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

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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

• 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.

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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-

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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:

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

D-2 D-2

SAFETY PRECAUTIONS

MAINTENANCE

WARNING

ELECTRIC SHOCK can kill.

• Have an electrician install and service this equipment.

• Turn the input power off at the fuse box, disconnect supply lines and allow machine to sit for five minutes minimum to allow the power capacitors to discharge before working inside this equipment.

• Do not touch electrically hot parts.

----------------------------------------------------------------------

INPUT FILTER CAPACITOR DISCHARGE PROCEDURE

WARNING

For any maintenance or repair operations it is recommended to contact the nearest technical service center or Lincoln Electric. Maintenance or repairs performed by unauthorized service centers or personnel will null and void the manufacturers warranty.

WARNING

Do not open this machine and do not introduce anything into its openings. Power supply must be disconnected from the machine before each maintenance and service. After each repair, perform proper tests to ensure safety.

CAUTION

Power supply must be disconnected from the machine before each maintenance and service. Always use gloves in compliance with the safety standards.

THERMAL PROTECTION

The V155-S has a thermal,protective device (PTC) on the Output Rectifier to protect against excessive durty cycle. It also has an auto resetting fuse (ARFU) on the Input Board to protect against incorrect line voltage when connectecd to 120VAC. If either device opens, the Thermal LED on the front panel will turn ON. See the Operarion Section or the Troubleshooting Section of this manual for corrective action.

The machine has internal capacitors which are charged to a high voltage during power-on conditions. This voltage is dangerous and must be discharged before the machine can be serviced. Discharging is done automatically by the machine each time the power is switched off. However, you must allow the machine to sit for at least 5 minutes to allow time for the process to take place.

------------------------------------------------------------------------

ROUTINE MAINTENANCE

The frequency of the maintenance operations may vary in accordance with the working environment. Any noticeable damage should be reported immediately.

• Check cables and connections integrity. Replace, if necessary.

• Clean the power source inside by means of low pressure compressed air.

• Keep the machine clean. Use a soft dry cloth to clean the external case, especially the airflow inlet / outlet louvers.

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INVERTEC® V155-S

D-3 D-3

1

12

11

13

3

5

9

10

4

8

6

7

2

MAINTENANCE

MAJOR COMPONENT LOCATIONS

1. Front Panel

2. Right Case Side

3. Left Case Side

4. Rear Panel

5. Fan

6. Cable Clamp

7. Input Cable

8. ON\OFFSwitch

9. Input P.C. Board

10. Inverter P.C. Board

11. Control P.C. Board

12. Knob

13. Output Connector

14. Carrying Strap *

15. Nameplate *

16. Side Decal Set *

* Not in picture

FIGURE D.1 - MAJOR COMPONENT LOCATIONS

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INVERTEC® V155-S

D-4 D-4

NOTES

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INVERTEC® V155-S

E-1 E-1

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TABLE OF CONTENTS-THEORY OF OPERATION SECTION

Theory of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .E-1

General Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .E-2

Input Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .E-3

Main IGBT Inverter Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .E-4

Main Transformer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .E-4

Control Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .E-5

Insulated Gate Bipolar Transistor (IGBT) Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .E-6

Pulse Width Modulation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .E-7

Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC

FIGURE E.1 — BLOCK LOGIC DIAGRAM.

INVERTEC® V155-S

E-2 E-2

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THEORY OF OPERATION

FIGURE E.2 — GENERAL DESCRIPTION

Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC

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 excelent results.

Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC

NOTE: Unshaded areas of Block Logic

Diagram are the subject of discussion

INVERTEC® V155-S

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 currents. It is capable of 105 amps, 14.2 volts at 100% duty cycle. If the duty cycle is exceeded, a thermal protector will shut off the output until the machine cools. See Technical Specifications in A-1 for other rated outputs.

the INVERTEC® V155-S is recommended for stick welding with such popular electrodes as Fleetweld® 35, Fleetweld 37, Fleetweld 180 and Jet-LH 78MR. It features adjustable arc control to adjust the arc force and start.

LIMITATIONS

The INVERTEC® V155-S is not recommeded for pipe thawing.

E-3 E-3

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THEORY OF OPERATION

FIGURE E.3 — INPUT BOARD

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INPUT BOARD

The Input Board includes the following circuits:

- Automatic Reconnect Circuit: This circuit monitors

the input voltage and automatically reconnects the inverter and auxiliary connections to configure the machine for either 115V or 230V ac input voltage. The proper configuration is achieved through the use of board mounted relays. These relays and others that activate the Pre-charge circuitry and the fan circuit are controlled through signals from a micro-processor on the board.

- Switching Power Supply: Supplied by a board

mounted transformer, the switching power supply provides +15 vdc and +5vdc supplies for use on all of the PC Boards.

- Input Rectifier and Precharge Circuit: The Pre-

charge rectifier and current limiting resistors apply a small charge to the filter capacitors when the Power Switch is turned ON.

Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC

NOTE: Unshaded areas of Block Logic

Diagram are the subject of discussion

INVERTEC® V155-S

An improper input voltage would be recognized during this time and an input error sent to the Control Board. A signal from the Control Board would prevent further power-up to prevent damage to the Inverter Board.

- The re-connect relays then apply full power from the input line (AC1 and AC2) to the Input Rectifier and the capacitors are fully charged to approximately 325VDC. (See the Machine Diagram and PC Board Schematics for more information).

- Auto Reset Fuse: A self reseting fuse circuit (ARFU) on the Input Board helps to prevent damage to the machine from over-current when in 120VAC operation. When the fuse is open, the output will be disabled and the yellow Temperature LED on the front panel will be ON.

