Lincoln Electric V155-S User Manual
INVERTEC
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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 thoughtful operation on your part. DO
NOT INSTALL, OPERATE OR
REPAIR THIS EQUIPMENT
WITHOUT READING THIS MANUAL AND THE SAFETY PRECAUTIONS CONTAINED
THROUGHOUT. And, most
importantly, think before you act
and be careful.
SVM183-A
July, 2008
®
V155-S
View Safety Info View Safety Info View Safety Info View Safety Info
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Cleveland, Ohio 44117-1199 U.S.A. TEL: 888.935.3877 FAX: 216.486.1751 WEB SITE: www.lincolnelectric.com
SERVICE MANUAL
Copyright © Lincoln Global Inc.
• World's Leader in Welding and Cutting Products •
• Sales and Service through Subsidiaries and Distributors Worldwide •
i i
SAFETY
WARNING
CALIFORNIA PROPOSITION 65 WARNINGS
Diesel engine exhaust and some of its constituents
are known to the State of California to cause cancer, birth defects, and other reproductive harm.
The Above For Diesel Engines
ARC WELDING CAN BE HAZARDOUS. PROTECT YOURSELF AND OTHERS FROM POSSIBLE SERIOUS INJURY OR DEATH.
KEEP CHILDREN AWAY. PACEMAKER WEARERS SHOULD CONSULT WITH THEIR DOCTOR BEFORE OPERATING.
Read and understand the following safety highlights. For additional safety information, it is strongly recommended that you
purchase a copy of “Safety in Welding & Cutting - ANSI Standard Z49.1” from the American Welding Society, P.O. Box 351040,
Miami, Florida 33135 or CSA Standard W117.2-1974. A Free copy of “Arc Welding Safety” booklet E205 is available from the
Lincoln Electric Company, 22801 St. Clair Avenue, Cleveland, Ohio 44117-1199.
BE SURE THAT ALL INSTALLATION, OPERATION, MAINTENANCE AND REPAIR PROCEDURES ARE
PERFORMED ONLY BY QUALIFIED INDIVIDUALS.
The engine exhaust from this product contains
chemicals known to the State of California to cause
cancer, birth defects, or other reproductive harm.
The Above For Gasoline Engines
FOR ENGINE
powered equipment.
1.a. Turn the engine off before troubleshooting and maintenance
work unless the maintenance work requires it to be running.
____________________________________________________
1.b.Operate engines in open, well-ventilated
areas or vent the engine exhaust fumes
outdoors.
____________________________________________________
1.c. Do not add the fuel near an open flame welding arc or when the engine is running. Stop
the engine and allow it to cool before refueling to prevent spilled fuel from vaporizing on
contact with hot engine parts and igniting. Do
not spill fuel when filling tank. If fuel is spilled,
wipe it up and do not start engine until fumes
have been eliminated.
____________________________________________________
1.d. Keep all equipment safety guards, covers and devices in position and in good repair.Keep hands, hair, clothing and tools
away from V-belts, gears, fans and all other moving parts
when starting, operating or repairing equipment.
____________________________________________________
1.e. In some cases it may be necessary to remove safety
guards to perform required maintenance. Remove
guards only when necessary and replace them when the
maintenance requiring their removal is complete.
Always use the greatest care when working near moving
parts.
___________________________________________________
1.f. Do not put your hands near the engine fan.
Do not attempt to override the governor or
idler by pushing on the throttle control rods
while the engine is running.
1.h. To avoid scalding, do not remove the
radiator pressure cap when the engine is
hot.
ELECTRIC AND
MAGNETIC FIELDS
may be dangerous
2.a. Electric current flowing through any conductor causes
localized Electric and Magnetic Fields (EMF). Welding
current creates EMF fields around welding cables and
welding machines
2.b. EMF fields may interfere with some pacemakers, and
welders having a pacemaker should consult their physician
before welding.
2.c. Exposure to EMF fields in welding may have other health
effects which are now not known.
2.d. All welders should use the following procedures in order to
minimize exposure to EMF fields from the welding circuit:
2.d.1.
Route the electrode and work cables together - Secure
them with tape when possible.
2.d.2. Never coil the electrode lead around your body.
2.d.3. Do not place your body between the electrode and
work cables. If the electrode cable is on your right
side, the work cable should also be on your right side.
___________________________________________________
1.g. To prevent accidentally starting gasoline engines while
turning the engine or welding generator during maintenance
work, disconnect the spark plug wires, distributor cap or
magneto wire as appropriate.
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2.d.4. Connect the work cable to the workpiece as close as
possible to the area being welded.
2.d.5. Do not work next to welding power source.
Mar ʻ95
ii ii
SAFETY
ELECTRIC SHOCK can kill.
3.a. The electrode and work (or ground) circuits
are electrically “hot” when the welder is on.
Do not touch these “hot” parts with your bare
skin or wet clothing. Wear dry, hole-free
gloves to insulate hands.
3.b. Insulate yourself from work and ground using dry insulation.
Make certain the insulation is large enough to cover your full
area of physical contact with work and ground.
