SVM183-A
July, 2008
INVERTEC Ā® V155-S
For use with machines having Code Numbers: 11326; 11327
Safety Depends on You
Lincoln arc welding and cutting
equipment is designed and built
with safety in mind. However, your
overall safety can be increased by
proper installation ... and thought-
ful operation on your part. DO
NOT INSTALL, OPERATE OR
REPAIR THIS EQUIPMENT
WITHOUT READING THIS MAN-
UAL AND THE SAFETY PRE-
CAUTIONS
THROUGHOUT.
CONTAINED
And, most
importantly, think before you act
and be careful.
SERVICE MANUAL
Copyright Ā© Lincoln Global Inc.
ā¢ World's Leader in Welding and Cutting Products ā¢
ā¢ Sales and Service through Subsidiaries and Distributors Worldwide ā¢
Cleveland, Ohio 44117-1199 U.S.A. TEL: 888.935.3877 FAX: 216.486.1751 WEB SITE: www.lincolnelectric.com
Download from Www.Somanuals.com. All Manuals Search And Download.
ii
ii
SAFETY
ELECTRIC SHOCK can kill.
ARC RAYS can burn.
3.a. The electrode and work (or ground) circuits
are electrically āhotā when the welder is on.
Do not touch these āhotā parts with your bare
skin or wet clothing. Wear dry, hole-free
gloves to insulate hands.
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.
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.
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.
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:
FUMES AND GASES
can be dangerous.
5.a. Welding may produce fumes and gases
hazardous to health. Avoid breathing these
ā¢ Semiautomatic DC Constant Voltage (Wire) Welder.
ā¢ DC Manual (Stick) Welder.
fumes and gases.When welding, keep
ā¢ AC Welder with Reduced Voltage Control.
your head out of the fume. Use enough
ventilation and/or exhaust at the arc to keep
3.c. In semiautomatic or automatic wire welding, the electrode,
electrode reel, welding head, nozzle or semiautomatic
welding gun are also electrically āhotā.
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.
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.
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 expo-
sure level should be checked upon installation and periodi-
cally thereafter to be certain it is within applicable OSHA PEL
and ACGIH TLV limits.
3.g. Never dip the electrode in water for cooling.
3.h. Never simultaneously touch electrically āhotā 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.
5.c. Do not weld in locations near chlorinated hydrocarbon vapors
coming from degreasing, cleaning or spraying operations.
The heat and rays of the arc can react with solvent vapors to
form phosgene, a highly toxic gas, and other irritating prod-
ucts.
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.
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.
5.e. Read and understand the manufacturerŹ¼s instructions for this
equipment and the consumables to be used, including the
material safety data sheet (MSDS) and follow your
employerŹ¼s safety practices. MSDS forms are available from
your welding distributor or from the manufacturer.
5.f. Also see item 1.b.
Aug Ź»06
Download from Www.Somanuals.com. All Manuals Search And Download.
iii
iii
SAFETY
WELDING and CUTTING
CYLINDER may explode
if damaged.
SPARKS can
cause fire or explosion.
6.a. Remove fire hazards from the welding area.
If this is not possible, cover them to prevent
the welding sparks from starting a fire.
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
Remember
that
welding
sparks
and
hot
pressure used. All hoses, fittings, etc. should be suitable for
the application and maintained in good condition.
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.
7.b. Always keep cylinders in an upright position securely
chained to an undercarriage or fixed support.
6.b. Where compressed gases are to be used at the job site,
special precautions should be used to prevent hazardous
situations. Refer to āSafety in Welding and Cuttingā (ANSI
Standard Z49.1) and the operating information for the
equipment being used.
7.c. Cylinders should be located:
ā¢Away from areas where they may be struck or subjected to
physical damage.
ā¢A safe distance from arc welding or cutting operations and
any other source of heat, sparks, or flame.
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.
7.d. Never allow the electrode, electrode holder or any other
electrically āhotā parts to touch a cylinder.
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 though they have
been ācleanedā. For information, purchase āRecommended
Safe Practices for the Preparation for Welding and Cutting of
Containers and Piping That Have Held Hazardous
Substancesā, AWS F4.1 from the American Welding Society
(see address above).
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,
āPrecautions for Safe Handling of Compressed Gases in
Cylinders,ā available from the Compressed Gas Association
1235 Jefferson Davis Highway, Arlington, VA 22202.
6.e. Vent hollow castings or containers before heating, cutting or
welding. They may explode.
6.f. Sparks and spatter are thrown from the welding arc. Wear oil
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.
FOR ELECTRICALLY
powered equipment.
8.a. Turn off input power using the disconnect
switch at the fuse box before working on
the equipment.
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.
8.b. Install equipment in accordance with the U.S. National
Electrical Code, all local codes and the manufacturerŹ¼s
recommendations.
8.c. Ground the equipment in accordance with the U.S. National
Electrical Code and the manufacturerŹ¼s recommendations.
6.h. Also see item 1.c.
6.I. Read and follow NFPA 51B ā Standard for Fire Prevention
During Welding, Cutting and Other Hot Workā, 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.
Jan Ź»07
Download from Www.Somanuals.com. All Manuals Search And Download.
iv
iv
SAFETY
6. Eloigner les matƩriaux inflammables ou les recouvrir afin de
PRĆCAUTIONS DE SĆRETĆ
prĆ©venir tout risque dŹ¼incendie dĆ» aux Ć©tincelles.
Pour votre propre protection lire et observer toutes les instructions
et les prƩcautions de sƻretƩ specifiques qui parraissent dans ce
manuel aussi bien que les prƩcautions de sƻretƩ gƩnƩrales suiv-
antes:
7. Quand on ne soude pas, poser la pince Ć une endroit isolĆ© de
la masse. Un court-circuit accidental peut provoquer un
Ć©chauffement et un risque dŹ¼incendie.
8. SŹ¼assurer que la masse est connectĆ©e le plus prĆ©s possible de
la zone de travail quŹ¼il est pratique de le faire. Si on place la
masse sur la charpente de la construction ou dŹ¼autres endroits
ƩloignƩs de la zone de travail, on augmente le risque de voir
passer le courant de soudage par les chaines de levage,
cĆ¢bles de grue, ou autres circuits. Cela peut provoquer des
risques dŹ¼incendie ou dŹ¼echauffement des chaines et des
cĆ¢bles jusquŹ¼Ć ce quŹ¼ils se rompent.
SĆ»retĆ© Pour Soudage A LŹ¼Arc
1. Protegez-vous contre la secousse Ć©lectrique:
a. Les circuits Ć lŹ¼Ć©lectrode et Ć la piĆ©ce sont sous tension
quand la machine Ć souder est en marche. Eviter toujours
tout contact entre les parties sous tension et la peau nue
ou les vƩtements mouillƩs. Porter des gants secs et sans
trous pour isoler les mains.
b. Faire trĆ©s attention de bien sŹ¼isoler de la masse quand on
soude dans des endroits humides, ou sur un plancher met-
allique ou des grilles metalliques, principalement dans
les positions assis ou couchƩ pour lesquelles une grande
partie du corps peut ĆŖtre en contact avec la masse.
c. Maintenir le porte-Ć©lectrode, la pince de masse, le cĆ¢ble de
soudage et la machine Ć souder en bon et sĆ»r Ć©tat defonc-
tionnement.
9. Assurer une ventilation suffisante dans la zone de soudage.
Ceci est particuliƩrement important pour le soudage de tƓles
galvanisƩes plombƩes, ou cadmiƩes ou tout autre mƩtal qui
produit des fumeƩs toxiques.
10. Ne pas souder en prƩsence de vapeurs de chlore provenant
dŹ¼opĆ©rations de dĆ©graissage, nettoyage ou pistolage. La
chaleur ou les rayons de lŹ¼arc peuvent rĆ©agir avec les vapeurs
du solvant pour produire du phosgƩne (gas fortement toxique)
ou autres produits irritants.
d.Ne jamais plonger le porte-Ć©lectrode dans lŹ¼eau pour le
refroidir.
e. Ne jamais toucher simultanƩment les parties sous tension
des porte-Ć©lectrodes connectĆ©s Ć deux machines Ć souder
parce que la tension entre les deux pinces peut ĆŖtre le total
de la tension Ć vide des deux machines.
f. Si on utilise la machine Ć souder comme une source de
courant pour soudage semi-automatique, ces precautions
pour le porte-Ć©lectrode sŹ¼applicuent aussi au pistolet de
soudage.
11. Pour obtenir de plus amples renseignements sur la sƻretƩ, voir
le code āCode for safety in welding and cuttingā CSA Standard
W 117.2-1974.
PRĆCAUTIONS DE SĆRETĆ POUR
LES MACHINES Ć SOUDER Ć
TRANSFORMATEUR ET Ć
REDRESSEUR
2. Dans le cas de travail au dessus du niveau du sol, se protƩger
contre les chutes dans le cas ou on recoit un choc. Ne jamais
enrouler le cĆ¢ble-Ć©lectrode autour de nŹ¼importe quelle partie du
corps.
3. Un coup dŹ¼arc peut ĆŖtre plus sĆ©vĆØre quŹ¼un coup de soliel, donc:
a. Utiliser un bon masque avec un verre filtrant appropriƩ ainsi
quŹ¼un verre blanc afin de se protĆ©ger les yeux du rayon-
nement de lŹ¼arc et des projections quand on soude ou
quand on regarde lŹ¼arc.
b. Porter des vĆŖtements convenables afin de protĆ©ger la peau
de soudeur et des aides contre le rayonnement de lŹ»arc.
c. ProtĆ©ger lŹ¼autre personnel travaillant Ć proximitĆ© au
soudage Ć lŹ¼aide dŹ¼Ć©crans appropriĆ©s et non-inflammables.
1. Relier Ć la terre le chassis du poste conformement au code de
lŹ¼Ć©lectricitĆ© et aux recommendations du fabricant. Le dispositif
de montage ou la piece Ć souder doit ĆŖtre branchĆ© Ć une
bonne mise Ć la terre.
2. Autant que possible, IŹ¼installation et lŹ¼entretien du poste seront
effectuƩs par un Ʃlectricien qualifiƩ.
3. Avant de faires des travaux Ć lŹ¼interieur de poste, la debranch-
er Ć lŹ¼interrupteur Ć la boite de fusibles.
4. Des gouttes de laitier en fusion sont Ć©mises de lŹ¼arc de
soudage. Se protĆ©ger avec des vĆŖtements de protection libres
de lŹ¼huile, tels que les gants en cuir, chemise Ć©paisse, pan-
talons sans revers, et chaussures montantes.
4. Garder tous les couvercles et dispositifs de sĆ»retĆ© Ć leur place.
5. Toujours porter des lunettes de sƩcuritƩ dans la zone de
soudage. Utiliser des lunettes avec Ć©crans lateraux dans les
zones oĆ¹ lŹ¼on pique le laitier.
Mar Ź»93
Download from Www.Somanuals.com. All Manuals Search And Download.
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 manufacturerŹ¼s
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 com-
plete 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 equip-
ment.
Assessment of Area
Before installing welding equipment the user shall make an assessment of potential electromagnetic prob-
lems 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;
h) the time of day that welding or other activities are to be carried out.
L10093
3-1-96H
Download from Www.Somanuals.com. All Manuals Search And Download.
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 manufacturerŹ¼s recommen-
dations. If interference occurs, it may be necessary to take additional precautions such as filtering of the
mains supply. Consideration should be given to shielding the supply cable of permanently installed welding
equipment, in metallic conduit or equivalent. Shielding should be electrically continuous throughout its
length. The shielding should be connected to the welding power source so that good electrical contact is
maintained between the conduit and the welding power source enclosure.
