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Lincoln Electric Invertec V155-S, Service Manual

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Lincoln Electric Invertec V155-S Service Manual Download Page 32

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INVERTEC® V155-S

All manuals and user guides at all-guides.com

Summary of Contents for Invertec V155-S

Page 1: ...6 1751 WEB SITE www lincolnelectric com World s Leader in Welding and Cutting Products Copyright Lincoln Global Inc Safety Depends on You Lincoln arc welding and cutting equipment is designed and buil...

Page 2: ...LDREN 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...

Page 3: ...s 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 protec...

Page 4: ...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 a...

Page 5: ...dage 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 e...

Page 6: ...situation with the technical assistance of the manufacturer In some cases this remedial action may be as simple as earthing grounding the welding circuit see Note In other cases it could involve cons...

Page 7: ...ommendations Welding Cables The welding cables should be kept as short as possible and should be positioned close together running at or close to floor level Equipotential Bonding Bonding of all metal...

Page 8: ...IN INDEX Page Safety i iv Installation Section A Operation Section B Accessories Section C Maintenance Section D Theory of Operation Section E Troubleshooting and Repair Section F Electrical Diagrams...

Page 9: ...ster TOC Return to Master TOC Return to Master TOC Return to Master TOC INVERTEC V155 S Installation A 1 Technical Specifications A 2 Safety Precautions A 3 Location A 3 Input Connection A 3 Output Co...

Page 10: ...ES OPERATING TEMPERATURE RANGE 10 C to 40 C STORAGE TEMPERATURE RANGE 25 C to 55 C RECOMMENDED INPUT WIRE AND FUSE SIZES FOR MAXIMUM RATED OUTPUT INPUT VOLTAGE FREQUENCY HZ 230 60 120 60 MAXIMUM TIME...

Page 11: ...damage Read the section on electromagnetic compatibility in this manual Do not operate in areas with an ambient temperature greater than 40 C STACKING The INVERTEC V155 S cannot be stacked TILTING Pl...

Page 12: ...chieve higher output To install the supplied 20A plug Connect the white neutral wire under terminal clamp with silver screw and black hot wire under terminal clamp with brass screw Connect green wire...

Page 13: ...e Controls and Operational Features in the Operation Section Note The ARFU device operates independently from the machine s duty cycle OUTPUT CONNECTIONS A quick disconnect system using Twist Mate cab...

Page 14: ...le insulation 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...

Page 15: ...Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC INVERTEC V155 S Operation B 1 Safety Precautions B 2 General Description B 2 Controls and Operational Features B 3 A...

Page 16: ...5 Fleetweld 37 Fleetweld 180 and LH 78 It features automatic arc control to adjust the arc force hot start and anti sticking The machine also features soft and crisp modes The INVERTEC V155 S performs...

Page 17: ...rnal components to cool When the indicator turns off normal operation is again possible 1 Output Current Knob 2 Welding Mode Switch 3 Thermal LED 4 Power On Off and Output LED s 5 Positive Quick Disco...

Page 18: ...increases the output current to clear intermittent shorts between the electrode and the weld puddle that may occur dur ing stick welding This is an active control feature that guarantees the best arr...

Page 19: ...C 1 Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC INVERTEC V155 S Accessories C 1 Factory Installed Options C 2 Field Installed Options C 2 Accessories C 2 All m...

Page 20: ...d torch K1781 7 25 0 Ft 1 Piece Cable PTA 17FV TIG Torch 150 Amp Gas Valve flexible head torch K1782 11 25 0 Ft 1 Piece Cable K1782 13 12 5 Ft 1 Piece Ultra Flex Cable K960 2 TIG Torch Adapter for con...

Page 21: ...n to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC INVERTEC V155 S Maintenance D 1 Safety Precautions D 2 Routine Maintenance D 2 Thermal Protection D 2 All manuals and use...