E-4 E-4

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THEORY OF OPERATION

FIGURE E.4 — MAIN INVERTER BOARD

Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC

MAIN INVERTER BOARD

The Inverter Board includes the following circuits:

- Inverter Circuit: Through the use of Insulated Gate

Bipolar Transistors (IGBTʼs) the high voltage (325VDC) input current is switched ON and OFF at a frequency of 80KHz and fed to the primary of the main transformer. The current is regulated via Pulse Width Modulation (PWM). The width of each pulse is determined by a ʻgateʼ signal from the Control Board. (See IGBT Operation and Pulse Width Modulation in this section).

- Main Transformer: The primary function of the main

Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC

transformer is to reduce the high voltge 80khz output to the proper voltage for welding. It also serves to insulate the operator from the input line. Additional windings of the transformer provide both piamary and secondary feeback signals to the PWM control circuit.

INVERTEC® V155-S

- Output Circuit: The output diodes and the output choke rectify and filter the current from the secondary of the main transformer to make it acceptable for welding. The shunt provides the necessary current feedback information to the Control Board.

Note: The shunt is shown off the board for clarity. It is

actually mounted on the Inverter Board.

E-5 E-5

CONTROL

BOARD

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THEORY OF OPERATION

FIGURE E.5 — CONTROL BOARD

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CONTROL BOARD

The Control Board receives status and analogue signals from the inverter board, input board and various sensors and feeds this information to the Weld Controller.

The Weld Controller is a micro-processor that uses these signals along with input from the Mode Switch and the Control Potentiometer to make decisions and change the machine mode and output to satisfy the requirements as decided by the operator. these changes are relayed to the PWM circuit on the Inverter Board to regulate the gate signals to the IGBT”s

Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC

INVERTEC® V155-S

The Weld Controler also responds to thermal and input errors to shut down the machine output. The error information is then displayed by the three LEDʼs on the front panel.

The Mode Switch , the Control Potentiometer and the three LEDʼs are all mounted on the Control Board.

E-6 E-6

DRAIN

S

OURCE

GATE

INJECTING LAYER

BUFFER LAYER

DRAIN DRIFT REGION

BODY REGION

p +

n +

n -

p

n + n +

D

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S

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G

ATE

INJECTING LAYER

BUFFER LAYER

DRAIN DRIFT REGION

BODY REGION

p +

n +

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p

n + n +

POSITIVE VOLTAGE A

PPLIED

B. ACTIVE

A. PASSIVE

THEORY OF OPERATION

FIGURE E.6 – IGBT OPERATION

INSULATED GATE BIPOLAR TRANSISTOR (IGBT) OPERATION

An IGBT is a type of transistor. IGBTs are semiconductors well suited for high frequency switching and high current applications.

Drawing A shows an IGBT in a passive mode. There is no gate signal, zero volts relative to the source, and therefore, no current flow. The drain terminal of the IGBT may be connected to a voltage supply; but since there is no conduction the circuit will not supply current to components connected to the source. The circuit is turned off like a light switch in the OFF position.

Drawing B shows the IGBT in an active mode. When the gate signal, a positive DC voltage relative to the source, is applied to the gate terminal of the IGBT, it is capable of conducting current. A voltage supply connected to the drain terminal will allow the IGBT to conduct and supply current to circuit components coupled to the source. Current will flow through the conducting IGBT to downstream components as long as the positive gate signal is present. This is similar to turning ON a light switch.

Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC

Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC

INVERTEC® V155-S

E-7 E-7

MINIMUM OUTPUT

MAXIMUM OUTPUT

31 33

m/sec

sec

31 33

m/sec

2

m/sec m/sec

THEORY OF OPERATION

Figure E-7

PULSE WIDTH MODULATION

The term PULSE WIDTH MODULATION is used to describe how much time is devoted to conduction in the cycle. Changing the pulse width is known as MODULATION. Pulse Width Modulation (PWM) is the varying of the pulse width over the allowed range of a cycle to affect the output of the machine.

MAXIMUM OUTPUT

By holding the gate signals on for 31 microseconds and allowing only 2 microseconds of off time during the 33 microsecond cycle, the output is maximized. The darkened area under the min. curve can be compared to the darkened area under the max. curve. The more darkened area, the more power is present.

MINIMUM OUTPUT

By controlling the duration of the gate signal, the IGBT is turned on and off for different durations during a cycle. The top drawing shows the minimum output signal possible over a 33-microsecond time period.

The shaded portion of the signal represents the IGBT, conducting for 2 microseconds. Since only 2 microseconds of the 33-microsecond time period is devoted to conducting, the output power is minimized.

Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC

Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC

INVERTEC® V155-S

E-8 E-8

NOTES

Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC

Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC

INVERTEC® V155-S

F-1 F-1

Troubleshooting and Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .F-1

TABLE OF CONTENTS - TROUBLESHOOTING & REPAIR

How to Use Troubleshooting Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .F-2

PC Board Troubleshooting Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .F-3

Troubleshooting Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .F-4

Case Cover Removal Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .F-7

Input Filter Capacitor Discharge Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .F-9

Input Board Resistance Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .F-13

Inverter Board Resistance Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .F-15

Input Board Voltage Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .F-19

Inverter Board Voltage Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .F-23

Input Board Removal and Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .F-25

Inverter Board Removal and Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .F-27

Control Board Removal and Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .F-31

Retest After Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .F-33

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INVERTEC® V155-S

F-2 F-2

TROUBLESHOOTING & REPAIR

HOW TO USE TROUBLESHOOTING GUIDE

WARNING

Service and Repair should only be performed by Lincoln Electric Factory Trained Personnel. Unauthorized repairs performed on this equipment may result in danger to the technician and machine operator and will invalidate your factory warranty. For your safety and to avoid Electrical Shock, please observe all safety notes and precautions detailed throughout this manual.

---------------------------------------------------------------------------------------------------------------------------

This Troubleshooting Guide is provided to help you locate and repair possible machine malfunctions. Simply follow the three-step procedure listed below.

Step 1. LOCATE PROBLEM (SYMPTOM).

