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Summary of Contents for Lincoln Electric ASPECT 200
- Page 1 SVM 3109 Rev.00 07-2019 ASPECT ® For use with machines having code numbers: 50455 LINCOLN ELECTRIC EUROPE www.lincolnelectric.eu...
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Page 2: Table Of Contents
INDEX OF CONTENTS TECHNICAL SPECIFICATIONS AND ACCESSORIES ................... 3 INTRODUCTION ..............................5 INSTALLATION AND OPERATOR INSTRUCTIONS ..................6 MAINTENANCE ..............................3 INPUT DC BUS CAPACITORS DISCHARGE PROCEDURE ................3 INPUT ................................. 7 BOOST & INVERTER PCB – OUTPUT TRANSFORMER ................8 OUTPUT, POWER CONTROL BOARD, HF BOARD .................. -
Page 3: Technical Specifications And Accessories
TECHNICAL SPECIFICATIONS AND ACCESSORIES ® ASPECT NAME INDEX ® Aspect 200ACDC K14189-1 INPUT Input Voltage U EMC Class Frequency 115 - 230Vac ± 15% 50/60 Hz Input Amperes Input Line Mode 100% PFmax 1max STICK 3.2 kW 1.9 kW 1.4 kW TIG DC 2.4 kW 1.8 kW... - Page 4 Failure to follow the instructions in this manual could cause serious personal injury, loss of life, or damage to this equipment. Read and understand the following explanations of the warning symbols. Lincoln Electric is not responsible for damages caused by improper installation, improper care or abnormal operation.
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Page 5: Introduction
ARTIFICIAL OPTICAL RADIATION: According with the requirements in 2006/25/EC Directive and EN 12198 Standard, the equipment is a category 2. It makes mandatory the adoption of Personal Protective Equipments (PPE) having filter with a protection degree up to a maximum of 15, as required by EN169 Standard. -
Page 6: Installation And Operator Instructions
Installation and Operator Instructions Read this entire section before installation or operation need to change overcurrent protection for 25A type D of the machine. and change for a proper input plug (or connect directly to a power network) Location and Environment Example: This machine will operate in harsh environments. - Page 7 Polarity for Stick can be selected between (DC+, DC-, Remote Control Connection AC) by front panel push button and menu, see following. Refer to the accessories section for a list of remote controls. If a remote control is used, TIG Welding (GTAW) it will be connected to the remote connector This machine does not include a TIG torch necessary for on the front of the machine.
- Page 8 D. Gas Inlet: Connector for the TIG shielding gas. Use the supplied connector to connect the machine to the gas source line. The gas source must have a pressure regulator and flow gage installed. Connecting the Remote command excludes the Output Current Knob of the Machine’s user interface.
- Page 9 AC Wave Shape: This icon is designated to set the polarity of the process in use: DC+, AC stick, DC- & AC TIG operations. NOTE: Pressing the button assigned to process These icons allow the operator to customize the arc- POLARITY will toggle the illumination of the icon performance for TIG welding in AC polarity only.
- Page 10 Sequencer Functions: Pulse Sequencer Functions: Table 4. Percent Peak Current: This functions sets the amount of time the pulse waveform spends at the peak current setting. This function is set as a percentage of the total time for the pulse cycle. The sequencer allows for the customization of the TIG Pulses-Per-Second: Sets the welding operation both in AC &...
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Page 11: Operation
Memory Selection: Menu: The memory function is designed to allow the operator to save up to 9 specific welding procedures. This memory This unit permits an advance setting divided in 3 menu: button will have two functions: 1. Save memory settings 1. - Page 12 Operating Instruction AC Stick Welding To start AC Stick welding process: DC Stick (SMAW) Welding To start DC Stick welding process: 1. Set polarity 2. To select Stick welding: 1. Set polarity Process Visualization 2. To select Stick welding: Process Visualization Crisp Crisp...
- Page 13 HF TIG 2-Step Trigger Sequence When the mode pushbutton is in HF TIG position, the To select 2-Step sequence: machine is ready for HF TIG welding. During the HF Output Visualization TIG mode, the TIG arc is started by HF without pressing the electrode on the work piece.
- Page 14 4-Step Trigger Sequence To select 4-Step sequence: Output Visualization Press several times until the LED above lights up With the 4-step trigger mode and a TIG welding mode selected, the following welding sequence will occur. As shown above, it is possible to press and hold the TIG torch trigger a second time during downslope to end the downslope function and maintain the output current at the Crater current.
