPLAY BOARD LOCATION
TROUBLESHOOTING & REPAIR F-25 F-25 V205-T AC/DC Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC CONTROL/DISPLAY BOARD TEST (CONTINUED) CN1 CN7 CN2 FIGURE F.9 CONTRO...
Page 62 - TABLE F.2 PLUG CN1 TEST POINTS
TROUBLESHOOTING & REPAIR CONTROL/DISPLAY BOARD TEST (CONTINUED) F-26 F-26 V205-T AC/DC Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC FIGURE F.10 PLUGS CN1, CN2 &a...
Page 63 - BUS BOARD TEST
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 ormachine operator and will invalidate your factory warranty. For your safety and to avoidelectrical shock,...
Page 64 - Do not remove plugs from the board.; BUS BOARD
Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC TROUBLESHOOTING & REPAIR F-28 F-28 V205-T AC/DC BUS BOARD TEST (continued) TEST PROCEDURE 1. Remove input power to t...
Page 65 - TABLE F.5 PLUG CN2 TEST POINTS
TROUBLESHOOTING & REPAIR F-29 F-29 V205-T AC/DC Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC BUS BOARD TEST (continued) TABLE F.5 PLUG CN2 TEST POINTS TABLE F.6 ...
Page 66 - FIGURE F.12 BUS BOARD PLUG LOCATIONS
TROUBLESHOOTING & REPAIR BUS BOARD TEST (continued) F-30 F-30 V205-T AC/DC Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC FIGURE F.13 PLUGS CN2, CN3, CN4 FIGURE F....
Page 67 - MAIN INVERTER BOARD “UPFR” SECTION TEST
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 ormachine operator and will invalidate your factory warranty. For your safety and ...
Page 68 - Using a phillips head screwdriver, remove the; Do not remove; ON; TABLE F.11 RESISTANCE CHECKS
Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC TROUBLESHOOTING & REPAIR F-32 F-32 V205-T AC/DC MAIN INVERTER BOARD “UPFR” SECTION TEST (continued) TEST PROCEDURE 1...
Page 69 - FIGURE F.15 UPFR AREA ON MAIN BOARD; TP9 GNDPWR
TROUBLESHOOTING & REPAIR F-33 F-33 V205-T AC/DC Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC FIGURE F.15 UPFR AREA ON MAIN BOARD TP9 GNDPWR R82 F1 TP20 MF8 RL1 P...
Page 71 - TROUBLESHOOTING AND REPAIR; OUTPUT FILTER BOARD TEST
TROUBLESHOOTING AND REPAIR F-35 F-35 V205-T AC/DC Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC OUTPUT FILTER BOARD TEST Service and repair should be performed by onl...
Page 72 - Do not remove plugs from the; Output Filter Board
TROUBLESHOOTING AND REPAIR OUTPUT FILTER BOARD TEST (continued) F-36 F-36 V205-T AC/DC Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC TEST PROCEDURE 1. Remove input po...
Page 73 - FIGURE F.17 OUTPUT FILTER BOARD PLUG LOCATION; Description; Trigger; Expected Voltage
TROUBLESHOOTING AND REPAIR OUTPUT FILTER BOARD TEST (continued) F-37 F-37 V205-T AC/DC Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC FIGURE F.17 OUTPUT FILTER BOARD P...
Page 75 - SECONDARY POWER BOARD TEST
TROUBLESHOOTING AND REPAIR F-39 F-39 V205-T AC/DC Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC SECONDARY POWER BOARD TEST Service and repair should be performed by o...
Page 77 - FIGURE F.20 SECONDARY POWER BOARD TEST POINT LOCATIONS; OCV; Value
TROUBLESHOOTING AND REPAIR SECONDARY POWER BOARD TEST (continued) F-41 F-41 V205-T AC/DC Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC GA SA SB GB I I I I 10K Ohms 10...
Page 79 - MAIN INVERTER BOARD
TROUBLESHOOTING AND REPAIR F-43 F-43 V205-T AC/DC Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC MAIN INVERTER BOARD “WELDING LOGIC AND INVERTER” SECTION TEST Service ...
Page 83 - VDS
TROUBLESHOOTING AND REPAIR MAIN INVERTER BOARD “WELDING LOGIC AND INVERTER” SECTION TEST (continued) F-47 F-47 V205-T AC/DC Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master ...
Page 85 - INPUT FILTER BOARD REMOVAL AND REPLACEMENT; mm Nut Driver
INPUT 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 ormachine operator and will invalidate your factory warranty. For your safety a...
Page 86 - PROCEDURE; Using a phillips head screwdriver remove the case; FIGURE F.24 INPUT FILTER BOARD LOCATION
Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC V205-T AC/DC TROUBLESHOOTING & REPAIR F-50 F-50 PROCEDURE 1. Remove input power to the V205-T. 2. Using a phillips h...