Maintenance of the Welding Equipment
The welding equipment should be routinely maintained according to the manufacturerŹ¼s recommendations.
All access and service doors and covers should be closed and properly fastened when the welding equip-
ment is in operation. The welding equipment should not be modified in any way except for those changes
and adjustments covered in the manufacturers instructions. In particular, the spark gaps of arc striking and
stabilizing devices should be adjusted and maintained according to the manufacturerŹ¼s recommendations.
Welding Cables
The welding cables should be kept as short as possible and should be positioned close together, running at
or close to floor level.
Equipotential Bonding
Bonding of all metallic components in the welding installation and adjacent to it should be considered.
However, metallic components bonded to the work piece will increase the risk that the operator could
receive a shock by touching these metallic components and the electrode at the same time. The operator
should be insulated from all such bonded metallic components.
Earthing of the Workpiece
Where the workpiece is not bonded to earth for electrical safety, not connected to earth because of its size
and position, e.g., ships hull or building steelwork, a connection bonding the workpiece to earth may reduce
emissions in some, but not all instances. Care should be taken to prevent the earthing of the workpiece
increasing the risk of injury to users, or damage to other electrical equipment. Where necessary, the con-
nection of the workpiece to earth should be made by a direct connection to the workpiece, but in some
countries where direct connection is not permitted, the bonding should be achieved by suitable capaci-
tance, selected according to national regulations.
Screening and Shielding
Selective screening and shielding of other cables and equipment in the surrounding area may alleviate
problems of interference. Screening of the entire welding installation may be considered for special applica-
1
tions.
_________________________
1
Portions of the preceding text are contained in EN 60974-10: āElectromagnetic Compatibility (EMC)
product standard for arc welding equipment.ā
L10093
3-1-96H
Download from Www.Somanuals.com. All Manuals Search And Download.
I
I
- MASTER TABLE OF CONTENTS FOR ALL SECTIONS -
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
INVERTECĀ® V155-S
Download from Www.Somanuals.com. All Manuals Search And Download.
A-1
A-1
TABLE OF CONTENTS - INSTALLATION SECTION
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-1
Technical Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-2
Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-3
Input Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-3
Output Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-5
INVERTECĀ® V155-S
Download from Www.Somanuals.com. All Manuals Search And Download.
A-2
A-2
INSTALLATION
INPUT - SINGLE PHASE ONLY
Input Voltages / 50 /60 Hz.
Max. Input Current at rated Output Input Power at Rated Output
100%
25A
30%
34 A
33 A
100%
2.2kw
3.0kw
30%
120Vac 10%
230Vac 10%
3.0kw
5.0kw
23A
RATED OUTPUT
Output Amps
Output Volts
Input Circuit
Duty Cycle
75A (Stick)
105A (TIG)
23.0 Vdc
14.2 Vdc
120 Vac
230 Vac
120 Vac
230 Vac
100%
100A (Stick)
100A (TIG)
24.0 Vdc
14.0 Vdc
100A (Stick)
130A (TIG)
24.0 Vdc
15.2 Vdc
30%
145A (Stick)
155A (TIG)
25.8 Vdc
16.2 Vdc
OUTPUT
Output Current Range
Type of Output
Maximum Open Circuit Voltage
5-155 Amps
75 Volts Max.
DC
RECOMMENDED INPUT WIRE AND FUSE SIZES FOR MAXIMUM RATED OUTPUT
TYPE S, SO ST, STO, OR EXTRA
MAXIMUM TIME-DELAY CIRCUIT
INPUT VOLTAGE /
FREQUENCY (HZ)
HARD USAGE INPUT CORD AWG BREAKER OR FUSE SIZE (AMPS)
230/60
120/60
3 Conductor, 12 AWG
30
PHYSICAL DIMENSIONS
Height
Width
Depth
Weight
11.3
6.2 in.
15.4in.
Approx. 14.7lbs.
6.7 kgs.
288 mm
158 mm
392 mm
TEMPERATURE RANGES
OPERATING TEMPERATURE RANGE
STORAGE TEMPERATURE RANGE
-10Ā°C to +40Ā°C
-25Ā°C to +55Ā°C
INVERTECĀ® V155-S
Download from Www.Somanuals.com. All Manuals Search And Download.
A-3
A-3
INSTALLATION
TILTING
Read entire installation section before starting
installation.
Place the machine directly on a secure, level surface.
Do not place or operate this machine on a surface with
an incline greater than 15Ā° from horizontal. The
machine may topple over if this procedure is not fol-
lowed.
SAFETY PRECAUTIONS
WARNING
INPUT CONNECTIONS
ELECTRIC SHOCK can kill.
ā¢ Only qualified personnel should per-
WARNING
form this installation.
ā¢ Disconnect input power by removing
plug from receptacle before working
inside INVERTECĀ® V155-S. Allow
machine to sit for 5 minutes mini-
mum to allow the power capacitors
to discharge before working inside
this equipment.
ELECTRIC SHOCK can kill.
ā¢ Have a qualified electrician install
and service this equipment.
ā¢ Disconnect input power by removing
plug from receptacle before working
inside INVERTECĀ® V155-S. Allow
machine to sit for 5 minutes minimum
to allow the power capacitors to discharge before
working inside this equipment.
ā¢ Insulate yourself from the work and ground.
ā¢ Always wear dry insulating gloves.
ā¢ Do not touch electrically live parts.
ā¢ Always connect the INVERTECĀ® V155-S to a power
-----------------------------------------------------------------------
supply grounded according to the National
GROUND CONNECTION
Electrical Code and local codes.
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.
------------------------------------------------------------
SELECT SUITABLE LOCATION
This machine can operate in harsh environments.
However, it is important that simple preventative mea-
sures are followed to assure long life and reliable oper-
ation:
CAUTION
ā¢ Do not use this machine for pipe thawing.
ā¢ This machine must be located where there is free cir-
culation of clean air without restrictions for air move-
ment to and from the air vents. Do not cover the
machine with paper, cloth or rags when switched on.
ā¢ Dirt and dust that can be drawn into the machine
should be kept to a minimum.
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 quali-
fied electrician to ensure correct connections of
the leads to the plug spades.
ā¢ This machine has a protection rating of IP23. Keep
it dry when possible and do not place it on wet
ground or in puddles.
ā¢ 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.
ā¢ 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.
ā¢ Do not operate in areas with an ambient temperature
greater than 40Ā°C.
ā¢ The welding power source supply cable is pro-
vided 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 con-
ductors.
STACKING
The INVERTECĀ® V155-S cannot be stacked.
ā¢ lnstall only plugs that confirm with safety regula-
tions.
INVERTECĀ® V155-S
Download from Www.Somanuals.com. All Manuals Search And Download.
A-4
A-4
INSTALLATION
INPUT POWER CONNECTION
WARNING
Check the input voltage, phase, and frequency sup-
plied to this machine before turning it on.
The allowable input voltage is indicated in the techni-
cal specification section of this manual and on the rat-
ing plate of the machine. Be sure that the machine is
grounded.
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.
ā¢
---------------------------------------------------------------------------
230V INPUT
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.
To achieve the full output capacity of the INVERTECĀ®
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).
Fuse the input circuit with time delay fuses marked āDā
1
or delay type circuit breakers. Using fuses or circuit
ATTACHMENT PLUG
breakers smaller than recommended may result in
ānuisanceā shut-offs from welder inrush currents even
if not welding at high currents.
In all cases, the green or green/yellow grounding wire
must be connected to the grounding pin of the plug, usu-
ally identified by a green screw.
1Also called āinverse timeā or āthermal/magneticā circuit breakers.
These circuit breakers have a delay in tripping action that decreases
as the magnitude of the current increases.
All attachment plugs must comply with the Standard for
Attachment Plugs and Receptacles, UL498.
The INVERTECĀ® V155-S is recommended for use on
an individual branch circuit.
The product is considered acceptable for use only when
an attachment plug as specified is properly attached to
the supply cord.
120V INPUT
The rated output of the INVERTECĀ® V155-S is avail-
able 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 approx-
imate 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 avail-
able output. Do not exceed these welding conditions:
(See Table A.1)
The INVERTECĀ® 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 ade-
quate 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:
The INVERTECĀ® V155-S is provided with a 120/230V
cable, 6.6ft.(2m) in length, with a 15Amp 5-15P plug
molded onto the cord.
ā¢ Vac peak voltage: below 205V (for 115Vac input) or
410V (for 230Vac input).
The INVERTECĀ® V155-S is supplied with an addition-
al 20A plug that can replace the 15A plug to achieve
higher output. To install the supplied 20A plug:
ā¢ Vac frequency: in the range of 50 or 60 Hertz.
ā¢ RMS voltage of the AC waveform: 115Vac or
230Vac 10%
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 ter-
minal clamp with green screw.
It is important to check these conditions because many
engine driven generators produce high voltage spikes.
Operation of this machine with engine driven genera-
tors not conforming to these conditions is not recom-
mended and may damage the machine.
TABLE A.1
BRANCH
120V Input
Output Current
Stick
TIG
Plug Branch 10% Duty 30% Duty 100% Duty
10% Duty 30% Duty 100% Duty
Rating Rating
15 Amp 15 Amp
15 Amp 20 Amp
20 Amp 20 Amp
Cycle
65A
Cycle
55A
Cycle
45A
Cycle
100A
110A
130A
Cycle
85A
Cycle
75A
75A
70A
60A
100A
130A
95A
85A
75A
60A
95A
INVERTECĀ® V155-S
Download from Www.Somanuals.com. All Manuals Search And Download.
A-5
A-5
INSTALLATION
ARFU (Auto-Restore Fuse)
FIGURE A.1
The dual input voltage machine is provided with the
ARFU device. It operates only when the input is con-
nected 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-Mateā¢ cable
plugs is used for the welding cable connections. Refer
to the following sections for more information on con-
necting the machine for operation of stick welding
(SMAW) or TIG welding.
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-Mateā¢ TIG Torch adapter is also required. Refer
to the accessories section for more information about
TIG Torches and required Twist-Mateā¢ adapter. Most
TIG welding is done with DC(-) polarity shown here. If
DC(+) polarity is necessary switch the cable connec-
tions at the machine. (See Figure A.2)
WARNING
ELECTRIC SHOCK can kill.
ā¢ Keep the electrode holder and
cable insulation in good condition.
ā¢ Do not touch electrically live parts
or electrode with skin or wet cloth-
ing.
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-Mateā¢ adapter
gas hose to the gas regulator on the cylinder of gas to
be used.
ā¢ Insulate yourself from work and ground.
ā¢ Turn the input line Switch on the INVERTECĀ®
V155-S āoffā before connecting or disconnecting
output cables or other equipment.
-----------------------------------------------------------
STICK WELDING (SMAW)
FIGURE A.2
First determine the proper electrode polarity for the elec-
trode to be used. Consult the electrode data for this infor-
mation. Then connect the output cables to the output ter-
minals of the machine for the selected polarity. Shown
here is the connection method for DC(+) welding. (See
Figure A.1)
Work Clamp
Work Cable
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 approximate-
ly 1/4 turn clockwise. Do not over tighten.
Twist-Mateā¢ Adapter K-960-2
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 (+).
Gas Hose
To Bottle
Gas Valve
TIG Torch
INVERTECĀ® V155-S
Download from Www.Somanuals.com. All Manuals Search And Download.