Look under the column labeled “PROBLEM (SYMPTOMS)”. This column describes possible symptoms that the machine may exhibit. Find the listing that best describes the symptom that the machine is exhibiting. Symptoms are grouped into the following categories: output problems, function problems, wire feeding problems, and welding problems.

Step 2. PERFORM EXTERNAL TESTS.

The second column labeled “POSSIBLE AREAS OF MISADJUSTMENT(S)” lists the obvious external possibilities that may contribute to the machine symptom. Perform these tests/checks in the order listed. In general, these tests can be conducted without removing the case wrap-around cover.

Step 3. RECOMMENDED COURSE OF ACTION

The last column labeled “Recommended Course of Action” lists the most likely components that may have failed in your machine. It also specifies the appropriate test procedure to verify that the subject component is either good or bad. If there are a number of possible components, check the components in the order listed one possibility at a time until you locate the cause of your problem.

All of the referenced test procedures referred to in the Troubleshooting Guide are described in detail at the end of this chapter. Refer to the Troubleshooting and Repair Table of Contents to locate each specific Test Procedure. All of the specified test points, components, terminal strips, etc. can be found on the referenced electrical wiring diagrams and schematics. Refer to the Electrical Diagrams Section Table of Contents to locate the appropriate diagram.

to eliminate

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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.

-----------------------------------------------------------------------------------------------------------------------------------

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INVERTEC® V155-S

F-3 F-3

TROUBLESHOOTING & REPAIR

PC BOARD TROUBLESHOOTING PROCEDURES

WARNING

ELECTRIC SHOCK can kill.

•

Have an electrician install and service this equipment. Turn the input power OFF at the fuse box before working on equipment. Do not touch electrically hot parts.

CAUTION

Sometimes machine failures appear to be due to PC board failures. These problems can sometimes be traced to poor electrical connections. To avoid problems when troubleshooting and replacing PC boards, please use the following procedure:

1. Determine to the best of your technical ability that the PC board is the most likely component causing the failure symptom.

2. Check for loose connections at the PC board to a ssu r e t h at t he PC b o ard is p rop e rly connected.

3. If the problem persists, replace the suspect PC board using standard practices to avoid static electrical damage and electrical shock. Read the warning inside the static resistant bag and perform the following procedures:

PC board can be damaged by static electricity.

- Remo v e your b o dyʼs st atic charge before opening the staticshielding bag. Wear an anti-static wri s t s t r a p . F o r s a f e t y, use a 1 Meg ohm resistive cord connected

ATTENTION Static-Sensitive Devices Handle only at Static-Safe Workstations

to a gro u nde d p art of t h e equipment frame.

- If you donʼt have a wrist strap, touch an un-painte d, groun ded, part of the equipment frame. Keep touc h ing th e fr a me to preve n t stat i c b u ild- u p. B e s u re n ot t o touch any electrically live parts at the same time.

- Remove the PC board from the static-shielding bag and place it directly into the equipment. Donʼt set the PC board on or near paper, plastic or cloth which could have a static charge. If the PC board canʼt be installed immediately, put it back in the static-shielding bag.

- If the PC board uses protective shorting jumpers, donʼt remove them until installation is complete.

- If you return a PC board to The Lincoln Electric Company for credit, it must be in the static-shielding bag. This will prevent further damage and allow proper failure analysis.

4. Test the machine to determine if the f ailure

symp t om has be e n corr e cted b y t he replacement PC board.

NOTE: It is desirable to have a spare (known good) PC board available for PC board troubleshooting.

NOTE: Allow the machine to heat up so that all electrica l compon ents can reach their opera ting temperature.

5. Re m ove t h e re p lace ment P C bo a rd a n d

subs t itu t e it w ith t he o r igi n al P C boa r d to recreate the original problem.

a. If the original problem does not reappear by

substituting the original board, then the PC board was not the problem. Continue to look fo r bad conne ctions in t he control wiring harness, junction blocks, and terminal strips.

b. If the original problem is recreated by the

substitution of the original board, then the PC boar d w a s t he prob l em. Rei n stal l t h e replacement PC board and test the machine.

6. Al w ays ind i cate tha t t his pro c edur e w a s

foll o wed whe n w a rran t y r epo r ts a re to be submitted.

NOTE: Following this procedure and writing on the warranty report, “INSTALLED AND SWITCHED PC BOARDS TO VERIFY PROBLEM,” will help avoid denial of legitimate PC board warranty claims.

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- Tools which come in contact with the PC board must be either conductive, anti-static or static-dissipative.

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INVERTEC® V155-S

F-4 F-4

Observe Safety Guidelines detailed in the beginning of this manual.

THEORY OF OPERATION

PROBLEMS

(SYMPTOMS)

The line circuit breaker trips when power switch is “ON”

The machine is dead, no output, no fan

POSSIBLE AREAS OF

MISADJUSTMENT(S)

OUTPUT PROBLEMS

1. Input power Bridge is shorted.

2. Failed Electrolytic Capacitors.

3. Failed Inverter IGBTʼs.

1. No input power on line.

2. Line Switch failure.

3. Defective Input Board.

4. Defective Inverter Board

RECOMMENDED

COURSE OF ACTION

1. Perform the Input Board Resistance Test.

2. Perform the Inverter Board Resistance Test.

1. Restore correct Input power

2. Replace Line switch.

3. Perform Input Board Voltage

Test.

4. Perform Inverter Board Voltage Test.

The GREEN LED is “ON” but there is no output And yellow thermal overload LED is “ON”

The YELLOW LED is “ON” and the RED and GREEN LEDʼs blink alternately

1. Thermal Protection has tripped.

2. Logic Circuit Error on Control Board.

3. ARFU System Damage on the Input Board

1. The machine is unable to cool

itself.

1. Check Fan and Thermal Protection Circuits.

2. Perform Input Board

Resistance and Input Board Voltage Tests

3. The Control Board may be faulty. Replace.

1. Turn the Power Switch OFF and wait several minutes for the machine to cool. Turn the Power Switch back ON and check for proper fan operation.

