Lincoln Electric V155-S service manual Controls and Operational, Features, Function, Off

Page 17

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B-3

 

THEORY OF OPERATION

 

B-3

CONTROLS AND OPERATIONAL

 

If the Yellow LED illuminates, and the Red and Green

FEATURES

 

 

 

LEDʼs blink on and off alternately, the unit is unable to

 

Potentiometer used to

cool itself adequately. Check to make sure the fan is

1. Output Current Knob: A

not obstructed and the fan is operating properly. Prior

set the output current used during welding, from 5A

to resuming normal operation, the unit must be turned

to 155A.

 

 

 

off and turned back on to reset this error condition.

2. Welding Mode Switch: With three positions, con-

 

 

 

 

WARNING

 

trols the welding mode of the machine: two for Stick

 

 

 

 

 

 

welding (Soft and Crisp) and one for Lift TIG weld-

If blinking, the Thermal LED indicates that the input

ing.

 

 

 

• Soft Stick:

 

 

 

 

 

 

 

For a welding with a low spatter

voltage is out of ranges.

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

• Crisp Stick:

presence.

 

 

4. Power On/Off & OUTPUT LEDs: These LEDs (one

For an aggressive welding arc,

green and one red) operates as described in the

 

 

 

 

 

 

 

 

 

with an increased Arc stability.

 

table below:

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

• Lift TIG:

 

 

 

When the mode switch is in the Lift

 

 

 

 

 

 

 

 

 

 

 

 

LED status

 

 

FUNCTION

TIG position, the stick welding functions are disabled

 

 

and the machine is ready for Lift TIG welding. Lift

Green

Red

 

V

 

 

TIG is a method of starting a TIG weld by first press-

ON

OFF

 

 

 

 

The machine is turned ON.

ing the TIG torch electrode on the work piece in

 

 

 

 

ON condition: The machine is at

order to create a low current short circuit. Then, the

 

 

 

 

electrode is lifted from the work piece to start the TIG

 

 

 

idle (no-welding time) and OCV

arc.

This indicator will turn on when

 

 

 

is present.

 

3. Thermal LED:

OFF

ON

 

AThe machine is turned ON.

the machine is overheated and the output has been

 

disabled. This normally occurs when the duty cycle

 

 

 

 

On condition: Presence of weld-

of the machine has been

exceeded. Leave

the

 

 

 

ing current at the output leads.

machine on to allow the internal components to cool.

 

 

 

This permanent

LED condition,

When the indicator turns off, normal operation is

 

 

 

again possible.

 

 

 

 

 

 

showed at idle (no-welding time), indi-

 

 

 

 

 

FIGURE B.1

 

 

OFF

OFF

 

cates machine damage.

 

 

 

 

 

 

 

 

The machine is turned OFF and/or the

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

input cord could be disconnected from

4

 

 

 

 

 

 

 

1

 

 

 

 

the mains.

With the Power

 

 

 

 

 

 

 

 

 

 

 

ERROR condition:

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Switch turned ON and the input cord

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

properly connected to a "live" main

2

 

 

 

 

 

 

 

 

 

 

 

 

 

 

supply, this LED condition indicates

 

 

 

 

 

 

 

 

 

 

 

ON

ON

 

machine damage.

 

3

 

 

 

 

 

 

 

 

 

 

 

 

ERROR condition: This LED condition

 

 

 

 

 

 

 

 

 

 

5

1. Output Current Knob

 

 

 

 

 

 

 

 

 

 

 

 

2. Welding Mode Switch

 

 

 

 

 

 

 

 

 

 

 

 

6

3. Thermal LED

 

 

 

 

 

 

 

 

 

 

 

 

 

4. Power On/Off and Output LEDʼs

 

 

 

 

 

 

 

 

 

 

 

 

5. Positive Quick Disconnect

 