- Page 15 As shown here, after the As shown here, after the TIG torch trigger is quickly TIG torch trigger is quickly pressed and released from pressed and released from step 3A, it is possible to step 3A, it is possible to press and hold the TIG press and hold the TIG torch trigger another time...
- Page 16 To set the spot time, user has to push SEL button until main part of the weld is complete. The machine text SPT appears on the left display: turning now the will now decrease the output current at a main know is possible to set SPT time from 0 to 100s controlled rate, or downslope time, until the Crater current is reached.
- Page 17 Percent of Peak Current / 5-95 (step 5%) Duty Cycle PEAK % of FREQ (Only when pulse function is Note B enabled) 0,1 – 10 Hz (step 0.1Hz) Pulses-Per-Second DC Current FREQ 10 – 500Hz (step 1Hz) (Only when pulse function is selected value 500 –...
- Page 18 Note A: When AUTO is selected means 1s/10A; Note D: Once AUTO is selected the default parameter minimun value is 3s. are used. Note B: For frequency value higher than 500Hz, PEAK Menu GTAW is locked to 50%. To enter into Menu GTAW see section Menu, described above.
- Page 19 Note E. When AUTO is selected, the starting Following picture show the meaning of the parameter for parameters are automatically recalled based on the set a local hand working. The ramp in SSLP time ends when current adjustable by main knob in the front panel. STRT current level is reached: if STRT is lower than Diameter of the electrode is automatically recalled based PCRT, the level will be PCRT.
- Page 20 Restart 2S, Restart 4S, Spot and Bi-level Menu SMAW See GTAW section above for details about mode of To enter into Menu SMAW see section Menu, descriped working. above In AC polarity only the HOT Start parameter is visible and can be changed Table 11.
- Page 21 RSET Reset YES/NO Current Green Mode ON/OFF selected value Current LOCK Lockout YES/NO selected value...
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Page 22: Amp Mode
LED Brightness/Intensity follows the timeline of welding, green mode and idle state. By this option is possible to select the intensity of the Cooler is switched OFF when green mode is activated; LEDs present in the user interface: three level can be the entering in IDLE mode confirms the OFF status of selected by the user. - Page 23 ON again. If the error remains, a maintenance is required. Please contact the nearest FAN fault technical service center or Lincoln Electric and report This error message indicates the fan is not the error code displayed on the meter of the Front operating properly.
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Page 24: Maintenance
MAINTENANCE WARNING INPUT DC BUS CAPACITORS DISCHARGE PROCEDURE ® Remove input power to the ASPECT ELECTRIC SHOCK can kill Remove the cover following the instruction available in this Service manual. Have an electrician install and service this equipment Check the voltage across the two terminals. Voltage Turn the input power off at the fuse box before working on should be zero. -
Page 25: Routine Maintenance
ROUTINE MAINTENANCE THERMAL PROTECTION Keep the welding area around the machine clean and free of combustible materials. No debris should be Thermal detection device protect the machine from allowed to collect which could obstruct air flow to the excessive operating temperatures. Excessive temperatures machine may be caused by a lack of cooling air or operating the The frequency of the maintenance operations may vary... - Page 26 MAJOR COMPONENTS LOCATION ® ASPECT 1. Mains switch 7. HF Board 2. Gas solenoid valve 8. Input Board 3. Fan and Fan1 9. Input Filter Board 4. Right side: Boost & Inverter Board 10. Display & UI Board 5. Output Power Board 11.
- Page 27 THEORY OF OPERATION ® ASPECT 200 - SCHEMATIC DIAGRAM code 50455...