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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.

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INVERTEC® V155-S

F-5 F-5

Observe Safety Guidelines detailed in the beginning of this manual.

THEORY OF OPERATION

PROBLEMS

(SYMPTOMS)

RED and GREEN LEDʼs are always “ON”

The machine welds but there is no output control

The machine does not have maximum output

POSSIBLE AREAS OF

MISADJUSTMENT(S)

OUTPUT PROBLEMS

1. Control Board failure.

1. Potentiometer failure.

2. The Shunt screw connections are bad.

3. Inverter Board failure.

1. Loose connections on output secondary leads.

RECOMMENDED

COURSE OF ACTION

1. Check all PC Board Connections.

2. Replace Control Board.

1. Potentiometer or Control Board needs Replaced.

2. Tighten and check all shunt connections.

3. Perform Inverter Board Voltage Test.

1. Check all secondary connections.

2. The Control Board is out of Calibration.

2. Recalibrate the Control Board. Replace if needed.

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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.

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INVERTEC® V155-S

F-6 F-6

Observe Safety Guidelines detailed in the beginning of this manual.

THEORY OF OPERATION

PROBLEMS

(SYMPTOMS)

The machine has high welding output and no control

RED LED stays ON continuously

Flashing YELLOW LED

POSSIBLE AREAS OF

MISADJUSTMENT(S)

OUTPUT PROBLEMS

1. Potentiometer failure.

2. Control Board failure.

1. Shunt Cable damaged.

2. Control Board defective.

1. Input Supply Voltage out of tolerance.

RECOMMENDED

COURSE OF ACTION

1. Replace Potentiometer.

2. Replace Control Board.

1. Check connection of white, red and black leads on the Inverter Board

2. Replace Shunt Cable Assembly.

3. Replace Conrol Board.

1. Supply correct Input Voltage.

2. Check Control Board conections.

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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.

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INVERTEC® V155-S

F-7 F-7

TROUBLESHOOTING & REPAIR

CASE COVER REMOVAL PROCEDURE

WARNING

Service and repair should be performed by only Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty. For your safety and to avoid electrical shock, please observe all safety notes and precautions detailed throughout this manual.

If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call 1-888-935-3877.

TEST DESCRIPTION

This procedure will aid the technician in the removal and replacement of the case cover(s).

MATERIALS NEEDED

8” Magnetized #2 Phillips Head Screwdriver or Socket with Magnetized 6 inch Extension and #2 Phillips Tip

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INVERTEC® V155-S

I

N

V

E

R

T

E

C

V

1

5

Five Screws

I

n

v

e

t

e

r

B

o

a

r

d

Three Screws

Ground

F-8 F-8

TROUBLESHOOTING & REPAIR

CASE COVER REMOVAL PROCEDURE (CONTINUED)

FIGURE F.1 – CASE COVER SCREW LOCATIONS

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PROCEDURE

1. Disconnect power to the INVERTEC® V155-S.

2. Using a phillips head screwdriver remove the five screws securing the case cover sides together. See Figure F.1.

Note: The two bottom screws are machine screws that

thread into nuts. The nuts will fall out of the right side.

3. Carefully remove the left side case cover from the machine.

Note: Be careful. The case back and fan will be loose

when the cover is removed.

4. Perform the Input Capacitor Discharge Procedure

steps 3 thru 7.

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5. Using a phillips screwdriver, remove the three screws securing the Inverter board to the right side case cover.

Note: These screws can only be accessed from the

inside of the machine and only after the left side case cover has been removed. It may be necessary to cut the plastic tie that secures the Input power cord to the top bracket

6. Note placement of ground lead secured by lower front phillips screw on inverter board for re-assembly.

7. Remove case back and fan. Lay unit on the left side and remove the right side cover.

INVERTEC® V155-S

F-9 F-9

TROUBLESHOOTING & REPAIR

INPUT FILTER CAPACITOR DISCHARGE PROCEDURE

WARNING

Service and repair should be performed by only Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty. For your safety and to avoid electrical shock, please observe all safety notes and precautions detailed throughout this manual.

If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call 1-888-935-3877.

TEST DESCRIPTION

This procedure will drain off any charge stored in the four capacitors that are part of the Inverter Board assembly. This procedure MUST be performed, as a safety precaution, before conducting any test or repair procedure that requires you to touch internal components of the machine.

MATERIALS NEEDED

Phillips Head Screwdriver High Resistance and High Wattage Resistor (25-1000 ohms and 25 watts minimum) Insulated Gloves Insulated Pliers

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INVERTEC® V155-S

DC+

DC-

I

N

P

U

T

B

O

A

R

D

CAPACITOR TERMINALS (4 places)

F-10 F-10

INSULATED

PLIERS

INSULATED

GLOVES

RESISTOR

TROUBLESHOOTING & REPAIR

INPUT FILTER CAPACITOR DISCHARGE PROCEDURE (CONTINUED)

FIGURE F.2 – CAPACITOR DISCHARGE LOCATIONS

WARNING

ELECTRIC SHOCK can kill.

• Have an electrician install and service this equipment.

• Turn the input power off at the fuse box before working on equipment.

• Do not touch electrically hot parts.

• Prior to performing preventative maintenance, perform the following capacitor discharge procedure to avoid electric shock.

PROCEDURE

1. Disconnect power to the INVERTEC® V155-S.

2. Perform the Case Cover Removal Procedure,

steps 1 thru 3.

3. Locate the Input Board.

FIGURE F.3 – GLOVE, PLIERS & REISISTOR

4. Obtain a high resistance and high wattage resistor (25-1000 ohms and 25 watts minimum). This resistor is NOT supplied with the machine. NEVER USE A SHORTING STRAP FOR THIS PROCEDURE.