In addition to the normal safety precautions, if welding
must be performed under electrically hazardous
conditions (in damp locations or while wearing wet
clothing; on metal structures such as floors, gratings or
scaffolds; when in cramped positions such as sitting,
kneeling or lying, if there is a high risk of unavoidable or
accidental contact with the workpiece or ground) use
the following equipment:
• Semiautomatic DC Constant Voltage (Wire) Welder.
• DC Manual (Stick) Welder.
• AC Welder with Reduced Voltage Control.
3.c. In semiautomatic or automatic wire welding, the electrode,
electrode reel, welding head, nozzle or semiautomatic
welding gun are also electrically “hot”.
3.d. Always be sure the work cable makes a good electrical
connection with the metal being welded. The connection
should be as close as possible to the area being welded.
3.e. Ground the work or metal to be welded to a good electrical
(earth) ground.
3.f.
Maintain the electrode holder, work clamp, welding cable and
welding machine in good, safe operating condition. Replace
damaged insulation.
3.g. Never dip the electrode in water for cooling.
3.h. Never simultaneously touch electrically “hot” parts of
electrode holders connected to two welders because voltage
between the two can be the total of the open circuit voltage
of both welders.
3.i. When working above floor level, use a safety belt to protect
yourself from a fall should you get a shock.
3.j. Also see Items 6.c. and 8.
ARC RAYS can burn.
4.a. Use a shield with the proper filter and cover
plates to protect your eyes from sparks and
the rays of the arc when welding or observing
open arc welding. Headshield and filter lens
should conform to ANSI Z87. I standards.
4.b. Use suitable clothing made from durable flame-resistant
material to protect your skin and that of your helpers from
the arc rays.
4.c. Protect other nearby personnel with suitable, non-flammable
screening and/or warn them not to watch the arc nor expose
themselves to the arc rays or to hot spatter or metal.
FUMES AND GASES
can be dangerous.
5.a. Welding may produce fumes and gases
hazardous to health. Avoid breathing these
fumes and gases.When welding, keep
your head out of the fume. Use enough
ventilation and/or exhaust at the arc to keep
fumes and gases away from the breathing zone. When
welding with electrodes which require special
ventilation such as stainless or hard facing (see
instructions on container or MSDS) or on lead or
cadmium plated steel and other metals or coatings
which produce highly toxic fumes, keep exposure as
low as possible and below Threshold Limit Values (TLV)
using local exhaust or mechanical ventilation. In
confined spaces or in some circumstances, outdoors, a
respirator may be required. Additional precautions are
also required when welding on galvanized steel.
5. b. The operation of welding fume control equipment is affected
by various factors including proper use and positioning of the
equipment, maintenance of the equipment and the specific
welding procedure and application involved. Worker exposure level should be checked upon installation and periodically thereafter to be certain it is within applicable OSHAPEL
and ACGIH TLV limits.
5.c.
Do not weld in locations near chlorinated hydrocarbon
coming from degreasing, cleaning or spraying operations.
The heat and rays of the arc can react with solvent vapors
form phosgene, a highly toxic gas, and other irritating products.
5.d. Shielding gases used for arc welding can displace air and
cause injury or death. Always use enough ventilation,
especially in confined areas, to insure breathing air is safe.
vapors
to
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5.e. Read and understand the manufacturerʼs instructions for this
equipment and the consumables to be used, including the
material safety data sheet (MSDS) and follow your
employerʼs safety practices. MSDS forms are available from
your welding distributor or from the manufacturer.
5.f. Also see item 1.b.
Aug ʻ06
iiiiii iiiiii
SSAAFFEETTYY
WELDING and CUTTING
SPARKS can
cause fire or explosion.
6.a.
Remove fire hazards from the welding area.
If this is not possible, cover them to prevent
Remember that welding sparks and hot
materials from welding can easily go through small cracks
and openings to adjacent areas. Avoid welding near
hydraulic lines. Have a fire extinguisher readily available.
6.b. Where compressed gases are to be used at the job site,
special precautions should be used to prevent hazardous
situations. Refer to “Safety in Welding and Cutting” (ANSI
Standard Z49.1) and the operating information for the
equipment being used.
6.c. When not welding, make certain no part of the electrode
circuit is touching the work or ground. Accidental contact can
cause overheating and create a fire hazard.
6.d. Do not heat, cut or weld tanks, drums or containers until the
proper steps have been taken to insure that such procedures
will not cause flammable or toxic vapors from substances
inside. They can cause an explosion even
been “cleaned”. For information, purchase “Recommended
Safe Practices for the
Containers and Piping That Have Held Hazardous
Substances”, AWS F4.1 from the American Welding Society
(see address above).
6.e. Vent hollow castings or containers before heating, cutting or
welding. They may explode.
Sparks and spatter are thrown from the welding arc. Wear oil
6.f.
free protective garments such as leather gloves, heavy shirt,
cuffless trousers, high shoes and a cap over your hair. Wear
ear plugs when welding out of position or in confined places.
Always wear safety glasses with side shields when in a
welding area.