A-6
A-6
INSTALLATION
REPLACEMENT QUICK DISCONNECT PLUG (FOR
STICK ELECTRODE CABLE)
The INVERTECĀ® V155-S comes with a factory assem-
bled stick electrode holder, cable and Twist-Mateā¢
adapter plug. If a replacement cable is ever needed a
K852-25 Twist-Mateā¢ 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.
BOOT
WELDING CABLE
.75 in.
TRIM, IF REQ'D
TO FIT OVER CABLE
19 mm
4. Cut 45-50% of the copper strands back 1/4ā (6 mm).
5. Fold copper strands over cut strands and insert into
WELDING CABLE
.25 in.
6 mm
ferrule.
6. Slide the copper ferrule into the brass plug.
COPPER FERRULE
WELDING CABLE
.50 in. max
12 mm max.
7. Tighten set screw to collapse copper tube. Screw
SET SCREW
BRASS PLUG
COPPER TUBE
must apply pressure against welding cable. The top
of the set screw will be well below the surface of the
brass plug after tightening.
INVERTECĀ® V155-S
Download from Www.Somanuals.com. All Manuals Search And Download.
B-1
B-1
TABLE OF CONTENTS - OPERATION SECTION
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-1
Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-2
General Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-2
Controls and Operational Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-3
INVERTECĀ® V155-S
Download from Www.Somanuals.com. All Manuals Search And Download.
B-2
B-2
THEORY OF OPERATION
Read and understand this entire section before
operating your machine.
GENERAL DESCRIPTION
The INVERTECĀ® 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.
SAFETY INSTRUCTIONS
WARNING
ELECTRIC SHOCK can kill.
The INVERTECĀ® 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.
ā¢ Do not touch electrically live parts such
as output terminals or internal wiring.
ā¢ Insulate yourself from the work and
ground.
The INVERTECĀ® V155-S performs DC Touch Start Tig
Starting with excellent results.
ā¢ Always wear dry insulating gloves.
____________________________________
WELDING CAPABILITY
FUMES AND GASES
can be dangerous.
The INVERTECĀ® 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-
ā¢ Keep your head out of fumes.
(1)
rents . If the duty cycle is exceeded, a thermal protec-
ā¢ Use ventilation or exhaust to
remove fumes from breathing
zone.
tor will shut off the output until the machine cools. See
Technical Specifications in the Installation Section for
other rated outputs.
____________________________________
The INVERTECĀ® V155-S is recommended for stick
Ā®
welding with such popular electrodes as Fleetweld 35,
WELDING, CUTTING and
GOUGING SPARKS
Fleetweld 37, Fleetweld 180 and Jet-LH 78 MR. It fea-
tures adjustable arc control to adjust the arc force and
start.
can cause fire or explosion
ā¢ Keep flammable material away.
LIMITATIONS
ā¢ Do not weld, cut or gouge on
containers that have held com-
bustibles.
The INVERTECĀ® V155-S is not recommended for
pipe thawing.
(1)
Refer to Technical Specifications in the Installation Section for other ratings.
____________________________________
ARC RAYS
can burn.
ā¢ Wear eye, ear and body
protection.
____________________________________
Only qualified personnel should operate this equip-
ment. Observe all safety information throughout this
manual.
INVERTECĀ® V155-S
Download from Www.Somanuals.com. All Manuals Search And Download.
B-3
B-3
THEORY OF OPERATION
If the Yellow LED illuminates, and the Red and Green
LEDŹ¼s 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.
CONTROLS AND OPERATIONAL
FEATURES
A
1. Output Current Knob:
set the output current used during welding, from 5A
to 155A.
Potentiometer used to
WARNING
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 weld-
ing.
If blinking, the Thermal LED indicates that the input
voltage is out of ranges.
ā¢ Soft Stick:
ā¢ Crisp Stick:
ā¢ Lift TIG:
For a welding with a low spatter
presence.
4. Power On/Off & OUTPUT LEDs: These LEDs (one
green and one red) operates as described in the
table below:
For an aggressive welding arc,
with an increased Arc stability.
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 press-
ing 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.
LED status
Green Red
FUNCTION
ON
OFF
The machine is turned ON.
V
ON condition: The machine is at
idle (no-welding time) and OCV
is present.
3. Thermal LED:
This indicator will turn on when
OFF
ON
The machine is turned ON.
A
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.
On condition: Presence of weld-
ing current at the output leads.
This permanent LED condition,
showed at idle (no-welding time), indi-
cates machine damage.
FIGURE B.1
OFF
OFF
ON
The machine is turned OFF and/or the
input cord could be disconnected from
the mains.
1
4
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.
2
ON
ERROR condition: This LED condition
3
1. Output Current Knob
5
2. Welding Mode Switch
3. Thermal LED
6
4. Power On/Off and Output LEDŹ¼s
5. Positive Quick Disconnect
6. Negative Quick Disconnect
INVERTECĀ® V155-S
Download from Www.Somanuals.com. All Manuals Search And Download.
B-4
B-4
THEORY OF OPERATION
5. Positive Quick Disconnect: Positive output con-
AUTO ADAPTIVE ARC FORCE
(WITH STICK WELDING)
nector for the welding circuit.
6. Negative Quick Disconnect: Negative output con-
The Auto Adaptive Arc Force function is activated dur-
ing stick welding. This function temporarily increases
the output current, to clear intermittent shorts between
the electrode and the weld puddle that may occur dur-
ing stick welding.
nector for the welding circuit.
REAR CONTROL PANEL
(See Figure B.2)
7. Power Switch: It turns ON / OFF the input power
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 out-
put voltage and is controlled by the microprocessor on
the Control Board.
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.
The circuit determines the amount of current neces-
sary to release the metal droplet that is being trans-
ferred from the electrode to the workpiece to guarantee
the arc stability without going too high, to minimize the
spatter levels. That means:
ā¢ 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 when-
ever the machine is welding. The fan will turn OFF
five minutes after the welding is stopped.
ā¢ Electrode to workpiece sticking prevention, even at
low current values.
ā¢ Spatter reduction.
ā¢ 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 min-
utes after the welding is stopped.
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 strik-
ing.
The following features are also enabled in the stick
welding modes:
FIGURE B.2
ā¢ Hot Start: This is a temporary increase in the initial
welding current. This helps ignite the arc
quickly and reliably.
8
ā¢ 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.
7
9
INVERTECĀ® V155-S
Download from Www.Somanuals.com. All Manuals Search And Download.
C-1
C-1
TABLE OF CONTENTS - ACCESSORIES SECTION
Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .C-1
Factory Installed Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .C-2
Field Installed Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .C-2
Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .C-2
INVERTECĀ® V155-S
Download from Www.Somanuals.com. All Manuals Search And Download.
C-2
C-2
ACCESSORIES
CABLE PLUGS
OPTIONAL ACCESSORIES
AND COMPATIBLE EQUIPMENT
K852-25 - Cable Plug Kit attaches to welding cable to
provide quick disconnect from machine.
Factory Installed
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.
Electrical Holder and Cable Assembly
Work Cable and Clamp
Strap Packet
Instruction Manual
Order KP508 for PTA-17 torches
Order KP507 for PTA-9 torches
Field Installed
See publication E12.150 for parts kits breakdown.
Cut Length Consumables - TIG welding filler metals
are available for welding stainless steel, mild steel, alu-
minum and copper alloys. See publication C9.10.
PTA-17V TIG Torch - 150 Amp air-cooled compact and
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:
ā¢ K1782-6 (12.50 Ft.) 1-Piece Cable
ā¢ K1782-8 (25.0 Ft.) 1-Piece Cable
PTA-9FV TIG Torch - 125 Amp Gas Valve flexible
head torch:
ā¢ K1781-7 (25.0 Ft.) 1-Piece Cable
PTA-17FV TIG Torch - 150 Amp Gas Valve flexible
head torch:
ā¢ K1782-11 (25.0 Ft.) 1-Piece Cable
ā¢ K1782-13 (12.5 Ft.) 1-Piece Ultra Flex Cable
K960-2-TIG Torch Adapter - for connection of PTA-
17V torches (1-piece cable) to power sources without
gas passing through the Twist Mate connection.
INVERTECĀ® V155-S
Download from Www.Somanuals.com. All Manuals Search And Download.
D-1
D-1
TABLE OF CONTENTS - MAINTENANCE SECTION
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-1
Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-2
INVERTECĀ® V155-S
Download from Www.Somanuals.com. All Manuals Search And Download.
D-2
D-2
MAINTENANCE
SAFETY PRECAUTIONS
WARNING
WARNING
Do not open this machine and do not introduce any-
thing into its openings. Power supply must be discon-
nected from the machine before each maintenance
and service. After each repair, perform proper tests to
ensure safety.
ELECTRIC SHOCK can kill.
ā¢ Have an electrician install and ser-
vice this equipment.
ā¢ 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 capaci-
tors to discharge before working
inside this equipment.
CAUTION
Power supply must be disconnected from the machine
before each maintenance and service. Always use
gloves in compliance with the safety standards.
ā¢ Do not touch electrically hot parts.
----------------------------------------------------------------------
INPUT FILTER CAPACITOR
DISCHARGE PROCEDURE
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.
WARNING
For any maintenance or repair operations it is recom-
mended 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
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.
ā¢ Check cables and connections integrity. Replace, if
necessary.
ā¢ Clean the power source inside by means of low -
pressure compressed air.
ā¢ Keep the machine clean. Use a soft dry cloth to clean
the external case, especially the airflow inlet / outlet
louvers.
INVERTECĀ® V155-S
Download from Www.Somanuals.com. All Manuals Search And Download.
D-3
D-3
MAINTENANCE
MAJOR COMPONENT LOCATIONS
1. Front Panel
2. Right Case Side
3. Left Case Side
4. Rear Panel
5. Fan
10. Inverter P.C. Board
11. Control P.C. Board
12. Knob
13. Output Connector
14. Carrying Strap *
15. Nameplate *
6. Cable Clamp
7. Input Cable
8. ON\OFFSwitch
9. Input P.C. Board
16. Side Decal Set *
* Not in picture
FIGURE D.1 - MAJOR COMPONENT LOCATIONS
7
6
8
4
5
3
9
10
2
1
12
11
13
INVERTECĀ® V155-S
Download from Www.Somanuals.com. All Manuals Search And Download.
D-4
D-4
NOTES
INVERTECĀ® V155-S
Download from Www.Somanuals.com. All Manuals Search And Download.
E-1
E-1
TABLE OF CONTENTS-THEORY OF OPERATION SECTION
Theory of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .E-1
General Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .E-2
Main IGBT Inverter Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .E-4
Main Transformer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .E-4
Insulated Gate Bipolar Transistor (IGBT) Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .E-6
Pulse Width Modulation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .E-7
FIGURE E.1 ā BLOCK LOGIC DIAGRAM.
BLUE
WHITE
5
4
2
1
RED
BLACK
DC+
DC-
ON/OFF SWITCH
WHITE
BLUE
RED
BLACK
WIRE TIE
PWR4
PWR3
PWR2
PWR1
L
N
G
BLACK
WHITE
DC+
DC-
AC1
Y/G
PE
AC2
INPUT BOARD
PE
W05X0701
JP1
JP1
JP1
(SCHEMATIC: X0701)
115/230Vac
50/60 Hz
INVERTER BOARD
W05X0519
(SCHEMATIC: X0519)
RECONNECT
BOARD
W05X0408
BLUE
RED
(SCHEMATIC: X0408)
WHITE
+
-
FAN
JP4
P1
N1
BLACK
TWISTED CABLE
RIBBON CABLE
SHUNT
CONTROL BOARD
PCB CONNECTOR CAVITY NUMBERIN
W05X0708-1
G SEQUENCE
P.C. BOARD)
(VIEWED FROM COMPONENT SIDE OF
(SCHEMATIC: X0708)
2
1
16
1
4
RED
PE
BLACK
WHITE
JP2
4 PINS
15
16 PINS
INVERTECĀ® V155-S
Download from Www.Somanuals.com. All Manuals Search And Download.