5. Locate the two terminals DC+ and DC- on the Input Board. See Figure F.2.

6. Use electrically insulated gloves and insulated pliers. Hold the body of the resistor and connect the resistor leads across the two terminals. Hold the resistor in place for 10 seconds. DO NOT TOUCH CAPACITOR TERMINALS WITH YOUR BARE HANDS. See Figure F.3.

7. Check the voltage across the terminals of all capacitors with a DC voltmeter. Voltage should be zero. If any voltage remains, repeat this capacitor discharge procedure.

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INVERTEC® V155-S

F-11 F-11

INVERTER BOARD

Red

Black

TROUBLESHOOTING & REPAIR

INPUT FILTER CAPACITOR DISCHARGE PROCEDURE (CONTINUED)

FIGURE F.4 – CAPACITOR DISCHARGE LOCATIONS

8. Remove the right side cover per Case Cover Removal Procedure steps 5 thru 7.

9. Use electrically insulated gloves and insulated pliers. Hold the body of the resistor and connect the resistor leads across the two terminals where the RED and BLACK leads are connected. Hold the resistor in place for 10 seconds. DO NOT TOUCH CAPACITOR TERMINALS WITH YOUR BARE HANDS. See Figures F.3 and F.4

10. Check the voltage across the terminals with a DC

voltmeter. Voltage should be zero. If any voltage remains, repeat this capacitor discharge procedure.

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INVERTEC® V155-S

F-12 F-12

NOTES

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INVERTEC® V155-S

F-13 F-13

TROUBLESHOOTING & REPAIR

INPUT BOARD RESISTANCE TEST

WARNING

Service and repair should be performed by only Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty. For your safety and to avoid electrical shock, please observe all safety notes and precautions detailed throughout this manual.

If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call 1-888-935-3877.

TEST DESCRIPTION

This procedure will determine if the Input Board has any copper wires burned or any faulty components.

MATERIALS NEEDED

Volt/Ohmmeter Wiring Diagram W05X0701 Phillips Screwdriver

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INVERTEC® V155-S

DC+

D

C

-

INPUT

BO

ARD

D

1

In

p

u

t R

e

c

ti

fi

e

r

R4

R2

~

+

–

F-14 F-14

TROUBLESHOOTING & REPAIR

INPUT BOARD RESISTANCE TEST (CONTINUED)

FIGURE F.5 – INPUT BOARD TEST POINTS

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PROCEDURE

1. Disconnect power to the INVERTEC® V155-S.

2. Perform the Case Cover Removal Procedure.

3. Perform the Input Filter Capacitor Discharge

Procedure.

4. Visually check for burned areas ont The Input Board (solder side).

5. Disconnect the Blachk lead from the DC- terminal.

6. Check the Input Rectifier Bridge “D1”.

7. Check start resistors “R2” and “R4”. Each should

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read 20 Ohms. See Figure F.5.

INVERTEC® V155-S

F-15 F-15

TROUBLESHOOTING & REPAIR

INVERTER BOARD RESISTANCE TEST

WARNING

Service and repair should be performed by only Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty. For your safety and to avoid electrical shock, please observe all safety notes and precautions detailed throughout this manual.

If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call 1-888-935-3877.

TEST DESCRIPTION

This procedure will determine if the Inverter Board has any “shorted” or “leaky” power diodes or Insulated Gate Bipolar Transistors.

MATERIALS NEEDED

Digital Volt/Ohmmeter Wiring Diagram X0519 Phillips Screwdriver 4mm Nutdriver

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INVERTEC® V155-S

I

NVERTER BOARD

IGBT C

hannel A

IGBT channel B

Emitter

Gate

C

ollector

Channel A

Collector Channel B

Emitter

Gate

F-16 F-16

TROUBLESHOOTING & REPAIR

INVERTER BOARD RESISTANCE TEST (CONTINUED)

FIGURE F.6 – INVERTER BOARD TEST POINTS

PROCEDURE

1. Disconnect power to the INVERTEC® V155-S.

2. Perform the Case Cover Removal Procedure.

3. Perform the Input Filter Capacitor Discharge

4. Visually check for burned areas on both sides of the

Note: The following tests may be performed without

5. Check the IGBTʼs for “shorts” using the

Note: Normal value is approximately 0.40 VDC in one

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Procedure

Inverter Board. If no obvious damage is evident, continue to Step 5.

dis-connecting the Board

volt/ohmmeter in the diode test position, check each IGBT from emitter to collector. See Figure F.6.

polarity and a charging value in the opposite polarity.

INVERTEC® V155-S

The IGBTʼs of each channel are connected in parallel so it is only necessary to check one Emitter to Collector of each channel.

6. Check each device from gate to emitter. See Figure F.6

Note: Normal value is approximately .5VDC in both

polarities.

Note: Actual readings will vary depending on the meter

being used. Similar tests on all devices should give similar results.

These devices will usually fail “shorted” resulting in a zero or very low resistance reading from Emitter to Collector. If they “open” physical damage should be evident.

INVERTER BOARD

D9

Collector Channel B

D7

D3

Output Terminals

Point 2

Point 1 (center leg)

R24 = PTC

(solder pad)

Collector Channel A

Red

Black

F-17 F-17

TROUBLESHOOTING & REPAIR

INVERTER BOARD RESISTANCE TEST (CONTINUED)

FIGURE F.7 – INVERTER BOARD TEST POINTS

7. Check the diodes D3 and D9 for “shorts” or “opens”.

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See Figure F.7.

8. Check diode D7, but remember, some resistance (approx. 27-28 ohms) will be read in both polarities. This will occur because D7 is a snubber diode and is connected in parallel to the snubber resistors R8, R9 and R10. See wiring diagram X0519. See Figure F.7.

9. Check the five output diodes for “shorts” or “opens”. Check from the center terminal (Point 1) of each Diode (all center terminals of the diodes are common with the heatsink) to the large copperl area “point 2”. See Figure F.7.

