service v155-s
SVM183-A
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INVERTEC ® V155-S
July, 2008
For use with machines having Code Numbers: 11326; 11327
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Safety Depends on You
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Lincoln arc welding and cutting
equipment is designed and built
with safety in mind. However, your
overall safety can be increased by
proper installation ... and thoughtful operation on your part. DO
NOT INSTALL, OPERATE OR
REPAIR THIS EQUIPMENT
WITHOUT READING THIS MANUAL AND THE SAFETY PRECAUTIONS
CONTAINED
THROUGHOUT.
And,
most
importantly, think before you act
and be careful.
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SERVICE MANUAL
Copyright © Lincoln Global Inc.
• World's Leader in Welding and Cutting Products •
• Sales and Service through Subsidiaries and Distributors Worldwide •
Cleveland, Ohio 44117-1199 U.S.A. TEL: 888.935.3877 FAX: 216.486.1751 WEB SITE: www.lincolnelectric.com
SAFETY
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i
WARNING
CALIFORNIA PROPOSITION 65 WARNINGS
Diesel engine exhaust and some of its constituents
The engine exhaust from this product contains
are known to the State of California to cause canchemicals known to the State of California to cause
cer, birth defects, and other reproductive harm.
cancer, birth defects, or other reproductive harm.
The Above For Gasoline Engines
The Above For Diesel Engines
ARC WELDING CAN BE HAZARDOUS. PROTECT YOURSELF AND OTHERS FROM POSSIBLE SERIOUS INJURY OR DEATH.
KEEP CHILDREN AWAY. PACEMAKER WEARERS SHOULD CONSULT WITH THEIR DOCTOR BEFORE OPERATING.
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Read and understand the following safety highlights. For additional safety information, it is strongly recommended that you
purchase a copy of “Safety in Welding & Cutting - ANSI Standard Z49.1” from the American Welding Society, P.O. Box 351040,
Miami, Florida 33135 or CSA Standard W117.2-1974. A Free copy of “Arc Welding Safety” booklet E205 is available from the
Lincoln Electric Company, 22801 St. Clair Avenue, Cleveland, Ohio 44117-1199.
BE SURE THAT ALL INSTALLATION, OPERATION, MAINTENANCE AND REPAIR PROCEDURES ARE
PERFORMED ONLY BY QUALIFIED INDIVIDUALS.
FOR ENGINE
powered equipment.
1.a. Turn the engine off before troubleshooting and maintenance
work unless the maintenance work requires it to be running.
____________________________________________________
1.b.Operate engines in open, well-ventilated
areas or vent the engine exhaust fumes
outdoors.
____________________________________________________
1.c. Do not add the fuel near an open flame welding arc or when the engine is running. Stop
the engine and allow it to cool before refueling to prevent spilled fuel from vaporizing on
contact with hot engine parts and igniting. Do
not spill fuel when filling tank. If fuel is spilled,
wipe it up and do not start engine until fumes
have been eliminated.
____________________________________________________
1.d. Keep all equipment safety guards, covers and devices in position and in good repair.Keep hands, hair, clothing and tools
away from V-belts, gears, fans and all other moving parts
when starting, operating or repairing equipment.
____________________________________________________
1.e. In some cases it may be necessary to remove safety
guards to perform required maintenance. Remove
guards only when necessary and replace them when the
maintenance requiring their removal is complete.
Always use the greatest care when working near moving
parts.
___________________________________________________
1.f. Do not put your hands near the engine fan.
Do not attempt to override the governor or
idler by pushing on the throttle control rods
while the engine is running.
___________________________________________________
1.g. To prevent accidentally starting gasoline engines while
turning the engine or welding generator during maintenance
work, disconnect the spark plug wires, distributor cap or
magneto wire as appropriate.
1.h. To avoid scalding, do not remove the
radiator pressure cap when the engine is
hot.
ELECTRIC AND
MAGNETIC FIELDS
may be dangerous
2.a. Electric current flowing through any conductor causes
localized Electric and Magnetic Fields (EMF). Welding
current creates EMF fields around welding cables and
welding machines
2.b. EMF fields may interfere with some pacemakers, and
welders having a pacemaker should consult their physician
before welding.
2.c. Exposure to EMF fields in welding may have other health
effects which are now not known.
2.d. All welders should use the following procedures in order to
minimize exposure to EMF fields from the welding circuit:
2.d.1. Route the electrode and work cables together - Secure
them with tape when possible.
2.d.2. Never coil the electrode lead around your body.
2.d.3. Do not place your body between the electrode and
work cables. If the electrode cable is on your right
side, the work cable should also be on your right side.
2.d.4. Connect the work cable to the workpiece as close as
possible to the area being welded.
2.d.5. Do not work next to welding power source.
Mar ʻ95
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SAFETY
ELECTRIC SHOCK can kill.
3.a. The electrode and work (or ground) circuits
are electrically “hot” when the welder is on.
Do not touch these “hot” parts with your bare
skin or wet clothing. Wear dry, hole-free
gloves to insulate hands.
3.b. Insulate yourself from work and ground using dry insulation.
Make certain the insulation is large enough to cover your full
area of physical contact with work and ground.
In addition to the normal safety precautions, if welding
must be performed under electrically hazardous
conditions (in damp locations or while wearing wet
clothing; on metal structures such as floors, gratings or
scaffolds; when in cramped positions such as sitting,
kneeling or lying, if there is a high risk of unavoidable or
accidental contact with the workpiece or ground) use
the following equipment:
• Semiautomatic DC Constant Voltage (Wire) Welder.
• DC Manual (Stick) Welder.
• AC Welder with Reduced Voltage Control.
3.c. In semiautomatic or automatic wire welding, the electrode,
electrode reel, welding head, nozzle or semiautomatic
welding gun are also electrically “hot”.
3.d. Always be sure the work cable makes a good electrical
connection with the metal being welded. The connection
should be as close as possible to the area being welded.
3.e. Ground the work or metal to be welded to a good electrical
(earth) ground.
3.f. Maintain the electrode holder, work clamp, welding cable and
welding machine in good, safe operating condition. Replace
damaged insulation.
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3.g. Never dip the electrode in water for cooling.
3.h. Never simultaneously touch electrically “hot” parts of
electrode holders connected to two welders because voltage
between the two can be the total of the open circuit voltage
of both welders.
3.i. When working above floor level, use a safety belt to protect
yourself from a fall should you get a shock.
3.j. Also see Items 6.c. and 8.
ARC RAYS can burn.
4.a.
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Use a shield with the proper filter and cover
plates to protect your eyes from sparks and
the rays of the arc when welding or observing
open arc welding. Headshield and filter lens
should conform to ANSI Z87. I standards.
4.b. Use suitable clothing made from durable flame-resistant
material to protect your skin and that of your helpers from
the arc rays.
4.c. Protect other nearby personnel with suitable, non-flammable
screening and/or warn them not to watch the arc nor expose
themselves to the arc rays or to hot spatter or metal.
FUMES AND GASES
can be dangerous.
5.a. Welding may produce fumes and gases
hazardous to health. Avoid breathing these
fumes and gases.When welding, keep
your head out of the fume. Use enough
ventilation and/or exhaust at the arc to keep
fumes and gases away from the breathing zone. When
welding with electrodes which require special
ventilation such as stainless or hard facing (see
instructions on container or MSDS) or on lead or
cadmium plated steel and other metals or coatings
which produce highly toxic fumes, keep exposure as
low as possible and below Threshold Limit Values (TLV)
using local exhaust or mechanical ventilation. In
confined spaces or in some circumstances, outdoors, a
respirator may be required. Additional precautions are
also required when welding on galvanized steel.
5. b. The operation of welding fume control equipment is affected
by various factors including proper use and positioning of the
equipment, maintenance of the equipment and the specific
welding procedure and application involved. Worker exposure level should be checked upon installation and periodically thereafter to be certain it is within applicable OSHA PEL
and ACGIH TLV limits.
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 products.
5.d. Shielding gases used for arc welding can displace air and
cause injury or death. Always use enough ventilation,
especially in confined areas, to insure breathing air is safe.
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5.e. Read and understand the manufacturerʼs instructions for this
equipment and the consumables to be used, including the
material safety data sheet (MSDS) and follow your
employerʼs safety practices. MSDS forms are available from
your welding distributor or from the manufacturer.
5.f. Also see item 1.b.
Aug ʻ06
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iii
SAFETY
WELDING and CUTTING
SPARKS can
cause fire or explosion.
6.a. Remove fire hazards from the welding area.
If this is not possible, cover them to prevent
the welding sparks from starting a fire.
Remember
that
welding
sparks
and
hot
materials from welding can easily go through small cracks
and openings to adjacent areas. Avoid welding near
hydraulic lines. Have a fire extinguisher readily available.
6.b. Where compressed gases are to be used at the job site,
special precautions should be used to prevent hazardous
situations. Refer to “Safety in Welding and Cutting” (ANSI
Standard Z49.1) and the operating information for the
equipment being used.
6.c. When not welding, make certain no part of the electrode
circuit is touching the work or ground. Accidental contact can
cause overheating and create a fire hazard.
6.d. Do not heat, cut or weld tanks, drums or containers until the
proper steps have been taken to insure that such procedures
will not cause flammable or toxic vapors from substances
inside. They can cause an explosion even though they have
been “cleaned”. For information, purchase “Recommended
Safe Practices for the Preparation for Welding and Cutting of
Containers and Piping That Have Held Hazardous
Substances”, AWS F4.1 from the American Welding Society
(see address above).
6.e. Vent hollow castings or containers before heating, cutting or
welding. They may explode.
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.
6.g. Connect the work cable to the work as close to the welding
area as practical. Work cables connected to the building
framework or other locations away from the welding area
increase the possibility of the welding current passing
through lifting chains, crane cables or other alternate circuits.
This can create fire hazards or overheat lifting chains or
cables until they fail.
6.h. Also see item 1.c.
6.I. Read and follow NFPA 51B “ Standard for Fire Prevention
During Welding, Cutting and Other Hot Work”, available from
NFPA, 1 Batterymarch Park,PO box 9101, Quincy, Ma
022690-9101.
CYLINDER may explode
if damaged.
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7.a. Use only compressed gas cylinders
containing the correct shielding gas for the
process used and properly operating
regulators designed for the gas and
pressure used. All hoses, fittings, etc. should be suitable for
the application and maintained in good condition.
7.b. Always keep cylinders in an upright position securely
chained to an undercarriage or fixed support.
7.c. Cylinders should be located:
• Away from areas where they may be struck or subjected to
physical damage.
• A safe distance from arc welding or cutting operations and
any other source of heat, sparks, or flame.
7.d. Never allow the electrode, electrode holder or any other
electrically “hot” parts to touch a cylinder.
7.e. Keep your head and face away from the cylinder valve outlet
when opening the cylinder valve.
7.f. Valve protection caps should always be in place and hand
tight except when the cylinder is in use or connected for
use.
7.g. Read and follow the instructions on compressed gas
cylinders, associated equipment, and CGA publication P-l,
“Precautions for Safe Handling of Compressed Gases in
Cylinders,” available from the Compressed Gas Association
1235 Jefferson Davis Highway, Arlington, VA 22202.
FOR ELECTRICALLY
powered equipment.
8.a. Turn off input power using the disconnect
switch at the fuse box before working on
the equipment.
8.b. Install equipment in accordance with the U.S. National
Electrical Code, all local codes and the manufacturerʼs
recommendations.
8.c. Ground the equipment in accordance with the U.S. National
Electrical Code and the manufacturerʼs recommendations.
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6.j. Do not use a welding power source for pipe thawing.
Jan ʻ07
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iv
PRÉCAUTIONS DE SÛRETÉ
SAFETY
Pour votre propre protection lire et observer toutes les instructions
et les précautions de sûreté specifiques qui parraissent dans ce
manuel aussi bien que les précautions de sûreté générales suivantes:
Sûreté Pour Soudage A LʼArc
1. Protegez-vous contre la secousse électrique:
a. Les circuits à lʼélectrode et à la piéce sont sous tension
quand la machine à souder est en marche. Eviter toujours
tout contact entre les parties sous tension et la peau nue
ou les vétements mouillés. Porter des gants secs et sans
trous pour isoler les mains.
b. Faire trés attention de bien sʼisoler de la masse quand on
soude dans des endroits humides, ou sur un plancher metallique ou des grilles metalliques, principalement dans
les positions assis ou couché pour lesquelles une grande
partie du corps peut être en contact avec la masse.
c. Maintenir le porte-électrode, la pince de masse, le câble de
soudage et la machine à souder en bon et sûr état defonctionnement.
d.Ne jamais plonger le porte-électrode dans lʼeau pour le
refroidir.
e. Ne jamais toucher simultanément les parties sous tension
des porte-électrodes connectés à deux machines à souder
parce que la tension entre les deux pinces peut être le total
de la tension à vide des deux machines.
f. Si on utilise la machine à souder comme une source de
courant pour soudage semi-automatique, ces precautions
pour le porte-électrode sʼapplicuent aussi au pistolet de
soudage.
2. Dans le cas de travail au dessus du niveau du sol, se protéger
contre les chutes dans le cas ou on recoit un choc. Ne jamais
enrouler le câble-électrode autour de nʼimporte quelle partie du
corps.
3. Un coup dʼarc peut être plus sévère quʼun coup de soliel, donc:
a. Utiliser un bon masque avec un verre filtrant approprié ainsi
quʼun verre blanc afin de se protéger les yeux du rayonnement de lʼarc et des projections quand on soude ou
quand on regarde lʼarc.
b. Porter des vêtements convenables afin de protéger la peau
de soudeur et des aides contre le rayonnement de lʻarc.
c. Protéger lʼautre personnel travaillant à proximité au
soudage à lʼaide dʼécrans appropriés et non-inflammables.