E-2
E-2
THEORY OF OPERATION
FIGURE E.2 ā GENERAL DESCRIPTION
BLUE
WHITE
5
4
2
1
RED
BLACK
DC+
DC-
ON/OFF SWITCH
WHITE
BLUE
RED
BLACK
WIRE TIE
PWR4
PWR3
PWR2
PWR1
L
N
G
BLACK
WHITE
DC+
DC-
AC1
Y/G
PE
AC2
INPUT BOARD
PE
W05X0701
JP1
JP1
JP1
(SCHEMATIC: X0701)
115/230Vac
50/60 Hz
INVERTER BOARD
W05X0519
(SCHEMATIC: X0519)
RECONNECT
BOARD
W05X0408
BLUE
RED
(SCHEMATIC: X0408)
WHITE
+
-
FAN
JP4
P1
N1
BLACK
TWISTED CABLE
RIBBON CABLE
SHUNT
CONTROL BOARD
PCB CONNECTOR CAVITY NUMBERIN
W05X0708-1
G SEQUENCE
(VIEWED FROM COMPONENT SIDE O
F P.C. BOARD)
(SCHEMATIC: X0708)
2
1
16
1
4
RED
PE
BLACK
WHITE
JP2
4 PINS
15
16 PINS
GENERAL DESCRIPTION
The INVERTECĀ® 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 protec-
tor will shut off the output until the machine cools. See
Technical Specifications in A-1 for other rated outputs.
The INVERTECĀ® 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 INVERTECĀ® V155-S is recommended for stick
welding with such popular electrodes as FleetweldĀ®
35, Fleetweld 37, Fleetweld 180 and Jet-LH 78MR. It
features adjustable arc control to adjust the arc force
and start.
The INVERTECĀ® 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.
LIMITATIONS
The INVERTECĀ® V155-S performs DC Touch Start Tig
starting with excelent results.
The INVERTECĀ® V155-S is not recommeded for pipe
thawing.
NOTE: Unshaded areas of Block Logic
Diagram are the subject of discussion
INVERTECĀ® V155-S
Download from Www.Somanuals.com. All Manuals Search And Download.
E-3
E-3
THEORY OF OPERATION
FIGURE E.3 ā INPUT BOARD
BLUE
WHITE
5
4
2
1
RED
BLACK
DC+
DC-
ON/OFF SWITCH
WHITE
BLUE
RED
BLACK
WIRE TIE
PWR4
PWR3
PWR2
PWR1
L
N
G
BLACK
WHITE
DC+
DC-
AC1
Y/G
PE
AC2
INPUT BOARD
PE
W05X0701
JP1
JP1
JP1
(SCHEMATIC: X0701)
115/230Vac
50/60 Hz
INVERTER BOARD
W05X0519
(SCHEMATIC: X0519)
RECONNECT
BOARD
W05X0408
BLUE
RED
(SCHEMATIC: X0408)
WHITE
+
-
FAN
JP4
P1
N1
BLACK
TWISTED CABLE
RIBBON CABLE
SHUNT
CONTROL BOARD
PCB CONNECTOR CAVITY NUMBERIN
W05X0708-1
G SEQUENCE
(VIEWED FROM COMPONENT SIDE O
F P.C. BOARD)
(SCHEMATIC: X0708)
2
1
16
1
4
RED
PE
BLACK
WHITE
JP2
4 PINS
15
16 PINS
INPUT BOARD
The Input Board includes the following circuits:
An improper input voltage would be recognized dur-
ing 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.
- 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.
- 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 opera-
tion. When the fuse is open, the output will be dis-
abled and the yellow Temperature LED on the front
panel will be ON.
- 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.
NOTE: Unshaded areas of Block Logic
Diagram are the subject of discussion
INVERTECĀ® V155-S
Download from Www.Somanuals.com. All Manuals Search And Download.
E-4
E-4
THEORY OF OPERATION
FIGURE E.4 ā MAIN INVERTER BOARD
BLUE
WHITE
5
4
2
1
RED
BLACK
DC+
DC-
ON/OFF SWITCH
WHITE
BLUE
RED
BLACK
WIRE TIE
PWR4
PWR3
PWR2
PWR1
L
N
G
BLACK
WHITE
DC+
DC-
AC1
Y/G
PE
AC2
INPUT BOARD
PE
W05X0701
JP1
JP1
JP1
(SCHEMATIC: X0701)
115/230Vac
50/60 Hz
INVERTER BOARD
W05X0519
(SCHEMATIC: X0519)
RECONNECT
BOARD
W05X0408
BLUE
RED
(SCHEMATIC: X0408)
WHITE
+
-
FAN
JP4
P1
N1
BLACK
TWISTED CABLE
RIBBON CABLE
SHUNT
CONTROL BOARD
PCB CONNECTOR CAVITY NUMBERIN
W05X0708-1
G SEQUENCE
(VIEWED FROM COMPONENT SIDE O
F P.C. BOARD)
(SCHEMATIC: X0708)
2
1
16
1
4
RED
PE
BLACK
WHITE
JP2
4 PINS
15
16 PINS
MAIN INVERTER BOARD
The Inverter Board includes the following circuits:
- 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.
- Inverter Circuit: Through the use of Insulated Gate
Bipolar Transistors (IGBTŹ¼s) 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 Ź»gateŹ¼ signal from the Control Board.
in this section).
Note: The shunt is shown off the board for clarity. It is
actually mounted on the Inverter Board.
- Main Transformer: The primary function of the main
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.
INVERTECĀ® V155-S
Download from Www.Somanuals.com. All Manuals Search And Download.
E-5
E-5
THEORY OF OPERATION
FIGURE E.5 ā CONTROL BOARD
BLUE
WHITE
5
4
2
1
RED
BLACK
DC+
DC-
ON/OFF SWITCH
WHITE
BLUE
RED
BLACK
WIRE TIE
PWR4
PWR3
PWR2
PWR1
L
N
G
BLACK
WHITE
DC+
DC-
AC1
Y/G
PE
AC2
INPUT BOARD
PE
W05X0701
JP1
JP1
JP1
(SCHEMATIC: X0701)
115/230Vac
50/60 Hz
INVERTER BOARD
W05X0519
(SCHEMATIC: X0519)
RECONNECT
BOARD
W05X0408
BLUE
RED
(SCHEMATIC: X0408)
WHITE
+
-
FAN
JP4
P1
N1
BLACK
TWISTED CABLE
RIBBON CABLE
SHUNT
CONTROL BOARD
PCB CONNECTOR CAVITY NUMBERIN
W05X0708-1
G SEQUENCE
(VIEWED FROM COMPONENT SIDE O
F P.C. BOARD)
(SCHEMATIC: X0708)
2
1
16
1
4
RED
PE
BLACK
WHITE
JP2
4 PINS
15
16 PINS
CONTROL BOARD
The Control Board receives status and analogue sig-
nals from the inverter board, input board and various
sensors and feeds this information to the Weld
Controller.
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 LEDŹ¼s on the
front panel.
The Mode Switch , the Control Potentiometer and the
three LEDŹ¼s are all mounted on the Control Board.
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 IGBTās
INVERTECĀ® V155-S
Download from Www.Somanuals.com. All Manuals Search And Download.
E-6
E-6
THEORY OF OPERATION
FIGURE E.6 ā IGBT OPERATION
POSITIVE
VOLTAGE
APPLIED
GATE
GATE
SOURCE
SOURCE
n +
n +
n +
n +
p
BODY REGION
p
BODY REGION
DRAIN DRIFT REGION
DRAIN DRIFT REGION
n -
n -
n +
p +
BUFFER LAYER
n +
p +
BUFFER LAYER
INJECTING LAYER
INJECTING LAYER
DRAIN
DRAIN
B. ACTIVE
A. PASSIVE
INSULATED GATE BIPOLAR
TRANSISTOR (IGBT) OPERATION
An IGBT is a type of transistor. IGBTs are semicon-
ductors 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 con-
nected to the drain terminal will allow the IGBT to con-
duct and supply current to circuit components coupled
to the source. Current will flow through the conducting
IGBT to downstream components as long as the posi-
tive gate signal is present. This is similar to turning ON
a light switch.
INVERTECĀ® V155-S
Download from Www.Somanuals.com. All Manuals Search And Download.
E-7
E-7
THEORY OF OPERATION
Figure E-7
MINIMUM OUTPUT
m/sec
31
sec
2
m/sec
33
MAXIMUM OUTPUT
m/sec
m/sec
31
33
MAXIMUM OUTPUT
PULSE WIDTH MODULATION
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 com-
pared to the darkened area under the max. curve. The
more darkened area, the more power is present.
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.
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.
INVERTECĀ® V155-S
Download from Www.Somanuals.com. All Manuals Search And Download.
E-8
E-8
NOTES
INVERTECĀ® V155-S
Download from Www.Somanuals.com. All Manuals Search And Download.
F-1
F-1
TABLE OF CONTENTS - TROUBLESHOOTING & REPAIR
Troubleshooting and Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .F-1
How to Use Troubleshooting Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .F-2
PC Board Troubleshooting Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .F-3
Troubleshooting Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .F-4
Case Cover Removal Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .F-7
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
INVERTECĀ® V155-S
Download from Www.Somanuals.com. All Manuals Search And Download.
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.
---------------------------------------------------------------------------------------------------------------------------
Step 3. RECOMMENDED
COURSE OF ACTION
This Troubleshooting Guide is provided to
help you locate and repair possible machine
The last column labeled āRecommended
Course of Actionā lists the most likely com-
ponents that may have failed in your
machine. It also specifies the appropriate
test procedure to verify that the subject com-
ponent is either good or bad. If there are a
number of possible components, check the
components in the order listed to eliminate
one possibility at a time until you locate the
cause of your problem.
malfunctions. Simply follow the three-step
procedure listed below.
Step 1. LOCATE PROBLEM (SYMPTOM).
Look under the column labeled āPROBLEM
(SYMPTOMS)ā. This column describes pos-
sible symptoms that the machine may exhib-
it. Find the listing that best describes the
symptom that the machine is exhibiting.
Symptoms are grouped into the following
categories: output problems, function prob-
lems, wire feeding problems, and welding
problems.
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.
Step 2. PERFORM EXTERNAL TESTS.
The second column labeled āPOSSIBLE
AREAS OF MISADJUSTMENT(S)ā lists the
obvious external possibilities that may con-
tribute to the machine symptom. Perform
these tests/checks in the order listed. In
general, these tests can be conducted with-
out removing the case wrap-around cover.
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.
-----------------------------------------------------------------------------------------------------------------------------------
INVERTECĀ® V155-S
Download from Www.Somanuals.com. All Manuals Search And Download.
F-3
F-3
TROUBLESHOOTING & REPAIR
PC BOARD TROUBLESHOOTING PROCEDURES
- Remove the PC board from the static-shielding bag
and place it directly into the equipment. DonŹ¼t set the
PC board on or near paper, plastic or cloth which
could have a static charge. If the PC board canŹ¼t be
installed immediately, put it back in the static-shield-
ing bag.
WARNING
ELECTRIC SHOCK
can kill.
ā¢
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.
- If the PC board uses protective shorting jumpers,
donŹ¼t 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 prop-
er failure analysis.
