Lincoln Electric V155-S service manual Troubleshooting & Repair, HOW to USE Troubleshooting Guide

Page 34

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F-2

TROUBLESHOOTING & REPAIR

F-2

 

HOW TO USE TROUBLESHOOTING GUIDE

 

 

 

 

 

WARNING

 

Service and Repair s

hould only be performed by Lincoln Electric Factory Trained

Personnel. Unauthorized repairs performed on this equipment may result in danger to

the technician and machine operator and will invalidate your factory warranty. For your

safety and to avoid Electrical Shock, please observe all safety notes and precautions

detailed throughout this manual.

 

 

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This Troubleshooting Guide is provided to

Step 3. RECOMMENDED

 

COURSE OF ACTION

 

help you locate and repair possible machine

The last column labeled “Recommended

malfunctions. Simply follow the three-step

procedure listed below.

 

Course of Action” lists the most likely com-

 

ponents that may have failed in your

Step 1. LOCATE PROBLEM (SYMPTOM).

machine. It also specifies the appropriate

Look under the column labeled “PROBLEM

test procedure to verify that the subject com-

(SYMPTOMS)”. This column describes pos-

ponent is either good or bad. If there are a

sible symptoms that the machine may exhib-

number of possible components, check the

it. Find the listing that best describes the

components in the order listed

to eliminate

symptom that the machine is exhibiting.

one possibility at a time until you locate the

Symptoms are grouped into the following

cause of your problem.

 

categories: output problems, function prob-

All of the referenced test procedures

lems,

wire feeding problems, and

welding

problems.

 

referred to in the Troubleshooting Guide are

 

described in detail at the end of this chapter.

St p 2. PERFORM EXTERNAL TE TS.

Refer to the Troubleshooting and Repair

The second column labeled “POSSIBLE

Table of Contents to locate each specific

AREAS OF MISADJUSTMENT(S)” lists the

Test Procedure. All of the specified test

obvious external possibilities that may con-

points, components, terminal strips, etc. can

tribute to the machine symptom.

Perform

be found on the referenced electrical wiring

these

tests/checks in the order listed. In

diagrams and schematics. Refer to the

general, these tests can be conducted with-

Electrical Diagrams Section Table of

out removing the case wrap-around cover.

Contents to locate the appropriate diagram.

CAUTION

If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact the Lincoln Electric Service Department for technical troubleshooting assistance before you proceed. Call 1-888-935-3877.

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INVERTEC® V155-S

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Contents Invertec V155-S For Engine SafetyElectric Magnetic Fields 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 GeneratorTIG Welding Output ConnectionsStick Welding Smaw Replacement Quick Disconnect Plug for Stick Electrode Cable Table of Contents Operation Section General Description Safety InstructionsTheory of Operation Welding CapabilityFunction FeaturesControls and Operational OFFWith Stick Welding Auto Adaptive ARC ForceRear Control Panel 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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