Note: Actual voltage readings will vary depending on

the meter being used. Similar tests on all devices should give similar results

INVERTEC® V155-S

10. Check the resistance between the thermal protection terminals R24. It should be about 36-40 ohms. See Figure F.7.

11. Check the resistance between output terminal con-

nections. It should be about 8.5Kohms.

F-18 F-18

NOTES

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INVERTEC® V155-S

F-19 F-19

TROUBLESHOOTING & REPAIR

INPUT BOARD VOLTAGE TEST

WARNING

Service and repair should be performed by only Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty. For your safety and to avoid electrical shock, please observe all safety notes and precautions detailed throughout this manual.

If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call 1-888-935-3877.

TEST DESCRIPTION

This test will help determine if the correct input voltage is being applied to the Input Board and will also determine if the correct voltages are being processed on the Input Board.

MATERIALS NEEDED

Volt/Ohmmeter Wiring Diagram Phillips Screwdriver

• 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.

WARNING

ELECTRIC SHOCK can kill.

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INVERTEC® V155-S

DC+

DC-

I

NPUT BOARD

AC2

AC1

JP1

PIN 2

PIN 1

PIN 3

PIN 4

PIN 8

PIN 12

PIN 14

F-20 F-20

TROUBLESHOOTING & REPAIR

INPUT BOARD VOLTAGE TEST (CONTINUED)

FIGURE F.8 – INPUT BOARD TEST POINTS

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PROCEDURE

1. Disconnect power to the INVERTEC® V155-S.

2. Perform the Case Cover Removal Procedure (left

side only).

3. Connect the main 230VAC to the the machine and switch ON the input switch.

Note: Pay attention to wiring diagram very closely.

When connecting cables from the Input Board to the Power Switch. You must connect the cables as shown in Figure F.9.

PWR 2(white) to 4 PWR 1(blue) to 1

PWR 4(white) to 5 PWR 3(blue) to 2

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4. Using a multimeter, check for 230VAC between AC1 and AC2. See Figure F.8.

5. Check for 320-325VDC between DC+ and DC-

6. Using pin 8,9,15 or 16 of JP1 as a common (-) point:

Check pin 2,4 and 14 for +15VDC.

Check pin 12 for +5VDC.

INVERTEC® V155-S

White from PWR 2

White from PWR4

Blue from PWR 1

Blue from PWR 3

3

1

2

6

4

5

F-21 F-21

TROUBLESHOOTING & REPAIR

INPUT BOARD VOLTAGE TEST (CONTINUED)

FIGURE F.9 – MAIN SWITCH PLUG LOCATION

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1. Put the blue wire from PWR3 in position 2 of the main switch while the white wire from PWR4 in position 5.

2. Put the blue wire from PWR1 in position 1 of the main switch while the white wire from PWR2 in position 4.

INVERTEC® V155-S

F-22 F-22

NOTES

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INVERTEC® V155-S

F-23 F-23

TROUBLESHOOTING & REPAIR

INVERTER BOARD VOLTAGE TEST

WARNING

Service and repair should be performed by only Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty. For your safety and to avoid electrical shock, please observe all safety notes and precautions detailed throughout this manual.

If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call 1-888-935-3877.

TEST DESCRIPTION

This test will help determine if the main inverter board is receiving the correct input voltages and if the correct regulated voltages are being processed and maintained by the main inverter board.

MATERIALS NEEDED

Volt/Ohmmeter Wiring Diagram X0701 and X0519 Phillips Screwdriver

• 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.

WARNING

ELECTRIC SHOCK can kill.

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INVERTEC® V155-S

DC+

DC-

INPUT BOARD

AC2

AC1

JP1

PIN 2

PIN 1

15 1

3 11 9

7 5 3

16 1

4 12 10

8 6 4

F-24 F-24

TROUBLESHOOTING & REPAIR

INVERTER BOARD VOLTAGE TEST (CONTINUED)

FIGURE F.10 – PLUG JP1 TESTPOINTS

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NOTE: DUE TO SAFETY REASONS AND THE PHYS-

ICAL LOCATION OF THE INVERTER, IT IS NOT EASY TO PERFORM THE VOLTAGE TEST AT THE INVERTER BOARD. CHECKS CAN BE DONE AT THE INPUT BOARD CONNECTOR JP1. See Fig. F.10.

PROCEDURE

1. Disconnect power to the INVERTEC® V155-S.

2. Perform the Case Cover Removal Procedure (left

side only).

3. Connect the main 230VAC to the machine and switch ON the input switch.

4. Set the machine to STICK mode.

5. Locate the JP1 connector points. See figure F.10.

6. Using pins 8,9,16 or 15 as a common (-) ground:

Check pin 1-> +15VDC means fan is ON. 0VDC means fan is OFF.

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INVERTEC® V155-S

Check pin 3-> 0VDC during OCV condition.

Check pin 5-> +11.6VDC means the inverter is ON (the first 5 minutes after activity) while 1.5VDC means the inverter is OFF.

Check pin 6-> value changes from 7.6 to 8.5VDC during reading when the inverter is ON. 50-60 mVDC when the inverter is OFF.

Check pin 7-> +15VDC.

Check pin 11-> +5VDC.

Check pin 12-> +5VDC (supply voltage generated on input board).

Check pin 14-> +15VDC (supply voltage generated on input board).

7. Check to see if the correct microcontroller program is preset: H490000005-004X where X is the revision number.

F-25 F-25

TROUBLESHOOTING & REPAIR

INPUT BOARD REMOVAL AND REPLACEMENT PROCEDURE

WARNING

Service and repair should be performed by only Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty. For your safety and to avoid electrical shock, please observe all safety notes and precautions detailed throughout this manual.

If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call 1-888-935-3877.

TEST DESCRIPTION

This procedure will aid the technician in the removal and replacement of the Input Board.