CAUTION
Sometimes machine failures appear to be due to PC
board failures. These problems can sometimes be
traced to poor electrical connections. To avoid prob-
lems when troubleshooting and replacing PC boards,
please use the following procedure:
4. Test the machine to determine if the failure
symptom has been corrected by the
replacement PC board.
NOTE: It is desirable to have a spare (known good)
PC board available for PC board troubleshooting.
1. Determine to the best of your technical ability
that the PC board is the most likely component
causing the failure symptom.
NOTE: Allow the machine to heat up so that all
electrical components can reach their operating
temperature.
5. Remove the replacement PC board and
substitute it with the original PC board to
recreate the original problem.
2. Check for loose connections at the PC board
to assure that the PC board is properly
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:
a. If the original problem does not reappear by
substituting the original board, then the PC
board was not the problem. Continue to look
for bad connections in the 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
board was the problem. Reinstall the
replacement PC board and test the machine.
PC board can be damaged by static electricity.
- Remove your bodyŹ¼s static
charge before opening the static-
shielding bag. Wear an anti-static
wrist strap. For safety, use a 1
Meg ohm resistive cord connected
6. Always indicate that this procedure was
followed when warranty reports are to be
submitted.
to
a
grounded part of the
ATTENTION
Static-Sensitive
Devices
equipment frame.
NOTE: Following this procedure and writing on the
warranty report, āINSTALLED AND SWITCHED PC
BOARDS TO VERIFY PROBLEM,ā will help avoid
denial of legitimate PC board warranty claims.
- If you donŹ¼t have a wrist strap,
touch an un-painted, grounded,
part of the equipment frame. Keep
touching the frame to prevent
static build-up. Be sure not to
touch any electrically live parts at
the same time.
Handle only at
Static-Safe
Workstations
- Tools which come in contact with the PC board must
be either conductive, anti-static or static-dissipative.
INVERTECĀ® V155-S
Download from Www.Somanuals.com. All Manuals Search And Download.
F-4
Observe Safety Guidelines detailed in the beginning of this manual.
F-4
THEORY OF OPERATION
PROBLEMS
POSSIBLE AREAS OF
MISADJUSTMENT(S)
RECOMMENDED
(SYMPTOMS)
COURSE OF ACTION
OUTPUT PROBLEMS
1. Input power Bridge is shorted.
2. Failed Electrolytic Capacitors.
3. Failed Inverter IGBTŹ¼s.
The line circuit breaker trips
when power switch is āONā
1. Perform the Input Board
2. Perform the Inverter Board
1. Restore correct Input power
2. Replace Line switch.
1. No input power on line.
2. Line Switch failure.
The machine is dead, no output,
no fan
3. Perform Input Board Voltage
3. Defective Input Board.
4. Defective Inverter Board
4. Perform Inverter Board
1. Thermal Protection has
tripped.
1. Check Fan and Thermal
Protection Circuits.
The GREEN LED is āONā but
there is no output And yellow
thermal overload LED is āONā
2. Logic Circuit Error on Control
Board.
2. Perform Input Board
3. ARFU System Damage on the
Input Board
3. The Control Board may be
faulty. Replace.
The YELLOW LED is āONā and
the RED and GREEN LEDŹ¼s blink
alternately
1. The machine is unable to cool
itself.
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.
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.
INVERTECĀ® V155-S
Download from Www.Somanuals.com. All Manuals Search And Download.
F-5
Observe Safety Guidelines detailed in the beginning of this manual.
F-5
THEORY OF OPERATION
PROBLEMS
POSSIBLE AREAS OF
MISADJUSTMENT(S)
RECOMMENDED
(SYMPTOMS)
COURSE OF ACTION
OUTPUT PROBLEMS
RED and GREEN LEDŹ¼s are
always āONā
1. Check all PC Board
Connections.
1. Control Board failure.
2. Replace Control Board.
1. Potentiometer or Control
Board needs Replaced.
1. Potentiometer failure.
The machine welds but there is
no output control
2. The Shunt screw
connections are bad.
2. Tighten and check all shunt
connections.
3. Inverter Board failure.
3. Perform Inverter Board
The machine does not have
maximum output
1. Loose connections on output
secondary leads.
1. Check all secondary
connections.
2. The Control Board is out of
Calibration.
2. Recalibrate the Control Board.
Replace if needed.
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.
INVERTECĀ® V155-S
Download from Www.Somanuals.com. All Manuals Search And Download.
F-6
Observe Safety Guidelines detailed in the beginning of this manual.
F-6
THEORY OF OPERATION
PROBLEMS
POSSIBLE AREAS OF
MISADJUSTMENT(S)
RECOMMENDED
(SYMPTOMS)
COURSE OF ACTION
OUTPUT PROBLEMS
1. Potentiometer failure.
2. Control Board failure.
The machine has high welding
output and no control
1. Replace Potentiometer.
2. Replace Control Board.
1. Check connection of white,
red and black leads on the
Inverter Board
1. Shunt Cable damaged.
2. Control Board defective.
RED LED stays ON continuously
2. Replace Shunt Cable
Assembly.
3. Replace Conrol Board.
Flashing YELLOW LED
1. Input Supply Voltage out of
tolerance.
1. Supply correct Input Voltage.
2. Check Control Board
conections.
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.
INVERTECĀ® V155-S
Download from Www.Somanuals.com. All Manuals Search And Download.
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 trou-
bleshooting 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
8ā Magnetized #2 Phillips Head Screwdriver or
Socket with Magnetized 6 inch Extension and #2 Phillips Tip
INVERTECĀ® V155-S
Download from Www.Somanuals.com. All Manuals Search And Download.
F-8
F-8
TROUBLESHOOTING & REPAIR
CASE COVER REMOVAL PROCEDURE (CONTINUED)
FIGURE F.1 ā CASE COVER SCREW LOCATIONS
Five Screws
Three Screws
Ground
PROCEDURE
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 nec-
essary to cut the plastic tie that secures the Input
power cord to the top bracket
1. Disconnect power to the INVERTECĀ® 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
6. Note placement of ground lead secured by lower
front phillips screw on inverter board for re-assem-
bly.
machine.
Note: Be careful. The case back and fan will be loose
when the cover is removed.
7. Remove case back and fan. Lay unit on the left
side and remove the right side cover.
INVERTECĀ® V155-S
Download from Www.Somanuals.com. All Manuals Search And Download.
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 trou-
bleshooting 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
INVERTECĀ® V155-S
Download from Www.Somanuals.com. All Manuals Search And Download.
F-10
F-10
TROUBLESHOOTING & REPAIR
INPUT FILTER CAPACITOR DISCHARGE PROCEDURE (CONTINUED)
FIGURE F.2 ā CAPACITOR DISCHARGE LOCATIONS
D
BOAR
INPUT
CAPACITOR TERMINALS
(4 places)
DC
-
DC+
WARNING
4. Obtain a high resistance and high wattage resistor
(25-1000 ohms and 25 watts minimum). This resis-
tor is NOT supplied with the machine. NEVER USE
A SHORTING STRAP FOR THIS PROCEDURE.
ELECTRIC SHOCK can kill.
ā¢ Have an electrician install and service
this equipment.
ā¢ Turn the input power off at the fuse box
before working on equipment.
5. Locate the two terminals DC+ and DC- on the Input
Board. See Figure F.2.
ā¢ Do not touch electrically hot parts.
6. Use electrically insulated gloves and insulated pli-
ers. 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.
ā¢ Prior to performing preventative maintenance,
perform the following capacitor discharge procedure
to avoid electric shock.
PROCEDURE
1. Disconnect power to the INVERTECĀ® V155-S.
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.
2. Perform the Case Cover Removal Procedure,
3. Locate the Input Board.
FIGURE F.3 ā GLOVE, PLIERS & REISISTOR
INSULATED
PLIERS
INSULATED
GLOVES
RESISTOR
INVERTECĀ® V155-S
Download from Www.Somanuals.com. All Manuals Search And Download.
F-11
F-11
TROUBLESHOOTING & REPAIR
INPUT FILTER CAPACITOR DISCHARGE PROCEDURE (CONTINUED)
FIGURE F.4 ā CAPACITOR DISCHARGE LOCATIONS
INVERTER BOARD
Red
Black
8. Remove the right side cover per Case Cover
9. Use electrically insulated gloves and insulated pli-
ers. 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 proce-
dure.
INVERTECĀ® V155-S
Download from Www.Somanuals.com. All Manuals Search And Download.
F-12
F-12
NOTES
INVERTECĀ® V155-S
Download from Www.Somanuals.com. All Manuals Search And Download.
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 trou-
bleshooting 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
INVERTECĀ® V155-S
Download from Www.Somanuals.com. All Manuals Search And Download.
F-14
F-14
TROUBLESHOOTING & REPAIR
INPUT BOARD RESISTANCE TEST (CONTINUED)
FIGURE F.5 ā INPUT BOARD TEST POINTS
INPU
T BO
ARD
~
r
ectifie
put R
D1 In
ā
+
R2
~
R4
PROCEDURE
1. Disconnect power to the INVERTECĀ® V155-S.
3. Perform the Input Filter Capacitor Discharge
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 āD1ā.
7. Check start resistors āR2ā and āR4ā. Each should
read 20 Ohms. See Figure F.5.
INVERTECĀ® V155-S
Download from Www.Somanuals.com. All Manuals Search And Download.
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 trou-
bleshooting assistance before you proceed. Call 1-888-935-3877.
TEST DESCRIPTION
This procedure will determine if the Inverter Board has any āshortedā or āleakyā power
diodes or Insulated Gate Bipolar Transistors.
MATERIALS NEEDED
Digital Volt/Ohmmeter
Wiring Diagram X0519
Phillips Screwdriver
4mm Nutdriver
INVERTECĀ® V155-S
Download from Www.Somanuals.com. All Manuals Search And Download.
F-16
F-16
TROUBLESHOOTING & REPAIR
INVERTER BOARD RESISTANCE TEST (CONTINUED)
FIGURE F.6 ā INVERTER BOARD TEST POINTS
IGBT
Channel A
Collector
Channel A
Emitter
Gate
INVERTER BOARD
IGBT
channel B
Gate
Collector
Channel B
Emitter
The IGBTŹ¼s of each channel are connected in par-
allel so it is only necessary to check one Emitter
to Collector of each channel.
PROCEDURE
1. Disconnect power to the INVERTECĀ® V155-S.
3. Perform the Input Filter Capacitor Discharge
6. Check each device from gate to emitter. See Figure
F.6
4. Visually check for burned areas on both sides of the
Inverter Board. If no obvious damage is evident,
continue to Step 5.
Note: Normal value is approximately .5VDC in both
polarities.
Note: The following tests may be performed without
Note: Actual readings will vary depending on the meter
being used. Similar tests on all devices should
give similar results.
dis-connecting the Board
5. Check the IGBTŹ¼s for āshortsā using the
volt/ohmmeter in the diode test position, check each
IGBT from emitter to collector. See Figure F.6.
Note: Normal value is approximately 0.40 VDC in one
polarity and a charging value in the opposite
polarity.
These devices will usually fail āshortedā resulting
in a zero or very low resistance reading from
Emitter to Collector. If they āopenā physical dam-
age should be evident.
INVERTECĀ® V155-S
Download from Www.Somanuals.com. All Manuals Search And Download.
F-17
F-17
TROUBLESHOOTING & REPAIR
INVERTER BOARD RESISTANCE TEST (CONTINUED)
FIGURE F.7 ā INVERTER BOARD TEST POINTS
Output
Terminals
Collector
Channel A
D9
INVERTER BOARD
Red
Black
Point 1
(center leg)
D3
D7
R24 = PTC
Collector
Channel B
Point 2
(solder pad)
7. Check the diodes D3 and D9 for āshortsā or āopensā.
See Figure F.7.
