Lincoln Invertec V155 Manual - Official Safety and Operation Guidelines

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		July, 2008
		July, 2008

INVERTEC ® V155-S

For use with machines having Code Numbers: 11326; 11327

Safety Depends on You

Lincoln arc welding and cutting equipment is designed and built with safety in mind. However, your overall safety can be increased by proper installation ... and thought- ful operation on your part. DO NOT INSTALL, OPERATE OR REPAIR THIS EQUIPMENT WITHOUT READING THIS MAN- UAL AND THE SAFETY PRE-

CAUTIONS CONTAINED THROUGHOUT. And, most importantly, think before you act and be careful.

SERVICE MANUAL

Copyright © Lincoln Global Inc.

• World's Leader in Welding and Cutting Products •

• Sales and Service through Subsidiaries and Distributors Worldwide •

Cleveland, Ohio 44117-1199 U.S.A. TEL: 888.935.3877 FAX: 216.486.1751 WEB SITE: www.lincolnelectric.com

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Lincoln Electric service manual Invertec V155-S

Contents

Invertec V155-S For Engine SafetyElectric Magnetic Fields Fumes and Gases Electric Shock can kill ARC Rays can burn Iii For Electrically Précautions DE Sûreté Pour Précautions DE SûretéLES Machines À Souder À Transformateur ET À Electromagnetic Compatibility EMC L10093 3-1-96H Master Table of Contents for ALL Sections Table of Contents Installation Section Operating Temperature Range Storage Temperature Range Installation Input Connections Safety PrecautionsSelect Suitable Location Tilting 230V Input Input Power Connection120V Input Engine Driven Generator TIG Welding Output ConnectionsStick Welding Smaw Replacement Quick Disconnect Plug for Stick Electrode Cable Table of Contents Operation Section Theory of Operation Safety InstructionsGeneral Description Welding Capability Controls and Operational FeaturesFunction OFF With Stick Welding Auto Adaptive ARC ForceRear Control Panel Table of Contents Accessories Section Cable Plugs Compatible Equipment Accessories Table of Contents Maintenance Section Input Filter Capacitor Discharge Procedure MaintenanceRoutine Maintenance Thermal Protection Figure D.1 Major Component Locations Major Component Locations Invertec V155-S 1TABLE of CONTENTS-THEORY of Operation Section E-1 Figure E.2 General Description Figure E.3 Input Board Input Board Figure E.4 Main Inverter Board Main Inverter Board Figure E.5 Control Board Control Board Figure E.6 Igbt Operation Insulated Gate Bipolar Transistor Igbt Operation Minimum Output Pulse Width ModulationSec 31 m/sec 33 m/sec Maximum Output Invertec V155-S 1TABLE of Contents Troubleshooting & Repair F-1 HOW to USE Troubleshooting Guide Troubleshooting & Repair Electric Shock PC Board Troubleshooting Procedures Resistance Test Perform Inverter Board Voltage Test Machine has high welding Case Cover Removal Procedure 7TROUBLESHOOTING & REPAIRF-7Test Description Materials Needed Disconnect power to the Invertec V155-S Procedure 9TROUBLESHOOTING & REPAIRF-9 Input Filter Capacitor Discharge Procedure Figure F.4 Capacitor Discharge Locations 11TROUBLESHOOTING & REPAIRF-11 Invertec V155-S Input Board Resistance Test 13TROUBLESHOOTING & REPAIRF-13 DC+ Inverter Board Resistance Test 15TROUBLESHOOTING & REPAIRF-15 Figure F.6 Inverter Board Test Points Inverter Board Resistance Test Invertec V155-S Input Board Voltage Test 19TROUBLESHOOTING & REPAIRF-19 PWR 2white to PWR 1blue to PWR 4white to PWR 3blue to 20TROUBLESHOOTING & REPAIRF-20 Figure F.9 Main Switch Plug Location 21TROUBLESHOOTING & REPAIRF-21 Invertec V155-S Inverter Board Voltage Test 23TROUBLESHOOTING & REPAIRF-23 Figure F.10 Plug JP1 Testpoints Input Board Removal and Replacement Procedure 25TROUBLESHOOTING & REPAIRF-25 AC2 Inverter Board Removal and Replacement Procedure 27TROUBLESHOOTING & REPAIRF-27 Perform the Case Cover Removal Procedure Figure F.13 Inverter Board Removal 29TROUBLESHOOTING & REPAIRF-29 Invertec V155-S Control Board Removal and Replacement Procedure 31TROUBLESHOOTING & REPAIRF-31 Figure F.14 Control Board Removal 32TROUBLESHOOTING & REPAIRF-32 Rated Output INPUT- Single Phase onlyOutput Recommended Meters for Machine Output Tests Invertec V155-S Table of Contents Diagram Section Electrical Diagrams Schematic Complete Machine Codes 11326 Electrical Diagrams Aux Potenza Schematic Input PC Board PC Board Assembly Input Board PTC Schematic Inverter PC Board Sheet #1 FEED-FORWARD Schematic Inverter PC Board Sheet #2 PC Board ASSEMBLY- Inverter Board Sheet # PC Board Assembly Inverter Board Sheet #2 U1A Schematic Control PC Board See Page 2 for more detailed component information PC Board Assembly Control Board page Sheet #1 PC Board Assembly Control Board Sheet #2