4. Des gouttes de laitier en fusion sont émises de lʼarc de
soudage. Se protéger avec des vêtements de protection libres
de lʼhuile, tels que les gants en cuir, chemise épaisse, pantalons sans revers, et chaussures montantes.
5. Toujours porter des lunettes de sécurité dans la zone de
soudage. Utiliser des lunettes avec écrans lateraux dans les
zones où lʼon pique le laitier.
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6. Eloigner les matériaux inflammables ou les recouvrir afin de
prévenir tout risque dʼincendie dû aux étincelles.
7. Quand on ne soude pas, poser la pince à une endroit isolé de
la masse. Un court-circuit accidental peut provoquer un
échauffement et un risque dʼincendie.
8. Sʼassurer que la masse est connectée le plus prés possible de
la zone de travail quʼil est pratique de le faire. Si on place la
masse sur la charpente de la construction ou dʼautres endroits
éloignés de la zone de travail, on augmente le risque de voir
passer le courant de soudage par les chaines de levage,
câbles de grue, ou autres circuits. Cela peut provoquer des
risques dʼincendie ou dʼechauffement des chaines et des
câbles jusquʼà ce quʼils se rompent.
9. Assurer une ventilation suffisante dans la zone de soudage.
Ceci est particuliérement important pour le soudage de tôles
galvanisées plombées, ou cadmiées ou tout autre métal qui
produit des fumeés toxiques.
10. Ne pas souder en présence de vapeurs de chlore provenant
dʼopérations de dégraissage, nettoyage ou pistolage. La
chaleur ou les rayons de lʼarc peuvent réagir avec les vapeurs
du solvant pour produire du phosgéne (gas fortement toxique)
ou autres produits irritants.
11. Pour obtenir de plus amples renseignements sur la sûreté, voir
le code “Code for safety in welding and cutting” CSA Standard
W 117.2-1974.
PRÉCAUTIONS DE SÛRETÉ POUR
LES MACHINES À SOUDER À
TRANSFORMATEUR ET À
REDRESSEUR
1. Relier à la terre le chassis du poste conformement au code de
lʼélectricité et aux recommendations du fabricant. Le dispositif
de montage ou la piece à souder doit être branché à une
bonne mise à la terre.
2. Autant que possible, Iʼinstallation et lʼentretien du poste seront
effectués par un électricien qualifié.
3. Avant de faires des travaux à lʼinterieur de poste, la debrancher à lʼinterrupteur à la boite de fusibles.
4. Garder tous les couvercles et dispositifs de sûreté à leur place.
Mar ʻ93
SAFETY
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v
v
Electromagnetic Compatibility (EMC)
Conformance
Products displaying the CE mark are in conformity with European Community Council Directive of 3 May
1989 on the approximation of the laws of the Member States relating to electromagnetic compatibility
(89/336/EEC). It was manufactured in conformity with a national standard that implements a harmonized
standard: EN 60974-10 Electromagnetic Compatibility (EMC) Product Standard for Arc Welding Equipment.
It is for use with other Lincoln Electric equipment. It is designed for industrial and professional use.
Introduction
All electrical equipment generates small amounts of electromagnetic emission. Electrical emission may be
transmitted through power lines or radiated through space, similar to a radio transmitter. When emissions
are received by other equipment, electrical interference may result. Electrical emissions may affect many
kinds of electrical equipment; other nearby welding equipment, radio and TV reception, numerical controlled
machines, telephone systems, computers, etc. Be aware that interference may result and extra precautions
may be required when a welding power source is used in a domestic establishment.
Installation and Use
The user is responsible for installing and using the welding equipment according to the manufacturerʼs
instructions. If electromagnetic disturbances are detected then it shall be the responsibility of the user of the
welding equipment to resolve the situation with the technical assistance of the manufacturer. In some cases
this remedial action may be as simple as earthing (grounding) the welding circuit, see Note. In other cases
it could involve construction of an electromagnetic screen enclosing the power source and the work complete with associated input filters. In all cases electromagnetic disturbances must be reduced to the point
where they are no longer troublesome.
Note: The welding circuit may or may not be earthed for safety reasons according to national
codes. Changing the earthing arrangements should only be authorized by a person who is
competent to access whether the changes will increase the risk of injury, e.g., by allowing
parallel welding current return paths which may damage the earth circuits of other equipment.
Assessment of Area
Before installing welding equipment the user shall make an assessment of potential electromagnetic problems in the surrounding area. The following shall be taken into account:
a) other supply cables, control cables, signaling and telephone cables; above, below and adjacent to the
welding equipment;
b) radio and television transmitters and receivers;
c) computer and other control equipment;
d) safety critical equipment, e.g., guarding of industrial equipment;
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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
SAFETY
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vi
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Electromagnetic Compatibility (EMC)
The size of the surrounding area to be considered will depend on the structure of the building and other
activities that are taking place. The surrounding area may extend beyond the boundaries of the premises.
Methods of Reducing Emissions
Mains Supply
Welding equipment should be connected to the mains supply according to the manufacturerʼs recommendations. If interference occurs, it may be necessary to take additional precautions such as filtering of the
mains supply. Consideration should be given to shielding the supply cable of permanently installed welding
equipment, in metallic conduit or equivalent. Shielding should be electrically continuous throughout its
length. The shielding should be connected to the welding power source so that good electrical contact is
maintained between the conduit and the welding power source enclosure.
Maintenance of the Welding Equipment
The welding equipment should be routinely maintained according to the manufacturerʼs recommendations.
All access and service doors and covers should be closed and properly fastened when the welding equipment is in operation. The welding equipment should not be modified in any way except for those changes
and adjustments covered in the manufacturers instructions. In particular, the spark gaps of arc striking and
stabilizing devices should be adjusted and maintained according to the manufacturerʼs recommendations.
Welding Cables
The welding cables should be kept as short as possible and should be positioned close together, running at
or close to floor level.
Equipotential Bonding
Bonding of all metallic components in the welding installation and adjacent to it should be considered.
However, metallic components bonded to the work piece will increase the risk that the operator could
receive a shock by touching these metallic components and the electrode at the same time. The operator
should be insulated from all such bonded metallic components.
Earthing of the Workpiece
Where the workpiece is not bonded to earth for electrical safety, not connected to earth because of its size
and position, e.g., ships hull or building steelwork, a connection bonding the workpiece to earth may reduce
emissions in some, but not all instances. Care should be taken to prevent the earthing of the workpiece
increasing the risk of injury to users, or damage to other electrical equipment. Where necessary, the connection of the workpiece to earth should be made by a direct connection to the workpiece, but in some
countries where direct connection is not permitted, the bonding should be achieved by suitable capacitance, selected according to national regulations.
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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 applications. 1
_________________________
1 Portions of the preceding text are contained in EN 60974-10: “Electromagnetic Compatibility (EMC)
product standard for arc welding equipment.”
L10093
3-1-96H
I
- MASTER TABLE OF CONTENTS FOR ALL SECTIONS RETURN TO MAIN INDEX
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Page
Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .i-iv
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Section A
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Section B
Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Section C
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Section D
Theory of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Section E
Troubleshooting and Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Section F
Electrical Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Section G
Parts Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .P-559
INVERTEC® V155-S
I
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A-1
TABLE OF CONTENTS - INSTALLATION SECTION
A-1
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-1
Technical Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-2
Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-3
Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-3
Input Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-3
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Output Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-5
INVERTEC® V155-S
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A-2
Input Voltages / 50 /60 Hz.
120Vac ± 10%
230Vac ± 10%
Duty Cycle
100%
30%
Output Current Range
5-155 Amps
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INPUT - SINGLE PHASE ONLY
Max. Input Current at rated Output
100%
30%
25A
34 A
23A
33 A
RATED OUTPUT
Output Amps
Output Volts
75A (Stick)
105A (TIG)
23.0 Vdc
14.2 Vdc
100A (Stick)
100A (TIG)
A-2
Input Power at Rated Output
100%
30%
2.2kw
3.0kw
3.0kw
5.0kw
Input Circuit
120 Vac
24.0 Vdc
14.0 Vdc
25.8 Vdc
16.2 Vdc
100A (Stick)
130A (TIG)
230 Vac
230 Vac
24.0 Vdc
15.2 Vdc
145A (Stick)
155A (TIG)
OUTPUT
Maximum Open Circuit Voltage
75 Volts Max.
120 Vac
Type of Output
DC
RECOMMENDED INPUT WIRE AND FUSE SIZES FOR MAXIMUM RATED OUTPUT
INPUT VOLTAGE /
FREQUENCY (HZ)
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INSTALLATION
230/60
120/60
Height
11.3
288 mm
TYPE S, SO ST, STO, OR EXTRA
HARD USAGE INPUT CORD AWG
3 Conductor, 12 AWG
PHYSICAL DIMENSIONS
Width
6.2 in.
158 mm
Depth
15.4in.
392 mm
TEMPERATURE RANGES
OPERATING TEMPERATURE RANGE
-10°C to +40°C
MAXIMUM TIME-DELAY CIRCUIT
BREAKER OR FUSE SIZE (AMPS)
30
Weight
Approx. 14.7lbs.
6.7 kgs.
STORAGE TEMPERATURE RANGE
-25°C to +55°C
INVERTEC® V155-S
INSTALLATION
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A-3
Read entire installation section before starting
installation.
SAFETY PRECAUTIONS
WARNING
ELECTRIC SHOCK can kill.
• Only qualified personnel should perform this installation.
• Disconnect input power by removing
plug from receptacle before working
inside INVERTEC® V155-S. Allow
machine to sit for 5 minutes minimum to allow the power capacitors
to discharge before working inside
this equipment.
• Insulate yourself from the work and ground.
• Always wear dry insulating gloves.
• Always connect the INVERTEC® V155-S to a power
supply grounded according to the National
Electrical Code and local codes.
------------------------------------------------------------
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TILTING
Place the machine directly on a secure, level surface.
Do not place or operate this machine on a surface with
an incline greater than 15° from horizontal. The
machine may topple over if this procedure is not followed.
INPUT CONNECTIONS
WARNING
ELECTRIC SHOCK can kill.
• Have a qualified electrician install
and service this equipment.
• Disconnect input power by removing
plug from receptacle before working
inside INVERTEC® V155-S. Allow
machine to sit for 5 minutes minimum
to allow the power capacitors to discharge before
working inside this equipment.
• Do not touch electrically live parts.
-----------------------------------------------------------------------
GROUND CONNECTION
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 measures are followed to assure long life and reliable operation:
• Do not use this machine for pipe thawing.
• This machine must be located where there is free circulation of clean air without restrictions for air movement to and from the air vents. Do not cover the
machine with paper, cloth or rags when switched on.
• Dirt and dust that can be drawn into the machine
should be kept to a minimum.
• This machine has a protection rating of IP23. Keep
it dry when possible and do not place it on wet
ground or in puddles.
• Locate the machine away from radio controlled
machinery. Normal operation may adversely affect
the operation of nearby radio controlled machinery,
which may result in injury or equipment damage.
Read the section on electromagnetic compatibility in
this manual.
• Do not operate in areas with an ambient temperature
greater than 40°C.
STACKING
The INVERTEC® V155-S cannot be stacked.
A-3
CAUTION
A grounding conductor is supplied in the input
cord, it is important that the supply receptacle
ground is connected.
-----------------------------------------------------------------------
WARNING
This installation should be performed by a qualified electrician to ensure correct connections of
the leads to the plug spades.
• The electrical system must be made by skilled
technicians with the specific professional and
technical qualifications and in compliance with
the regulations in force in the country where the
equipment is installed.
• The welding power source supply cable is provided with a green or yellow/green wire that must
ALWAYS be earthed. This green or yellow/green
wire must NEVER be used with other voltage conductors.
• lnstall only plugs that confirm with safety regulations.
INVERTEC® V155-S
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A-4
INPUT POWER CONNECTION
INSTALLATION
Check the input voltage, phase, and frequency supplied to this machine before turning it on.
The allowable input voltage is indicated in the technical specification section of this manual and on the rating plate of the machine. Be sure that the machine is
grounded.
Make sure the power available at the input connection
is adequate for normal operation of the machine. The
fuse rating and cable sizes are both indicated in the
technical specification section of this manual.
Fuse the input circuit with time delay fuses marked “D”
or delay type1 circuit breakers. Using fuses or circuit
breakers smaller than recommended may result in
“nuisance” shut-offs from welder inrush currents even
if not welding at high currents.
1
Also called “inverse time” or “thermal/magnetic” circuit breakers.
These circuit breakers have a delay in tripping action that decreases
as the magnitude of the current increases.
The INVERTEC® V155-S is recommended for use on
an individual branch circuit.
120V INPUT
The rated output of the INVERTEC® V155-S is available when connected to a 30A branch circuit. When
connected to a branch circuit with lower ampacity,
lower welding current and duty cycle must be used. An
output guide is provided below. The values are approximate and must be adjusted downward if the fuse or
circuit breaker trips off. Other loads on the circuit and
fuse/circuit breaker characteristics will affect the available output. Do not exceed these welding conditions:
(See Table A.1)
The INVERTEC® V155-S is provided with a 120/230V
cable, 6.6ft.(2m) in length, with a 15Amp 5-15P plug
molded onto the cord.
The INVERTEC® V155-S is supplied with an additional 20A plug that can replace the 15A plug to achieve
higher output. To install the supplied 20A plug:
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Connect the white (neutral) wire under terminal clamp
with silver screw, and black (hot) wire under terminal
clamp with brass screw. Connect green wire under terminal clamp with green screw.