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Page 28: Input
INPUT GENERAL DESCRIPTION Boost and Inverter Board. ® The ASPECT 200 is an inverter based welding power The Input board is providing all the auxiliary supplies source that offers multi-mode (TIG DC, TIG AC STICK for the machine circuits. DC and STICK AC) constant current welding. The The Input board houses the Buck/Boost PWM and machine operates on single phase input voltage driver circuits;... -
Page 29: Boost & Inverter Pcb - Output Transformer
BOOST & INVERTER PCB – OUTPUT TRANSFORMER BOOST & INVERTER, OUTPUT TRANSFORMER The input rectifier voltage coming from the Input board The main transformer insulate the primary circuit from are applied to the Boost circuit, integrated into the the secondary circuit and reduces the high voltage inverter board. -
Page 30: Output, Power Control Board, Hf Board
OUTPUT, POWER CONTROL BOARD, HF BOARD OUTPUT CONTROL BOARD and OUTPUT POWER BOARD The OUTPUT CONTROL board provides the polarity change of the machine that can be either DC managing signals and the insulated power supply for positive, DC negative or AC. the driver of the Output IGBTs. -
Page 31: Ui And Display Board
UI and DISPLAY BOARD DISPLAY BOARD The Display board houses the control panel, LEDs, push buttons, encoder and functions as the interface ® between the user and the ASPECT 200 machine. The Display board receives signals and power from Input Power board and it creates the reference signals for the inverter and the output IGBT modules. -
Page 32: Overload Protection
Excessive temperature may be caused by a lack of OVERLOAD PROTECTION cooling air or by operating the machine beyond the duty cycle and output rating. If excessive operating ® ASPECT 200 is electrically protected from producing temperature should occur, the Thermal LED indicator higher than normal output currents. -
Page 33: Insulated Gate Bipolar Transistor (Igbt) Operation
INSULATED GATE BIPOLAR TRANSISTOR (IGBT) OPERATION Drawing B shows the IGBT in an active mode. An IGBT is a type of transistor. IGBTs are When the gate signal, a positive DC voltage semicon-ductors well suited for high frequency relative to the source, is applied to the gate switching and high current applications. -
Page 34: Troubleshooting And Repair Section
TROUBLESHOOTING AND REPAIR SECTION How to use troubleshooting Guide Troubleshooting Guide Case cover removal and DC BUS capacitor discharge procedure EMI Filter board test Input Rectifier test Input Power board test Buck Boost and Inverter board test ... -
Page 35: How To Use Troubleshooting Guide
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. - Page 36 WARNING NOTE: Allow the machine to heat up so that all electrical components can reach their operating temperature. 5. Remove the replacement PC board and ELECTRIC SHOCK can kill substitute it with the original PC board to recreate the original problem. ...
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Page 37: Troubleshooting
FAN TEST DISPLAYED This tests and repair should only be performed by Lincoln Electric 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... -
Page 38: Case Cover Removal And Dc Bus Capacitor Discharge Procedure
DISCHARGE PROCEDURE WARNING Service and repair should be performed only by Lincoln Electric factory trained personnel.Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty. For your safety and to avoid electrical shock, please observe all safety notes and precautions detailed throughout this manual. - Page 39 ® ASPECT 200 - CASE COVER REMOVAL Procedure: 1. Turn ON/OFF switch to OFF position. 2. Disconnect Input Power from the machine 3. Remove the 2 screws (A) of the rear and front plastic handle using the PH02 type screwdriver 4.
- Page 40 DC BUS CAPACITORS DISCHARGE PROCEDURE WARNING INPUT DC BUS CAPACITORS DISCHARGE PROCEDURE ® Remove input power to the ASPEC ELECTRIC SHOCK can kill Remove the cover following the instruction available in this Service manual. Have an electrician install and service this equipment Check the voltage across the two terminals.
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Page 41: Emi Filter Board Test
EMI FILTER BOARD TEST WARNING 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. -
Page 42: Test Procedure
EMI FILTER BOARD TES (continued) Figure 2 – W05X1665 – EMI FILTER BOARD TEST PROCEDURE Use always electrically insulate gloves during this test procedure ® 1. Remove main input power to the ASPECT 2. Perform the Case removal and Discharge procedure 3. -
Page 43: Input Rectifier Test
INPUT RECTIFIER TEST WARNING 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. - Page 44 INPUT RECTIFIER TEST (continued) DC - DC + Figure 3 – W05X1665-1 Input Rectifier Bridge location and Test Points TEST PROCEDURE Use always electrically insulate gloves during this test procedure ® 1. Remove main input power to the ASPECT 200. 2.
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Page 45: Input Power Board Test
INPUT POWER BOARD TEST WARNING 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. - Page 46 INPUT POWER BOARD TEST (continued) Input Power Board JC10 JC18 JC19 JC13 JC12 JC15 JC17 JC16 JC11 Figure 4 – W05X1604-2 Input Power Board location VOLTAGE TEST PROCEDURE Use always electrically insulate gloves during this test procedure ® 1. Remove main input power to the ASPECT 200.
- Page 47 INPUT POWER BOARD TEST (continued) Test table 4 – INPUT POWER BOARD - Voltage Tests (continued) Machine AC input Expected Test Points LEDs status and color Note voltage reading 115Vac +/-15% or Green while the machine is wake up, flashing LD6 ON Green 230Vac +/-15% when machine is in idle mode...
