Lincoln-electric V155-S User Manual

INVERTEC®V155-SSVM183-AJuly, 2008For use with machines having Code Numbers: 11326; 11327SERVICE MANUALReturn to Master TOC Return to Master TOC Return

INSTALLATIONA-2 A-2INVERTEC® V155-SReturn to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn to Master TOC Return

INSTALLATIONA-3 A-3INVERTEC® V155-SReturn to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn to Master TOC Return

INSTALLATIONA-4 A-4INVERTEC® V155-SReturn to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn to Master TOC Return

INSTALLATIONA-5 A-5INVERTEC® V155-SReturn to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn to Master TOC Return

INSTALLATIONA-6 A-6INVERTEC® V155-SReturn to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn to Master TOC Return

TABLE OF CONTENTS - OPERATION SECTIONB-1 B-1Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOCINVERTEC® V155-SOperati

THEORY OF OPERATIONB-2 B-2INVERTEC® V155-SReturn to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn to Master TOC

THEORY OF OPERATIONB-3 B-3INVERTEC® V155-SReturn to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn to Master TOC

THEORY OF OPERATIONB-4 B-4INVERTEC® V155-SReturn to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn to Master TOC

TABLE OF CONTENTS - ACCESSORIES SECTIONC-1 C-1Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOCINVERTEC® V155-SAcces

SAFETYi iReturn to Master TOC Return to Master TOC Return to Master TOC Return to Master TOCFOR ENGINEpowered equipment.1.a. Turn the engine off befor

ACCESSORIESC-2 C-2INVERTEC® V155-SReturn to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn to Master TOC Return t

TABLE OF CONTENTS - MAINTENANCE SECTIOND-1 D-1Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOCINVERTEC® V155-SMaint

MAINTENANCED-2 D-2INVERTEC® V155-SReturn to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn to Master TOC Return t

MAINTENANCED-3 D-3INVERTEC® V155-SReturn to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn to Master TOC Return t

Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn to Master TOC Return to Master TOC Return to Master TOC

TABLE OF CONTENTS-THEORY OF OPERATION SECTIONE-1 E-1Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOCINVERTEC® V155-

THEORY OF OPERATIONE-2 E-2INVERTEC® V155-SReturn to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn to Master TOC

THEORY OF OPERATIONE-3 E-3INVERTEC® V155-SReturn to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn to Master TOC

THEORY OF OPERATIONE-4 E-4INVERTEC® V155-SReturn to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn to Master TOC

THEORY OF OPERATIONE-5 E-5INVERTEC® V155-SReturn to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn to Master TOC

SAFETYii iiReturn to Master TOC Return to Master TOC Return to Master TOC Return to Master TOCFUMES AND GASEScan be dangerous.5.a. Welding may produce

THEORY OF OPERATIONE-6 E-6INVERTEC® V155-SReturn to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn to Master TOC

THEORY OF OPERATIONE-7 E-7INVERTEC® V155-SReturn to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn to Master TOC

Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn to Master TOC Return to Master TOC Return to Master TOC

TABLE OF CONTENTS - TROUBLESHOOTING & REPAIRF-1 F-1Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOCINVERTEC® V1

TROUBLESHOOTING & REPAIRF-2 F-2INVERTEC® V155-SReturn to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn to Ma

TROUBLESHOOTING & REPAIRF-3 F-3INVERTEC® V155-SReturn to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn to Ma

OUTPUT PROBLEMSObserve Safety Guidelines detailed in the beginning of this manual.PROBLEMS(SYMPTOMS)POSSIBLE AREAS OFMISADJUSTMENT(S)RECOMMENDEDCOURSE

OUTPUT PROBLEMSObserve Safety Guidelines detailed in the beginning of this manual.PROBLEMS(SYMPTOMS)POSSIBLE AREAS OFMISADJUSTMENT(S)RECOMMENDEDCOURSE