120V Input
Plug
Rating
15 Amp
15 Amp
20 Amp
Branch
Rating
15 Amp
20 Amp
20 Amp
TABLE A.1
BRANCH
WARNING
A-4
• Failure to wire as instructed may cause personal
injury or damage to equipment. To be installed or
checked by an electrician or qualified person
only.
---------------------------------------------------------------------------
230V INPUT
To achieve the full output capacity of the INVERTEC®
V155-S, 230VAC inputs should be used. The change
over is accomplished by replacing the 120VAC plug
with a 30 Amp 230VAC plug (NEMA 6-30P).
ATTACHMENT PLUG
In all cases, the green or green/yellow grounding wire
must be connected to the grounding pin of the plug, usually identified by a green screw.
All attachment plugs must comply with the Standard for
Attachment Plugs and Receptacles, UL498.
The product is considered acceptable for use only when
an attachment plug as specified is properly attached to
the supply cord.
The INVERTEC® V155-S will auto reconnect to either
120V or 230V supplies.
ENGINE DRIVEN GENERATOR
The machine is designed to operate on engine driven
generators as long as the auxiliary can supply adequate voltage, frequency and power as indicated in the
" Technical Specification " Installation Section of this
manual. The auxiliary supply of the generator must
also meet the following conditions:
• Vac peak voltage: below 205V (for 115Vac input) or
410V (for 230Vac input).
• Vac frequency: in the range of 50 or 60 Hertz.
• RMS voltage of the AC waveform: 115Vac or
230Vac ± 10%
It is important to check these conditions because many
engine driven generators produce high voltage spikes.
Operation of this machine with engine driven generators not conforming to these conditions is not recommended and may damage the machine.
Output Current
Stick
TIG
10% Duty 30% Duty 100% Duty 10% Duty 30% Duty 100% Duty
Cycle
Cycle
Cycle
Cycle
Cycle
Cycle
65A
45A
55A
100A
75A
85A
75A
60A
70A
110A
95A
100A
85A
60A
75A
130A
95A
130A
INVERTEC® V155-S
INSTALLATION
ARFU (Auto-Restore Fuse)
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A-5
A-5
FIGURE A.1
The dual input voltage machine is provided with the
ARFU device. It operates only when the input is connected to the 120Vac mains and protects from input
overcurrent. When active, the " Thermal LED " lights
(see " Controls and Operational Features " in the
Operation Section).
Electrode
Holder
Note: The ARFU device operates independently from
the machine's duty-cycle.
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OUTPUT CONNECTIONS
A quick disconnect system using Twist-Mate™ cable
plugs is used for the welding cable connections. Refer
to the following sections for more information on connecting the machine for operation of stick welding
(SMAW) or TIG welding.
WARNING
ELECTRIC SHOCK can kill.
• Keep the electrode holder and
cable insulation in good condition.
• Do not touch electrically live parts
or electrode with skin or wet clothing.
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• Insulate yourself from work and ground.
• Turn the input line Switch on the INVERTEC®
V155-S “off” before connecting or disconnecting
output cables or other equipment.
----------------------------------------------------------STICK WELDING (SMAW)
Work Clamp
Work Cable
TIG WELDING
This machine does not have a built in Gas Solenoid so
a one piece gas valve TIG Torch is required. A K960-2
Twist-Mate™ TIG Torch adapter is also required. Refer
to the accessories section for more information about
TIG Torches and required Twist-Mate™ adapter. Most
TIG welding is done with DC(-) polarity shown here. If
DC(+) polarity is necessary switch the cable connections at the machine. (See Figure A.2)
Connect the torch cable to the (-) terminal of the
machine and the work clamp to the (+) terminal. Insert
the connector with the key lining up with the keyway
and rotate approximately 1/4 turn clockwise. Do not
over tighten. Finally, connect the Twist-Mate™ adapter
gas hose to the gas regulator on the cylinder of gas to
be used.
FIGURE A.2
First determine the proper electrode polarity for the electrode to be used. Consult the electrode data for this information. Then connect the output cables to the output terminals of the machine for the selected polarity. Shown
here is the connection method for DC(+) welding. (See
Figure A.1)
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 approximately 1/4 turn clockwise. Do not over tighten.
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Twist-Mate™ 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
INVERTEC® V155-S
Gas Valve
TIG Torch
INSTALLATION
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A-6
REPLACEMENT QUICK DISCONNECT PLUG (FOR
STICK ELECTRODE CABLE)
The INVERTEC® V155-S comes with a factory assembled stick electrode holder, cable and Twist-Mate™
adapter plug. If a replacement cable is ever needed a
K852-25 Twist-Mate™ plug will be needed.
To
1.
2.
3.
attach the K852-25 plug:
Cut off welding cable lug, if present.
Remove .75 in. (19mm) of welding cable insulation.
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
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WELDING CABLE
.75 in.
19 mm
TRIM, IF REQ'D
TO FIT OVER CABLE
4. Cut 45-50% of the copper strands back 1/4” (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.
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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
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must apply pressure against welding cable. The top
of the set screw will be well below the surface of the
brass plug after tightening.
INVERTEC® V155-S
A-6
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B-1
TABLE OF CONTENTS - OPERATION SECTION
B-1
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-1
Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-2
General Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-2
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Controls and Operational Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-3
INVERTEC® V155-S
THEORY OF OPERATION
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B-2
Read and understand this entire section before
operating your machine.
SAFETY INSTRUCTIONS
WARNING
ELECTRIC SHOCK can kill.
• Do not touch electrically live parts such
as output terminals or internal wiring.
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• Insulate yourself from the work and
ground.
• Always wear dry insulating gloves.
____________________________________
FUMES AND GASES
can be dangerous.
• Keep your head out of fumes.
• Use ventilation or exhaust to
remove fumes from breathing
zone.
WELDING, CUTTING and
GOUGING SPARKS
can cause fire or explosion
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____________________________________
• Keep flammable material away.
• Do not weld, cut or gouge on
containers that have held combustibles.
____________________________________
GENERAL DESCRIPTION
The INVERTEC® V155-S is an industrial 155 amp arc
welding power source which utilizes single phase input
power, to produce constant current output. The welding
response of this Invertec has been optimized for stick
(SMAW) and Touch Start TIG (GTAW). The unit is ideal
for industrial applications where portability is important.
The INVERTEC® V155-S is recommended for stick
welding with such popular electrodes as Fleetweld 35,
Fleetweld 37, Fleetweld 180 and LH 78. It features
automatic arc control to adjust the arc force, hot start
and anti sticking. The machine also features soft and
crisp modes.
The INVERTEC® V155-S performs DC Touch Start Tig
Starting with excellent results.
WELDING CAPABILITY
The INVERTEC® V155-S is rated at 155 amps, 16.2
volts, at 30% duty cycle on a ten minute basis. It is
capable of higher duty cycles at lower output currents(1). If the duty cycle is exceeded, a thermal protector will shut off the output until the machine cools. See
Technical Specifications in the Installation Section for
other rated outputs.
The INVERTEC® V155-S is recommended for stick
welding with such popular electrodes as Fleetweld® 35,
Fleetweld 37, Fleetweld 180 and Jet-LH 78 MR. It features adjustable arc control to adjust the arc force and
start.
LIMITATIONS
The INVERTEC® V155-S
pipe thawing.
(1)
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is not recommended for
Refer to Technical Specifications in the Installation Section for other ratings.
ARC RAYS
can burn.
• Wear eye, ear and body
protection.
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B-2
____________________________________
Only qualified personnel should operate this equipment. Observe all safety information throughout this
manual.
INVERTEC® V155-S
THEORY OF OPERATION
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B-3
CONTROLS AND OPERATIONAL
FEATURES
1. Output Current Knob: A
Potentiometer used to
set the output current used during welding, from 5A
to 155A.
2. Welding Mode Switch: With three positions, controls the welding mode of the machine: two for Stick
welding (Soft and Crisp) and one for Lift TIG welding.
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• Soft Stick:
For a welding with a low spatter
presence.
• Crisp Stick:
For an aggressive welding arc,
with an increased Arc stability.
• Lift TIG:
When the mode switch is in the Lift
TIG position, the stick welding functions are disabled
and the machine is ready for Lift TIG welding. Lift
TIG is a method of starting a TIG weld by first pressing the TIG torch electrode on the work piece in
order to create a low current short circuit. Then, the
electrode is lifted from the work piece to start the TIG
arc.
3. Thermal LED:
This indicator will turn on when
the machine is overheated and the output has been
disabled. This normally occurs when the duty cycle
of the machine has been exceeded. Leave the
machine on to allow the internal components to cool.
When the indicator turns off, normal operation is
again possible.
FIGURE B.1
4
2
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WARNING
If blinking, the Thermal LED indicates that the input
voltage is out of ranges.
4. Power On/Off & OUTPUT LEDs: These LEDs (one
green and one red) operates as described in the
table below:
LED status
Green Red
ON
OFF
The machine is turned ON.
OFF
A
ON
3
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If the Yellow LED illuminates, and the Red and Green
LEDʼs blink on and off alternately, the unit is unable to
cool itself adequately. Check to make sure the fan is
not obstructed and the fan is operating properly. Prior
to resuming normal operation, the unit must be turned
off and turned back on to reset this error condition.
OFF
1
5
6
B-3
ON
OFF
ON
FUNCTION
ON condition: The machine is at
idle (no-welding time) and OCV
is present.
V
The machine is turned ON.
On condition: Presence of welding current at the output leads.
This permanent LED condition,
showed at idle (no-welding time), indicates machine damage.
The machine is turned OFF and/or the
input cord could be disconnected from
the mains.
ERROR condition: With the Power
Switch turned ON and the input cord
properly connected to a " live " main
supply, this LED condition indicates
machine damage.
ERROR condition: This LED condition
1. Output Current Knob
2. Welding Mode Switch
3. Thermal LED
4. Power On/Off and Output LEDʼs
5. Positive Quick Disconnect
6. Negative Quick Disconnect
INVERTEC® V155-S
THEORY OF OPERATION
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B-4
5. Positive Quick Disconnect: Positive output connector for the welding circuit.
6. Negative Quick Disconnect: Negative output connector for the welding circuit.
REAR CONTROL PANEL
(See Figure B.2)
7. Power Switch: It turns ON / OFF the input power
to the machine.
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8. Input cable: This machine is provided with a
plugged input cord. Connect it to the mains.
9. Fan: This machine has a F.A.N. (Fan As Needed)
circuitry inside: the fan is automatically turned ON
or OFF. This feature reduces the amount of dirt
which can be drawn inside the machine and reduces
power consumption. The F.A.N. operates differently
in different weld mode.
• Stick mode: When the machine is turned ON the
fan will turn ON for a short time and then go off if a
weld is not started. The fan will continue to run whenever the machine is welding. The fan will turn OFF
five minutes after the welding is stopped.
• TIG modes: When the machine is turned ON the
fan is OFF. The fan will turn ON only when a weld
is started and it will continue to run whenever the
machine is welding. The fan will turn OFF five minutes after the welding is stopped.
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9
The Auto Adaptive Arc Force function is activated during stick welding. This function temporarily increases
the output current, to clear intermittent shorts between
the electrode and the weld puddle that may occur during stick welding.
This is an active control feature that guarantees the
best arrangement between the arc stability and spatter
presence. The feature " Auto Adaptive Arc Force " has
instead of a fixed or manual regulation, an automatic
and multilevel setting: its intensity depends by the output voltage and is controlled by the microprocessor on
the Control Board.
The circuit determines the amount of current necessary to release the metal droplet that is being transferred from the electrode to the workpiece to guarantee
the arc stability without going too high, to minimize the
spatter levels. That means:
• Electrode to workpiece sticking prevention, even at
low current values.
• Spatter reduction.
The welding operations are simplified and the welded
joints look better, even if not brushed after the welding.
This feature is available in both the Soft Stick and Crisp
Stick operating modes. The Crisp Stick feature also
increases the Hot Start action, facilitating the arc striking.
The following features are also enabled in the stick
welding modes:
FIGURE B.2
8
AUTO ADAPTIVE ARC FORCE
(WITH STICK WELDING)
B-4
7
• Hot Start: This is a temporary increase in the initial
welding current. This helps ignite the arc
quickly and reliably.
• Anti-Sticking: This is a function that decreases the
output current of the machine to a low
level when the operator makes an
error and sticks the electrode to the
work piece. This decrease in current
allows the operator to remove the
electrode from the electrode holder
without creating large sparks that can
damage the electrode holder.
INVERTEC® V155-S
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C-1
TABLE OF CONTENTS - ACCESSORIES SECTION
C-1
Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .C-1
Factory Installed Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .C-2
Field Installed Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .C-2
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Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .C-2
INVERTEC® V155-S
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C-2
OPTIONAL ACCESSORIES
AND COMPATIBLE EQUIPMENT
ACCESSORIES
CABLE PLUGS
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
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Field Installed
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:
Order KP507 for PTA-9 torches
See publication E12.150 for parts kits breakdown.
Cut Length Consumables - TIG welding filler metals
are available for welding stainless steel, mild steel, aluminum and copper alloys. See publication C9.10.
• K1782-6 (12.50 Ft.) 1-Piece Cable
• K1782-8 (25.0 Ft.) 1-Piece Cable
PTA-9FV TIG Torch - 125 Amp Gas Valve flexible
head torch:
• K1781-7 (25.0 Ft.) 1-Piece Cable
PTA-17FV TIG Torch - 150 Amp Gas Valve flexible
head torch:
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• K1782-11 (25.0 Ft.) 1-Piece Cable
• K1782-13 (12.5 Ft.) 1-Piece Ultra Flex Cable
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C-2
K960-2-TIG Torch Adapter - for connection of PTA17V torches (1-piece cable) to power sources without
gas passing through the Twist Mate connection.