MATERIALS NEEDED

Phillips Screwdriver 7mm Nutdriver

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INVERTEC® V155-S

DC+

DC-

INPUT BOARD

AC2

AC

1

MOUNTING SCREWS

F-26 F-26

TROUBLESHOOTING & REPAIR

INPUT BOARD REMOVAL AND REPLACEMENT PROCEDURE

FIGURE F.11 – SCREW AND LEAD LOCATION

PROCEDURE

1. Disconnect power to the INVERTEC® V155-S.

2. Perform the Case Cover Removal Procedure

(Left side only).

3. Perform the Input Filter Capacitor Discharge Procedure.

4. Label and disconnect the four leads at the Power Switch located on the case back.

5. Using a 7mm nutdriver, remove the four input board mounting screws. This will allow the board to be gently pulled forward to gain access to associated leads and plugs. See Figure F.11.

.

6. Label and remove all associated leads and plugs. Some leads will require a 7mm nutdriver for removal

7. Remove and replace the Input board.

8. Connect all leads and plugs previosly removed

9. Replace the four mounting screws previously removed.

10. Replace the case cover.

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INVERTEC® V155-S

F-27 F-27

TROUBLESHOOTING & REPAIR

INVERTER BOARD REMOVAL AND REPLACEMENT PROCEDURE

WARNING

Service and repair should be performed by only Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty. For your safety and to avoid electrical shock, please observe all safety notes and precautions detailed throughout this manual.

If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call 1-888-935-3877.

TEST DESCRIPTION

This procedure will aid the technician in the removal and replacement of the Inverter Board.

MATERIALS NEEDED

Phillips Screwdriver 7mm Nutdriver 10mm Nutdriver Socket extension (6” minimum)

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INVERTEC® V155-S

I

N

V

E

R

T

E

C

V

1

5

Five Screws

I

n

v

e

t

e

r

B

o

a

r

d

Three Screws

Ground

F-28 F-28

TROUBLESHOOTING & REPAIR

INVERTER BOARD REMOVAL AND REPLACEMENT PROCEDURE (CONTINUED)

FIGURE F.12 – DOOR REMOVAL

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PROCEDURE

1. Disconnect power to the INVERTEC® V155-S.

2. Perform the Case Cover Removal Procedure.

3. Perform the Input Filter Capacitor Discharge

Procedure.

4. Perform the Input Board Removal Procedure.

5. Using phillips screwdriver, remove the three screws mounting the inverter board to the right side case cover. These screws can only be seen/accesed through the left side of the machine with the left side case cover removed. See Figure F.12.

6. Note location of ground lead upon removal of lower right phillips screw.

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Note: Pay attention to wiring diagram very closely.

When connecting cables from the Input Board to the Power Switch. You must connect the cables as shown in Figure F.9.

INVERTEC® V155-S

PWR 2(white) to 4 PWR 1(blue) to 1

PWR 4(white) to 5 PWR 3(blue) to 2

OUTPUT TERMINALS

10MM BOLTS

DC-

DC+

F-29 F-29

TROUBLESHOOTING & REPAIR

INVERTER BOARD REMOVAL AND REPLACEMENT PROCEDURE (CONTINUED)

FIGURE F.13 – INVERTER BOARD REMOVAL

7. Using a 10mm nutdriver with extension, remove the two bolts mounting the inverter board to the positive (+) and negative (-) leads that connect to the output terminals on the front ot the macine. See Figure F.13

Note: One 10mm mounting bolt can be accessed from

the soldered side of the inverter board. The other bolt must be accessed from the left side of the machine using the socket extension. Note washer placement for reassembly,

8. Label and disconnect any associated plugs and leads.

9. Remove the inverter board.

10. Connect JP 1 connector and make sure that the upper front corner of the board is in the locator slot of the front panel.

11. Be sure that the white lead is re-connected to the

Positive Input terminal.

12. Re-connect the red and black leads to the DC+ and DC- points on the Inverter Board.

13. Re-install the Inverter to the case, making sure the ground lead is re-connected to the lower front corner.

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INVERTEC® V155-S

F-30 F-30

NOTES

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INVERTEC® V155-S

F-31 F-31

TROUBLESHOOTING & REPAIR

CONTROL BOARD REMOVAL AND REPLACEMENT PROCEDURE

WARNING

Service and repair should be performed by only Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty. For your safety and to avoid electrical shock, please observe all safety notes and precautions detailed throughout this manual.

If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call 1-888-935-3877.

TEST DESCRIPTION

This procedure will aid the technician in the removal and replacement of the Control Board.

MATERIALS NEEDED

Phillips Screwdriver Metric Nut Drivers Socket extension (6” minimum)

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INVERTEC® V155-S

CONTROL BOARD

MOUNTING SCREWS

RED CAP

KNOB

WASHER

NUT

F-32 F-32

TROUBLESHOOTING & REPAIR

CONTROL BOARD REMOVAL AND REPLACEMENT PROCEDURE (CONTINUED)

FIGURE F.14 CONTROL BOARD REMOVAL

PROCEDURE

1. Disconnect power to the INVERTEC® V155-S.

2. Perform the Case Cover Removal Procedure (left

side only).

3. Perform the Input Filter Capacitor Discharge Procedure.

4. Perform the Input Board Removal Procedure.

5. Perform the Inverter Board Removal Procedure.

6. Using a thin knife blade, remove the red plastic on the end of the output knob, See Figure F.14.

7. Using a 6mm nutdriver, remove the outpout knob mounting nut and washer located behind the red plastic cap previously removed. See Figure F.14.

8. Disconnect the JP1 connector.

9. Using a phillips screwdriver, remove the four mount-

10. Disconnect the JP2 connector.

11. Remove and replace the control board.

Note: When installing the new control board, be sure

ing screws located on the corners of the solder side of the control board.

to turn the output potentiometer shaft completely counter clockwise prior to fastening knob into place. This will assure that the output setting is at itʼs lowest setting. This will allow proper install ation of the output knob with the red arrow pointing to the lowest setting possible. If this is not done properly, the machine output will not match the set current.