6.g. Connect the work cable to the work as close to the welding
area as practical. Work cables connected to the building
framework or other locations away from the welding area
increase the possibility of the welding current passing
through lifting chains, crane cables or other alternate circuits.
This can create fire hazards or overheat lifting chains or
cables until they fail.
6.h. Also see item 1.c.
the welding sparks from starting a fire.
though
they have
Preparation
for Welding and Cutting of
CYLINDER may explode
if damaged.
7.a. Use only compressed gas cylinders
containing the correct shielding gas for the
process used and properly operating
regulators designed for the gas and
pressure used. All hoses, fittings, etc. should be suitable for
the application and maintained in good condition.
7.b. Always keep cylinders in an upright position securely
chained to an undercarriage or fixed support.
7.c. Cylinders should be located:
• Away from areas where they may be struck or subjected to
physical damage.
• A safe distance from arc welding or cutting operations and
any other source of heat, sparks, or flame.
7.d. Never allow the electrode, electrode holder or any other
electrically “hot” parts to touch a cylinder.
7.e. Keep your head and face away from the cylinder valve outlet
when opening the cylinder valve.
7.f. Valve protection caps should always be in place and hand
tight except when the cylinder is in use or connected for
use.
7.g. Read and follow the instructions on compressed gas
cylinders, associated equipment, and CGA publication P-l,
“Precautions for Safe Handling of Compressed Gases in
Cylinders,” available from the Compressed Gas Association
1235 Jefferson Davis Highway, Arlington, VA 22202.
FOR ELECTRICALLY
powered equipment.
8.a. Turn off input power using the disconnect
switch at the fuse box before working on
the equipment.
8.b. Install equipment in accordance with the U.S. National
Electrical Code, all local codes and the manufacturerʼs
recommendations.
8.c. Ground the equipment in accordance with the U.S. National
Electrical Code and the manufacturerʼs recommendations.
6.I. Read and follow NFPA 51B “ Standard for Fire Prevention
During Welding, Cutting and Other Hot Work”, available from
NFPA, 1 Batterymarch Park,PO box 9101, Quincy, Ma
022690-9101.
6.j. Do not use a welding power source for pipe thawing.
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Jan ʻ07
iv iv
SAFETY
PRÉCAUTIONS DE SÛRETÉ
Pour votre propre protection lire et observer toutes les instructions
et les précautions de sûreté specifiques qui parraissent dans ce
manuel aussi bien que les précautions de sûreté générales suivantes:
Sûreté Pour Soudage A LʼArc
1. Protegez-vous contre la secousse électrique:
a. Les circuits à lʼélectrode et à la piéce sont sous tension
quand la machine à souder est en marche. Eviter toujours
tout contact entre les parties sous tension et la peau nue
ou les vétements mouillés. Porter des gants secs et sans
trous pour isoler les mains.
b. Faire trés attention de bien sʼisoler de la masse quand on
soude dans des endroits humides, ou sur un plancher metallique ou des grilles metalliques, principalement dans
les positions assis ou couché pour lesquelles une grande
partie du corps peut être en contact avec la masse.
c. Maintenir le porte-électrode, la pince de masse, le câble de
soudage et la machine à souder en bon et sûr état defonctionnement.
d.Ne jamais plonger le porte-électrode dans lʼeau pour le
refroidir.
e. Ne jamais toucher simultanément les parties sous tension
des porte-électrodes connectés à deux machines à souder
parce que la tension entre les deux pinces peut être le total
de la tension à vide des deux machines.
f. Si on utilise la machine à souder comme une source de
courant pour soudage semi-automatique, ces precautions
pour le porte-électrode sʼapplicuent aussi au pistolet de
soudage.
6. Eloigner les matériaux inflammables ou les recouvrir afin de
prévenir tout risque dʼincendie dû aux étincelles.
7. Quand on ne soude pas, poser la pince à une endroit isolé de
la masse. Un court-circuit accidental peut provoquer un
échauffement et un risque dʼincendie.
8. Sʼassurer que la masse est connectée le plus prés possible de
la zone de travail quʼil est pratique de le faire. Si on place la
masse sur la charpente de la construction ou dʼautres endroits
éloignés de la zone de travail, on augmente le risque de voir
passer le courant de soudage par les chaines de levage,
câbles de grue, ou autres circuits. Cela peut provoquer des
risques dʼincendie ou dʼechauffement des chaines et des
câbles jusquʼà ce quʼils se rompent.
9. Assurer une ventilation suffisante dans la zone de soudage.
Ceci est particuliérement important pour le soudage de tôles
galvanisées plombées, ou cadmiées ou tout autre métal qui
produit des fumeés toxiques.
10. Ne pas souder en présence de vapeurs de chlore provenant
dʼopérations de dégraissage, nettoyage ou pistolage. La
chaleur ou les rayons de lʼarc peuvent réagir avec les vapeurs
du solvant pour produire du phosgéne (gas fortement toxique)
ou autres produits irritants.
11. Pour obtenir de plus amples renseignements sur la sûreté, voir
le code “Code for safety in welding and cutting” CSA Standard
W 117.2-1974.