INVERTEC® V155-S
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D-1
TABLE OF CONTENTS - MAINTENANCE SECTION
D-1
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-1
Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-2
Routine Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-2
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Thermal Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-2
INVERTEC® V155-S
MAINTENANCE
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D-2
SAFETY PRECAUTIONS
WARNING
D-2
WARNING
ELECTRIC SHOCK can kill.
• Have an electrician install and service this equipment.
• Turn the input power off at the fuse
box, disconnect supply lines and
allow machine to sit for five minutes
minimum to allow the power capacitors to discharge before working
inside this equipment.
• Do not touch electrically hot parts.
Do not open this machine and do not introduce anything into its openings. Power supply must be disconnected from the machine before each maintenance
and service. After each repair, perform proper tests to
ensure safety.
CAUTION
Power supply must be disconnected from the machine
before each maintenance and service. Always use
gloves in compliance with the safety standards.
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----------------------------------------------------------------------
INPUT FILTER CAPACITOR
DISCHARGE PROCEDURE
WARNING
THERMAL PROTECTION
For any maintenance or repair operations it is recommended to contact the nearest technical service center
or Lincoln Electric. Maintenance or repairs performed
by unauthorized service centers or personnel will null
and void the manufacturers warranty.
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.
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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.
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• Check cables and connections integrity. Replace, if
necessary.
• Clean the power source inside by means of low pressure compressed air.
• Keep the machine clean. Use a soft dry cloth to clean
the external case, especially the airflow inlet / outlet
louvers.
INVERTEC® V155-S
MAINTENANCE
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1.
2.
3.
4.
5.
6.
7.
8.
9.
Front Panel
Right Case Side
Left Case Side
Rear Panel
Fan
Cable Clamp
Input Cable
ON\OFFSwitch
Input P.C. Board
D-3
MAJOR COMPONENT LOCATIONS
10. Inverter P.C. Board
11. Control P.C. Board
12. Knob
13. Output Connector
14. Carrying Strap *
15. Nameplate *
16. Side Decal Set *
* Not in picture
FIGURE D.1 - MAJOR COMPONENT LOCATIONS
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D-3
4
6
8
7
5
9
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3
10
1
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12
11
13
INVERTEC® V155-S
2
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D-4
NOTES
INVERTEC® V155-S
D-4
TABLE OF CONTENTS-THEORY OF OPERATION SECTION
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E-1
E-1
Theory of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .E-1
General Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .E-2
Input Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .E-3
Main IGBT Inverter Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .E-4
Main Transformer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .E-4
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Control Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .E-5
Insulated Gate Bipolar Transistor (IGBT) Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .E-6
Pulse Width Modulation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .E-7
FIGURE E.1 — BLOCK LOGIC DIAGRAM.
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BLUE
ON/OFF SWITCH
115/230Vac
50/60 Hz
5
4
1
WIRE TIE
L
N
G
FAN
WHITE
2
WHITE
BLUE
BLACK AC1
WHITE
AC2
PE
WHITE
BLUE
RED
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4
4 PINS
16
2
1
16 PINS
15
(SCHEMATIC: X0701)
DC-
RED
BLACK
JP1
Y/G
JP1
RECONNECT
BOARD
W05X0408
PE
JP1
INVERTER BOARD
W05X0519
(SCHEMATIC: X0519)
(SCHEMATIC: X0408)
+
P1
N1
CONTROL BOARD
W05X0708-1
(SCHEMATIC: X0708)
PE
JP2
INVERTEC® V155-S
SHUNT
RED
BLACK
WHITE
-
RED
PCB CONNECTOR CAVITY NUMBERING SEQUENCE
(VIEWED FROM COMPONENT SIDE OF P.C. BOARD)
INPUT BOARD
W05X0701
DC+
DC-
WHITE
RIBBON CABLE
1
PWR1 PWR2 PWR4 PWR3
JP4
BLACK
DC+
BLACK
TWISTED CABLE
RED
BLACK
THEORY OF OPERATION
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E-2
FIGURE E.2 — GENERAL DESCRIPTION
BLUE
ON/OFF SWITCH
115/230Vac
50/60 Hz
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WHITE
BLUE
BLACK AC1
WHITE
AC2
PE
WHITE
TWISTED CABLE
RED
BLUE
RED
PWR1 PWR2 PWR4 PWR3
JP4
BLACK
INPUT BOARD
W05X0701
(SCHEMATIC: X0701)
4 PINS
2
1
DC-
RED
BLACK
JP1
PE
JP1
INVERTER BOARD
W05X0519
(SCHEMATIC: X0519)
+
P1
N1
CONTROL BOARD
W05X0708-1
(SCHEMATIC: X0708)
PE
15
GENERAL DESCRIPTION
The INVERTEC® V155-S is an industrial 155 amp arc
welding power source which utilizes single phase input
power, to produce constant current output. The welding
response of this Invertec has been optimized for stick
(SMAW) and Touch Start TIG (GTAW). The unit is
ideal for industrial applications where portability is
important.
The INVERTEC® V155-S is recommended for stick
welding with such popular electrodes as Fleetweld 35,
Fleetweld 37, Fleetweld 180 and LH 78. It features
automatic arc control to adjust the arc force, hot start
and anti sticking. The machine also features soft and
crisp modes.
The INVERTEC® V155-S performs DC Touch Start Tig
starting with excelent results.
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Y/G
JP1
16
16 PINS
DC-
(SCHEMATIC: X0408)
RIBBON CABLE
4
DC+
RECONNECT
BOARD
W05X0408
PCB CONNECTOR CAVITY NUMBERING SEQUENCE
(VIEWED FROM COMPONENT SIDE OF P.C. BOARD)
1
DC+
BLACK
JP2
SHUNT
-
RED
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1
WHITE
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4
WHITE
2
BLACK
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5
WIRE TIE
L
N
G
FAN
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E-2
RED
BLACK
WHITE
The INVERTEC® V155-S is rated at 155 amps, 16.2
volts, at 30% duty cycle on a ten minute basis. It is
capable of higher duty cycles at lower output currents.
It is capable of 105 amps, 14.2 volts at 100% duty
cycle. If the duty cycle is exceeded, a thermal protector will shut off the output until the machine cools. See
Technical Specifications in A-1 for other rated outputs.
the INVERTEC® V155-S is recommended for stick
welding with such popular electrodes as Fleetweld®
35, Fleetweld 37, Fleetweld 180 and Jet-LH 78MR. It
features adjustable arc control to adjust the arc force
and start.
LIMITATIONS
The INVERTEC® V155-S is not recommeded for pipe
thawing.
NOTE: Unshaded areas of Block Logic
Diagram are the subject of discussion
INVERTEC® V155-S
THEORY OF OPERATION
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E-3
FIGURE E.3 — INPUT BOARD
BLUE
ON/OFF SWITCH
115/230Vac
50/60 Hz
1
WHITE
BLUE
BLACK AC1
WHITE
AC2
PE
WHITE
TWISTED CABLE
RED
BLUE
RED
PWR1 PWR2 PWR4 PWR3
JP4
BLACK
INPUT BOARD
W05X0701
DC+
DC-
RED
BLACK
JP1
(SCHEMATIC: X0701)
(SCHEMATIC: X0408)
N1
CONTROL BOARD
W05X0708-1
(SCHEMATIC: X0708)
15
16 PINS
PE
INPUT BOARD
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The Input Board includes the following circuits:
Return to Section TOC
INVERTER BOARD
W05X0519
+
P1
16
1
JP1
- Automatic Reconnect Circuit: This circuit monitors
the input voltage and automatically reconnects the
inverter and auxiliary connections to configure the
machine for either 115V or 230V ac input voltage. The
proper configuration is achieved through the use of
board mounted relays. These relays and others that
activate the Pre-charge circuitry and the fan circuit
are controlled through signals from a micro-processor
on the board.
- Switching Power Supply: Supplied by a board
mounted transformer, the switching power supply
provides +15 vdc and +5vdc supplies for use on all of
the PC Boards.
- Input Rectifier and Precharge Circuit: The Precharge rectifier and current limiting resistors apply a
small charge to the filter capacitors when the Power
Switch is turned ON.
JP2
SHUNT
-
RED
4 PINS
2
PE
(SCHEMATIC: X0519)
PCB CONNECTOR CAVITY NUMBERING SEQUENCE
(VIEWED FROM COMPONENT SIDE OF P.C. BOARD)
4
DC-
Y/G
JP1
RECONNECT
BOARD
W05X0408
RIBBON CABLE
1
DC+
BLACK
WHITE
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4
WHITE
2
BLACK
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5
WIRE TIE
L
N
G
FAN
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E-3
RED
BLACK
WHITE
An improper input voltage would be recognized during this time and an input error sent to the Control
Board. A signal from the Control Board would prevent
further power-up to prevent damage to the Inverter
Board.
- The re-connect relays then apply full power from the
input line (AC1 and AC2) to the Input Rectifier and the
capacitors are fully charged to approximately
325VDC. (See the Machine Diagram and PC Board
Schematics for more information).
- Auto Reset Fuse: A self reseting fuse circuit (ARFU)
on the Input Board helps to prevent damage to the
machine from over-current when in 120VAC operation. When the fuse is open, the output will be disabled and the yellow Temperature LED on the front
panel will be ON.
NOTE: Unshaded areas of Block Logic
Diagram are the subject of discussion
INVERTEC® V155-S
THEORY OF OPERATION
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E-4
FIGURE E.4 — MAIN INVERTER BOARD
BLUE
ON/OFF SWITCH
115/230Vac
50/60 Hz
1
WHITE
BLUE
BLACK AC1
WHITE
AC2
PE
WHITE
TWISTED CABLE
RED
BLUE
RED
PWR1 PWR2 PWR4 PWR3
JP4
BLACK
INPUT BOARD
W05X0701
(SCHEMATIC: X0701)
DC+
DC-
1
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PE
JP1
INVERTER BOARD
W05X0519
(SCHEMATIC: X0519)
(SCHEMATIC: X0408)
+
P1
N1
CONTROL BOARD
W05X0708-1
(SCHEMATIC: X0708)
PE
15
MAIN INVERTER BOARD
The Inverter Board includes the following circuits:
Return to Section TOC
Y/G
JP1
16
16 PINS
DC-
- Inverter Circuit: Through the use of Insulated Gate
Bipolar Transistors (IGBTʼs) the high voltage
(325VDC) input current is switched ON and OFF at a
frequency of 80KHz and fed to the primary of the
main transformer. The current is regulated via Pulse
Width Modulation (PWM). The width of each pulse is
determined by a ʻgateʼ signal from the Control Board.
(See IGBT Operation and Pulse Width Modulation
in this section).
JP2
SHUNT
-
RED
4 PINS
2
BLACK
RECONNECT
BOARD
W05X0408
RIBBON CABLE
4
RED
JP1
PCB CONNECTOR CAVITY NUMBERING SEQUENCE
(VIEWED FROM COMPONENT SIDE OF P.C. BOARD)
1
DC+
BLACK
WHITE
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4
WHITE
2
BLACK
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5
WIRE TIE
L
N
G
FAN
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E-4
RED
BLACK
WHITE
- Output Circuit: The output diodes and the output
choke rectify and filter the current from the secondary
of the main transformer to make it acceptable for
welding. The shunt provides the necessary current
feedback information to the Control Board.
Note: The shunt is shown off the board for clarity. It is
actually mounted on the Inverter Board.
- 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.
INVERTEC® V155-S
THEORY OF OPERATION
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E-5
FIGURE E.5 — CONTROL BOARD
BLUE
ON/OFF SWITCH
115/230Vac
50/60 Hz
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WHITE
BLUE
BLACK AC1
WHITE
AC2
PE
WHITE
TWISTED CABLE
BLUE
RED
BLACK
PCB CONNECTOR CAVITY NUMBERING SEQUENCE
(VIEWED FROM COMPONENT SIDE OF P.C. BOARD)
4
4 PINS
PWR1 PWR2 PWR4 PWR3
JP4
RIBBON CABLE
1
RED
2
INPUT BOARD
W05X0701
(SCHEMATIC: X0701)
DC+
DC-
RED
BLACK
JP1
RECONNECT
BOARD
W05X0408
PE
JP1
INVERTER BOARD
W05X0519
(SCHEMATIC: X0519)
(SCHEMATIC: X0408)
+
P1
N1
CONTROL BOARD
W05X0708-1
(SCHEMATIC: X0708)
15
16 PINS
DC-
Y/G
JP1
16
1
DC+
BLACK
PE
CONTROL BOARD
The Control Board receives status and analogue signals from the inverter board, input board and various
sensors and feeds this information to the Weld
Controller.
The Weld Controller is a micro-processor that uses
these signals along with input from the Mode Switch
and the Control Potentiometer to make decisions and
change the machine mode and output to satisfy the
requirements as decided by the operator. these
changes are relayed to the PWM circuit on the Inverter
Board to regulate the gate signals to the IGBT”s
JP2
SHUNT
-
RED
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1
WHITE
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4
WHITE
2
BLACK
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5
WIRE TIE
L
N
G
FAN
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E-5
RED
BLACK
WHITE
The Weld Controler also responds to thermal and input
errors to shut down the machine output. The error
information is then displayed by the three LEDʼs on the
front panel.
The Mode Switch , the Control Potentiometer and the
three LEDʼs are all mounted on the Control Board.