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Page 48: Boost And Inverter Board Test
BOOST AND INVERTER BOARD TEST WARNING 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. - Page 49 BOOST AND INVERTER BOARD TEST (continued) BUCK/BOOST INVERTER Board Figure 5 – W05X1605 BOOST and INVERTER Board location RESISTANCE TEST PROCEDURE Use always electrically insulate gloves during this test procedure ® 1. Remove main input power to the ASPECT 200. 2.
- Page 50 BOOST AND INVERTER BOARD TEST (continued) PTC1 Machine disconnected Between solder points of PTC1 from input voltage and 60-70 Ohm +/-25% @20°C Boost IGBTs PTC (ohm mode) capacitors discharged PTC2 Figure 5a Q17 – Q18 Q19 – Q20 Test table 5a – INVERTER circuit - Resistance Tests Machine condition Test Points Expected reading...
- Page 51 BOOST AND INVERTER BOARD TEST (continued) JC20 JC21 Figure 6 VOLTAGE TEST PROCEDURE Use always electrically insulate gloves during this test procedure 7. Carefully apply the correct input voltage 115Vac/1ph +/-15% or 230Vac/1ph +/-15% via the input cable to the ®...
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Page 52: Output Control Board Test
OUTPUT CONTROL BOARD TEST WARNING 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. - Page 53 OUTPUT CONTROL BOARD TEST (continued) JC31 JC30 JC33 JC34 OUTPUT JC32 CONTROL Board Figure 7 W05X1606-2 OUTPUT CONTROL board location TEST PROCEDURE Use always electrically insulate gloves during this test procedure ® 1. Remove main input power to the ASPECT 200.
- Page 54 OUTPUT BOARD TEST (continued) 6. Carefully apply the correct input voltage 115Vac/1ph +/-15% or 230Vac/1ph +/-15% via the input cable to the ® ASPECT 200. 7. Switch to ON position the main switch and using the voltmeter perform the tests as indicated in Test Table 8. See Figure 7 for correct test points location.
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Page 55: Output Power Board Test
OUTPUT POWER BOARD TEST WARNING 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. - Page 56 OUTPUT POWER BOARD TEST (continued) OUTPUT POWER Board Figure 8 – OUTPUT POWER board location Figure 9 – OUTPUT POWER Diodes location TEST PROCEDURE Use always electrically insulate gloves during this test procedure 1. Remove main input power to the ASPECT ®...
- Page 57 OUTPUT POWER BOARD TEST (continued) TEST PROCEDURE Use always electrically insulate gloves during this test procedure 7. Check each IGBT module (Q5,Q6,Q7,Q8), with multimeter in diode test mode, following the test table 10, below. See Figure 10 for Test Point locations. Table 10 –...
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Page 58: Hf Board Test
HF BOARD TEST WARNING 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. - Page 59 HF BOARD TEST (continued) HF Board Figure 11 – W05X1615-2 HF board location to Input control Board HV-RTN (to the HF transformer) Diode D12 Figure 12 – W05X1615-2 HF board test points (to the HF transformer) Diode D10...
- Page 60 HF BOARD TEST (continued) TEST PROCEDURE Use always electrically insulate gloves during this test procedure ® 1. Remove main input power to the ASPECT 200. 2. Perform the Case removal and Discharge procedure 3. Locate the HF Board. See Figure 11. 4.
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Page 61: Display Board Test
DISPLAY BOARD TEST WARNING 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. -
Page 62: Gas Solenoid Test
GAS SOLENOID TEST WARNING 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. - Page 63 GAS SOLENOID TEST (continued) solenoid terminals Figure 14 – Gas Solenoid location TEST PROCEDURE Use always electrically insulate gloves during this test procedure ® 1. Remove main input power to the ASPECT 200. 2. Perform the Case removal and Discharge procedure 3.
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Page 64: Disassembly Operations
DISASSEMBLY OPERATIONS EMI FILTER BOARD REMOVAL AND REPLACEMENT PROCEDURE Yellow / WARNING Green cable Disconnect input power before servicing. Do not operate with covers removed. Do not touch electrically live parts. Only qualified persons should install, use ELECTRIC SHOCK or service this equipment. CAN KILL Figure 15 REMOVAL PROCEDURE... - Page 65 DISASSEMBLY OPERATIONS INPUT POWER BOARD REMOVAL AND REPLACEMENT PROCEDURE WARNING Disconnect input power before servicing. Do not operate with covers removed. Do not touch electrically live parts. Only qualified persons should install, use ELECTRIC SHOCK or service this equipment. CAN KILL Figure 16 REMOVAL PROCEDURE !! During performing the following steps...