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INVERTEC® V155-S

F-33 F-33

TROUBLESHOOTING & REPAIR

RETEST AFTER REPAIR

Should a machine under test be rejected for any reason requiring the removal of any mechanical part that could affect the machineʼs electrical characteristics, or if any electrical components are repaired or replaced, the machine must be retested.

INPUT- SINGLE PHASE ONLY

Input Volts 50/60-HertzMax. Input Current at Rated Output Input Power at Rated Output

100% 30% 120VAC +/- 10% 34 A 2kw 3kw 230VAC +/- 10% 33 A 2kw 3kw

RATED OUTPUT

Duty Cycle Output Amps Output Volts Input Circuit

75A (stick) 105A (TIG)

23.0 Vdc

14.2 Vdc

100%

100A (stick) 100A (TIG)

100A (stick) 130A (TIG)

24.0 Vdc

14.0 Vdc

24.0 Vdc

15.2 Vdc

30%

145A (stick) 155A (TIG)

25.8 Vdc

16.2 Vdc

OUTPUT

Output Current Range Type of OutputMaximum Open Circuit Voltage

5-155 Amps

RECOMMENDED METERS FOR MACHINE OUTPUT TESTS

VOLTMETER: AC and DC True RMS Meter - Fluke 8922A or equivalent

AMMETER: Columbia Type AX AC or DC Tong Ammeter

75 Volts Max.

120 Vac

230 Vac

120 Vac

230 Vac

DC

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IMPORTANT: IF OTHER TYPE METERS ARE USED RESULTS MAY NOT BE ACCURATE.

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INVERTEC® V155-S

F-34 F-34

NOTES

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INVERTEC® V155-S

G-1 G-1

Electrical Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .G-1

Wiring Diagram (W07X071) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .G-2

Schematic - Complete Machine (X0931) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .G-3

Schematic - Input Board (X0791) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .G-4

PC Board Assembly - Input Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .G-5

Schematic - Inverter Board (X0519 - Sheet 1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .G-6

Schematic - Inverter Board (X0519 - Sheet 2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .G-7

PC Board Assembly - Inverter Board - Sheet 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .G-8

PC Board Assembly - Inverter Board - Sheet 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .G-9

TABLE OF CONTENTS - DIAGRAM SECTION

Schematic - Control Board (W05X0708) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .G-10

PC Board Assembly - Control Board - Sheet 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .G-11

PC Board Assembly - Control Board - Sheet 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .G-12

* NOTE: Many PC Board Assemblies are now totally encapsulated, surface mounted and or multi-layered

and are therefore considered to be unserviceable. Assembly drawings of these boards are no longer provided.

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INVERTEC® V155-S

G-2 WIRING DIAGRAM - CODES 11326 & 11327

ELECTRICAL DIAGRAMS

G-2

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NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual. The wiring diagram specific to your code is pasted inside one of the enclosure panels of your machine.

INVERTEC® V155-S

Power Up

On

–

with

i

de-energizedfor a 230Vac

windings

control output turning on full

them

G-3 SCHEMATIC - COMPLETE MACHINE - CODES 11326 & 11327

ELECTRICAL DIAGRAMS

G-3

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NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual.

INVERTEC® V155-S

SCHEMATIC - INPUT PC BOARD

RL_AUX

RL_PRE

RESET

RL_PAR

RL_AUX

IRQ

RL_PRE

INPUT_ERR

RL_PARRL_PARRL_PAR

RL_SER

VIN2

RL_SERRL_SERRL_SERRL_SERRL_SERRL_SERRL_SERRL_SERRL_SERRL_SERRL_SERRL_SER

V++

AD1

V++V++V++V++V++V++V++V++V ++V++V++V++V++V++V++V++V ++V++V++V++V++V++V++V++V++V ++V++V++V ++V++V++V++V++V++V++V++V ++V++V++V++V++V++V++V++V ++V++V++V++

+15V

V_FB DUTY

GND

+5V

GND

Fan_ONn

+15V

Fan_ONnFan_ONnFan_ONn

PRES

GND

Passive Detect

INPUT_ERR

+5V

SET_PASSIVE

VIN1VIN1VIN1VIN1VIN1VIN1V IN1VIN1VIN1VIN1V IN1VIN1VIN1V IN1VIN1VIN1VIN1VIN1VIN1VIN1V IN1VIN1VIN1VIN1VIN1VIN1VIN1V IN1VIN1VIN1VIN1VIN1VIN1VIN1V IN1VIN1VIN1VIN1VIN1VIN1VIN1V IN1VIN1VIN1VIN1VIN1VIN1VIN1V IN1VIN1VIN1VIN1VIN1VIN1VIN1V IN1VIN1VIN1VIN1VIN1VIN1VIN1V IN1VIN1VIN1VIN1VIN1VIN1VIN1VIN1V IN1VIN1VIN1V IN1VIN1VIN1VIN1VIN1VIN1VIN1V IN1VIN1VIN1VIN1VIN1VIN1VIN1V IN1VIN1VIN1VIN1VIN1VIN1VIN1V IN1VIN1VIN1VIN1VIN1VIN1VIN1V IN1VIN1VIN1VIN1VIN1VIN1VIN1V IN1VIN1VIN1VIN1VIN1VIN1VIN1V IN1VIN1VIN1VIN1VIN1VIN1VIN1VIN1V IN1VIN1VIN1

ELECTRICAL DIAGRAMS

G-4

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INVERTEC® V155-S

Lincoln Electric V155-S User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual

SAFETY

The line circuit breaker trips when power switch is “ON”

The machine is dead, no output, no fan

The GREEN LED is “ON” but there is no output And yellow thermal overload LED is “ON”

The machine welds but there is no output control

The machine does not have maximum output

The machine has high welding output and no control

RED LED stays ON continuously

Flashing YELLOW LED