OUTPUT PROBLEMSObserve Safety Guidelines detailed in the beginning of this manual.PROBLEMS(SYMPTOMS)POSSIBLE AREAS OFMISADJUSTMENT(S)RECOMMENDEDCOURSE

CASE COVER REMOVAL PROCEDUREWARNINGService and repair should be performed by only Lincoln Electric factory trained personnel.Unauthorized repairs perf

SSAAFFEETTYYiiiiii iiiiiiReturn to Master TOC Return to Master TOC Return to Master TOC Return to Master TOCJan ʻ07FOR ELECTRICALLYpowered equipment.8

INVERTEC V155Five ScrewsInveter BoardThree ScrewsGroundFIGURE F.1 – CASE COVER SCREW LOCATIONSCASE COVER REMOVAL PROCEDURE (CONTINUED)PROCEDURE1. Dis

INPUT FILTER CAPACITOR DISCHARGE PROCEDUREService and repair should be performed by only Lincoln Electric factory trained personnel.Unauthorized repai

DC+DC-INPUT BOARDCAPACITOR TERMINALS (4 places)FIGURE F.2 – CAPACITOR DISCHARGE LOCATIONSFIGURE F.3 – GLOVE, PLIERS & REISISTORINPUT FILTER

TROUBLESHOOTING & REPAIRF-11 F-11INVERTEC® V155-SReturn to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn to

Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn to Master TOC Return to Master TOC Return to Master TOC

INPUT BOARD RESISTANCE TESTService and repair should be performed by only Lincoln Electric factory trained personnel.Unauthorized repairs performed on

DC+DC-INPUT BOARDD1 Input RectifierR4R2~~+–FIGURE F.5 – INPUT BOARD TEST POINTSINPUT BOARD RESISTANCE TEST (CONTINUED)PROCEDURE1. Disconnect power to

INVERTER BOARD RESISTANCE TESTService and repair should be performed by only Lincoln Electric factory trained personnel.Unauthorized repairs performed

INVERTER BOARDIGBT Channel AIGBT channel BEmitterGateCollector Channel ACollector Channel BEmitterGateFIGURE F.6 – INVERTER BOARD TEST POINTSINVERTER

INVERTER BOARDD9Collector Channel BD7D3OutputTerminalsPoint 2 Point 1(center leg)R24 = PTC(solder pad)Collector Channel ARedBlackFIGURE F.7 – INVERT

SAFETYiv ivReturn to Master TOC Return to Master TOC Return to Master TOC Return to Master TOCMar ʻ93PRÉCAUTIONS DE SÛRETÉPour votre propre protection

Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn to Master TOC Return to Master TOC Return to Master TOC

INPUT BOARD VOLTAGE TESTService and repair should be performed by only Lincoln Electric factory trained personnel.Unauthorized repairs performed on th

DC+DC-INPUT BOARDAC2AC1JP1PIN 2PIN 1PIN 3PIN 4PIN 8PIN 12PIN 14FIGURE F.8 – INPUT BOARD TEST POINTSINPUT BOARD VOLTAGE TEST (CONTINUED)PROCEDURE1. Di

White fromPWR 2White fromPWR4Blue fromPWR 1Blue fromPWR 3312645FIGURE F.9 – MAIN SWITCH PLUG LOCATIONINPUT BOARD VOLTAGE TEST (CONTINUED)1. Put the

Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn to Master TOC Return to Master TOC Return to Master TOC

INVERTER BOARD VOLTAGE TESTService and repair should be performed by only Lincoln Electric factory trained personnel.Unauthorized repairs performed on

DC+DC-INPUT BOARDAC2AC1JP1PIN 2PIN 1151311 9 7 5 316141210 8 6 4FIGURE F.10 – PLUG JP1 TESTPOINTSINVERTER BOARD VOLTAGE TEST (CONTINUED)NOTE: DUE TO S

INPUT BOARD REMOVAL AND REPLACEMENT PROCEDUREService and repair should be performed by only Lincoln Electric factory trained personnel.Unauthorized re