INVERTEC® V155-S
THEORY OF OPERATION
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E-6
E-6
FIGURE E.6 – IGBT OPERATION
POSITIVE
VOLTAGE
APPLIED
GATE
GATE
SOURCE
SOURCE
n+
n+
n+
n+
p
BODY REGION
DRAIN DRIFT REGION
n-
DRAIN DRIFT REGION
n+
BUFFER LAYER
n+
BUFFER LAYER
p+
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BODY REGION
n-
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p
INJECTING LAYER
p+
INJECTING LAYER
DRAIN
DRAIN
B. ACTIVE
A. PASSIVE
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INSULATED GATE BIPOLAR
TRANSISTOR (IGBT) OPERATION
An IGBT is a type of transistor. IGBTs are semiconductors well suited for high frequency switching and
high current applications.
Drawing A shows an IGBT in a passive mode. There is
no gate signal, zero volts relative to the source, and
therefore, no current flow. The drain terminal of the
IGBT may be connected to a voltage supply; but since
there is no conduction the circuit will not supply current
to components connected to the source. The circuit is
turned off like a light switch in the OFF position.
Drawing B shows the IGBT in an active mode. When
the gate signal, a positive DC voltage relative to the
source, is applied to the gate terminal of the IGBT, it is
capable of conducting current. A voltage supply connected to the drain terminal will allow the IGBT to conduct and supply current to circuit components coupled
to the source. Current will flow through the conducting
IGBT to downstream components as long as the positive gate signal is present. This is similar to turning ON
a light switch.
INVERTEC® V155-S
THEORY OF OPERATION
Figure E-7
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E-7
MINIMUM OUTPUT
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2 sec
31 m/sec
33 m/sec
MAXIMUM OUTPUT
PULSE WIDTH MODULATION
31 m/sec
33 m/sec
MAXIMUM OUTPUT
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.
By holding the gate signals on for 31 microseconds
and allowing only 2 microseconds of off time during
the 33 microsecond cycle, the output is maximized.
The darkened area under the min. curve can be compared to the darkened area under the max. curve. The
more darkened area, the more power is present.
MINIMUM OUTPUT
By controlling the duration of the gate signal, the IGBT
is turned on and off for different durations during a
cycle. The top drawing shows the minimum output
signal possible over a 33-microsecond time period.
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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.
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E-7
INVERTEC® V155-S
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E-8
NOTES
INVERTEC® V155-S
E-8
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F-1
TABLE OF CONTENTS - TROUBLESHOOTING & REPAIR
F-1
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
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Input Filter Capacitor Discharge Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .F-9
Input Board Resistance Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .F-13
Inverter Board Resistance Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .F-15
Input Board Voltage Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .F-19
Inverter Board Voltage Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .F-23
Input Board Removal and Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .F-25
Inverter Board Removal and Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .F-27
Control Board Removal and Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .F-31
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Retest After Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .F-33
INVERTEC® V155-S
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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.
---------------------------------------------------------------------------------------------------------------------------
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This Troubleshooting Guide is provided to
help you locate and repair possible machine
malfunctions. Simply follow the three-step
procedure listed below.
Step 1. LOCATE PROBLEM (SYMPTOM).
Look under the column labeled “PROBLEM
(SYMPTOMS)”. This column describes possible symptoms that the machine may exhibit. Find the listing that best describes the
symptom that the machine is exhibiting.
Symptoms are grouped into the following
categories: output problems, function problems, wire feeding problems, and welding
problems.
Step 2. PERFORM EXTERNAL TESTS.
The second column labeled “POSSIBLE
AREAS OF MISADJUSTMENT(S)” lists the
obvious external possibilities that may contribute to the machine symptom. Perform
these tests/checks in the order listed. In
general, these tests can be conducted without removing the case wrap-around cover.
Step 3. RECOMMENDED
COURSE OF ACTION
The last column labeled “Recommended
Course of Action” lists the most likely components that may have failed in your
machine. It also specifies the appropriate
test procedure to verify that the subject component is either good or bad. If there are a
number of possible components, check the
components in the order listed to eliminate
one possibility at a time until you locate the
cause of your problem.
All of the referenced test procedures
referred to in the Troubleshooting Guide are
described in detail at the end of this chapter.
Refer to the Troubleshooting and Repair
Table of Contents to locate each specific
Test Procedure. All of the specified test
points, components, terminal strips, etc. can
be found on the referenced electrical wiring
diagrams and schematics. Refer to the
Electrical Diagrams Section Table of
Contents to locate the appropriate diagram.
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.
-----------------------------------------------------------------------------------------------------------------------------------
INVERTEC® V155-S
F-2
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F-3
TROUBLESHOOTING & REPAIR
PC BOARD TROUBLESHOOTING PROCEDURES
WARNING
ELECTRIC SHOCK
can kill.
• Have an electrician install and
service this equipment. Turn the
input power OFF at the fuse box
before working on equipment. Do
not touch electrically hot parts.
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CAUTION
Sometimes machine failures appear to be due to PC
board failures. These problems can sometimes be
traced to poor electrical connections. To avoid problems when troubleshooting and replacing PC boards,
please use the following procedure:
1. Determine to the best of your technical ability
that the PC board is the most likely component
causing the failure symptom.
2. Check for loose connections at the PC board
to 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:
PC board can be damaged by static electricity.
- Remove your bodyʼs static
charge before opening the staticshielding bag. Wear an anti-static
wrist strap. For safety, use a 1
Meg ohm resistive cord connected
to a grounded part of the
ATTENTION
Static-Sensitive equipment frame.
Devices
- If you donʼt have a wrist strap,
Handle only at touch an un-painted, grounded,
Static-Safe
part of the equipment frame. Keep
Workstations
touching the frame to prevent
static build-up. Be sure not to
touch any electrically live parts at
the same time.
F-3
- Remove the PC board from the static-shielding bag
and place it directly into the equipment. Donʼt set the
PC board on or near paper, plastic or cloth which
could have a static charge. If the PC board canʼt be
installed immediately, put it back in the static-shielding bag.
- If the PC board uses protective shorting jumpers,
donʼt remove them until installation is complete.
- If you return a PC board to The Lincoln Electric
Company for credit, it must be in the static-shielding
bag. This will prevent further damage and allow proper failure analysis.
4. Test the machine to determine if the 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.
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.
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.
6. Always indicate that this procedure was
followed when warranty reports are to be
submitted.
NOTE: Following this procedure and writing on the
warranty report, “INSTALLED AND SWITCHED PC
BOARDS TO VERIFY PROBLEM,” will help avoid
denial of legitimate PC board warranty claims.
- Tools which come in contact with the PC board must
be either conductive, anti-static or static-dissipative.
INVERTEC® V155-S
THEORY OF OPERATION
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F-4
Observe Safety Guidelines detailed in the beginning of this manual.
PROBLEMS
(SYMPTOMS)
POSSIBLE AREAS OF
MISADJUSTMENT(S)
OUTPUT PROBLEMS
F-4
RECOMMENDED
COURSE OF ACTION
The line circuit breaker trips
when power switch is “ON”
1. Input power Bridge is shorted.
3. Failed Inverter IGBTʼs.
2. Perform the Inverter Board
Resistance Test.
The machine is dead, no output,
no fan
1. No input power on line.
1. Restore correct Input power
3. Defective Input Board.
3. Perform Input Board Voltage
Test.
2. Failed Electrolytic Capacitors.
2. Line Switch failure.
4. Defective Inverter Board
The GREEN LED is “ON” but
there is no output And yellow
thermal overload LED is “ON”
1. Thermal Protection has
tripped.
2. Logic Circuit Error on Control
Board.
3. ARFU System Damage on the
Input Board
The YELLOW LED is “ON” and
the RED and GREEN LEDʼs blink
alternately
1. The machine is unable to cool
itself.
CAUTION
1. Perform the Input Board
Resistance Test.
2. Replace Line switch.
4. Perform Inverter Board
Voltage Test.
1. Check Fan and Thermal
Protection Circuits.
2. Perform Input Board
Resistance and Input Board
Voltage Tests
3. The Control Board may be
faulty. Replace.
1. Turn the Power Switch OFF and
wait several minutes for the
machine to cool. Turn the Power
Switch back ON and check for
proper fan operation.
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.
INVERTEC® V155-S
THEORY OF OPERATION
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Observe Safety Guidelines detailed in the beginning of this manual.
PROBLEMS
(SYMPTOMS)
POSSIBLE AREAS OF
MISADJUSTMENT(S)
OUTPUT PROBLEMS
F-5
RECOMMENDED
COURSE OF ACTION
1. Control Board failure.
1. Check all PC Board
Connections.
1. Potentiometer failure.
1. Potentiometer or Control
Board needs Replaced.
2. The Shunt screw
connections are bad.
3. Inverter Board failure.
The machine does not have
maximum output
1. Loose connections on output
secondary leads.
2. The Control Board is out of
Calibration.
2. Replace Control Board.
2. Tighten and check all shunt
connections.
3. Perform Inverter Board
Voltage Test.
1. Check all secondary
connections.
2. Recalibrate the Control Board.
Replace if needed.
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RED and GREEN LEDʼs are
always “ON”
The machine welds but there is
no output control
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F-5
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.
INVERTEC® V155-S
THEORY OF OPERATION
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F-6
Observe Safety Guidelines detailed in the beginning of this manual.
PROBLEMS
(SYMPTOMS)
The machine has high welding
output and no control
POSSIBLE AREAS OF
MISADJUSTMENT(S)
OUTPUT PROBLEMS
1. Potentiometer failure.
2. Control Board failure.
RED LED stays ON continuously 1. Shunt Cable damaged.
RECOMMENDED
COURSE OF ACTION
1. Replace Potentiometer.
2. Replace Control Board.
1. Check connection of white,
red and black leads on the
Inverter Board
2. Replace Shunt Cable
Assembly.
3. Replace Conrol Board.
Flashing YELLOW LED
1. Input Supply Voltage out of
tolerance.
1. Supply correct Input Voltage.
2. Check Control Board
conections.
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2. Control Board defective.
F-6
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.
INVERTEC® V155-S
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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.
TEST DESCRIPTION
This procedure will aid the technician in the removal and replacement of the case
cover(s).
MATERIALS NEEDED
8” Magnetized #2 Phillips Head Screwdriver or
Socket with Magnetized 6 inch Extension and #2 Phillips Tip
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Return to Section TOC
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If for any reason you do not understand the test procedures or are unable to perform the
test/repairs safely, contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call 1-888-935-3877.
INVERTEC® V155-S
F-7
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F-8
TROUBLESHOOTING & REPAIR
CASE COVER REMOVAL PROCEDURE (CONTINUED)
F-8
FIGURE F.1 – CASE COVER SCREW LOCATIONS
Five Screws
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Three Screws
ete
Inv
o ar
rB
d
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Ground
INV
PROCEDURE
1. Disconnect power to the INVERTEC® V155-S.
2. Using a phillips head screwdriver remove the five
screws securing the case cover sides together. See
Figure F.1.
Note: The two bottom screws are machine screws that
thread into nuts. The nuts will fall out of the right
side.
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3. Carefully remove the left side case cover from the
machine.
Note: Be careful. The case back and fan will be loose
when the cover is removed.
4. Perform the Input Capacitor Discharge Procedure
steps 3 thru 7.
C
TE
ER
V1
55
5. Using a phillips screwdriver, remove the three
screws securing the Inverter board to the right side
case cover.
Note: These screws can only be accessed from the
inside of the machine and only after the left side
case cover has been removed. It may be necessary to cut the plastic tie that secures the Input
power cord to the top bracket
6. Note placement of ground lead secured by lower
front phillips screw on inverter board for re-assembly.
7. Remove case back and fan. Lay unit on the left
side and remove the right side cover.
INVERTEC® V155-S
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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.
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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
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Phillips Head Screwdriver
High Resistance and High Wattage Resistor (25-1000 ohms and 25 watts minimum)
Insulated Gloves
Insulated Pliers
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If for any reason you do not understand the test procedures or are unable to perform the
test/repairs safely, contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call 1-888-935-3877.
INVERTEC® V155-S
F-9
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F-10
TROUBLESHOOTING & REPAIR
INPUT FILTER CAPACITOR DISCHARGE PROCEDURE (CONTINUED)
F-10
FIGURE F.2 – CAPACITOR DISCHARGE LOCATIONS
INPUT BOARD
CAPACITOR TERMINALS
(4 places)
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DC-
DC+
WARNING
ELECTRIC SHOCK can kill.
• Have an electrician install and service
this equipment.
• Turn the input power off at the fuse box
before working on equipment.
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• Do not touch electrically hot parts.
• Prior to performing preventative maintenance,
perform the following capacitor discharge procedure
to avoid electric shock.
PROCEDURE
1. Disconnect power to the INVERTEC® V155-S.
2. Perform the Case Cover Removal Procedure,
steps 1 thru 3.
3. Locate the Input Board.
4. Obtain a high resistance and high wattage resistor
(25-1000 ohms and 25 watts minimum). This resistor is NOT supplied with the machine. NEVER USE
A SHORTING STRAP FOR THIS PROCEDURE.
5. Locate the two terminals DC+ and DC- on the Input
Board. See Figure F.2.
6. Use electrically insulated gloves and insulated pliers. Hold the body of the resistor and connect the
resistor leads across the two terminals. Hold the
resistor in place for 10 seconds. DO NOT TOUCH
CAPACITOR TERMINALS WITH YOUR BARE
HANDS. See Figure F.3.
7. Check the voltage across the terminals of all
capacitors with a DC voltmeter. Voltage should be
zero. If any voltage remains, repeat this capacitor
discharge procedure.