2. Dans le cas de travail au dessus du niveau du sol, se protéger
contre les chutes dans le cas ou on recoit un choc. Ne jamais
enrouler le câble-électrode autour de nʼimporte quelle partie du
corps.
3. Un coup dʼarc peut être plus sévère quʼun coup de soliel, donc:
a. Utiliser un bon masque avec un verre filtrant approprié ainsi
quʼun verre blanc afin de se protéger les yeux du rayonnement de lʼarc et des projections quand on soude ou
quand on regarde lʼarc.
b. Porter des vêtements convenables afin de protéger la peau
de soudeur et des aides contre le rayonnement de lʻarc.
c. Protéger lʼautre personnel travaillant à proximité au
soudage à lʼaide dʼécrans appropriés et non-inflammables.
4. Des gouttes de laitier en fusion sont émises de lʼarc de
soudage. Se protéger avec des vêtements de protection libres
de lʼhuile, tels que les gants en cuir, chemise épaisse, pantalons sans revers, et chaussures montantes.
5. Toujours porter des lunettes de sécurité dans la zone de
soudage. Utiliser des lunettes avec écrans lateraux dans les
zones où lʼon pique le laitier.
PRÉCAUTIONS DE SÛRETÉ POUR
LES MACHINES À SOUDER À
TRANSFORMATEUR ET À
REDRESSEUR
1. Relier à la terre le chassis du poste conformement au code de
lʼélectricité et aux recommendations du fabricant. Le dispositif
de montage ou la piece à souder doit être branché à une
bonne mise à la terre.
2. Autant que possible, Iʼinstallation et lʼentretien du poste seront
effectués par un électricien qualifié.
3. Avant de faires des travaux à lʼinterieur de poste, la debrancher à lʼinterrupteur à la boite de fusibles.
4. Garder tous les couvercles et dispositifs de sûreté à leur place.
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Mar ʻ93
v v
SAFETY
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 60974-10 Electromagnetic 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 complete 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 equipment.
Assessment of Area
Before installing welding equipment the user shall make an assessment of potential electromagnetic problems 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;
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h) the time of day that welding or other activities are to be carried out.
L10093 3-1-96H
vi vi
SAFETY
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 recommendations. 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 equipment 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 connection 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 capacitance, 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-
1
tions.
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_________________________
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
I I
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- MASTER TABLE OF CONTENTS FOR ALL SECTIONS -
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Page
Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .i-iv
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Section A
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Section B
Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Section C
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Section D
Theory of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Section E
Troubleshooting and Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Section F
Electrical Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Section G
Parts Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .P-559
INVERTEC® V155-S
A-1 A-1
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-1
Technical Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-2
Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-3
Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-3
Input Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-3
Output Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-5
TABLE OF CONTENTS - INSTALLATION SECTION
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INVERTEC® V155-S
A-2 A-2
INSTALLATION
INPUT - SINGLE PHASE ONLY
Input Voltages / 50 /60 Hz.
120Vac ± 10%
230Vac ± 10%
Max. Input Current at rated Output
100% 30%
25A 34 A
23A 33 A
Input Power at Rated Output
100% 30%
2.2kw 3.0kw
3.0kw 5.0kw
RATED OUTPUT
Duty Cycle
Output Amps
Output Volts
Input Circuit
100%
30%
75A (Stick)
105A (TIG)
100A (Stick)
100A (TIG)
100A (Stick)
130A (TIG)
145A (Stick)
155A (TIG)
23.0 Vdc
14.2 Vdc
24.0 Vdc
14.0 Vdc
24.0 Vdc
15.2 Vdc
25.8 Vdc
16.2 Vdc
120 Vac
230 Vac
120 Vac
230 Vac
OUTPUT
Output Current Range
5-155 Amps
Maximum Open Circuit Voltage
75 Volts Max.
Type of Output
DC
RECOMMENDED INPUT WIRE AND FUSE SIZES FOR MAXIMUM RATED OUTPUT
INPUT VOLTAGE /
FREQUENCY (HZ)
230/60
120/60
TYPE S, SO ST, STO, OR EXTRA
HARD USAGE INPUT CORD AWG
3 Conductor, 12 AWG
MAXIMUM TIME-DELAY CIRCUIT
BREAKER OR FUSE SIZE (AMPS)
30
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PHYSICAL DIMENSIONS
Height Width Depth Weight
11.3 6.2 in. 15.4in. Approx. 14.7lbs.
288 mm 158 mm 392 mm 6.7 kgs.
TEMPERATURE RANGES
OPERATING TEMPERATURE RANGE
-10°C to +40°C
INVERTEC® V155-S
STORAGE TEMPERATURE RANGE
-25°C to +55°C
A-3 A-3
Read entire installation section before starting
installation.
SAFETY PRECAUTIONS
INSTALLATION
TILTING
Place the machine directly on a secure, level surface.
Do not place or operate this machine on a surface with
an incline greater than 15° from horizontal. The
machine may topple over if this procedure is not followed.