Page 87 - FIGURE F.26 MAIN IGBT BOARD LEAD REMOVAL
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 yourthumbs. Depressing these...
Page 89 - MAIN IGBT BOARD REMOVAL AND REPLACEMENT; mm Nut driver
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 ormachine operator and will invalidate your factory warranty. For your safety and ...
Page 90 - FIGURE F.27 – MAIN IGBT BOARD LOCATION; MAIN IGBT BOARD REMOVAL & REPLACEMENT; Input Filter Capacitor
Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC V205-T AC/DC TROUBLESHOOTING & REPAIR F-54 F-54 FIGURE F.27 – MAIN IGBT BOARD LOCATION BACK SIDE MAIN BOARD MAIN IGB...
Page 91 - FIGURE F.28 MAIN BOARD PLUG AND MOUNTING SCREW LOCATIONS; Reconnect previously removed leads RV1
TROUBLESHOOTING & REPAIR MAIN IGBT BOARD REMOVAL & REPLACEMENT (continued) F-55 F-55 V205-T AC/DC Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC FIGURE F.28 MA...
Page 93 - CONTROL/DISPLAY BOARD REMOVAL AND REPLACEMENT
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 ormachine operator and will invalidate your factory warranty. For your safet...
Page 94 - See; FIGURE F.29 – CONTROL/DISPLAY BOARD LOCATION; CONTROL/DISPLAY BOARD REMOVAL & REPLACEMENT
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 s...
Page 95 - FIGURE F.30 METAL DISPLAY PLATE; Phillips Head Screws
V205-T AC/DC Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC TROUBLESHOOTING & REPAIR F-59 F-59 FIGURE F.30 METAL DISPLAY PLATE FIGURE F.31 CN1 CN2 CN7 CN3 GroundWi...
Page 97 - Large Crescent Wrench
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 ormachine operator and will invalidate your factory warranty. For your safety ...
Page 98 - FIGURE F.32 OUTPUT FILTER BOARD LOCATION; OUTPUT FILTER BOARD; Input Filter Capacitor Discharge
V205-T AC/DC Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC TROUBLESHOOTING & REPAIR F-62 F-62 FIGURE F.32 OUTPUT FILTER BOARD LOCATION Output Filter Board OUTPUT ...
Page 99 - FIGURE F.33 CASE FRONT SCREW REMOVAL; Phillips Head Screws; See Figure
TROUBLESHOOTING & REPAIR F-63 F-63 V205-T AC/DC Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC FIGURE F.33 CASE FRONT SCREW REMOVAL Phillips Head Screws ® PARAMETE...
Page 100 - FIGURE F.34 OUTPUT FILTER BOARD; Nut
TROUBLESHOOTING & REPAIR F-64 F-64 V205-T AC/DC Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC OUTPUT FILTER BOARD REMOVAL AND REPLACEMENT (continued) FIGURE F.34 ...
Page 101 - OUTPUT DIODES REMOVAL AND REPLACEMENT
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 ormachine operator and will invalidate your factory warranty. For your safety and to...
Page 102 - FIGURE F.35 OUTPUT DIODE LOCATION
V205-T AC/DC Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC TROUBLESHOOTING & REPAIR F-66 F-66 FIGURE F.35 OUTPUT DIODE LOCATION OUTPUTDIODES OUTPUT DIODES REMOVAL...
Page 103 - OUTPUT TRANSISTOR REMOVAL AND REPLACEMENT
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 ormachine operator and will invalidate your factory warranty. For your safety an...
Page 104 - FIGURE F.36 OUTPUT TRANSISTOR LOCATION
PROCEDURE 1. Remove input power to the V205-T. 2. Using a phillips head screwdriver, remove the case wraparound cover. 3. Perform the Input Filter Capacitor Discharge Procedure detailed earlier in this section. 4. Locate the output transistor. See Figure F.36. 5. Disconnect plug CN1 from the output ...
Page 105 - FIGURE F.37 OUTPUT TRANSISTOR LEAD LOCATION; Plug CN1
TROUBLESHOOTING & REPAIR F-69 F-69 V205-T AC/DC Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC OUTPUT TRANSISTOR REMOVAL AND REPLACEMENT (continued) FIGURE F.37 OU...
Page 107 - ELECTRICAL DIAGRAMS
G-1 ELECTRICAL DIAGRAMS G-1 TABLE OF CONTENTS -ELECTRICAL DIAGRAMS SECTION- ELECTRICAL DIAGRAMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SECTION G WIRING DIAGRAM (CODE 10860 ONLY) . . . . . . . . . . . . . . . . . . . . . . ....
Page 109 - SVM ERROR REPORTING FORM; Please give detailed description below:
SVM ERROR REPORTING FORM We need to know if there are errors in our manuals. We also value any suggestions as toadditional 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 troubleshoo...
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