Lincoln Electric V155-S service manual L10093 3-1-96H

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vi

SAFETY

vi

 

 

 

 

 

 

 

 

Electromagnetic Compatibility (EMC)

 

 

 

The size of the surrounding area to be considered will depend on the structure of the building and other

 

 

 

activities that are taking place. The surrounding area may extend beyond the boundaries of the premises.

 

 

 

Methods of Reducing Emissions

 

 

 

Mains Supply

 

 

 

Welding equipment should be connected to the mains supply according to the manufacturerʼs recommen-

 

 

 

dations. If interference occurs, it may be necessary to take additional precautions such as filtering of the

 

 

 

mains supply. Consideration should be given to shielding the supply cable of permanently installed welding

 

 

 

equipment, in metallic conduit or equivalent. Shielding should be electrically continuous throughout its

 

 

 

length. The shielding should be connected to the welding power source so that good electrical contact is

 

 

 

maintained between the conduit and the welding power source enclosure.

 

 

 

Maintenance of the Welding Equipment

 

 

 

The welding equipment should be routinely maintained according to the manufacturerʼs recommendations.

 

 

 

All access and service doors and covers should be closed and properly fastened when the welding equip-

 

 

 

ment is in operation. The welding equipment should not be modified in any way except for those changes

 

 

 

and adjustments covered in the manufacturers instructions. In particular, the spark gaps of arc striking and

 

 

 

stabilizing devices should be adjusted and maintained according to the manufacturerʼs recommendations.

 

 

 

Welding Cables

 

 

 

The welding cables should be kept as short as possible and should be positioned close together, running at

 

 

 

or close to floor level.

 

 

 

Equipotential Bonding

 

 

 

Bonding of all metallic components in the welding installation and adjacent to it should be considered.

 

 

 

However, metallic components bonded to the work piece will increase the risk that the operator could

 

 

 

receive a shock by touching these metallic components and the electrode at the same time. The operator

 

 

 

should be insulated from all such bonded metallic components.

 

 

 

Earthing of the Workpiece

 

 

 

Where the workpiece is not bonded to earth for electrical safety, not connected to earth because of its size

 

 

 

and position, e.g., ships hull or building steelwork, a connection bonding the workpiece to earth may reduce

 

 

 

emissions in some, but not all instances. Care should be taken to prevent the earthing of the workpiece

 

 

 

increasing the risk of injury to users, or damage to other electrical equipment. Where necessary, the con-

 

 

 

nection of the workpiece to earth should be made by a direct connection to the workpiece, but in some

 

 

 

countries where direct connection is not permitted, the bonding should be achieved by suitable capaci-

 

 

 

tance, selected according to national regulations.

 

 

 

Screening and Shielding

 

 

 

Selective screening and shielding of other cables and equipment in the surrounding area may alleviate

 

 

 

problems of interference. Screening of the entire welding installation may be considered for special applica-

 

 

 

tions. 1

 

 

 

_________________________

 

 

 

1

Portions of the preceding text are contained in EN 60974-10: “Electromagnetic Compatibility (EMC)

 

 

 

 

product standard for arc welding equipment.”

 

 

L10093 3-1-96H

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Contents Invertec V155-S For Engine SafetyElectric 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 InputTIG Welding Output ConnectionsStick 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 FunctionWith Stick Welding Auto Adaptive ARC ForceRear 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 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 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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