WARNING
INPUT CONNECTIONS
ELECTRIC SHOCK can kill.
• Only qualified personnel should perform this installation.
• Disconnect input power by removing
plug from receptacle before working
inside INVERTEC® V155-S. Allow
machine to sit for 5 minutes
mum to allow the power capacitors
to discharge before working inside
this equipment.
• Insulate yourself from the work and ground.
• Always wear dry insulating gloves.
• Always connect the INVERTEC® V155-S to a power
supply grounded according to the National
Electrical Code and local codes.
mini-
------------------------------------------------------------
SELECT SUITABLE LOCATION
This machine can operate in harsh environments.
However, it is important that simple preventative measures are followed to assure long life and reliable operation:
ELECTRIC SHOCK can kill.
• Have a qualified electrician install
• Disconnect input power by removing
plug from receptacle before working
inside INVERTEC® V155-S. Allow
machine to sit for 5 minutes
to allow the power capacitors to discharge before
working inside this equipment.
• Do not touch electrically live parts.
-----------------------------------------------------------------------
The frame of the welder must be
grounded. A ground terminal marked
with the symbol is located on the under
panel for this purpose. See your local
and national electrical codes for proper
grounding methods.
WARNING
and service this equipment.
minimum
GROUND CONNECTION
CAUTION
• Do not use this machine for pipe thawing.
• This machine must be located where there is free circulation of clean air without restrictions for air movement to and from the air vents. Do not cover the
machine with paper, cloth or rags when switched on.
• Dirt and dust that can be drawn into the machine
should be kept to a minimum.
• This machine has a protection rating of IP23. Keep
it dry when possible and do not place it on wet
ground or in puddles.
• Locate the machine away from radio controlled
machinery. Normal operation may adversely affect
the operation of nearby radio controlled machinery,
which may result in injury or equipment damage.
Read the section on electromagnetic compatibility in
this manual.
• Do not operate in areas with an ambient temperature
greater than 40°C.
STACKING
The INVERTEC® V155-S cannot
be stacked.
A grounding conductor is supplied in the input
cord, it is important that the supply receptacle
ground is connected.
-----------------------------------------------------------------------
WARNING
This installation should be performed by a qualified electrician to ensure correct connections of
the leads to the plug spades.
• The electrical system must be made by skilled
technicians with the specific professional and
technical qualifications and in compliance with
the regulations in force in the country where the
equipment is installed.
• The welding power source supply cable is provided with a green or yellow/green wire that must
ALWAYS be earthed. This green or yellow/green
wire must NEVER be used with other voltage conductors.
• lnstall only plugs that confirm with safety regulations.
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INVERTEC® V155-S
A-4 A-4
INSTALLATION
INPUT POWER CONNECTION
Check the input voltage, phase, and frequency supplied to this machine before turning it on.
The allowable input voltage is indicated in the technical specification section of this manual and on the rating plate of the machine. Be sure that the machine is
grounded.
Make sure the power available at the input connection
is adequate for normal operation of the machine. The
fuse rating and cable sizes are both indicated in the
technical specification section of this manual.
Fuse the input circuit with time delay fuses marked “D”
or delay type1circuit breakers. Using fuses or circuit
breakers smaller than recommended may result in
“nuisance” shut-offs from welder inrush currents even
if not welding at high currents.
1
Also called “inverse time” or “thermal/magnetic” circuit breakers.
These circuit breakers have a delay in tripping action that decreases
as the magnitude of the current increases.
The INVERTEC® V155-S is recommended for use on
an individual branch circuit.
120V INPUT
The rated output of the INVERTEC® V155-S is available when connected to a 30A branch circuit. When
connected to a branch circuit with lower ampacity,
lower welding current and duty cycle must be used. An
output guide is provided below. The values are approximate and must be adjusted downward if the fuse or
circuit breaker trips off. Other loads on the circuit and
fuse/circuit breaker characteristics will affect the available output. Do not exceed these welding conditions:
(See Table A.1)
The INVERTEC® V155-S is provided with a 120/230V
cable, 6.6ft.(2m) in length, with a 15Amp 5-15P plug
molded onto the cord.
The INVERTEC® V155-S is supplied with an additional 20A plug that can replace the 15A plug to achieve
higher output. To install the supplied 20A plug:
Failure to wire as instructed may cause personal
•
injury or damage to equipment. To be installed or
checked by an electrician or qualified person
only.
---------------------------------------------------------------------------
230V INPUT
To achieve the full output capacity of the INVERTEC®
V155-S, 230VAC inputs should be used. The change
over is accomplished by replacing the 120VAC plug
with a 30 Amp 230VAC plug (NEMA 6-30P).
ATTACHMENT PLUG
In all cases, the green or green/yellow grounding wire
must be connected to the grounding pin of the plug, usually identified by a green screw.
All attachment plugs must comply with the Standard for
Attachment Plugs and Receptacles, UL498.
The product is considered acceptable for use only when
an attachment plug as specified is properly attached to
the supply cord.
The INVERTEC® V155-S will auto reconnect to either
120V or 230V supplies.