FIGURE F.3 – GLOVE, PLIERS & REISISTOR
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INSULATED
PLIERS
RESISTOR
INSULATED
GLOVES
INVERTEC® V155-S
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F-11
TROUBLESHOOTING & REPAIR
INPUT FILTER CAPACITOR DISCHARGE PROCEDURE (CONTINUED)
F-11
FIGURE F.4 – CAPACITOR DISCHARGE LOCATIONS
INVERTER BOARD
Red
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Black
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8. Remove the right side cover per Case Cover
Removal Procedure steps 5 thru 7.
9. Use electrically insulated gloves and insulated pliers. Hold the body of the resistor and connect the
resistor leads across the two terminals where the
RED and BLACK leads are connected. Hold the
resistor in place for 10 seconds. DO NOT TOUCH
CAPACITOR TERMINALS WITH YOUR BARE
HANDS. See Figures F.3 and F.4
10. Check the voltage across the terminals with a DC
voltmeter. Voltage should be zero. If any voltage
remains, repeat this capacitor discharge procedure.
INVERTEC® V155-S
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F-12
NOTES
INVERTEC® V155-S
F-12
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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.
TEST DESCRIPTION
This procedure will determine if the Input Board has any copper wires burned or any faulty
components.
MATERIALS NEEDED
Volt/Ohmmeter
Wiring Diagram W05X0701
Phillips Screwdriver
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Return to Section TOC
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If for any reason you do not understand the test procedures or are unable to perform the
test/repairs safely, contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call 1-888-935-3877.
INVERTEC® V155-S
F-13
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F-14
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INPUT BOARD RESISTANCE TEST (CONTINUED)
FIGURE F.5 – INPUT BOARD TEST POINTS
INPUT BOARD
D1 Input Rectifier
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TROUBLESHOOTING & REPAIR
DC-
~
–
+
R2
~
DC+
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R4
PROCEDURE
1. Disconnect power to the INVERTEC® V155-S.
2. Perform the Case Cover Removal Procedure.
3. Perform the Input Filter Capacitor Discharge
Procedure.
4. Visually check for burned areas ont The Input Board
(solder side).
5. Disconnect the Blachk lead from the DC- terminal.
6. Check the Input Rectifier Bridge “D1”.
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7. Check start resistors “R2” and “R4”. Each should
read 20 Ohms. See Figure F.5.
INVERTEC® V155-S
F-14
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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.
TEST DESCRIPTION
This procedure will determine if the Inverter Board has any “shorted” or “leaky” power
diodes or Insulated Gate Bipolar Transistors.
MATERIALS NEEDED
Digital Volt/Ohmmeter
Wiring Diagram X0519
Phillips Screwdriver
4mm Nutdriver
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Return to Section TOC
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If for any reason you do not understand the test procedures or are unable to perform the
test/repairs safely, contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call 1-888-935-3877.
INVERTEC® V155-S
F-15
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F-16
TROUBLESHOOTING & REPAIR
INVERTER BOARD RESISTANCE TEST (CONTINUED)
F-16
FIGURE F.6 – INVERTER BOARD TEST POINTS
Collector
Channel A
Gate
Emitter
IGBT
Channel A
Gate
IGBT
channel B
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INVERTER BOARD
PROCEDURE
Collector
Channel B
Emitter
1. Disconnect power to the INVERTEC® V155-S.
2. Perform the Case Cover Removal Procedure.
3. Perform the Input Filter Capacitor Discharge
Procedure
4. Visually check for burned areas on both sides of the
Inverter Board. If no obvious damage is evident,
continue to Step 5.
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Note: The following tests may be performed without
dis-connecting the Board
5. Check the IGBTʼs for “shorts” 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.
The IGBTʼs of each channel are connected in parallel so it is only necessary to check one Emitter
to Collector of each channel.
6. Check each device from gate to emitter. See Figure
F.6
Note: Normal value is approximately .5VDC in both
polarities.
Note: Actual readings will vary depending on the meter
being used. Similar tests on all devices should
give similar results.
These devices will usually fail “shorted” resulting
in a zero or very low resistance reading from
Emitter to Collector. If they “open” physical damage should be evident.
INVERTEC® V155-S
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F-17
TROUBLESHOOTING & REPAIR
F-17
INVERTER BOARD RESISTANCE TEST (CONTINUED)
FIGURE F.7 – INVERTER BOARD TEST POINTS
Output
Terminals
Collector
Channel A
D9
INVERTER BOARD
Red
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Black
D7
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D3
R24 = PTC
Point 2
(solder pad)
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Point 1
(center leg)
Collector
Channel B
7. Check the diodes D3 and D9 for “shorts” or “opens”.
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.
10. Check the resistance between the thermal protection terminals R24. It should be about 36-40 ohms.
See Figure F.7.
11. Check the resistance between output terminal connections. It should be about 8.5Kohms.
9. Check the five output diodes for “shorts” or “opens”.
Check from the center terminal (Point 1) of each
Diode (all center terminals of the diodes are common with the heatsink) to the large copperl area
“point 2”. See Figure F.7.
Note: Actual voltage readings will vary depending on
the meter being used. Similar tests on all devices
should give similar results
INVERTEC® V155-S
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F-18
NOTES
INVERTEC® V155-S
F-18
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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.
Return to Master TOC
Return to Master TOC
Return to Master TOC
Return to Section TOC
Return to Section TOC
Return to Section TOC
If for any reason you do not understand the test procedures or are unable to perform the
test/repairs safely, contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call 1-888-935-3877.
TEST DESCRIPTION
This test will help determine if the correct input voltage is being applied to the Input Board
and will also determine if the correct voltages are being processed on the Input Board.
MATERIALS NEEDED
Volt/Ohmmeter
Wiring Diagram
Phillips Screwdriver
WARNING
ELECTRIC SHOCK can kill.
• Do not touch electrically live parts such as output terminals or internal wiring.
• Insulate yourself from the work and ground.
• Always wear dry insulating gloves.
INVERTEC® V155-S
F-19
TROUBLESHOOTING & REPAIR
F-20
INPUT BOARD VOLTAGE TEST (CONTINUED)
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F-20
FIGURE F.8 – INPUT BOARD TEST POINTS
PIN 14
PIN 12
JP1
PIN 8
PIN 4
PIN 1 PIN 2
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PIN 3
INPUT BOARD
AC1
AC2
DC-
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DC+
PROCEDURE
1. Disconnect power to the INVERTEC® V155-S.
2. Perform the Case Cover Removal Procedure (left
side only).
3. Connect the main 230VAC to the the machine and
switch ON the input switch.
Note: Pay attention to wiring diagram very closely.
When connecting cables from the Input
Board to the Power Switch. You must connect the cables as shown in Figure F.9.
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PWR 2(white) to 4
5. Check for 320-325VDC between DC+ and DC-
6. Using pin 8,9,15 or 16 of JP1 as a common (-) point:
Check pin 2,4 and 14 for +15VDC.
Check pin 12 for +5VDC.
PWR 1(blue) to 1
PWR 4(white) to 5
4. Using a multimeter, check for 230VAC between AC1
and AC2. See Figure F.8.
PWR 3(blue) to 2
INVERTEC® V155-S
TROUBLESHOOTING & REPAIR
INPUT BOARD VOLTAGE TEST (CONTINUED)
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F-21
FIGURE F.9 – MAIN SWITCH PLUG LOCATION
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White from
PWR 2
White from
PWR4
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3
4
1
5
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6
Blue from
PWR 3
Blue from
PWR 1
2
1. Put the blue wire from PWR3 in position 2 of the
main switch while the white wire from PWR4 in position 5.
2. Put the blue wire from PWR1 in position 1 of the
main switch while the white wire from PWR2 in position 4.
INVERTEC® V155-S
F-21
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F-22
NOTES
INVERTEC® V155-S
F-22
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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.
Return to Master TOC
Return to Section TOC
If for any reason you do not understand the test procedures or are unable to perform the
test/repairs safely, contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call 1-888-935-3877.
TEST DESCRIPTION
This test will help determine if the main inverter board is receiving the correct input voltages and if the correct regulated voltages are being processed and maintained by the
main inverter board.
MATERIALS NEEDED
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Volt/Ohmmeter
Wiring Diagram X0701 and X0519
Phillips Screwdriver
WARNING
ELECTRIC SHOCK can kill.
• Do not touch electrically live parts such as output terminals or internal wiring.
• Insulate yourself from the work and ground.
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• Always wear dry insulating gloves.
INVERTEC® V155-S
F-23
TROUBLESHOOTING & REPAIR
F-24
INVERTER BOARD VOLTAGE TEST (CONTINUED)
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F-24
FIGURE F.10 – PLUG JP1 TESTPOINTS
15
13
11
9
7
5
3
16
14
12
10
8
6
4
JP1
PIN 1 PIN 2
INPUT BOARD
AC1
AC2
DC-
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DC+
NOTE: DUE TO SAFETY REASONS AND THE PHYSICAL LOCATION OF THE INVERTER, IT IS
NOT EASY TO PERFORM THE VOLTAGE
TEST AT THE INVERTER BOARD. CHECKS
CAN BE DONE AT THE INPUT BOARD CONNECTOR JP1. See Fig. F.10.
PROCEDURE
1. Disconnect power to the INVERTEC® V155-S.
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2. Perform the Case Cover Removal Procedure (left
side only).
3. Connect the main 230VAC to the machine and
switch ON the input switch.
4. Set the machine to STICK mode.
5. Locate the JP1 connector points. See figure F.10.
6. Using pins 8,9,16 or 15 as a common (-) ground:
Check pin 1- & gt; +15VDC means fan is ON. 0VDC
means fan is OFF.
Check pin 3- & gt; 0VDC during OCV condition.
Check pin 5- & gt; +11.6VDC means the inverter is ON
(the first 5 minutes after activity) while 1.5VDC
means the inverter is OFF.
Check pin 6- & gt; 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- & gt; +15VDC.
Check pin 11- & gt; +5VDC.
Check pin 12- & gt; +5VDC (supply voltage generated
on input board).
Check pin 14- & gt; +15VDC (supply voltage generated on input board).
7. Check to see if the correct microcontroller program
is preset: H490000005-004X where X is the revision number.
INVERTEC® V155-S
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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.
TEST DESCRIPTION
This procedure will aid the technician in the removal and replacement of the Input Board.
MATERIALS NEEDED
Phillips Screwdriver
7mm Nutdriver
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Return to Section TOC
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If for any reason you do not understand the test procedures or are unable to perform the
test/repairs safely, contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call 1-888-935-3877.
INVERTEC® V155-S
F-25
Return to Master TOC
Return to Section TOC
F-26
TROUBLESHOOTING & REPAIR
INPUT BOARD REMOVAL AND REPLACEMENT PROCEDURE
F-26
FIGURE F.11 – SCREW AND LEAD LOCATION
INPUT BOARD
AC1
AC2
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Return to Section TOC
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DC-
DC+
PROCEDURE
MOUNTING SCREWS
1. Disconnect power to the INVERTEC® V155-S.
2. Perform the Case Cover Removal Procedure
(Left side only).
3. Perform the Input Filter Capacitor Discharge
Procedure.
4. Label and disconnect the four leads at the Power
Switch located on the case back.
5. Using a 7mm nutdriver, remove the four input board
mounting screws. This will allow the board to be
gently pulled forward to gain access to associated
leads and plugs. See Figure F.11.
.
6. Label and remove all associated leads and plugs.
Some leads will require a 7mm nutdriver for
removal
7. Remove and replace the Input board.
8. Connect all leads and plugs previosly removed
9. Replace the four mounting screws previously
removed.
10. Replace the case cover.
INVERTEC® V155-S
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Return to Section TOC
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.
TEST DESCRIPTION
This procedure will aid the technician in the removal and replacement of the Inverter
Board.
MATERIALS NEEDED
Phillips Screwdriver
7mm Nutdriver
10mm Nutdriver
Socket extension (6” minimum)
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Return to Section TOC
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If for any reason you do not understand the test procedures or are unable to perform the
test/repairs safely, contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call 1-888-935-3877.
INVERTEC® V155-S
F-27
Return to Master TOC
Return to Section TOC
F-28
TROUBLESHOOTING & REPAIR
F-28
INVERTER BOARD REMOVAL AND REPLACEMENT PROCEDURE (CONTINUED)
FIGURE F.12 – DOOR REMOVAL
Five Screws
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Three Screws
In
er
ve t
ar
Bo
d
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Ground
INV
PROCEDURE
1. Disconnect power to the INVERTEC® V155-S.
2. Perform the Case Cover Removal Procedure.
3. Perform the Input Filter Capacitor Discharge
Procedure.
4. Perform the Input Board Removal Procedure.
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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.
C
TE
ER
V1
55
Note: Pay attention to wiring diagram very closely.
When connecting cables from the Input
Board to the Power Switch. You must connect the cables as shown in Figure F.9.
PWR 2(white) to 4
PWR 1(blue) to 1
PWR 4(white) to 5
PWR 3(blue) to 2
6. Note location of ground lead upon removal of lower
right phillips screw.
INVERTEC® V155-S
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F-29
TROUBLESHOOTING & REPAIR
F-29
INVERTER BOARD REMOVAL AND REPLACEMENT PROCEDURE (CONTINUED)
FIGURE F.13 – INVERTER BOARD REMOVAL
10MM
BOLTS
DC+
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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,
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Return to Section TOC
8. Label and disconnect any associated plugs and
leads.
9. Remove the inverter board.
10. Connect JP 1 connector and make sure that the
upper front corner of the board is in the locator slot
of the front panel.
11. Be sure that the white lead is re-connected to the
Positive Input terminal.
12. Re-connect the red and black leads to the DC+ and
DC- points on the Inverter Board.
