Lincoln Electric V155-S service manual Figure E.3 Input Board

Page 27

E-3

THEORY OF OPERATION

E-3

 

FIGURE E.3 — INPUT BOARD

 

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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

 

 

 

 

 

 

BLUE

 

W05X0408

R3

DC+

 

DC-

JP1

RED BLACK

RED

 

DC+

 

BLACK

 

DC-

 

JP1

Y/G

PE

 

 

JP1

INVERTER BOARD

 

 

 

W05X0519

 

 

 

(SCHEMATIC: X0519)

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FAN

WHITE

RED

 

JP4

(SCHEMATIC: X0408)

 

 

 

 

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

 

 

 

 

 

 

 

 

 

CONTROL BOARD

W05X0708-1

(SCHEMATIC: X0708)

PE

JP2

 

P1

N1

RED

BLACK

WHITE

SHUNT

-

WHITE

BLACK

 

RED

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INPUT BOARD

The Input Board includes the following circuits:

- Automatic Reconnect Circuit: This circuit monitors the input voltage and automatically reconnects the inverter and auxiliary connections to configure the machine for either 115V or 230V ac input voltage. The proper configuration is achieved through the use of board mounted relays. These relays and others that activate the Pre-charge circuitry and the fan circuit are controlled through signals from a micro-processor on the board.

- Switching Power Supply: Supplied by a board mounted transformer, the switching power supply provides +15 vdc and +5vdc supplies for use on all of the PC Boards.

- Input Rectifier and Precharge Circuit: The Pre- charge rectifier and current limiting resistors apply a small charge to the filter capacitors when the Power Switch is turned ON.

An improper input voltage would be recognized dur- ing this 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 from the input line (AC1 and AC2) to the Input Rectifier and the capacitors are fully charged to approximately 325VDC. (See the Machine Diagram and PC Board Schematics for more information).

-A self reseting fuse circuit (ARFU) onAutotheResetInputFuse:Board helps to prevent damage to the machine from over-current when in 120VAC opera- tion. When the fuse is open, the output will be dis- abled and the yellow Temperature LED on the front panel will be ON.

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

INVERTEC® V155-S

Image 27
Contents Invertec V155-S Safety For EngineElectric Magnetic Fields Fumes and Gases Electric Shock can kill ARC Rays can burnIii For ElectricallyTransformateur ET À Précautions DE SûretéPrécautions DE Sûreté Pour LES Machines À Souder 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 InstallationTilting Safety PrecautionsInput Connections Select Suitable LocationEngine Driven Generator Input Power Connection230V Input 120V InputOutput Connections TIG WeldingStick Welding Smaw Replacement Quick Disconnect Plug for Stick Electrode Cable Table of Contents Operation Section Welding Capability Safety InstructionsTheory of Operation General DescriptionOFF FeaturesControls and Operational FunctionAuto Adaptive ARC Force With Stick WeldingRear Control Panel Table of Contents Accessories Section Cable Plugs Compatible Equipment AccessoriesTable of Contents Maintenance Section Thermal Protection MaintenanceInput Filter Capacitor Discharge Procedure Routine MaintenanceFigure D.1 Major Component Locations Major Component Locations Invertec 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 OperationMaximum Output Pulse Width ModulationMinimum Output Sec 31 m/sec 33 m/secInvertec 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 Materials Needed 7TROUBLESHOOTING & REPAIRF-7Case Cover Removal Procedure Test DescriptionDisconnect 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-32Recommended Meters for Machine Output Tests INPUT- Single Phase onlyRated Output OutputInvertec 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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