ENGINE DRIVEN GENERATOR
The machine is designed to operate on engine driven
generators as long as the auxiliary can supply adequate voltage, frequency and power as indicated in the
"Technical Specification" Installation Section of this
manual. The auxiliary supply of the generator must
also meet the following conditions:
• Vac peak voltage: below 205V (for 115Vac input) or
• Vac frequency: in the range of 50 or 60 Hertz.
• RMS voltage of the AC waveform: 115Vac or
WARNING
410V (for 230Vac input).
230Vac ± 10%
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Connect the white (neutral) wire under terminal clamp
with silver screw, and black (hot) wire under terminal
clamp with brass screw. Connect green wire under terminal clamp with green screw.
TABLE A.1
BRANCH
120V Input
Stick
Plug
Rating
15 Amp
15 Amp
20 Amp
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Branch
Rating
15 Amp
20 Amp
20 Amp
10% Duty
Cycle
65A
75A
85A
30% Duty
Cycle
55A
70A
75A
100% Duty
Output Current
10% Duty
Cycle
45A
60A
60A
INVERTEC® V155-S
Cycle
100A
110A
130A
It is important to check these conditions because many
engine driven generators produce high voltage spikes.
Operation of this machine with engine driven generators not conforming to these conditions is not recommended and may damage the machine.
TIG
30% Duty
Cycle
85A
100A
130A
100% Duty
Cycle
75A
95A
95A
A-5 A-5
ARFU (Auto-Restore Fuse)
INSTALLATION
FIGURE A.1
The dual input voltage machine is provided with the
ARFU device. It operates only when the input is connected to the 120Vac mains and protects from input
overcurrent. When active, the "Thermal LED" lights
(see "Controls and Operational Features" in the
Operation Section).
Electrode
Holder
Note: The ARFU device operates independently from
the machine's duty-cycle.
OUTPUT CONNECTIONS
A quick disconnect system using Twist-Mate™ cable
plugs is used for the welding cable connections. Refer
to the following sections for more information on connecting the machine for operation of stick welding
(SMAW) or TIG welding.
WARNING
ELECTRIC SHOCK can kill.
• Keep the electrode holder and
cable insulation in good condition.
• Do not touch electrically live parts
or electrode with skin or wet clothing.
• Insulate yourself from work and ground.
• Turn the input line Switch on the INVERTEC®
V155-S “off” before connecting or disconnecting
output cables or other equipment.
-----------------------------------------------------------
STICK WELDING (SMAW)
First determine the proper electrode polarity for the electrode to be used. Consult the electrode data for this information. Then connect the output cables to the output terminals of the machine for the selected polarity. Shown
here is the connection method for DC(+) welding. (See
Figure A.1)
Connect the electrode cable to the (+) terminal and the
work clamp to the (-) terminal. Insert the connector with
the key lining up with the keyway and rotate approximately 1/4 turn clockwise. Do not over tighten.
For DC(-) welding, switch the cable connections at the
machine so that the electrode cable is connected to (-)
and the work clamp is connected to (+).
Work Clamp
Work Cable
TIG WELDING
This machine does not have a built in Gas Solenoid so
a one piece gas valve TIG Torch is required. A K960-2
Twist-Mate™ TIG Torch adapter is also required. Refer
to the accessories section for more information about
TIG Torches and required Twist-Mate™ adapter. Most
TIG welding is done with DC(-) polarity shown here. If
DC(+) polarity is necessary switch the cable connections at the machine. (See Figure A.2)
Connect the torch cable to the (-) terminal of the
machine and the work clamp to the (+) terminal. Insert
the connector with the key lining up with the keyway
and rotate approximately 1/4 turn clockwise. Do not
over tighten. Finally, connect the Twist-Mate™ adapter
gas hose to the gas regulator on the cylinder of gas to
be used.
FIGURE A.2
Work Clamp
Work Cable
Twist-Mate™ Adapter K-960-2
Gas Hose
To Bottle
Gas Valve
TIG Torch
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INVERTEC® V155-S
A-6 A-6
19 mm
.
75 in.
WELDING CABLE
BOOT
TRIM, IF REQ'D
TO FIT OVER CABLE
6 mm
.25 in.
WELDING CABLE
12 mm max.
.50 in. max
WELDING CABLE
COPPER FERRULE
SET SCREW
BRASS PLUG
COPPER TUBE
INSTALLATION
REPLACEMENT QUICK DISCONNECT PLUG (FOR
STICK ELECTRODE CABLE)
The INVERTEC® V155-S comes with a factory assembled stick electrode holder, cable and Twist-Mate™
adapter plug. If a replacement cable is ever needed a
K852-25 Twist-Mate™ plug will be needed.
To attach the K852-25 plug:
1. Cut off welding cable lug, if present.
2. Remove .75 in. (19mm) of welding cable insulation.
3. Slide rubber boot onto cable end. The boot end may
be trimmed to match the cable diameter. Use soap
or other nonpetroleum-based lubricant to help slide
the boot over the cable, if needed.