10. Check the resistance between the thermal protec-
tion terminals R24. It should be about 36-40 ohms.
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.
11. Check the resistance between output terminal con-
nections. It should be about 8.5Kohms.
9. Check the five output diodes for āshortsā or āopensā.
Check from the center terminal (Point 1) of each
Diode (all center terminals of the diodes are com-
mon with the heatsink) to the large copperl area
āpoint 2ā. 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
INVERTECĀ® V155-S
Download from Www.Somanuals.com. All Manuals Search And Download.
F-18
F-18
NOTES
INVERTECĀ® V155-S
Download from Www.Somanuals.com. All Manuals Search And Download.
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 trou-
bleshooting 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
WARNING
ELECTRIC SHOCK can kill.
ā¢ Do not touch electrically live parts such as output terminals or inter-
nal wiring.
ā¢ Insulate yourself from the work and ground.
ā¢ Always wear dry insulating gloves.
INVERTECĀ® V155-S
Download from Www.Somanuals.com. All Manuals Search And Download.
F-20
F-20
TROUBLESHOOTING & REPAIR
INPUT BOARD VOLTAGE TEST (CONTINUED)
FIGURE F.8 ā INPUT BOARD TEST POINTS
PIN 14
PIN 12
JP1
PIN 8
PIN 4
PIN 3
PIN 1
PIN 2
INPUT BOARD
AC1
AC2
DC-
DC+
PROCEDURE
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.
1. Disconnect power to the INVERTECĀ® V155-S.
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 con-
Check pin 12 for +5VDC.
PWR 2(white) to 4
PWR 4(white) to 5
PWR 1(blue) to 1
PWR 3(blue) to 2
INVERTECĀ® V155-S
Download from Www.Somanuals.com. All Manuals Search And Download.
F-21
F-21
TROUBLESHOOTING & REPAIR
INPUT BOARD VOLTAGE TEST (CONTINUED)
FIGURE F.9 ā MAIN SWITCH PLUG LOCATION
White from
PWR 2
White from
PWR4
Blue from
PWR 1
Blue from
PWR 3
3
1
2
6
4
5
1. Put the blue wire from PWR3 in position 2 of the
main switch while the white wire from PWR4 in posi-
tion 5.
2. Put the blue wire from PWR1 in position 1 of the
main switch while the white wire from PWR2 in posi-
tion 4.
INVERTECĀ® V155-S
Download from Www.Somanuals.com. All Manuals Search And Download.
F-22
F-22
NOTES
INVERTECĀ® V155-S
Download from Www.Somanuals.com. All Manuals Search And Download.
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 trou-
bleshooting 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 volt-
ages 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
WARNING
ELECTRIC SHOCK can kill.
ā¢ Do not touch electrically live parts such as output terminals or inter-
nal wiring.
ā¢ Insulate yourself from the work and ground.
ā¢ Always wear dry insulating gloves.
INVERTECĀ® V155-S
Download from Www.Somanuals.com. All Manuals Search And Download.
F-24
F-24
TROUBLESHOOTING & REPAIR
INVERTER BOARD VOLTAGE TEST (CONTINUED)
FIGURE F.10 ā PLUG JP1 TESTPOINTS
15
13
11
9
16
14
12
10
8
JP1
7
5
3
6
4
PIN 1
PIN 2
INPUT BOARD
AC1
AC2
DC-
DC+
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 CON-
NECTOR JP1. See Fig. F.10.
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.
PROCEDURE
1. Disconnect power to the INVERTECĀ® V155-S.
side only).
Check pin 12-> +5VDC (supply voltage generated
on input board).
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 14-> +15VDC (supply voltage generat-
ed on input board).
7. Check to see if the correct microcontroller program
is preset: H490000005-004X where X is the revi-
sion number.
Check pin 1-> +15VDC means fan is ON. 0VDC
means fan is OFF.
INVERTECĀ® V155-S
Download from Www.Somanuals.com. All Manuals Search And Download.
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 trou-
bleshooting 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
INVERTECĀ® V155-S
Download from Www.Somanuals.com. All Manuals Search And Download.
F-26
F-26
TROUBLESHOOTING & REPAIR
INPUT BOARD REMOVAL AND REPLACEMENT PROCEDURE
FIGURE F.11 ā SCREW AND LEAD LOCATION
INPUT BOARD
AC1
AC
2
DC-
DC+
MOUNTING SCREWS
.
PROCEDURE
1. Disconnect power to the INVERTECĀ® V155-S.
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.
(Left side only).
3. Perform the Input Filter Capacitor Discharge
8. Connect all leads and plugs previosly removed
9. Replace the four mounting screws previously
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.
removed.
10. Replace the case cover.
INVERTECĀ® V155-S
Download from Www.Somanuals.com. All Manuals Search And Download.
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 trou-
bleshooting 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 (6ā minimum)
INVERTECĀ® V155-S
Download from Www.Somanuals.com. All Manuals Search And Download.
F-28
F-28
TROUBLESHOOTING & REPAIR
INVERTER BOARD REMOVAL AND REPLACEMENT PROCEDURE (CONTINUED)
FIGURE F.12 ā DOOR REMOVAL
Five Screws
Three Screws
Ground
PROCEDURE
Note: Pay attention to wiring diagram very closely.
1. Disconnect power to the INVERTECĀ® V155-S.
When connecting cables from the Input
Board to the Power Switch. You must con-
3. Perform the Input Filter Capacitor Discharge
PWR 2(white) to 4
PWR 4(white) to 5
PWR 1(blue) to 1
PWR 3(blue) to 2
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.
INVERTECĀ® V155-S
Download from Www.Somanuals.com. All Manuals Search And Download.
F-29
F-29
TROUBLESHOOTING & REPAIR
INVERTER BOARD REMOVAL AND REPLACEMENT PROCEDURE (CONTINUED)
FIGURE F.13 ā INVERTER BOARD REMOVAL
10MM
BOLTS
DC+
DC-
OUTPUT
TERMINALS
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,
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 cor-
ner.
8. Label and disconnect any associated plugs and
leads.
INVERTECĀ® V155-S
Download from Www.Somanuals.com. All Manuals Search And Download.
F-30
F-30
NOTES
INVERTECĀ® V155-S
Download from Www.Somanuals.com. All Manuals Search And Download.
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 trou-
bleshooting 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 (6ā minimum)
INVERTECĀ® V155-S
Download from Www.Somanuals.com. All Manuals Search And Download.
F-32
F-32
TROUBLESHOOTING & REPAIR
CONTROL BOARD REMOVAL AND REPLACEMENT PROCEDURE (CONTINUED)
FIGURE F.14 CONTROL BOARD REMOVAL
MOUNTING
SCREWS
NUT
WASHER
CONTROL
BOARD
KNOB
RED CAP
PROCEDURE
1. Disconnect power to the INVERTECĀ® V155-S.
8. Disconnect the JP1 connector.
9. Using a phillips screwdriver, remove the four mount-
ing screws located on the corners of the solder side
of the control board.
10. Disconnect the JP2 connector.
side only).
3. Perform the Input Filter Capacitor Discharge
11. Remove and replace the control board.
Note: When installing the new control board, be sure
to turn the output potentiometer shaft complete-
ly counter clockwise prior to fastening knob into
place. This will assure that the output setting is
at itŹ¼s lowest setting. This will allow proper install
ation of the output knob with the red arrow point-
ing to the lowest setting possible. If this is not
done properly, the machine output will not match
the set current.
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.
INVERTECĀ® V155-S
Download from Www.Somanuals.com. All Manuals Search And Download.
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 machineŹ¼s 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%
2kw
30%
3kw
3kw
120VAC +/- 10%
230VAC +/- 10%
34 A
33 A
2kw
RATED OUTPUT
Duty Cycle
Output Amps
Output Volts
Input Circuit
120 Vac
75A (stick)
23.0 Vdc
105A (TIG)
14.2 Vdc
100%
100A (stick)
100A (TIG)
24.0 Vdc
14.0 Vdc
230 Vac
100A (stick)
130A (TIG)
24.0 Vdc
15.2 Vdc
120 Vac
230 Vac
30%
145A (stick)
155A (TIG)
25.8 Vdc
16.2 Vdc
OUTPUT
Output Current Range
Maximum Open Circuit Voltage
Type of Output
DC
75 Volts Max.
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
IMPORTANT: IF OTHER TYPE METERS ARE USED RESULTS MAY NOT BE ACCURATE.
INVERTECĀ® V155-S
Download from Www.Somanuals.com. All Manuals Search And Download.
F-34
F-34
NOTES
INVERTECĀ® V155-S
Download from Www.Somanuals.com. All Manuals Search And Download.
G-1
G-1
TABLE OF CONTENTS - DIAGRAM SECTION
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
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.
INVERTECĀ® V155-S
Download from Www.Somanuals.com. All Manuals Search And Download.
G-2
G-2
ELECTRICAL DIAGRAMS
WIRING DIAGRAM - CODES 11326 & 11327
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.
INVERTECĀ® V155-S
Download from Www.Somanuals.com. All Manuals Search And Download.
G-3
G-3
ELECTRICAL DIAGRAMS
SCHEMATIC - COMPLETE MACHINE - CODES 11326 & 11327
i
control
them
output
turning on full
with
Power Up
ā
ā
On
windings
de-energizedfor a 230Vac
NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual.
INVERTECĀ® V155-S
Download from Www.Somanuals.com. All Manuals Search And Download.
G-4
G-4
ELECTRICAL DIAGRAMS
SCHEMATIC - INPUT PC BOARD
PWR1
BLUE
RL3B
30A
ARFU1A
4 mm
2
30A
AC1
1
2
2
1
1
L1
DC+1
2
4
1
2
D1
54A
+
+
C1
+
+
C2
R1
15K
3W
HS1
RL1B
C8
1500ĀµF
250V
1500ĀµF
250V
47nF
250Vac
Y
RL2B
-
+
30A
W9199065
R3
180k
2W
C7
C9
1uF
275Vac
MKT
Earth
Faston
N.M.
VARISTOR
470nF
275Vac
MKT
RV1
N.M.
RL4B
30A
C4
C5
R5
15k
3W
DC-1
C10
1500ĀµF
250V
1500ĀµF
250V
AC2
47nF
250Vac
Y
PWR2
WHITE
RL8B
1
3
1
2
W58A4463
30A
R2
20
R11
R12
C13 220nF
10W 10%
MKT250Vac
Fan1
ARFU1B
90Ā°C NC
470
3W
470
3W
JP5
D5
1N4007
D9
2
1
U4A
CNY17-3
1KAB100E
1.5A 1000V
R4
M1
M2
M3
PE
C21 220nF
MKT250Vac
MODU1/2
N.M.
