Lincoln Electric Official Manual for Lincoln Invertec V155: Operation and Troubleshooting Guide

Page 36

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F-4

THEORY OF OPERATION

F-4

 

Observe Safety Guidelines detailed in the beginning of this manual.

 

 

 

PROBLEMS

 

POSSIBLE AREAS OF

RECOMMENDED

 

 

 

 

 

(SYMPTOMS)

 

MISADJUSTMENT(S)

COURSE OF ACTION

 

 

The line circuit breaker trips

 

OUTPUT PROBLEMS

1. Perform the Input Board

 

 

 

 

 

1.

Input power Bridge is shorted.

 

 

when power switch is “ON”

2.

Failed Electrolytic Capacitors.

Resistance Test.

 

 

 

 

3.

Failed Inverter IGBTʼs.

2. Perform the Inverter Board

 

 

 

 

Resistance Test.

 

 

 

 

 

 

 

 

The machine is dead, no output,

1.

No input power on line.

1. Restore correct Input power

 

 

no fan

 

2.

Line Switch failure.

2. Replace Line switch.

 

 

 

 

3.

Defective Input Board.

3. Perform Input Board Voltage

 

 

 

4.

Defective Inverter Board

4. Perform Inverter Board

 

 

 

 

 

 

Test.

 

 

 

 

 

 

Voltage Test.

 

 

 

 

 

 

 

 

The GREEN

LED is “ON” but

1. Thermal Protection has

1. Check Fan and Thermal

 

 

there is no output And yellow

 

tripped.

Protection Circuits.

 

 

thermal overload LED is “ON”

2. Logic Circuit Error on Control

2. Perform Input Board

 

 

 

 

 

Board.

Resistance and Input Board

 

 

 

3. ARFU System Damage on the

Voltage Tests

 

 

 

 

 

Input Board

3. The Control Board may be

 

 

 

 

 

 

faulty. Replace.

 

 

The YELLOW LED is “ON” and

1.

The machine is unable to cool

1. Turn the Power Switch OFF and

 

the RED and GREEN LEDʼs blink

 

itself.

wait several minutes for the

 

 

alternately

 

 

 

machine to cool. Turn the Power

 

 

 

 

 

Switch back ON and check for

 

 

 

 

 

proper fan operation.

 

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.

INVERTEC® V155-S

Image 36
Contents Invertec V155-S Safety For EngineElectric Magnetic Fields Electric Shock can kill ARC Rays can burn Fumes and GasesFor Electrically IiiPrécautions DE Sûreté Précautions DE Sûreté PourLES 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 Installation Operating Temperature Range Storage Temperature RangeSafety Precautions Input ConnectionsSelect Suitable Location TiltingInput Power Connection 230V Input120V Input Engine Driven GeneratorOutput Connections TIG WeldingStick Welding Smaw Replacement Quick Disconnect Plug for Stick Electrode Cable Table of Contents Operation Section Safety Instructions Theory of OperationGeneral Description Welding CapabilityFeatures Controls and OperationalFunction OFFAuto Adaptive ARC Force With Stick WeldingRear Control Panel Table of Contents Accessories Section Accessories Cable Plugs Compatible EquipmentTable of Contents Maintenance Section Maintenance Input Filter Capacitor Discharge ProcedureRoutine Maintenance 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 OperationPulse Width Modulation Minimum OutputSec 31 m/sec 33 m/sec 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 7TROUBLESHOOTING & REPAIRF-7 Case Cover Removal ProcedureTest Description 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 RemovalINPUT- Single Phase only Rated OutputOutput 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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