4. Cut 45-50% of the copper strands back 1/4” (6 mm).
5. Fold copper strands over cut strands and insert into
ferrule.
6. Slide the copper ferrule into the brass plug.
7. Tighten set screw to collapse copper tube. Screw
must apply pressure against welding cable. The top
of the set screw will be well below the surface of the
brass plug after tightening.
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INVERTEC® V155-S
B-1 B-1
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-1
Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-2
General Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-2
Controls and Operational Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-3
TABLE OF CONTENTS - OPERATION SECTION
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INVERTEC® V155-S
B-2 B-2
THEORY OF OPERATION
Read and understand this entire section before
operating your machine.
SAFETY INSTRUCTIONS
WARNING
ELECTRIC SHOCK can kill.
• Do not touch electrically live parts such
as output terminals or internal wiring.
• Insulate yourself from the work and
ground.
• Always wear dry insulating gloves.
____________________________________
FUMES AND GASES
can be dangerous.
• Keep your head out of fumes.
• Use ventilation or exhaust to
remove fumes from breathing
zone.
GENERAL DESCRIPTION
The INVERTEC® V155-S is an industrial 155 amp arc
welding power source which utilizes single phase input
power, to produce constant current output. The welding
response of this Invertec has been optimized for stick
(SMAW) and Touch Start TIG (GTAW). The unit is ideal
for industrial applications where portability is important.
The INVERTEC® V155-S is recommended for stick
welding with such popular electrodes as Fleetweld 35,
Fleetweld 37, Fleetweld 180 and LH 78. It features
automatic arc control to adjust the arc force, hot start
and anti sticking. The machine also features soft and
crisp modes.
The INVERTEC® V155-S performs DC Touch Start Tig
Starting with excellent results.
WELDING CAPABILITY
The INVERTEC® V155-S is rated at 155 amps, 16.2
volts, at 30% duty cycle on a ten minute basis. It is
capable of higher duty cycles at lower output cur-
(1)
. If the duty cycle is exceeded, a thermal protec-
rents
tor will shut off the output until the machine cools. See
Technical Specifications in the Installation Section for
other rated outputs.
____________________________________
WELDING, CUTTING and
GOUGING SPARKS
can cause fire or explosion
• Keep flammable material away.
• Do not weld, cut or gouge on
containers that have held com-
bustibles.
____________________________________
ARC RAYS
can burn.
• Wear eye, ear and body
protection.
____________________________________
Only qualified personnel should operate this equipment. Observe all safety information throughout this
manual.
The INVERTEC® V155-S is recommended for stick
®
welding with such popular electrodes as Fleetweld
Fleetweld 37, Fleetweld 180 and Jet-LH 78 MR. It features adjustable arc control to adjust the arc force and
start.
35,
LIMITATIONS
The INVERTEC® V155-S is not recommended for
pipe thawing.
(1)
Refer to Technical Specifications in the Installation Section for other ratings.
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INVERTEC® V155-S
B-3 B-3
AAV
CONTROLS AND OPERATIONAL
FEATURES
1. Output Current Knob: Potentiometer used to
set the output current used during welding, from 5A
to 155A.
THEORY OF OPERATION
If the Yellow LED illuminates, and the Red and Green
LEDʼs blink on and off alternately, the unit is unable to
cool itself adequately. Check to make sure the fan is
not obstructed and the fan is operating properly. Prior
to resuming normal operation, the unit must be turned
off and turned back on to reset this error condition.
2. Welding Mode Switch: With three positions, con-
trols the welding mode of the machine: two for Stick
welding (Soft and Crisp) and one for Lift TIG welding.
• Soft Stick: For a welding with a low spatter
presence.
• Crisp Stick: For an aggressive welding arc,
with an increased Arc stability.
• Lift TIG: When the mode switch is in the Lift
TIG position, the stick welding functions are disabled
and the machine is ready for Lift TIG welding. Lift
TIG is a method of starting a TIG weld by first pressing the TIG torch electrode on the work piece in
order to create a low current short circuit. Then, the
electrode is lifted from the work piece to start the TIG
arc.
3. Thermal LED: This indicator will turn on when
the machine is overheated and the output has been
disabled. This normally occurs when the duty cycle
of the machine has been exceeded. Leave the
machine on to allow the internal components to cool.
When the indicator turns off, normal operation is
again possible.
FIGURE B.1
4
1
2
WARNING
If blinking, the Thermal LED indicates that the input
voltage is out of ranges.
4. Power On/Off & OUTPUT LEDs: These LEDs (one
green and one red) operates as described in the
table below:
LED status FUNCTION
Green Red
ON OFF The machine is turned ON.
ON condition: The machine is at
idle (no-welding time) and OCV
is present.
OFF ON The machine is turned ON.
On condition: Presence of weld-
ing current at the output leads.
This permanent LED condition,
showed at idle (no-welding time), indicates machine damage.
OFF OFF The machine is turned OFF and/or the
input cord could be disconnected from
the mains.
ERROR condition: With the Power
Switch turned ON and the input cord
properly connected to a "live" main
supply, this LED condition indicates
machine damage.