20
10W 10%
AC2b
Vr5V
AC1b
PWR3
BLUE
T1
1
JP2
VIN1
Vr5V
9
7
1
VIN2
2
AC2b
D3
D4
3
+15V
4
V++
5
5
V++
6
PWR4
WHITE
1.5 VA
230Vac/15Vac
PTA0
1N4007
1N4007
7
PTA4-OSC2
OSC1
8
V++
9
D6 1N4148
AD1
IRQ
RESET
D8
1N4148
RL5A
6Vdc
JQX-115F
RL1A
12Vdc
RL8A
12Vdc
RL2A
12Vdc
RL4A
12Vdc
RL3A
12Vdc
10
11
12
13
14
15
16
17
18
R14
470
1W
R6
10k
RL5B
JQX-115F
0.4W 1%
RL_PRE
RL_SER
RL_AUX
RL_PAR
SET_PASSIVE
INPUT_ERR
RL7A
JZC-33F
Fan_ONn
A2
A1
Rele' Reconn Rele'
Aux. Potenza
Rele' 230V Rele' 115V
12Vdc
RL7B
JZC-33F
22
14
AC1b
11
JP4
RL5C
JQX-115F
RL6B
RL6C
JP3
14
12
11
21
1
2
3
4
Blue
Vr5V
White
Red
1
GND
OSC1
PTA4-OSC2
PTA0
AD1
IRQ
2
3
4
5
6
7
8
Black
RL6A
110Vac
FINDER 40.52
22
24
MODU1/4
R10
270
AC2b
RESET
0.4W
N.M.
C12
R7
0R
Fan1
1
T2
22nF
50V
+15V
D7
1.5A 1000V
1000V
JP1
W6300003
11
-
+
Fan_ONn
INPUT_ERR
V_FB
Passive Detect
GND
ERRORn
PRES
3
4
1
2
4
U1
+15V
DUTY
GND
VINint
+5V
+15V
GND
3
8
U4B
5
6
3
2
9
6
R13
FDBK1
FDBK2
DRVCOL
7
8
+15V
R16
N.M.
L2 350uH 1A
3
6
11
SWCOL
9
10
12
14
16
15VA
10
5
SWCOL
11
13
15
115-230Vac/21Vac
16
14
6
BTSTRP
SWEMIT
R15
56
GND
15
4
SWEMIT
8
6
ISEN
TIMCAP
Reconnect Power supply
1
LVIOUT
CNY17-3
0R18 2W 5%
R8
C14
22k
100nF
63V
7
VCC
U2
LM7805
Vr5V
U3
LM7805
MC33163
+
D2
1N5822
C16
1000ĀµF
25V
+5V
1
3
IN
OUT
1
3
IN
OUT
+
C11
680pF
100V
C18
3300ĀµF
35V
R9
2k
C3
+
C20
10uF
63V
C15
100nF
63V
100nF
63V
C6
100nF
63V
+
C17
10uF100nF
C19
LINCOLN ELECTRIC ITALIA s.r.l.
SERRA RICCO' (GE) - ITALIA
63V
63V
Title
Dr.
GND
INPUT V145 2V
HS2
HS3
Appr.
Size
A3
Document Number
X0701
Rev
F.Scorza
00
W9108165
W9108165
Date last rev.:
1st emis. dr.:
Sheet
1st emis. date:
2
of
2
Wednesday, July 19, 2006
I.Buscaglia
Tuesday, March 25,2003
This sheet contains proprietary information owned by LINCOLN ELECTRIC ITALIA s.r.l. and is not to be
reproduced, disclosed, or used without the express permission of LINCOLN ELECTRIC ITALIA
NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual.
INVERTECĀ® V155-S
Download from Www.Somanuals.com. All Manuals Search And Download.
G-5
G-5
ELECTRICAL DIAGRAMS
PC BOARD ASSEMBLY - INPUT BOARD
NOTE: Lincoln Electric assumes no responsibility for liablilities resulting from board level troubleshooting. PC Board repairs will invalidate your factory warranty. Individual Printed Circuit Board Components are not available from Lincoln Electric. This information is pro-
vided for reference only. Lincoln Electric discourages board level troubleshooting and repair since it may compromise the quality of the design and may result in danger to the Machine Operator or Technician. Improper PC board repairs could result in damage to the
machine.
INVERTECĀ® V155-S
Download from Www.Somanuals.com. All Manuals Search And Download.
G-6
G-6
ELECTRICAL DIAGRAMS
SCHEMATIC - INVERTER PC BOARD - SHEET #1
HS1
W91X0611
DC+
C1
D22
1nF
C2 2n2F
R5 22R
3W 5%
HS3
R24
PTC
HS3
1N4007
Q1
Q2
Q3
Q5
Q6
Q12
1600V
PTC
R6A
N.M.
SGP30N60HS
15K
R1
10R
3W 5%
630V
3W 5%
470R 80Ā°C
Eh
300V 2x30A
D1
U1A
W91X0610
CNY17-3
N.M.
D21
1N4007
N.M.
Vout
P1
P2
C17
R2
10R
R3
10R
R4
10R
R90
10R
R89
10R
R88
10R
L1
33nF
100V
N.M.
W5900651
1:100
T1
D2
W58X0455
7 uH
Gh
C6
2n2F
630V
C7
3n3F
R6B
C4
C3
C8
4n7F
4kV
15K
R39
470R
N.M.
10nF
1600V
470uF
450V
+
3W 5%
D3
C5
470uF
450V
+
BAL
STTA1206DI
ISOLATO
HS2
D4
D5
D6
D8
R11
10R
3W 5%
1.5KE250CA
R12
10K
5W
D10
1.5KE250CA
C9
PE
470uF
N.M.
R41
470R
N.M.
450V
R7A
15K
+
3W 5%
D9
R9
82R
10W 5%
R14
220R
2W 5%
D7
HS2
ISOLATO
BYT12PI-1000
R13
10R
3W 5%
U2A
R8
T2
C11
4n7F
4kV
CNY17-3
N.M.
STTA1206D
HS1
82R
1
2
3
D23
1N4007
N.M.
R10
82R
10W 5%
C18
HS2
W91X0611
10W 5%
33nF
100V
N.M.
4
5
N1
C10
1nF
1600V
D13
R7B
Q4
Q17
Q16
Q15
Q14
Q13
R27 15R
15K
D24
1N4007
N.M.
SGP30N60HS
R86
180
N.M.
VINint
3W 5%
R15
10R
3W 5%
BYV26B
6
C12
220nF
250V
R85
1K5
3W 5%
El
W59X0293
DC-
R18
10R
R19
10R
R20
10R
R91
10R
R92
10R
R93
10R
U1B
N.M.
6
5
Gl
4
CNY17-3
U2B
N.M.
C33
4n7F
6
5
COMP
COMP
D12
4
Vout
TA
CNY17-3
JP2 N.M.
D25
BAT43
BYV26B
1
3
MASTER
SLAVE
R32
3k3
R25
R17
1K
0.5W 5%
4R7
Gh
0.5W 5%
R26
470R
R35
47k
JP1
M/S
I_FB
V_FB
Passive Detect
GND
ERRORn
PRES
GND
1
2
4
R28
15V
3
DUTY
5
6
DUTY
15V
D14
1N4749
GND
7
8
Q7
IRFD110
100R
VINint
9
10
12
14
16
R38
10k
ERRORn
PRES
11
13
15
R29
470R
T3
15V
GND
15V
14
+
C15
1
3
D18
W6300006
220uF
1N4148
REC
Eh
Gl
10
12
GND
5
7
JP6
PILOT
R31
470R
15V
PWM
1
3
5
7
2
4
6
8
TA
PILOT
8
GND
GND
R33
W5998052
ERRORn
D19
D15
D16
D17
15V
W6110204
MODU2 90Ā°
N.M.
1N4749
Q8
IRFD110
100R
D33
R34
470R
1N4148
1N4148
1N4148
1N4148
W4004148
N.M.
LINCOLN ELECTRIC ITALIA s.r.l.
SERRA RICCO' (GE) - ITALIA
El
Title
Dr.
R87 4k7
Passive Detect
INVERTER BOARD V145
D20
1N4148
+
C13
220uF
C14
100nF
R30
2k7
N.M.
Appr.
Size
A3
Document Number
X0519
Rev
02
V. Natarelli
PASSIVEn
Date last rev.:
1st emis. dr.:
Friday, February 17, 2006
J. Daniel
S heet
2
of
3
1st emis. date: Thursday, June 14, 2001
This sheet contains proprietary information owned by LINCOLN ELECTRIC ITALIA s.r.l. and is not
to be reproduced, disclosed, or used without the express permission of LINCOLN ELECTRIC
ITALIA
NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual.
INVERTECĀ® V155-S
Download from Www.Somanuals.com. All Manuals Search And Download.
G-7
G-7
ELECTRICAL DIAGRAMS
SCHEMATIC - INVERTER PC BOARD - SHEET #2
15V
R42 22k
-
15V
15V
D26
6
VINint
7
+
5
PRES
C19
220nF
50V
R43
180R
U3B
1N4148
PRES
C20
100nF
50V
R44
270k
LM358
R47 10k
R45 100k
N.M.
GND
R46
2k2
GND
U3A
-
D27
R48 1k
2
3
1
+
1N4148
LM358
15V
FEED-FORWARD
R49 3k
R50 3k
R51 10k
15V
C31
100nF
50V
C32
100nF
50V
R52 10k
R53 10k
U5C
LM393
U3C
LM358
R54
1k
D28
3
2
+
-
R55
2k2
R56 100R
1
5
6
+
-
7
PTC
ERRORn
U5A
LM393
BAT43
U5B
C21
100nF
50V
R58
10k
R57 39k
LM393
R59
10k
15V
R60
68k
R61 2k2
TA
R62 820R
R63 10k
15V
R64
1k
R65
4k7
COMP
C22
100nF
50V
C23
100nF
50V
N.M.
R66
15R
U6
C24
Vref
Vref
R67 18k
16
Vref
Vref
13
9
VC
R68
1k5
C25
R69
1k
100nF
100nF
50V
15V
50V
R70
4k7
N.M.
8
3
1
2
4
SS
SHD
R72 4k7
R71
1k
N.M.
C27
220pF
100V
C28
100nF
50V
C26 100pF
Taratura
Duty Max
43%
EO
EII
MASTER
PWM
Q9
IRFD110
N.M.
R73
1k
R74
15k
N.M.
11
CLRef
DUTY
ENI
CLK
R75 10k
PILOT
R79 56R
Q10
BC337
N.M.
PASSIVEn
R76
10k
N.M.
D29
1N4148
N.M.
C29
N.M.
R77
4k7
N.M.
R78
4k7
Q11
IRFD110
1nF
5
6
7
14
RT
OUT
R80
1k8
630V
SLAVE
CT
R81
8k2
D30
R82
10k
R83
1k
D31
1N4148
Ramp
1N4148
N.M.
MC34023
D32
C30
REC
2n2F
2%
350Vdc
1N4148
Taratura
oscillatore
R84
2k
LINCOLN ELECTRIC ITALIA s.r.l.
A
SERRA RICCO' (GE) - ITALIA
Title
Dr.
INVERTER BOARD V145
Appr.
Size
A3
Document Number
Rev
X0519
02
V. Natarelli
Date last rev.:
1st emis. dr.:
Friday, February 17, 2006
J. Daniel
S heet
3
of
3
1st emis. date: Friday, January 31, 2003
This sheet contains proprietary information owned by LINCOLN ELECTRIC ITALIA s.r.l. and is not
to be reproduced, disclosed, or used without the express permission of LINCOLN ELECTRIC
ITALIA
NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual.
INVERTECĀ® V155-S
Download from Www.Somanuals.com. All Manuals Search And Download.
G-8
G-8
ELECTRICAL DIAGRAMS
PC BOARD ASSEMBLY- INVERTER BOARD - SHEET # 1
*See Page 2 for more
detailed component
information
NOTE: Lincoln Electric assumes no responsibility for liablilities resulting from board level troubleshooting. PC Board repairs will invalidate your factory warranty. Individual Printed Circuit Board Components are not available from Lincoln Electric. This information is pro-
vided for reference only. Lincoln Electric discourages board level troubleshooting and repair since it may compromise the quality of the design and may result in danger to the Machine Operator or Technician. Improper PC board repairs could result in damage to the
machine.