6. Negative Quick Disconnect INVERTEC® V155-S

Image 17
Contents Invertec V155-S Electric Magnetic Fields SafetyFor Engine Fumes and Gases Electric Shock can kill ARC Rays can burnIii For ElectricallyPrécautions DE Sûreté Pour Précautions DE SûretéLES Machines À Souder À Transformateur ET ÀElectromagnetic Compatibility EMC L10093 3-1-96H Master Table of Contents for ALL Sections Table of Contents Installation Section Operating Temperature Range Storage Temperature Range InstallationInput Connections Safety PrecautionsSelect Suitable Location Tilting230V Input Input Power Connection120V Input Engine Driven GeneratorStick Welding Smaw Output ConnectionsTIG Welding Replacement Quick Disconnect Plug for Stick Electrode Cable Table of Contents Operation Section Theory of Operation Safety InstructionsGeneral Description Welding CapabilityControls and Operational FeaturesFunction OFFRear Control Panel Auto Adaptive ARC ForceWith Stick Welding Table of Contents Accessories Section Cable Plugs Compatible Equipment AccessoriesTable of Contents Maintenance Section Input Filter Capacitor Discharge Procedure MaintenanceRoutine Maintenance Thermal ProtectionFigure D.1 Major Component Locations Major Component LocationsInvertec V155-S 1TABLE of CONTENTS-THEORY of Operation Section E-1 Figure E.2 General Description Figure E.3 Input Board Input BoardFigure E.4 Main Inverter Board Main Inverter BoardFigure E.5 Control Board Control BoardFigure E.6 Igbt Operation Insulated Gate Bipolar Transistor Igbt OperationMinimum Output Pulse Width ModulationSec 31 m/sec 33 m/sec Maximum OutputInvertec V155-S 1TABLE of Contents Troubleshooting & Repair F-1 HOW to USE Troubleshooting Guide Troubleshooting & RepairElectric Shock PC Board Troubleshooting ProceduresResistance Test Perform Inverter Board Voltage Test Machine has high welding Case Cover Removal Procedure 7TROUBLESHOOTING & REPAIRF-7Test Description Materials NeededDisconnect power to the Invertec V155-S Procedure9TROUBLESHOOTING & REPAIRF-9 Input Filter Capacitor Discharge Procedure Figure F.4 Capacitor Discharge Locations 11TROUBLESHOOTING & REPAIRF-11Invertec V155-S Input Board Resistance Test 13TROUBLESHOOTING & REPAIRF-13DC+ Inverter Board Resistance Test 15TROUBLESHOOTING & REPAIRF-15Figure F.6 Inverter Board Test Points Inverter Board Resistance Test Invertec V155-S Input Board Voltage Test 19TROUBLESHOOTING & REPAIRF-19PWR 2white to PWR 1blue to PWR 4white to PWR 3blue to 20TROUBLESHOOTING & REPAIRF-20Figure F.9 Main Switch Plug Location 21TROUBLESHOOTING & REPAIRF-21Invertec V155-S Inverter Board Voltage Test 23TROUBLESHOOTING & REPAIRF-23Figure F.10 Plug JP1 Testpoints Input Board Removal and Replacement Procedure 25TROUBLESHOOTING & REPAIRF-25AC2 Inverter Board Removal and Replacement Procedure 27TROUBLESHOOTING & REPAIRF-27Perform the Case Cover Removal Procedure Figure F.13 Inverter Board Removal 29TROUBLESHOOTING & REPAIRF-29Invertec V155-S Control Board Removal and Replacement Procedure 31TROUBLESHOOTING & REPAIRF-31Figure F.14 Control Board Removal 32TROUBLESHOOTING & REPAIRF-32Rated Output INPUT- Single Phase onlyOutput Recommended Meters for Machine Output TestsInvertec V155-S Table of Contents Diagram Section Electrical Diagrams Schematic Complete Machine Codes 11326 Electrical DiagramsAux Potenza Schematic Input PC BoardPC Board Assembly Input Board PTC Schematic Inverter PC Board Sheet #1FEED-FORWARD Schematic Inverter PC Board Sheet #2PC Board ASSEMBLY- Inverter Board Sheet # PC Board Assembly Inverter Board Sheet #2 U1A Schematic Control PC BoardSee Page 2 for more detailed component information PC Board Assembly Control Board page Sheet #1PC Board Assembly Control Board Sheet #2
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