Page 22: ...at least 5 minutes to allow time for the process to take place ROUTINE MAINTENANCE The frequency of the maintenance operations may vary in accordance with the working environment Any noticeable damage...

Page 23: ...OC MAJOR COMPONENT LOCATIONS 1 Front Panel 2 Right Case Side 3 Left Case Side 4 Rear Panel 5 Fan 6 Cable Clamp 7 Input Cable 8 ON OFFSwitch 9 Input P C Board 10 Inverter P C Board 11 Control P C Board...

Page 24: ...turn 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 D 4 D 4 INVERTEC V155 S All manuals and user g...

Page 25: ...M CONTROL BOARD W05X0708 1 SCHEMATIC X0708 JP1 INPUT BOARD W05X0701 SCHEMATIC X0701 115 230Vac 50 60 Hz ON OFF SWITCH 5 2 N L G WIRE TIE 4 1 BLUE WHITE WHITE BLUE WHITE BLACK AC2 AC1 PE PWR2 PWR1 PWR4...

Page 26: ...ble of higher duty cycles at lower output currents It is capable of 105 amps 14 2 volts at 100 duty cycle If the duty cycle is exceeded a thermal protec tor will shut off the output until the machine...

Page 27: ...is time and an input error sent to the Control Board A signal from the Control Board would prevent further power up to prevent damage to the Inverter Board The re connect relays then apply full power...

Page 28: ...line Additional windings of the transformer provide both piamary and secondary feeback signals to the PWM control circuit FIGURE E 4 MAIN INVERTER BOARD Output Circuit The output diodes and the output...

Page 29: ...e gate signals to the IGBT s FIGURE E 5 CONTROL BOARD The Weld Controler also responds to thermal and input errors to shut down the machine output The error information is then displayed by the three...

Page 30: ...ected to the source The circuit is turned off like a light switch in the OFF position Drawing B shows the IGBT in an active mode When the gate signal a positive DC voltage relative to the source is ap...

Page 31: ...on and off for different durations during a cycle The top drawing shows the minimum output signal possible over a 33 microsecond time period The shaded portion of the signal represents the IGBT conduc...

Page 32: ...turn 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 E 8 E 8 INVERTEC V155 S All manuals and user g...

Page 33: ...dures F 3 Troubleshooting Guide F 4 Case Cover Removal Procedure F 7 Input Filter Capacitor Discharge Procedure F 9 Input Board Resistance Test F 13 Inverter Board Resistance Test F 15 Input Board Vol...

Page 34: ...e appropriate test procedure to verify that the subject com ponent is either good or bad If there are a number of possible components check the components in the order listed to eliminate one possibil...

Page 35: ...lectrically 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 char...

Page 36: ...rrect Input power 2 Replace Line switch 3 Perform Input Board Voltage Test 4 Perform Inverter Board Voltage Test The GREEN LED is ON but there is no output And yellow thermal overload LED is ON 1 Ther...

Page 37: ...hine welds but there is no output control 1 Potentiometer failure 2 The Shunt screw connections are bad 3 Inverter Board failure 1 Potentiometer or Control Board needs Replaced 2 Tighten and check all...

Page 38: ...eter failure 2 Control Board failure 1 Replace Potentiometer 2 Replace Control Board RED LED stays ON continuously 1 Shunt Cable damaged 2 Control Board defective 1 Check connection of white red and b...

Page 39: ...re unable to perform the test repairs safely contact the Lincoln Electric Service Department for electrical trou bleshooting assistance before you proceed Call 1 888 935 3877 TEST DESCRIPTION This pro...

Page 40: ...ps 3 thru 7 5 Using a phillips screwdriver remove the three screws securing the Inverter board to the right side case cover Note These screws can only be accessed from the inside of the machine and on...

Page 41: ...assistance before you proceed Call 1 888 935 3877 TEST DESCRIPTION This procedure will drain off any charge stored in the four capacitors that are part of the Inverter Board assembly This procedure MU...