13. Re-install the Inverter to the case, making sure the
ground lead is re-connected to the lower front corner.
INVERTEC® V155-S
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F-30
NOTES
INVERTEC® V155-S
F-30
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Return to Section TOC
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.
TEST DESCRIPTION
This procedure will aid the technician in the removal and replacement of the Control
Board.
MATERIALS NEEDED
Phillips Screwdriver
Metric Nut Drivers
Socket extension (6” minimum)
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Return to Section TOC
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If for any reason you do not understand the test procedures or are unable to perform the
test/repairs safely, contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call 1-888-935-3877.
INVERTEC® V155-S
F-31
TROUBLESHOOTING & REPAIR
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F-32
F-32
Return to Master TOC
CONTROL BOARD REMOVAL AND REPLACEMENT PROCEDURE (CONTINUED)
FIGURE F.14 CONTROL BOARD REMOVAL
MOUNTING
SCREWS
NUT
WASHER
CONTROL
BOARD
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KNOB
PROCEDURE
RED CAP
1. Disconnect power to the INVERTEC® V155-S.
8. Disconnect the JP1 connector.
3. Perform the Input Filter Capacitor Discharge
Procedure.
10. Disconnect the JP2 connector.
2. Perform the Case Cover Removal Procedure (left
side only).
4. Perform the Input Board Removal Procedure.
5. Perform the Inverter Board Removal Procedure.
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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.
9. Using a phillips screwdriver, remove the four mounting screws located on the corners of the solder side
of the control board.
11. Remove and replace the control board.
Note: When installing the new control board, be sure
to turn the output potentiometer shaft completely counter clockwise prior to fastening knob into
place. This will assure that the output setting is
at itʼs lowest setting. This will allow proper install
ation of the output knob with the red arrow pointing to the lowest setting possible. If this is not
done properly, the machine output will not match
the set current.
INVERTEC® V155-S
TROUBLESHOOTING & REPAIR
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F-33
RETEST AFTER REPAIR
Should a machine under test be rejected for any reason requiring the removal of any mechanical part that could
affect the machineʼs electrical characteristics, or if any electrical components are repaired or replaced, the machine
must be retested.
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Input Volts 50/60-HertzMax.
120VAC +/- 10%
230VAC +/- 10%
Duty Cycle
100%
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30%
Return to Section TOC
F-33
Output Amps
75A (stick)
105A (TIG)
100A (stick)
100A (TIG)
100A (stick)
130A (TIG)
145A (stick)
155A (TIG)
Output Current Range
5-155 Amps
INPUT- SINGLE PHASE ONLY
Input Current at Rated Output
34 A
33 A
RATED OUTPUT
Output Volts
23.0 Vdc
14.2 Vdc
Input Power at Rated Output
100%
30%
2kw
3kw
2kw
3kw
Input Circuit
120 Vac
24.0 Vdc
14.0 Vdc
230 Vac
24.0 Vdc
15.2 Vdc
120 Vac
25.8 Vdc
16.2 Vdc
OUTPUT
230 Vac
Maximum Open Circuit Voltage
75 Volts Max.
Type of Output
DC
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
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IMPORTANT: IF OTHER TYPE METERS ARE USED RESULTS MAY NOT BE ACCURATE.
INVERTEC® V155-S
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F-34
NOTES
INVERTEC® V155-S
F-34
TABLE OF CONTENTS - DIAGRAM SECTION
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G-1
G-1
Electrical Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .G-1
Wiring Diagram (W07X071) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .G-2
Schematic - Complete Machine (X0931) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .G-3
Schematic - Input Board (X0791) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .G-4
PC Board Assembly - Input Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .G-5
Return to Master TOC
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
Return to Master TOC
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* 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.
INVERTEC® V155-S
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ELECTRICAL DIAGRAMS
G-2
WIRING DIAGRAM - CODES 11326 & 11327
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G-2
NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual. The wiring diagram specific to your code is pasted inside one of the enclosure panels of your machine.
INVERTEC® V155-S
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G-3
G-3
ELECTRICAL DIAGRAMS
SCHEMATIC - COMPLETE MACHINE - CODES 11326 & 11327
i
output
turning on full
control
them
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with
Power Up
–
On
–
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windings
de-energizedfor a 230Vac
NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual.
INVERTEC® V155-S
SCHEMATIC - INPUT PC BOARD
PW R1
BLUE
RL3B
30A
30A
AC1
ARFU1A
2
1
4 mm
2
1
L1
2
4
DC+1
2
1
C8
47nF
250Vac
Y
C7
470nF
275Vac
MKT
C9
1uF
275Vac
MKT
VARISTOR
RV1
N.M.
2
Earth
Faston
N.M.
C10
47nF
250Vac
Y
AC2
1
1500µF
250V
1
RL2B
30A
3
W 9199065
+ C4
RL4B
30A
1500µF
250V
1
R3
180k
2W
2
+ C1
D1
54A
HS1
RL1B
-
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G-4
ELECTRICAL DIAGRAMS
PW R2
W HITE
+ C2
R1
15K
3W
1500µF
250V
+
+
Return to Section TOC
G-4
+ C5
R5
15k
3W
1500µF
250V
DC-1
RL8B
1
2
30A
W 58A4463
R2
+
R12
470
3W
1
470
3W
D5
1N4007
T1
RL7B
22 JZC-33F
14
21
A2 24
22
11
RL6C
22
24
AC2b
Rele'
Potenza
A1
A2
A2
Rele' 230V
Rele' 115V
21
JP3
Vr5V
MODU1/4
C12
D7
1.5A 1000V
1000V
+
-
3
4
0R
+15V
JP1
W 6300003
Fan_ONn
INPUT_ERR
V_FB
Passive Detect
GND
ERRORn
PRES
GND
U1
FDBK1
FDBK2
BTSTRP
8
6
ISEN
TIMCAP
7
VCC
R15
Reconnect Power supply
Vr5V
OUT
2
C18
3300µF
35V
+ C17
C19
10uF100nF
63V
63V
C11
680pF
100V
5
4
CNY17-3
R8
22k
C16
1000µF
25V
R9
2k
56
+15V
DUTY
GND
VINint
+5V
+15V
GND
C14
100nF
63V
1
IN
OUT
+5V
3
C3
100nF
63V
+ C20
10uF
63V
C6
100nF
63V
LINCOLN ELECTRIC ITALIA s.r.l.
SERRA RICCO' (GE) - ITALIA
Title
INPUT V145 2V
HS3
Dr.
W 9108165
2
4
6
8
10
12
14
16
U2
LM7805
+
GND
HS2
R13
3
D2
1N5822
+
6
+15V
350uH 1A
MC33163
3
GND
IN
LVIOUT
1
L2
6
4
5
12
13
0R18 2W 5%
9
11
10
14
15
GND
GND
GND
GND
16
DRVCOL
SWCOL
SWCOL
SWEMIT
SWEMIT
1
3
5
7
9
11
13
15
GND
N.M.
3
2
U4B
2
R16
U3
LM7805
1
2
3
4
5
6
7
8
N.M.
8
6
15VA
115-230Vac/21Vac
GND
OSC1
PTA4-OSC2
PTA0
AD1
IRQ
RESET
R7
22nF
50V
T2
11
PE
RL3A
12Vdc
R10
270
0.4W
1
C15
100nF
63V
RL4A
12Vdc
Blue
White
Red
Black
1
2
3
4
Fan1
1
A1
A1
A1
A2
Rele' Reconn
Aux.
RL2A
12Vdc
RL8A
12Vdc
JP4
RL6B
RL6A
110Vac
FINDER 40.52
1N4007
A1
Return to Master TOC
RL1A
12Vdc
11
14
12
M3
+15V
RL_PAR
Fan_ONn
RL5A
6Vdc
JQX-115F
A2
R6
10k
0.4W 1%
D8
1N4148
RL_SER
11
R14
470
1W
AD1
IRQ
RESET
RL_PRE
RL_SER
RL_AUX
RL_PAR
SET_PASSIVE
INPUT_ERR
D4
1N4007
A2
D6 1N4148
D3
V++
A1
PTA0
PTA4-OSC2
OSC1
1.5 VA
230Vac/15Vac
V++
RL7A
JZC-33F
A2
A1
M2
Vr5V
RL_PRE
V++
A2
Vr5V
A1
7
SCHEDA RECONNECT 2V SMD
5
RL5C
JQX-115F
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1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
VIN2
RL5B
JQX-115F
M1
20
10W 10%
AC2b
RL_AUX
VIN1
9
AC2b
PW R4
W HITE
R4
90°C NC
JP2
1
AC1b
Return to Section TOC
MODU1/2
N.M.
AC1b
PW R3
BLUE
12Vdc
Return to Section TOC
D9
1KAB100E
1.5A 1000V
2
1
U4A
CNY17-3
20
10W 10%
Fan1
ARFU1B
JP5
2
C21 220nF
MKT 250Vac
14
12
Return to Master TOC
Return to Section TOC
MKT 250Vac
-
R11
C13 220nF
Appr.
F.Scorza
W 9108165
Date last rev.: W ednesday, July 19, 2006
1st emis. dr.: I.Buscaglia
Size
A3
Document Number
X0701
Rev
00
Sheet
2
2
of
1st emis. date:
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.
INVERTEC® V155-S
Return to Master TOC
G-5
ELECTRICAL DIAGRAMS
PC BOARD ASSEMBLY - INPUT BOARD
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Return to Section TOC
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G-5
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 provided 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.
INVERTEC® V155-S
G-6
ELECTRICAL DIAGRAMS
SCHEMATIC - INVERTER PC BOARD - SHEET #1
HS1
W91X0611
DC+
R6A
15K
3W 5%
Q2
Q1
SGP30N60HS
Q3
Q5
Q6
C1
1nF
1600V
Q12
C2
630V
Eh
U1A
CNY17-3
N.M.
C17
33nF
100V
N.M.
R5
R24
22R
3W 5%
300V 2x30A
HS3
W91X0610
R3
10R
R4
10R
R90
10R
R89
10R
R88
10R
Vout
W5900651
1:100
BAL
T1
P2
D2
R41
470R
N.M.
N.M.
R7A
15K
3W 5%
C3
10nF
1600V
D3
C5
470uF
450V
+
C9
470uF
450V
+
D4
2
D9
1
D23
1N4007
N.M.
R7B
15K
3W 5%
C6
2n2F
630V
STTA1206DI
ISOLATO
HS2
U2A
CNY17-3
N.M.
C18
33nF
100V
N.M.
D7
HS2
ISOLATO
BYT12PI-1000
STTA1206D
HS1
R8
82R
10W 5%
HS2
W91X0611
R9
82R
10W 5%
Q17
Q16
Q15
Q14
Q13
El
R18
10R
6
5
R19
10R
R20
10R
R91
10R
R92
10R
R11
10R
3W 5%
D8
1.5KE250CA
C8
4n7F
4kV
R12
10K
5W
D10
1.5KE250CA
R14
220R
2W 5%
R13
10R
3W 5%
PE
C11
4n7F
4kV
N1
5
6
D13
R27 15R
R86
180
N.M.
VINint
BYV26B
C12
220nF
250V
W59X0293
DCU1B
N.M.
C7
3n3F
4
C10
1nF
1600V
R15
10R
3W 5%
Q4
SGP30N60HS
D6
3
1
2
D24
1N4007
N.M.
D5
T2
R10
82R
10W 5%
W58X0455
7 uH
3
C4
470uF
450V
+
P1
L1
1
R2
10R
4
250-420Vdc
Return to Master TOC
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R39
470R
N.M.
PTC
D1
Gh
R6B
15K
3W 5%
HS3
PTC
470R 80°C
6
2
R1
10R
3W 5%
D21
1N4007
N.M.
2n2F
PTC
D22
1N4007
N.M.
1
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G-6
R85
1K5
3W 5%
R93
10R
Gl
4
CNY17-3
C33
4n7F
6
COMP
5
COMP
D12
Return to Master TOC
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4
Vout
TA
CNY17-3
JP2 N.M.
D25
BAT43
BYV26B
R25
4R7
0.5W 5%
Gh
R17
1K
0.5W 5%
R26
470R
Q7
IRFD110
100R
R38
10k
T3
R29
470R
14
SLAVE
2
4
6
8
10
12
14
16
15V
DUTY
GND
VINint
DUTY
15V
15V
GND
15V
+ C15
220uF
W6300006
3
REC
10
Gl
12
GND
5
R31
470R
R33
D19
1N4749
Return to Master TOC
ERRORn
PRES
1
3
5
7
9
11
13
15
1
D18
1N4148
3
JP1
M/S
I_FB
V_FB
Passive Detect
GND
ERRORn
PRES
GND
R28
D14
1N4749
1
R35
47k
Eh
Return to Section TOC
MASTER
R32
3k3
2
U2B
N.M.
JP6
7
8
1
3
5
7
W5998052
D15
Q8
IRFD110
PILOT
15V
TA
GND
PWM
D16
D17
1N4148
1N4148
1N4148
100R
R34
470R
15V
2
4
6
8
PILOT
GND
ERRORn
W6110204
MODU2 90°
D33
N.M.
1N4148
W4004148
N.M.
El
SERRA RICCO' (GE) - ITALIA
Title
R87 4k7
D20
LINCOLN ELECTRIC ITALIA s.r.l.
INVERTER BOARD V145
Passive Detect
1N4148
+ C13
220uF
C14
100nF
R30
2k7
N.M.
Dr.
PASSIVEn
Appr.
V. Natarelli
D a te la s t re v. :
1 s t e mis . dr. :
Friday, February 17, 2006
J. Daniel
Size
A3
Document Number
X0519
Rev
02
S he e t
2
3
of
1 s t e mis . da te : 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.