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3
ON ON ERROR condition: This LED condition
1. Output Current Knob
5
2. Welding Mode Switch
3. Thermal LED
6
4. Power On/Off and Output LEDʼs
5. Positive Quick Disconnect
6. Negative Quick Disconnect
INVERTEC® V155-S
B-4 B-4
THEORY OF OPERATION
5. Positive Quick Disconnect: Positive output con-
nector for the welding circuit.
6. Negative Quick Disconnect: Negative output con-
nector for the welding circuit.
REAR CONTROL PANEL
(See Figure B.2)
7. Power Switch: It turns ON / OFF the input power
to the machine.
8. Input cable: This machine is provided with a
plugged input cord. Connect it to the mains.
9. Fan: This machine has a F.A.N. (Fan As Needed)
circuitry inside: the fan is automatically turned ON
or OFF. This feature reduces the amount of dirt
which can be drawn inside the machine and reduces
power consumption. The F.A.N. operates differently
in different weld mode.
• Stick mode: When the machine is turned ON the
fan will turn ON for a short time and then go off if a
weld is not started. The fan will continue to run whenever the machine is welding. The fan will turn OFF
five minutes after the welding is stopped.
AUTO ADAPTIVE ARC FORCE
(WITH STICK WELDING)
The Auto Adaptive Arc Force function is activated during stick welding. This function temporarily increases
the output current, to clear intermittent shorts between
the electrode and the weld puddle that may occur during stick welding.
This is an active control feature that guarantees the
best arrangement between the arc stability and spatter
presence. The feature "Auto Adaptive Arc Force" has
instead of a fixed or manual regulation, an automatic
and multilevel setting: its intensity depends by the output voltage and is controlled by the microprocessor on
the Control Board.
The circuit determines the amount of current necessary to release the metal droplet that is being transferred from the electrode to the workpiece to guarantee
the arc stability without going too high, to minimize the
spatter levels. That means:
• Electrode to workpiece sticking prevention, even at
low current values.
• Spatter reduction.
• TIG modes: When the machine is turned ON the
fan is OFF. The fan will turn ON only when a weld
is started and it will continue to run whenever the
machine is welding. The fan will turn OFF five minutes after the welding is stopped.
FIGURE B.2
8
7
9
The welding operations are simplified and the welded
joints look better, even if not brushed after the welding.
This feature is available in both the Soft Stick and Crisp
Stick operating modes. The Crisp Stick feature also
increases the Hot Start action, facilitating the arc striking.
The following features are also enabled in the stick
welding modes:
• Hot Start: This is a temporary increase in the initial
welding current. This helps ignite the arc
quickly and reliably.
• Anti-Sticking: This is a function that decreases the
output current of the machine to a low
level when the operator makes an
error and sticks the electrode to the
work piece. This decrease in current
allows the operator to remove the
electrode from the electrode holder
without creating large sparks that can
damage the electrode holder.
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INVERTEC® V155-S
C-1 C-1
Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .C-1
Factory Installed Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .C-2
Field Installed Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .C-2
Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .C-2
TABLE OF CONTENTS - ACCESSORIES SECTION
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INVERTEC® V155-S
C-2 C-2
OPTIONAL ACCESSORIES
ACCESSORIES
CABLE PLUGS
AND COMPATIBLE EQUIPMENT
K852-25 - Cable Plug Kit attaches to welding cable to
Factory Installed
provide quick disconnect from machine.
Electrical Holder and Cable Assembly
Work Cable and Clamp
Strap Packet
Instruction Manual
Field Installed
PTA-17V TIG Torch -
durable Tig Torch with integral gas valve for gas control
at the torch. The following 1-piece cable torches can be
used with a K960-2 adapter:
• K1782-6 (12.50 Ft.) 1-Piece Cable
• K1782-8 (25.0 Ft.) 1-Piece Cable
PTA-9FV TIG Torch - 125 Amp Gas Valve flexible
• K1781-7 (25.0 Ft.) 1-Piece Cable
PTA-17FV TIG Torch - 150 Amp Gas Valve flexible
150 Amp air-cooled compact and
head torch:
head torch:
TIG Torch Parts Kits - Parts kits are available for the
PTA-9FV and PTA-17 TIG torch. These kits include
back cap, collets, collet bodies, nozzles and tungstens.
Order KP508 for PTA-17 torches
Order KP507 for PTA-9 torches
See publication E12.150 for parts kits breakdown.
Cut Length Consumables - TIG welding filler metals
are available for welding stainless steel, mild steel, aluminum and copper alloys. See publication C9.10.
• K1782-11 (25.0 Ft.) 1-Piece Cable
• K1782-13 (12.5 Ft.) 1-Piece Ultra Flex Cable
K960-2-TIG Torch Adapter - for connection of PTA17V torches (1-piece cable) to power sources without
gas passing through the Twist Mate connection.
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INVERTEC® V155-S
D-1 D-1
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-1
Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-2
Routine Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-2
Thermal Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-2
TABLE OF CONTENTS - MAINTENANCE SECTION
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INVERTEC® V155-S
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