Page 42: ...OCEDURE 1 Disconnect power to the INVERTEC V155 S 2 Perform the Case Cover Removal Procedure steps 1 thru 3 3 Locate the Input Board 4 Obtain a high resistance and high wattage resistor 25 1000 ohms a...

Page 43: ...de cover per Case Cover Removal Procedure steps 5 thru 7 9 Use electrically insulated gloves and insulated pli ers Hold the body of the resistor and connect the resistor leads across the two terminals...

Page 44: ...urn 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 12 F 12 INVERTEC V155 S All manuals and user...

Page 45: ...es or are unable to perform the test repairs safely contact the Lincoln Electric Service Department for electrical trou bleshooting assistance before you proceed Call 1 888 935 3877 TEST DESCRIPTION T...

Page 46: ...ed areas ont The Input Board solder side 5 Disconnect the Blachk lead from the DC terminal 6 Check the Input Rectifier Bridge D1 7 Check start resistors R2 and R4 Each should read 20 Ohms See Figure F...

Page 47: ...erform the test repairs safely contact the Lincoln Electric Service Department for electrical trou bleshooting assistance before you proceed Call 1 888 935 3877 TEST DESCRIPTION This procedure will de...

Page 48: ...alue is approximately 0 40 VDC in one polarity and a charging value in the opposite polarity The IGBT s of each channel are connected in par allel so it is only necessary to check one Emitter to Colle...

Page 49: ...opens Check from the center terminal Point 1 of each Diode all center terminals of the diodes are com mon with the heatsink to the large copperl area point 2 See Figure F 7 Note Actual voltage readin...

Page 50: ...urn 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 18 F 18 INVERTEC V155 S All manuals and user...

Page 51: ...fore you proceed Call 1 888 935 3877 TEST DESCRIPTION This test will help determine if the correct input voltage is being applied to the Input Board and will also determine if the correct voltages are...

Page 52: ...to the Power Switch You must con nect the cables as shown in Figure F 9 PWR 2 white to 4 PWR 1 blue to 1 PWR 4 white to 5 PWR 3 blue to 2 4 Using a multimeter check for 230VAC between AC1 and AC2 See...

Page 53: ...the white wire from PWR4 in posi tion 5 2 Put the blue wire from PWR1 in position 1 of the main switch while the white wire from PWR2 in posi tion 4 TROUBLESHOOTING REPAIR F 21 F 21 INVERTEC V155 S R...

Page 54: ...urn 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 22 F 22 INVERTEC V155 S All manuals and user...

Page 55: ...re you proceed Call 1 888 935 3877 TEST DESCRIPTION This test will help determine if the main inverter board is receiving the correct input volt ages and if the correct regulated voltages are being pr...

Page 56: ...C means fan is ON 0VDC means fan is OFF Check pin 3 0VDC during OCV condition Check pin 5 11 6VDC means the inverter is ON the first 5 minutes after activity while 1 5VDC means the inverter is OFF Che...

Page 57: ...nderstand the test procedures or are unable to perform the test repairs safely contact the Lincoln Electric Service Department for electrical trou bleshooting assistance before you proceed Call 1 888...

Page 58: ...s will allow the board to be gently pulled forward to gain access to associated leads and plugs See Figure F 11 6 Label and remove all associated leads and plugs Some leads will require a 7mm nutdrive...

Page 59: ...ocedures or are unable to perform the test repairs safely contact the Lincoln Electric Service Department for electrical trou bleshooting assistance before you proceed Call 1 888 935 3877 TEST DESCRIP...

Page 60: ...een accesed through the left side of the machine with the left side case cover removed See Figure F 12 6 Note location of ground lead upon removal of lower right phillips screw Note Pay attention to w...

Page 61: ...and disconnect any associated plugs and leads 9 Remove the inverter board 10 Connect JP 1 connector and make sure that the upper front corner of the board is in the locator slot of the front panel 11...