INVERTECĀ® V155-S
Download from Www.Somanuals.com. All Manuals Search And Download.
G-9
G-9
ELECTRICAL DIAGRAMS
PC BOARD ASSEMBLY - INVERTER BOARD - SHEET #2
NOTE: Lincoln Electric assumes no responsibility for liablilities resulting from board level troubleshooting. PC Board repairs will invalidate your factory warranty. Individual Printed Circuit Board Components are not available from Lincoln Electric. This information is pro-
vided for reference only. Lincoln Electric discourages board level troubleshooting and repair since it may compromise the quality of the design and may result in danger to the Machine Operator or Technician. Improper PC board repairs could result in damage to the
machine.
INVERTECĀ® V155-S
Download from Www.Somanuals.com. All Manuals Search And Download.
G-10
G-10
ELECTRICAL DIAGRAMS
SCHEMATIC - CONTROL PC BOARD
1
+15V
JP1
R2
+15V
+15V
4k7
0603
1%
FAN_ONn
CEVRD
1
2
4
+15V
Inputerr
+15V
DUTY
GND
3
Voutm
+15V
5
6
R1
U4C
U2C
7
8
VENn
Q1
BC817
SOT23
10k
0603
1%
C27
100nF
50V
C18
100nF
50V
GND
ERRORn
2
9
10
12
14
16
+5V
+15V
11
13
15
R32
1k2
1206
1%
R4
5k6
R5
LM358AM
SO8
0805
LM358AM
SO8
0805
GND
GND
4k7
0603
1%
0603
1%
+15V
R10
47R
0603
1%
HEADER 8X2 90Ā° P/I
THRCE35
+15V
PTCE
2
+15V
D9
Q2
BC817
SOT23
R7
YELLOW
D 5mm
D1
BAT54S
SOT23
C1
100nF
50V
R8
5k6
0603
1%
R38
4k7
0603
1%
R6
15k
0603
1%
R12
100k
0603
1%
4k7
0603
1%
C2
100nF
50V
0805
R15
100k
0603
1%
D3
LL4148
MINIMELF
U1B
LM324
SO14
0805
D2
LL4148
MINIMELF
THLED
2
-
+
+15V
2
3
Voutm
Voutfilt
C5
820pF
0603
50V
Q4
BC817
SOT23
5
6
1
+
-
Vout
R17
2k2
0805
1%
R41
5k6
+15V
7
R14
10k
0603
1%
R65
100k
0603
1%
R66
120k
0603
1%
C4
100nF
50V
U1A
LM324
SO14
R21
4k7
0603
1%
C6
220pF
50V
0603
1%
R20
10k
0603
1%
R67
5k6
0603
1%
R13
390k
0603
1%
0805
0603
R9
1k2
1206
1%
THRLED
R16
5k6
0603
1%
Led indicator for VRD system
R28
R68
910R
0603
1%
R23
3k9
0603
1%
ISET 100%DC->190A
4k7
0603
1%
U2B
LM358AM
SO8
R30
22R
0603
1%
U1D
LM324
SO14
D6
RED
D 5mm
ISET
5
10
9
+
-
+
-
+15V
DUTY
-
+
7
13
12
8
R27
1k8
0603
1%
C10
33nF
50V
C9
6
14
10nF
50V
0603
Voutfilt
NB: i led sono a montaggio through
hole
R24
U1C
LM324
SO14
R29
1k
0603
1%
D7
BAT54S
SOT23
1206
C13
22nF
50V
0603
N.M.
R36
4k7
0603
1%
100k
0603
1%
R25
1k2
C7
100nF
50V
C11
100pF
50V
R26
1206
1%
10k
0603
1%
U4B
0805
I+
OFF+
IMIS
0603
D16
5
6
+
LL4148
MINIMELF
7
-
R31
39k
0603
1%
C12
4n7F
50V
R34
R35
C14
4n7F
50V
D8
+15V
10k
0603
1%
10k
0603
1%
GREEN
D 5mm
IMIS=3.81V -> 145A
R33
LM358AM
SO8
R3
0603
220R
0603
1%
2k2
0805
1%
0603
D10
BAT54S
SOT23
U2A
SJ1
0R
0603
N.M.
R46
0603 1%
1M
3
+
-
Q6
BC807
SOT23
1
2
+5V
OFF+
LM358AM
SO8
+15V
R37
C15
22nF
50V
SJ2
0R
0603
N.M.
C28
4n7F
50V
2k2
0805
1%
R50
0603 1%
2M
I-
R69
2k2
0603
0603
R40
1k
0603
1%
0603
1%
SJ3
0R
0603
N.M.
R55
0603 1%
3M9
. CW
R42
18k
0603
1%
R43
R70
2k2
0603
1%
50k MONO
1%
Piste per regolazione offset.
SJ4
0R
0603
N.M.
R45
1% 0603
1M
Calibrazione Imax
Trimmer smd verticale
WELDING
Q7
BC817
SOT23
2
+5V
R71
SJ5
0R
0603
N.M.
C20
100nF
50V
4k7
0603
1%
R72
4k7
0603
1%
R48
1% 0603
2M
FAN_ONn
0805
A
A
+5V
+5V
+5V
SJ6
0R
0603
N.M.
R51
1% 0603
3M9
D13
BAT54S
SOT23
D14
BAT54S
SOT23
+5V
R58
4k7
0603
1%
U3
Q5
BC817
SOT23
2
S/T
PTCuM
WELDING
Arcset
Fan
VENn
PTCE
THLED
R52
15
PTB0
PTB1
PTB2
PTB3
PTB4
PTB5
PTB6
PTB7
Piste per regolazione offset.
2k2
0603
1%
R54
2k2
14
11
10
7
R61
. CW
2
ISET
AD1
CEVRD
VRD
AD2
AD0
13
12
9
AD0/PTA0/TCH0/KBIO
AD1/PTA1/TCH1/KBI1
IRQ/PTA2/KBI2
RST/PTA3/KBI3
AD2/PTA4/KBI4/OSC2
AD3/PTA5/KBI5/OSC1
POTENZIOMETRO LINEARE 2K5 20%
BOURMS 91U1D-T14-EAO/260
SET
0603
1%
IRQ
R60
2k5
20%
RESET
8
6
1k
1%
0603
1%
Vout
5
4
3
R64
3k3
0603
1%
C22
100nF
50V
R62
IMIS
OSC
2
100k
0603
1%
R63
10k
0603
1%
R83
R73
1k
0603
1%
ISET-> PWM of current set
SET -> Current set
CEVRD -> HV or CE version
C26
100nF
50V
0805
C23
10nF
50V
10k
0603
1%
C24
10nF
50V
MC68HC908QY4
SOIC16
0805
VRD -> Start signal in CE version
AD2 -> Ouptut voltage AD
OSC -> Oscillator pin
Vout -> output voltage
Imis -> Output current
S/T -> Stick / tig working
PTCuM -> Error signal
WELDING -> Green mode and VRD
detect
0603
0603
+5V
+5V
SET=3.81V ->145A
GND
OSC
AD2
AD0
AD1
IRQ
RESET
+5V
SW2
Da implementare per la programmazione in-circuit
Eseguire foratura per striscia pin berg.
THRVRDS
CEVRD
THRLED
THRCE35
R39
4k7
0603
1%
1
2
3
4
8
7
6
5
Arcset -> Arc force selection
Fan -> Fan setting
+5V
D11
BAT54S
SOT23
S/T
SW DIP-4
VENn -> OCV set
PTCE -> Inverter set
THLED -> thermal led
+5V
R59
4k7
0603
1%
R44
100R
0603
1%
D15
BAT54S
SOT23
C17
100nF
50V
+15V
D17
BAT54S
SOT23
Arcset
R57
4k7
0603
1%
0805
R74
12k
0603
1%
+5V
+5V
SW1
FEME T1C/1/L1/X/H
VRD
SW1: deviatore a tre posizioni
4X VITI FISSAGGIO SCHEDA
Q8
4
C21
100nF
50V
0805
N.M.
BC817
SOT23
THRVRDS
2
D12
BAT54S
SOT23
R75
4k7
0603
1%
R76
470k
0603
1%
R77
10k
0603
1%
R78
1k
0603
1%
C25
100nF
50V
0805
N.M.
R79
4k7
0603
1%
R47
R80
10k
0603
1%
18k
0603
1%
U4A
M5
1
+15V
PTCuM
ERRORn
3
+
M1
1
1
R49
100k
0603
1%
2
-
M2
1
LM358AM
SO8
C19
R81
M3
1
1nF
50V
4k7
0603
1%
JP2
M4
1
0603
I+
I-
1
2
3
4
LINCOLN ELECTRIC ITALIA s.r.l.
SERRA RICCO' (GE) - ITALIA
R82
100R
0603
1%
D5
S1M
DO 214AC
MODU2 2VIE 90Ā°
Title
C29
100nF
50V
Control Board V145S
0805
Dr.
Appr.
Size
A2
Document Number
X0708
Rev
00
F.Scorza
Date last rev.: Wednesday, April 05, 2006
1st emis. dr.: <1st emis. dr.>
Sheet
2
of
2
1st emis. date: Wednesday, February 18, 2004
This sheet contains proprietary information owned by LINCOLN ELECTRIC ITALIA s.r.l. and is not to be
reproduced, disclosed, or used without the express permission of LINCOLN ELECTRIC ITALIA
1
NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual.
INVERTECĀ® V155-S
Download from Www.Somanuals.com. All Manuals Search And Download.
G-11
G-11
ELECTRICAL DIAGRAMS
PC BOARD ASSEMBLY - CONTROL BOARD PAGE - SHEET #1
* See Page 2 for more
detailed component
information
NOTE: Lincoln Electric assumes no responsibility for liablilities resulting from board level troubleshooting. PC Board repairs will invalidate your factory warranty. Individual Printed Circuit Board Components are not available from Lincoln Electric. This information is pro-
vided for reference only. Lincoln Electric discourages board level troubleshooting and repair since it may compromise the quality of the design and may result in danger to the Machine Operator or Technician. Improper PC board repairs could result in damage to the
machine.
INVERTECĀ® V155-S
Download from Www.Somanuals.com. All Manuals Search And Download.
G-12
G-12
ELECTRICAL DIAGRAMS
PC BOARD ASSEMBLY - CONTROL BOARD - SHEET #2
NOTE: Lincoln Electric assumes no responsibility for liablilities resulting from board level troubleshooting. PC Board repairs will invalidate your factory warranty. Individual Printed Circuit Board Components are not available from Lincoln Electric. This information is pro-
vided for reference only. Lincoln Electric discourages board level troubleshooting and repair since it may compromise the quality of the design and may result in danger to the Machine Operator or Technician. Improper PC board repairs could result in damage to the
machine.
INVERTECĀ® V155-S
Download from Www.Somanuals.com. All Manuals Search And Download.
|
KWC Indoor Furnishings K12VB92700A26 User Manual
KWC Indoor Furnishings K38H470931A17 User Manual
Lenoxx Electronics Conference Phone PH 550 User Manual
LG Electronics Computer Monitor W2243S User Manual
Logitech Speaker System 980 000402 User Manual
Magellan GPS Receiver 315 User Manual
Magic Chef Refrigerator MCBR240B User Manual
Makita Air Compressor MAC2200 User Manual
Mark Levinson Stereo Amplifier 326S User Manual
Maytag Clothes Dryer MGD5707TQ0 User Manual