INVERTEC® V155-S
SCHEMATIC - INVERTER PC BOARD - SHEET #2
15V
R42 22k
15V
6
VINint
PRES
PRES
C19
220nF
50V
C20
100nF
50V
R47 10k
N.M.
R43
180R
D26
R44
270k
7
1N4148
U3B
LM358
R45 100k
GND
GND
5
R46
2k2
U3A
D27
-
15V
+
+
2
3
R48 1k
1
+
Return to Master TOC
G-7
ELECTRICAL DIAGRAMS
-
Return to Section TOC
G-7
1N4148
LM358
15V
R50 3k
R51 10k
FEED-FORWARD
8
8
R49 3k
U5C
LM393
C32
100nF
50V
R53 10k
R52 10k
4
4
Return to Master TOC
Return to Section TOC
15V
C31
100nF
50V
U3C
LM358
R54
1k
3
R55
2
PTC
2k2
C21
100nF
50V
D28
+
-
1
U5A
LM393
5
BAT43
6
R58
10k
R56 100R
+
7
-
ERRORn
U5B
LM393
R57 39k
R59
10k
15V
R60
68k
R61 2k2
TA
R62 820R
R63 10k
15V
COMP
R64
1k
C22
100nF
50V
N.M.
R65
4k7
C23
100nF
50V
15
R66
15R
8
Taratura
Duty Max
43%
R73
1k
R77
4k7
N.M.
R76
10k
N.M.
D29
1N4148
N.M.
EII
ENI
CLK
5
R78
4k7
RT
R72 4k7
C26
CLRef
100pF
MASTER
N.M.
11
PILOT
6
PWM
D30
1N4148
N.M.
Ramp
OUT
C29
1nF
630V
Q11
IRFD110
14
CT
7
SLAVE
C30
2n2F
2%
350Vdc
Taratura
oscillatore
CW
CW
Return to Master TOC
1
R70
4k7
9
R79 56R
R80
1k8
R81
8k2
Return to Section TOC
Vref
R82
10k
PGND
N.M.
R67 18k
13
EO
GND
PASSIVEn
3
2
100V
R74
15k
C28
100nF
50V
DUTY
R75 10k
Q10
BC337
N.M.
220pF
SHD
12
Q9
IRFD110
N.M.
C27
SS
4
R71
1k
N.M.
VC
100nF
50V
10
15V
C24
Vref
C25
100nF
50V
R68
1k5
R69
1k
N.M.
16
VCC
Vref
CW
Return to Master TOC
Return to Section TOC
Vref
U6
R83
1k
D31
1N4148
D32
MC34023
REC
1N4148
R84
2k
LINCOLN ELECTRIC ITALIA s.r.l.
A
SERRA RICCO' (GE) - ITALIA
Title
INVERTER BOARD V145
Dr.
Appr.
V. Natarelli
D a te la s t re v. :
1 s t e mis . dr. :
Friday, February 17, 2006
J. Daniel
Size
A3
Document Number
X0519
Rev
02
S he e t
3
3
of
1 s t e mis . da te : 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.
INVERTEC® V155-S
Return to Master TOC
G-8
ELECTRICAL DIAGRAMS
PC BOARD ASSEMBLY- INVERTER BOARD - SHEET # 1
*See Page 2 for more
detailed component
information
Return to Master TOC
Return to Master TOC
Return to Master TOC
Return to Section TOC
Return to Section TOC
Return to Section TOC
Return to Section TOC
G-8
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 provided 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.
INVERTEC® V155-S
Return to Master TOC
G-9
ELECTRICAL DIAGRAMS
PC BOARD ASSEMBLY - INVERTER BOARD - SHEET #2
Return to Master TOC
Return to Master TOC
Return to Master TOC
Return to Section TOC
Return to Section TOC
Return to Section TOC
Return to Section TOC
G-9
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 provided 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.
INVERTEC® V155-S
SCHEMATIC - CONTROL PC BOARD
1
+15V
R2
4k7
0603
1%
+15V
R10
47R
0603
1%
2
6 -
C5
820pF
0603
50V
R66
120k
0603
1%
R17
2k2
0805
1%
C4
100nF
50V
0805
U1A
LM324
SO14
R20
10k
0603
1%
C2
100nF
50V
0805
11
3
8
8
4
LM358AM
SO8
GND
R15
100k
0603
1%
D3
LL4148
MINIMELF
YELLOW
D 5mm
D2
LL4148
MINIMELF
R21
4k7
0603
1%
THLED
+15V
Q4
BC817
SOT23
R41
5k6
0603
1%
C6
220pF
50V
0603
+15V
R67
5k6
0603
1%
R13
390k
0603
1%
R9
1k2
1206
1%
THRLED
D7
BAT54S
SOT23
IMIS
3
IMIS=3.81V - & gt; 145A
U2A
4
11
1M
1%
SJ2
0R
0603
N.M.
R50
0603
Q6
BC807
SOT23
2M
1%
SJ3
0R
0603
N.M.
. CW
R43
50k MONO
1%
R55
0603
3M9
1%
R69
2k2
0603
1%
R70
2k2
0603
1%
Piste per regolazione offset.
Calibrazione Imax
Trimmer smd verticale
W ELDING
3
R58
4k7
0603
1%
R61
ISET
AD1
CEVRD
VRD
AD2
OSC
SET
1k
1%
0603
1%
Vout
R64
3k3
0603
1%
C22
100nF
50V
0805
R62
100k
0603
1%
IMIS
R63
10k
0603
1%
R83
10k
0603
1%
C23
10nF
50V
0603
FAN_ONn
A
AD0
IRQ
RESET
R73
1k
0603
1%
C24
10nF
50V
0603
U3
13
12
9
8
5
4
C26
100nF
50V
0805
1
D14
BAT54S
SOT23
3
3
1
. CW
2
Q7
BC817
SOT23
16
D13
BAT54S
SOT23
R60
2k5
20%
R72
4k7
0603
1%
+5V
2
VSS
2
1
2
R51
3M9
1% 0603
+5V
2
R71
4k7
0603
1%
C20
100nF
50V
0805
PTB0
PTB1
PTB2
PTB3
PTB4
PTB5
PTB6
PTB7
AD0/PTA0/TCH0/KBIO
AD1/PTA1/TCH1/KBI1
IRQ/PTA2/KBI2
RST/PTA3/KBI3
AD2/PTA4/KBI4/OSC2
AD3/PTA5/KBI5/OSC1
S/T
PTCuM
W ELDING
Arcset
Fan
VENn
PTCE
THLED
15
14
11
10
7
6
3
2
R52
2k2
0603
1%
R54
2k2
0603
1%
Q5
BC817
SOT23
MC68HC908QY4
SOIC16
+5V
+5V
GND
OSC
AD2
AD0
AD1
IRQ
RESET
+5V
+5V
1
2
3
4
8
7
6
5
SW DIP-4
+5V
R39
4k7
0603
1%
2
SW 2
THRVRDS
CEVRD
THRLED
THRCE35
D11
BAT54S
SOT23
S/T
2
R74
12k
0603
1%
SW 1
2
R79
4k7
0603
1%
R75
4k7
0603
1%
R76
470k
0603
1%
R77
10k
0603
1%
U4A
+
3
-
1
R80
18k
0603
1%
D12
BAT54S
SOT23
R78
1k
0603
1%
+15V
4X VITI FISSAGGIO SCHEDA
R47
10k
0603
1%
ERRORn
PTCuM
2
M5
M1
LM358AM
SO8
R81
4k7
0603
1%
C29
100nF
50V
0805
R82
100R
0603
1%
JP2
I+
I-
D5
S1M
DO 214AC
C19
1nF
50V
0603
FEME T1C/1/L1/X/H
4
SW1: deviatore a tre posizioni
2
1
THRVRDS
3
C25
100nF
50V
0805
N.M.
3
Q8
BC817
SOT23
Arcset
+5V
1
VRD
+5V
D15
BAT54S
SOT23
1
3
R57
4k7
0603
1%
3
D17
BAT54S
SOT23
R59
4k7
0603
1%
R44
100R
C17
0603
100nF
1%
50V
0805
+15V
R49
100k
0603
1%
M2
M3
M4
2
Da implementare per la programmazione in-circuit
Eseguire foratura per striscia pin berg.
2
SET=3.81V - & gt; 145A
1
Return to Master TOC
R46
0603
3
C15
22nF
50V
0603
POTENZIOMETRO LINEARE 2K5 20%
BOURMS 91U1D-T14-EAO/260
Return to Master TOC
NB: i led sono a montaggio through
hole
R25
1k2
1206
1%
+15V
R37
2k2
0805
1%
Piste per regolazione offset.
Return to Section TOC
U1C
LM324
SO14
D16
LL4148
MINIMELF
OFF+
+5V
Return to Section TOC
R26
10k
0603
1%
GREEN
D 5mm
SJ1
0R
0603
N.M.
R48
2M
1% 0603
ISET- & gt; PWM of current set
SET - & gt; Current set
CEVRD - & gt; HV or CE version
VRD - & gt; Start signal in CE version
AD2 - & gt; Ouptut voltage AD
OSC - & gt; Oscillator pin
Vout - & gt; output voltage
Imis - & gt; Output current
S/T - & gt; Stick / tig working
PTCuM - & gt; Error signal
WELDING - & gt; Green mode and VRD
detect
Arcset - & gt; Arc force selection
Fan - & gt; Fan setting
VENn - & gt; OCV set
PTCE - & gt; Inverter set
THLED - & gt; thermal led
C7
100nF
50V
0805
D8
+5V
SJ6
0R
0603
N.M.
9 R24
100k
0603
1%
R36
4k7
0603
1%
1
R45
1M
1% 0603
8
C14
4n7F
50V
0603
1
SJ5
0R
0603
N.M.
R3
2k2
0805
1%
R35
10k
0603
1%
+5V
I-
SJ4
0R
0603
N.M.
LM358AM
SO8
R34
10k
0603
1%
1
R42
18k
0603
1%
14
7
LM358AM
SO8
R40
1k
0603
1%
-
12
3
+
2
3
3
+
R33
220R
0603
1%
Voutfilt
C13
22nF
50V
0603
N.M.
C11
100pF
50V
0603
RED
D 5mm
10 +
1
D10
BAT54S
SOT23
A
-
VDD
2
1
+15V
C12
4n7F
50V
0603
13
D6
1
R31
39k
0603
1%
5
DUTY
7
R23
3k9
0603
1%
3
OFF+
6
+5V
6
U4B
I+
C28
4n7F
50V
0603
C9
10nF
50V
0603
Led indicator for VRD system
R16
5k6
0603
1%
11
2
1
Return to Master TOC
Return to Section TOC
R29
1k
0603
1%
C10
33nF
50V
1206
R68
910R
0603
1%
U1D
LM324
SO14
4
ISET
R30
22R
0603
1%
+
U2B
LM358AM
SO8
5 +
-
R28
4k7
0603
1%
+15V
R27
1k8
0603
1%
+5V
+15V
GND
R38
4k7
0603
1%
2
1
ISET 100%DC- & gt; 190A
+15V
DUTY
GND
1
R65
100k
0603
1%
2
Vout
7
11
R14
10k
0603
1%
5 +
R12
100k
0603
1%
LM358AM
SO8
C18
100nF
50V
0805
2
4
6
8
10
12
14
16
3
Voutfilt
R8
15k
0603
1%
R6
4k7
0603
1%
C27
100nF
50V
0805
1
3
5
7
9
11
13
15
HEADER 8X2 90° P/I
R7
5k6
0603
1%
3
4
Voutm
C1
100nF
50V
0805
U1B
LM324
SO14
U2C
D9
4
1
3
D1
BAT54S
SOT23
U4C
PTCE
2
Q2
BC817
SOT23
1
+15V
+15V
3
+15V
R32
1k2
1206
1%
R5
4k7
0603
1%
1
3
R4
5k6
0603
1%
R1
10k
0603
1%
Q1
BC817
SOT23
2
FAN_ONn
CEVRD
Voutm
+15V
GND
ERRORn
Inputerr
4
1
VENn
THRCE35
JP1
+15V
+15V
+
Return to Master TOC
G-10
ELECTRICAL DIAGRAMS
-
Return to Section TOC
G-10
C21
100nF
50V
0805
N.M.
1
1
1
1
1
1
2
3
4
LINCOLN ELECTRIC ITALIA s.r.l.
SERRA RICCO' (GE) - ITALIA
MODU2 2VIE 90°
Title
Control Board V145S
Dr.
Appr.
F.Scorza
Date last rev.: W ednesday, April 05, 2006
1st emis. dr.: & lt; 1st emis. dr. & gt;
Size
A2
Document Number
Rev
X0708
00
Sheet
2
2
of
1st emis. date: W ednesday, 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.
INVERTEC® V155-S
Return to Master TOC
G-11
ELECTRICAL DIAGRAMS
Return to Master TOC
PC BOARD ASSEMBLY - CONTROL BOARD PAGE - SHEET #1
* See Page 2 for more
detailed component
information
Return to Master TOC
Return to Master TOC
Return to Section TOC
Return to Section TOC
Return to Section TOC
Return to Section TOC
G-11
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 provided 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.
INVERTEC® V155-S
Return to Master TOC
G-12
ELECTRICAL DIAGRAMS
PC BOARD ASSEMBLY - CONTROL BOARD - SHEET #2
Return to Master TOC
Return to Master TOC
Return to Master TOC
Return to Section TOC
Return to Section TOC
Return to Section TOC
Return to Section TOC
G-12
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 provided 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.
INVERTEC® V155-S