Page 62: ...urn 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 30 F 30 INVERTEC V155 S All manuals and user...

Page 63: ...st procedures or are unable to perform the test repairs safely contact the Lincoln Electric Service Department for electrical trou bleshooting assistance before you proceed Call 1 888 935 3877 TEST DE...

Page 64: ...ng a phillips screwdriver remove the four mount ing screws located on the corners of the solder side of the control board 10 Disconnect the JP2 connector 11 Remove and replace the control board Note W...

Page 65: ...ed Output Input Power at Rated Output 100 30 120VAC 10 34 A 2kw 3kw 230VAC 10 33 A 2kw 3kw Duty Cycle Output Amps Output Volts Input Circuit RECOMMENDED METERS FOR MACHINE OUTPUT TESTS VOLTMETER AC an...

Page 66: ...on 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 34 F 34 INVERTEC V155 S All manuals and user guides at al...

Page 67: ...19 Sheet 1 G 6 Schematic Inverter Board X0519 Sheet 2 G 7 PC Board Assembly Inverter Board Sheet 1 G 8 PC Board Assembly Inverter Board Sheet 2 G 9 Schematic Control Board W05X0708 G 10 PC Board Assem...

Page 68: ...chines 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 Re...

Page 69: ...C Return to Master TOC ELECTRICAL DIAGRAMS G 3 INVERTEC V155 S SCHEMATIC COMPLETE MACHINE CODES 11326 11327 Power Up On with i de energizedfor a 230Vac windings control output turning on full them G 3...

Page 70: ...2 Wednesday July 19 2006 I Buscaglia Rele Potenza Rele 115V Rele Reconn Aux Tuesday March 25 2003 Rele 230V F Scorza Reconnect Power supply Blue White Red Black R13 56 R13 56 A1 A2 RL5A JQX 115F 6Vdc...

Page 71: ...rd level troubleshooting and repair since it may compromise the quality of the design and may result in danger to the Machine Operator or Technician Improper PC board repairs could result in damage to...

Page 72: ...48 D16 1N4148 C18 33nF 100V N M C18 33nF 100V N M 1 3 5 7 2 4 6 8 JP6 W6110204 MODU2 90 N M JP6 W6110204 MODU2 90 N M R89 10R R89 10R 7 10 3 14 12 8 1 5 T3 W5998052 T3 W5998052 C14 100nF C14 100nF PTC...

Page 73: ...c 2 R80 1k8 R80 1k8 R51 10k R51 10k Q10 BC337 N M Q10 BC337 N M C25 100nF 50V C25 100nF 50V D26 1N4148 D26 1N4148 VCC 15 GND 10 PGND 12 VC 13 Vref 16 CLRef 11 SHD 9 OUT 14 CLK 4 RT 5 CT 6 Ramp 7 EO 3...

Page 74: ...oting and repair since it may compromise the quality of the design and may result in danger to the Machine Operator or Technician Improper PC board repairs could result in damage to the machine ELECTR...

Page 75: ...es board level troubleshooting and repair since it may compromise the quality of the design and may result in danger to the Machine Operator or Technician Improper PC board repairs could result in dam...

Page 76: ...U2C LM358AM SO8 D3 MINIMELF LL4148 D3 MINIMELF LL4148 C18 50V 0805 100nF C18 50V 0805 100nF 2 3 1 D11 SOT23 BAT54S D11 SOT23 BAT54S 0603 SJ6 N M 0R 0603 SJ6 N M 0R R73 1k 0603 1 R73 1k 0603 1 D6 RED...

Page 77: ...ng and repair since it may compromise the quality of the design and may result in danger to the Machine Operator or Technician Improper PC board repairs could result in damage to the machine ELECTRICA...

Page 78: ...es board level troubleshooting and repair since it may compromise the quality of the design and may result in danger to the Machine Operator or Technician Improper PC board repairs could result in dam...

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