Lincoln Electric Comprehensive Guide to the Lincoln Invertec V155 Portable Generator

Page 29

E-5

THEORY OF OPERATION

E-5

 

FIGURE E.5 — CONTROL 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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CONTROL BOARD

The Control Board receives status and analogue sig- nals from the inverter board, input board and various sensors and feeds this information to the Weld Controller.

The Weld Controller is a micro-processor that uses these signals along with input from the Mode Switch and the Control Potentiometer to make decisions and change the machine mode and output to satisfy the requirements as decided by the operator. these changes are relayed to the PWM circuit on the Inverter Board to regulate the gate signals to the IGBT”s

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 LEDʼs on the front panel.

The Mode Switch , the Control Potentiometer and the three LEDʼs are all mounted on the Control Board.

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INVERTEC® V155-S

Image 29
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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