DC+DC-INPUT BOARDAC2AC1MOUNTING SCREWSFIGURE F.11 – SCREW AND LEAD LOCATIONINPUT BOARD REMOVAL AND REPLACEMENT PROCEDURE PROCEDURE1. Disconnect power

INVERTER BOARD REMOVAL AND REPLACEMENT PROCEDUREService and repair should be performed by only Lincoln Electric factory trained personnel.Unauthorized

SAFETYv vReturn to Master TOC Return to Master TOC Return to Master TOC Return to Master TOCElectromagnetic Compatibility (EMC)ConformanceProducts dis

INVERTEC V155Five ScrewsInveter BoardThree ScrewsGroundFIGURE F.12 – DOOR REMOVALINVERTER BOARD REMOVAL AND REPLACEMENT PROCEDURE (CONTINUED)PROCEDURE

OUTPUT TERMINALS10MMBOLTSDC-DC+FIGURE F.13 – INVERTER BOARD REMOVALINVERTER BOARD REMOVAL AND REPLACEMENT PROCEDURE (CONTINUED)7. Using a 10mm nutdri

Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn to Master TOC Return to Master TOC Return to Master TOC

CONTROL BOARD REMOVAL AND REPLACEMENT PROCEDUREService and repair should be performed by only Lincoln Electric factory trained personnel.Unauthorized

CONTROL BOARDMOUNTINGSCREWSRED CAP KNOB WASHER NUTFIGURE F.14 CONTROL BOARD REMOVALCONTROL BOARD REMOVAL AND REPLACEMENT PROCEDURE (CONT

Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn 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 TOCReturn to Master TOC Return to Master TOC Return to Master TOC

TABLE OF CONTENTS - DIAGRAM SECTIONG-1 G-1Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOCINVERTEC® V155-SElectrica

ELECTRICAL DIAGRAMSG-2INVERTEC® V155-SWIRING DIAGRAM - CODES 11326 & 11327G-2NOTE: This diagram is for reference only. It may not be accurate for

Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn to Master TOC Return to Master TOC Return to Master TOC

SAFETYvi viReturn to Master TOC Return to Master TOC Return to Master TOC Return to Master TOCElectromagnetic Compatibility (EMC)The size of the surro

Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn to Master TOC Return to Master TOC Return to Master TOC

NOTE: Lincoln Electric assumes no responsibility for liablilities resulting from board level troubleshooting. PC Board repairs will invalidate your fa

Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn to Master TOC Return to Master TOC Return to Master TOC

ELECTRICAL DIAGRAMSG-7INVERTEC® V155-SSCHEMATIC - INVERTER PC BOARD - SHEET #2AVrefVref15VGNDVrefPRES15V15V15V15V15V15VTASLAVERECDUTYPWMMASTERPASSIVEn

NOTE: Lincoln Electric assumes no responsibility for liablilities resulting from board level troubleshooting. PC Board repairs will invalidate your fa

NOTE: Lincoln Electric assumes no responsibility for liablilities resulting from board level troubleshooting. PC Board repairs will invalidate your fa

ELECTRICAL DIAGRAMSG-10INVERTEC® V155-SSCHEMATIC - CONTROL PC BOARD11A AI-VoutmOFF+I+AD1RESETIRQVoutm+15VDUTYPTCETHLEDVENnVoutIMISS/TPTCEPTCuMOSCGNDGN

NOTE: Lincoln Electric assumes no responsibility for liablilities resulting from board level troubleshooting. PC Board repairs will invalidate your fa

NOTE: Lincoln Electric assumes no responsibility for liablilities resulting from board level troubleshooting. PC Board repairs will invalidate your fa

I I- MASTER TABLE OF CONTENTS FOR ALL SECTIONS -INVERTEC® V155-SRETURN TO MAIN INDEXPageSafety . . . . . . . . . . . . . . . . . . . . . . . . . . .

TABLE OF CONTENTS - INSTALLATION SECTIONA-1 A-1Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOCINVERTEC® V155-SInst