Lincoln Electric V155-S service manual Figure E.2 General Description

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E-2

THEORY OF OPERATION

E-2

 

FIGURE E.2 — GENERAL DESCRIPTION

 

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BLUE

ON/OFF SWITCH

5

2

 

WHITE

 

 

 

 

4

1

WHITE

 

 

 

 

 

 

 

 

L

WIRE TIE

BLUE

PWR1 PWR2 PWR4 PW

 

BLACK

AC1

 

N

 

 

 

WHITE

AC2

 

INPUT BOARD

 

G

 

 

 

 

 

115/230Vac

 

 

 

 

PE

 

W05X0701

 

 

 

 

 

 

 

(SCHEMATIC: X0701)

50/60 Hz

 

 

 

 

 

 

 

 

 

 

 

 

 

 

RECONNECT

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

BOARD

 

 

 

 

WHITE

BLUE

 

 

W05X0408

 

 

FAN

 

 

 

(SCHEMATIC: X0408)

 

 

 

RED

JP4

 

 

 

 

TWISTED CABLE

BLACK

 

 

 

 

 

 

 

 

RIBBON CABLE

 

 

 

 

PCB CONNECTOR CAVITY NUMBERING SEQUENCE

(VIEWED FROM COMPONENT SIDE OF P.C. BOARD)

1

4

2

16

4 PINS

1

16 PINS

15

 

 

 

 

 

 

RED

 

DC+

 

 

 

 

 

 

BLACK

 

DC-

 

 

 

R3

DC+

RED

 

 

 

 

 

 

BLACK

 

Y/G

PE

 

 

 

 

DC-

JP1

 

 

 

JP1

 

 

JP1

INVERTER BOARD

 

 

 

 

 

 

 

 

W05X0519

 

 

 

 

 

 

 

 

(SCHEMATIC: X0519)

 

 

 

 

 

 

 

 

P1

 

-

 

 

 

 

 

 

N1

SHUNT

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

CONTROL BOARD

 

 

BLACK

RED

 

 

W05X0708-1

 

 

 

WHITE

 

 

(SCHEMATIC: X0708)

RED

 

 

 

 

 

PE

 

 

 

 

 

 

JP2

BLACK

 

 

 

 

 

 

WHITE

 

 

 

 

 

 

 

 

 

 

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GENERAL DESCRIPTION

The INVERTEC® V155-S is an industrial 155 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 Touch Start TIG (GTAW). The unit is ideal for industrial applications where portability is important.

The INVERTEC® V155-S is recommended for stick welding with such popular electrodes as Fleetweld 35, 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 DC Touch Start Tig starting with excelent results.

The INVERTEC® V155-S is rated at 155 amps, 16.2 volts, at 30% duty cycle on a ten minute basis. It is capable 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 cools. See Technical Specifications in A-1 for other rated outputs. the INVERTEC® V155-S is recommended for stick welding with such popular electrodes as Fleetweld® 35, Fleetweld 37, Fleetweld 180 and Jet-LH 78MR. It features adjustable arc control to adjust the arc force and start.

LIMITATIONS

The INVERTEC® V155-S is not recommeded for pipe thawing.

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NOTE: Unshaded areas of Block Logic Diagram are the subject of discussion

INVERTEC® V155-S

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Contents Invertec V155-S Electric Magnetic Fields SafetyFor Engine Electric Shock can kill ARC Rays can burn Fumes and GasesFor Electrically IiiLES Machines À Souder À Précautions DE SûretéPrécautions DE Sûreté Pour Transformateur ET ÀElectromagnetic Compatibility EMC L10093 3-1-96H Master Table of Contents for ALL Sections Table of Contents Installation Section Installation Operating Temperature Range Storage Temperature RangeSelect Suitable Location Safety PrecautionsInput Connections Tilting120V Input Input Power Connection230V Input Engine Driven GeneratorStick Welding Smaw Output ConnectionsTIG Welding Replacement Quick Disconnect Plug for Stick Electrode Cable Table of Contents Operation Section General Description Safety InstructionsTheory of Operation Welding CapabilityFunction FeaturesControls and Operational OFFRear Control Panel Auto Adaptive ARC ForceWith Stick Welding Table of Contents Accessories Section Accessories Cable Plugs Compatible EquipmentTable of Contents Maintenance Section Routine Maintenance MaintenanceInput Filter Capacitor Discharge Procedure Thermal ProtectionMajor Component Locations Figure D.1 Major Component LocationsInvertec V155-S 1TABLE of CONTENTS-THEORY of Operation Section E-1 Figure E.2 General Description Input Board Figure E.3 Input BoardMain Inverter Board Figure E.4 Main Inverter BoardControl Board Figure E.5 Control BoardInsulated Gate Bipolar Transistor Igbt Operation Figure E.6 Igbt OperationSec 31 m/sec 33 m/sec Pulse Width ModulationMinimum Output Maximum OutputInvertec V155-S 1TABLE of Contents Troubleshooting & Repair F-1 Troubleshooting & Repair HOW to USE Troubleshooting GuidePC Board Troubleshooting Procedures Electric ShockResistance Test Perform Inverter Board Voltage Test Machine has high welding Test Description 7TROUBLESHOOTING & REPAIRF-7Case Cover Removal Procedure Materials NeededProcedure Disconnect power to the Invertec V155-S9TROUBLESHOOTING & REPAIRF-9 Input Filter Capacitor Discharge Procedure 11TROUBLESHOOTING & REPAIRF-11 Figure F.4 Capacitor Discharge LocationsInvertec V155-S 13TROUBLESHOOTING & REPAIRF-13 Input Board Resistance TestDC+ 15TROUBLESHOOTING & REPAIRF-15 Inverter Board Resistance TestFigure F.6 Inverter Board Test Points Inverter Board Resistance Test Invertec V155-S 19TROUBLESHOOTING & REPAIRF-19 Input Board Voltage Test20TROUBLESHOOTING & REPAIRF-20 PWR 2white to PWR 1blue to PWR 4white to PWR 3blue to21TROUBLESHOOTING & REPAIRF-21 Figure F.9 Main Switch Plug LocationInvertec V155-S 23TROUBLESHOOTING & REPAIRF-23 Inverter Board Voltage TestFigure F.10 Plug JP1 Testpoints 25TROUBLESHOOTING & REPAIRF-25 Input Board Removal and Replacement ProcedureAC2 27TROUBLESHOOTING & REPAIRF-27 Inverter Board Removal and Replacement ProcedurePerform the Case Cover Removal Procedure 29TROUBLESHOOTING & REPAIRF-29 Figure F.13 Inverter Board RemovalInvertec V155-S 31TROUBLESHOOTING & REPAIRF-31 Control Board Removal and Replacement Procedure32TROUBLESHOOTING & REPAIRF-32 Figure F.14 Control Board RemovalOutput INPUT- Single Phase onlyRated Output Recommended Meters for Machine Output TestsInvertec V155-S Table of Contents Diagram Section Electrical Diagrams Electrical Diagrams Schematic Complete Machine Codes 11326Schematic Input PC Board Aux PotenzaPC Board Assembly Input Board Schematic Inverter PC Board Sheet #1 PTCSchematic Inverter PC Board Sheet #2 FEED-FORWARDPC Board ASSEMBLY- Inverter Board Sheet # PC Board Assembly Inverter Board Sheet #2 Schematic Control PC Board U1APC Board Assembly Control Board page Sheet #1 See Page 2 for more detailed component informationPC Board Assembly Control Board Sheet #2
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