Lincoln Electric V155-S service manual Electromagnetic Compatibility EMC

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L10093 3-1-96H

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v

SAFETY

v

Electromagnetic Compatibility (EMC)

Conformance

Products displaying the CE mark are in conformity with European Community Council Directive of 3 May 1989 on the approximation of the laws of the Member States relating to electromagnetic compatibility (89/336/EEC). It was manufactured in conformity with a national standard that implements a harmonized standard: EN 60974-10Electromagnetic Compatibility (EMC) Product Standard for Arc Welding Equipment. It is for use with other Lincoln Electric equipment. It is designed for industrial and professional use. Introduction

All electrical equipment generates small amounts of electromagnetic emission. Electrical emission may be transmitted through power lines or radiated through space, similar to a radio transmitter. When emissions are received by other equipment, electrical interference may result. Electrical emissions may affect many kinds of electrical equipment; other nearby welding equipment, radio and TV reception, numerical controlled machines, telephone systems, computers, etc. Be aware that interference may result and extra precautions may be required when a welding power source is used in a domestic establishment.

Installation and Use

The user is responsible for installing and using the welding equipment according to the manufacturerʼs instructions. If electromagnetic disturbances are detected then it shall be the responsibility of the user of the welding equipment to resolve the situation with the technical assistance of the manufacturer. In some cases this remedial action may be as simple as earthing (grounding) the welding circuit, see Note. In other cases it could involve construction of an electromagnetic screen enclosing the power source and the work com- plete with associated input filters. In all cases electromagnetic disturbances must be reduced to the point where they are no longer troublesome.

Note: The welding circuit may or may not be earthed for safety reasons according to national codes. Changing the earthing arrangements should only be authorized by a person who is competent to access whether the changes will increase the risk of injury, e.g., by allowing parallel welding current return paths which may damage the earth circuits of other equip- ment.

Assessment of Area

Before installing welding equipment the user shall make an assessment of potential electromagnetic prob- lems in the surrounding area. The following shall be taken into account:

a) other supply cables, control cables, signaling and telephone cables; above, below and adjacent to the welding equipment;

b) radio and television transmitters and receivers; c) computer and other control equipment;

d) safety critical equipment, e.g., guarding of industrial equipment;

e) the health of the people around, e.g., the use of pacemakers and hearing aids; f) equipment used for calibration or measurement

g) the immunity of other equipment in the environment. The user shall ensure that other equipment being used in the environment is compatible. This may require additional protection measures;

h) the time of day that welding or other activities are to be carried out.

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Contents Invertec V155-S Safety For EngineElectric 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 GeneratorOutput Connections TIG WeldingStick 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 OFFAuto Adaptive ARC Force With Stick WeldingRear 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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