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Page 66: Reassembly Procedure
DISASSEMBLY OPERATIONS INPUT RECTIFIER BRIDGE REMOVAL AND REPLACEMENT PROCEDURE WARNING Disconnect input power before servicing. Do not operate with covers removed. Do not touch electrically live parts. Only qualified persons should install, use ELECTRIC SHOCK or service this equipment. CAN KILL Figure 17 REMOVAL PROCEDURE !! During performing the following steps... - Page 67 DISASSEMBLY OPERATIONS BUCK/BOOST and INVERTER BOARD REMOVAL AND REPLACEMENT PROCEDURE WARNING Disconnect input power before servicing. Do not operate with covers removed. Do not touch electrically live parts. Only qualified persons should install, use ELECTRIC SHOCK or service this equipment. CAN KILL JC20 JC21...
- Page 68 DISASSEMBLY OPERATIONS OUTPUT CONTROL BOARD REMOVAL AND REPLACEMENT PROCEDURE WARNING Disconnect input power before servicing. Do not operate with covers removed. Do not touch electrically live parts. Only qualified persons should install, use ELECTRIC SHOCK or service this equipment. CAN KILL JC30 &...
- Page 69 DISASSEMBLY OPERATIONS OUTPUT CONTROL BOARD REMOVAL AND REPLACEMENT PROCEDURE (continue) WARNING Disconnect input power before servicing. Do not operate with covers removed. Do not touch electrically live parts. Only qualified persons should install, use ELECTRIC SHOCK or service this equipment. CAN KILL Figure 20 REMOVAL PROCEDURE...
- Page 70 DISASSEMBLY OPERATIONS OUTPUT POWER BOARD REMOVAL AND REPLACEMENT PROCEDURE WARNING Disconnect input power before servicing. Do not operate with covers removed. J41 & J42 Do not touch electrically live parts. Only qualified persons should install, use ELECTRIC SHOCK or service this equipment. CAN KILL &...
- Page 71 DISASSEMBLY OPERATIONS OUTPUT POWER BOARD REMOVAL AND REPLACEMENT PROCEDURE (continue) WARNING Disconnect input power before servicing. Do not operate with covers removed. Do not touch electrically live parts. Only qualified persons should install, use ELECTRIC SHOCK or service this equipment. CAN KILL Figure 22 9.
- Page 72 DISASSEMBLY OPERATIONS DISPLAY BOARD REMOVAL AND REPLACEMENT PROCEDURE WARNING Disconnect input power before servicing. Do not operate with covers removed. Do not touch electrically live parts. Only qualified persons should install, use ELECTRIC SHOCK or service this equipment. CAN KILL Control Knob Figure 23...
- Page 73 DISASSEMBLY OPERATIONS HF BOARD REMOVAL AND REPLACEMENT PROCEDURE WARNING Disconnect input power before servicing. Do not operate with covers removed. HF Board Do not touch electrically live parts. Only qualified persons should install, use ELECTRIC SHOCK or service this equipment. CAN KILL HV-RTN Figure 24...
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Page 74: Retest After Repair
RETEST AFTER REPAIR Should a machine under test be rejected for any reason requiring the removal of any mechanical part that could affect the machine’s electrical characteristics, or if any electrical components are repaired or replaced, the machine must be retested. -
Page 75: Calibration Procedure
CALIBRATION PROCEDURE Calibration must be done every time Display board is replaced Input Power board is replaced Display Board W05X1607-2 Calibration Procedure NOTE: An external voltmeter must be connected directly, as close as possible to the output terminals of the device to minimize the difference in reading between the external voltmeter and an internal meter of the device. - Page 76 CALIBRATION PROCEDURE (continue) Input Power board W05X1604-2 Calibration procedure NOTE: An external voltmeter must be connected directly, as close as possible to the output terminals of the device to minimize the difference in reading between the external voltmeter and an internal meter of the device. Input voltage: 1 phases 230 V.
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Page 77: Electrical Schematics
ELECTRICAL SCHEMATICS Block Diagram :... -
Page 78: Note
NOTE...
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